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DOE can be used to understand the sensitivity of results to processing parameters or thickness changes what influences the warpage of the part how critical dimensions are influenced by processing. DOE is a simulation tool for the simulation of injection moulding. It can be used for a Wide scope to get an overall understanding of processing variable sensitivity Narrow scope Determine what needs to be done to solve a problem DOE Objectives Must have a defined set of objectives to use DOE effectively Without objectives the DOE analysis may not be set up correctly and will be difficult
DOE can be used to understand the sensitivity of results to processing parameters or thickness changes what influences the warpage of the part how critical dimensions are influenced by processing. DOE is a simulation tool for the simulation of injection moulding. It can be used for a Wide scope to get an overall understanding of processing variable sensitivity Narrow scope Determine what needs to be done to solve a problem DOE Objectives Must have a defined set of objectives to use DOE effectively Without objectives the DOE analysis may not be set up correctly and will be difficult
DOE can be used to understand the sensitivity of results to processing parameters or thickness changes what influences the warpage of the part how critical dimensions are influenced by processing. DOE is a simulation tool for the simulation of injection moulding. It can be used for a Wide scope to get an overall understanding of processing variable sensitivity Narrow scope Determine what needs to be done to solve a problem DOE Objectives Must have a defined set of objectives to use DOE effectively Without objectives the DOE analysis may not be set up correctly and will be difficult
Overview and Examples 2008 Autodesk Content Information and Materials
DOE 2012 Overview
DOE in advanced Practice
Example 1 Sink Mark
Example 2 Optimise Warpage
Tips
2008 Autodesk Information and Materials 2008 Autodesk Information Wiki PPTs Videos http://wikihelp.autodesk.com/ http://wikihelp.autodesk.com/User:Jay.Shoemaker/Autodesk_Moldflow_Insight_ (AMI)/DOE 2008 Autodesk Materials PPT Model files
You can run exercises using the PPT and the model files Include useful tips
Wiki for further information
2008 Autodesk DOE 2012 Overview 2009 Autodesk What the DoE program does ... Melt temperature [+120,+160] C Flow rate [+25,+30] cm3/s - Single analysis 0 10 20 30 40 50 60 Mold temperature Melt temperature Flow rate %
Influences on result Mold Temperature [+60,+80] C Moldflow runs {+60, +120, +25} {+60, +120, +30} {+60, +160, +25} {+60, +160, +30} {+80, +120, +25} {+80, +120, +30} {+80, +160, +25} {+80, +160, +30} Optimum Solution 2009 Autodesk Customer benefits new DOE
Faster, better, cheaper
Only integrated DOE solution in the industry for the simulation of injection moulding,
Easy-to-use interface
Minimum number of single analysis runs for maximum information collected,
Optimum solution for each quality criterion. 2009 Autodesk Why Use DOE? Use DOE to understand The sensitivity of results to processing parameters or thickness changes What influences the warpage of the part How critical dimensions are influenced by processing DOE can be used for a Wide scope To get an overall understanding of processing variable sensitivity Narrow scope Determine what needs to be done to solve a problem DOE Objectives Must have a defined set of objectives to use DOE effectively Without objectives the DOE analysis may not be set up correctly and will be difficult to interpret the results 2009 Autodesk Why Use DOE? Look at how processing parameters influence results Possible uses for DOE include:
No. Parameters Results Why 1 Mold & melt temperature Pack pressure Volumetric shrinkage Sink mark depth Injection pressure Determine the sensitivity of the processing parameters on sink marks and how uniformly the part can be packed out 2 Melt temperature Injection time Pack profile Clamp force Injection pressure Volumetric shrinkage Determine if the mold will fit in the desired press size and uniformly pack out the part 3 Nominal wall thickness Rib thickness Inj. & pack pressure Shear stress Bulk temperature at EOF Sink mark depth Look at how thin the nominal wall and ribs can be to make the part and how the thickness will influence the mold ability of the part 4 Melt temperature Each coolant inlet temp Cycle time Mold surface temperature Volumetric shrinkage Determine how the coolant inlets need to be set to make the mold surface temperatures more uniform and how reducing hot spots improves shrinkage 5 Injection time Melt temperature Packing profile Volumetric shrinkage Flatness of an edge Dimension between 2 pts. What is the sensitivity of the deflection (warpage and shrinkage) to process inputs? Will the molding window be small? Should the part be stiffened? 