LIMS Features
The simulation allows the user to monitor flow progression, pressure distribution, and inflow rates during the mold filling process. Various inlet parameters including location can be changed during the simulated filling. It is even possible to modify the material data during the simulation.
This capability, tied with the built-in scripting language, allows the user to simulate complex filling schemes such as those using adaptive controls. A number of other effects, such as "race-tracking"-- the tendency for resin to flow much differently around corners where draped preforms have folded -- can also be modeled.
System Requirements
A standard installation package is available for 32-bit Windows environment, including Windows 9x, ME, NT 4, 2000 and XP. Implementation for UNIX workstations can be provided if there is interest. The simulation package itself, without the user interface, may be supplied for any platform that supports standard ANSI C compiler, including MS-DOS.
Typically, a Pentium CPU and 32MB of RAM are sufficient for a two-dimensional isothermal self-standing simulation.
For non-isothermal simulations or simulations run from within other applications, a fast Pentium II CPU or better with 128 MB of RAM is recommended.
For realistic three-dimensional simulations, a large amount of RAM -- at least 256 MB -- is recommended.
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Specific Capabilities
The mold geometry may be a three-dimensional solid, a three-dimensional shell, or any combination of both. One-dimensional “channel” elements may be added to any geometry to simulate phenomena like systems of injection tubes or racetracking.
Multiple injection gates, vents, sensors, and inserts are allowed.
The role of preform formation may be included using additional code, available from the University of Delaware for the simulation of draping (DRAPE) and permeability predictions (PERM). This code is easily integrated with LIMS.
The user may control the simulation through a built-in programming language. The program can monitor the filling and provide on-the-fly control.
All solution data are available to the interpreter during the simulation, thus effectively simulating a large array of sensors. These "numerical" sensors can be used to design or verify mold filling control strategies, as gates and vents can be adjusted in response to signals sent by these sensors.
Dry spot prediction is available.
The heat transfer solution -- currently available only for two-dimensional geometry -- uses a pseudo three-dimensional temperature field, providing acceptable performance even for non-isothermal simulation.
Output of the results is available at any time during execution of the program. Both the overall snapshot in any given instant, and the transient tracking of individual values is supported.
On MS Windows platforms, dynamic link libraries are provided for other programs to run and control the LIMS simulation and exchange data with the simulation in an efficient manner. An interface to Labview and Matlab has been implemented by the University of Delaware.
A graphical user interface (GUI) is available. It is tailored toward the specific needs of injection molding simulation. It facilitates modifications of preform properties, generation of additional race-tracking, and distribution media geometry, execution of filling simulation(s) and the display of results.
Input files can be prepared in
I-DEAS, PATRAN or any program that supports export to an ABACUS input file. Output is available through its graphical user interface or TECPLOT package.
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