by Young-Wook Chae, AnyCasting Seoul, Korea
The necessity of simulation
Recently, rapid technological development of the vehicle, electricity, and electronic industries means that the demands on product design have become more complex. Users want ever shorter development times, while demanding better quality in all parts of the product.
Software simulation is being used in almost all processes, and has now extended to polyurethane products made by foaming. The simulation extends from initial product design to product moulding, and can be applied in the foaming process and to mould design — aspects which are the basis of making foamed products.
In conventional foam part making, the product is developed from a trial object, requiring much trial and error and expense.
By using simulation in the design step, we can apply the result to the product and the process conditions, and so minimise trial and development times and expense.
Computer simulation is being used to raise productivity and improve the quality of foam products. It can predict all the physical phenomena that could happen in the process of getting the materials into the mould, and during the foaming process in the mould, in order to apply the right parameters to the mixhead and vent etc. But if simulation programs consider only change of material density, the simulation result is inaccurate.
Previous simulation software has suffered from other problems such as high cost, long calculation…