The trend towards lightweight construction — especially in the automotive industry — places increasingly high demands on die-cast parts and therefore on the moulds used for their manufacture. A filling simulation helps to optimise the injection moulding process when it is still in the development stage. It enables detailed studies of how problems can be avoided throughout the whole process chain. It also provides information on the distribution of pressure and temperature, as well as the position of trapped air and joint lines in the component to be manufactured.
In this way, potential fault locations — such as cavities at “hot spots” — can be avoided; the amount of reworking that is required can also be reduced and the service life of the tool maximised. For this purpose, gate design, overruns, geometries, filling progress and hardening of the casting material are shown in a virtual simulation. The mechanical characteristics of the moulded part can also be calculated in advance.
The main advantage of a filling simulation is the fact that all relevant parameters of the injection moulding procedure can be modified directly. The consequences of modifications made to the mould or manufacturing process can be tested immediately. Filling simulations are especially helpful when it comes to processing bulk moulding compound in the injection moulding procedure.