BASF, a global leader in the chemical industry, has devoted themselves to creating innovative solutions for customers. One of their products, Ultrasim®, integrates processing simulation and structural analysis software to provide users with a unique simulation workflow. Jin Jing, CAE Manager of BASF China, shared his insight into how the integration of Moldex3D and ANSA Morphing in Ultrasim® successfully accelerated the product design process.
 |
|
The comparison of the original and optimized design |
Take one case, for example. BASF had to reduce warpage while maintaining a maximum injection pressure of 100MPa. Additionally, 3 gate locations needed to be optimized, which added the complexity to the product design. For this part, 13 design parameters needed to be considered, and each parameter would be affected by 3 variables related to the gates. Considering all possible outcomes would result in over 1.5 million combinations, which would have been time-consuming to simulate and analyze each combination.
By integrating Moldex3D and ANSA Morphing in Ultrasim®, BASF was able to test hundreds of cases in a short time. The program can automatically adjust the size and shape without the need for manual re-modeling, enabling the BASF team to quickly identify the optimum design solution through a seamless and automated workflow. In this case, by adjusting product shape and optimizing geometry features with ANSA Morphing, the maximum warpage was successfully reduced from 19.23mm to 10.04mm, a 47.79% reduction (as shown in Fig 1). Additionally, the gate positions were optimized to meet the requirement of the injection pressure (as shown in Fig 2).
 |
|
Optimized gate locations |
BASF’s Ultrasim® has demonstrated its exceptional benefits with the integration of Moldex3D and ANSA Morphing. By carefully considering the impacts caused by different variables and accurately simulating each combination, it has successfully addressed the complex challenges of minimizing warpage, controlling the maximum injection pressure, and optimizing 3 gate locations simultaneously, ultimately identifying the optimum design.
By enabling precise adjustments of the part’s shape, this integration makes the product development more efficient. The case also successfully demonstrates Moldex3D’s pivotal role in intelligent design and highlights the importance of Ultrasim® in modern manufacturing.
The Benefits that Moldex3D Offers BASF Ultrasim®
• Optimized gate locations
• Decreased nearly 50% warpage
• Accelerated product development process
