Successful Flow Simulation Starts with You

Flow-simulation software is an invaluable tool in the world of injection molding. Although the technology is mature, there are still companies that doubt the accuracy of the software and its overall value. Many of the companies have a good reason to be critical – they paid for analysis that just did not meet with their expectations. In some cases, the results of the analysis did not match reality. In other instances, they got ridiculous recommendations that could not be implemented on the production floor. This may sound a little harsh, but my answer to the critics is – successful flow simulation starts with you.

If you have been burned by analysis in the past, you are not necessarily a victim. You simply did not get what you asked for and you probably did not even ask for what you wanted. The next time you need analysis, use this as an instructional guide to make sure it is a successful venture.

Goals and Objectives
(ask for what you want)

The range of capabilities of analytical software has grown tremendously in the past few years. Besides several processes other than standard injection molding, you can simulate how cores will deflect due to injection pressure and the impact that has on the wall thickness. Considering how much we can do with the software, there is no such thing as a standard flow analysis. So the first step to successful analysis is defining what you want to accomplish.

If you really think about it, the value of the analysis is defined at this point as well. If your goal is to reduce your cycle time by 10 seconds or if you want to minimize the number of drops, the value of doing the analysis is a simple calculation. Don’t be afraid to define multiple objectives and be as detailed as possible. Not only will you have a much better chance of obtaining the results you want, you will also only pay for what you need from the analysis. We approach life a little different than most firms – we know that our success depends on knowing what you anticipate from the analysis.

Select the Right Analyst

• After defining your objectives, the next step is finding an experienced organization that can deliver. Flow simulation firms vary. Most are small operations. Some are material suppliers that offer free analysis if the order is large enough. Before kicking off an analysis, make sure you know who is doing the analysis. I’ve outlined how to obtain what you need and pay for just that. For example, if you see little value in the analysis, then go for the lowest price. If you have specific objectives, make sure you employ a firm that can meet those objectives.
• Investigatethe modeling techniques they use.
• Inquire about their processing experience.
• Interview companies that have employed their services.

You can define goals for the analysis, but if you pick an inexperienced analyst who doesn’t use the complete software package, you are likely to get erroneous and/or incomplete recommendations.

Communicate

The last step is to communicate. Engage the analyst with the designer, the process technologist, the material supplier, and the tool shop. If you want to reduce cycle time, the analyst needs to know what ejection temperature you use and the tooling limitations for cooling. Communication is absolutely critical in attempting to obtain recommendations that are useful. In today’s fiercely competitive global marketplace, working with an analyst with a proven track record ought to be part of your track for success.