2009 Autodesk DOE Versus Pure Optimum Search Design of experiment Directed optimum search Primary objective Analyze the process enviroment Find the optimum Analysis runs Predefined before execution Defined step by step Favored execution Parallel Sequential End of execution Completion of initial set of runs Accuracy criteria or maximum number of runs Process mapping Homogeneous coverage Defined by step path Optimum Estimate based on fitted equation Accurate 2009 Autodesk DoE settings 2009 Autodesk 1. Influence analysis (Variable influence) Factorial and Taguchi based on orthogonal design Influence of each variable
2. Response analysis (One variable and Variable Responses) Face centered cubic design Quality response surfaces Optimum variable values
3. Combined Influence then Response analysis (Variable influences then Responses) Filter N most influential variables before determination of the quality responses. AMI DoE analysis modes Optimum Solution 0 10 20 30 40 50 60 Mold temperature Melt temperature Flow rate %
Influences on quality criteria { Response analysis supports up to 10 variables = 1045 runs} 2009 Autodesk Variables Melt temperature Mold temperature Hydraulic pressure Ram Time Flow rate IMM Part Cooling Nominal wall Rib thickness Gate diameter Coolant channel diameter *For Midplane and Dual Domain Runner diameter 2009 Autodesk Impact of the DOE results Failed jobs need to be restarted and completed One extreme point like a near short-shot may destabilize the fitting operation Short shot destabilize DOE analysis
2009 Autodesk Tip Efficient Job Manager utilization for DOE calculations Increase no. of Distribution queue max. running jobs Mix local and distributet Analyse in Cloud
2008 Autodesk 2007 Autodesk 17 DOE in advanced Practice Example 1 Sink Mark 2009 Autodesk Rippe etc layer am modell zeigen Part Detail 2009 Autodesk Special Components For variables Dimension scale factor Affect beam diameters and shell thicknesses for midplane and dual-domain meshes The selection of elements is based on custom layers This method allows the mixing of element types 2009 Autodesk Experiment 2009 Autodesk Variables 2009 Autodesk Variables
No. Parameters Results Why 3 Nominal wall thickness Rib thickness Inj. & pack pressure Shear stress Bulk temperature at EOF Sink mark depth Look at how thin the nominal wall and ribs can be to make the part and how the thickness will influence the moldability of the part 2009 Autodesk Quality Criteria
No. Parameters Results Why 3 Nominal wall thickness Rib thickness Inj. & pack pressure Shear stress Bulk temperature at EOF Sink mark depth Look at how thin the nominal wall and ribs can be to make the part and how the thickness will influence the moldability of the part 2009 Autodesk Example Sink Mark Results: 2009 Autodesk Example Sink Mark Change thickness Using a vbs script 2009 Autodesk Example Sink Mark New thickness New Process Settings based on DOE results 2009 Autodesk Example Sink Mark Result: Sink Marks Estimation 2008 Autodesk 2007 Autodesk 28 DOE in advanced Practice Example 2 Optimise Warpage 2009 Autodesk Example Warpage Review warp results first Define your criteria 2009 Autodesk Example Warpage Select Nodes where huge deflection exist Save Node List Set Anchor Plane in a good relationship to the part deflection 2009 Autodesk Special Components For qualities New Warp Criteria Custom quality criteria based on nodal warpage deflections
Save list Mesh menu Critical dimension Distance between two nodes Node list With custom axis & anchor plane Boundary conditions menu 2009 Autodesk Example Warpage Tip: When running a DOE analysis with warpage a selection of nodes can be used to define quality rather than all nodes in the part Save list Mesh menu Critical dimension Distance between two nodes Node list With custom axis & anchor plane Boundary conditions menu Worked best 2009 Autodesk Example Warpage Variable Influences then Responses is used for warpage DOE 2009 Autodesk Example Warpage Select variables which influence most Make the result interpretation more easy Reduce analysis time 2009 Autodesk Example Warpage Choose the node list Choose the Anchor plane 2009 Autodesk Example Warpage Log File: Ranking 2009 Autodesk Example Warpage DOE result Deflection Check tendencies
Recognize dependences
Are the results significant?
2009 Autodesk Example Warpage Log File: Settings 2009 Autodesk Example Warpage New Process Settings based on DOE results Run new Flow -> Warp analysis sequence 2009 Autodesk Example Warpage Result comparison 2009 Autodesk Example Warpage Result comparison Warpage result 1 Warpage result 2