True 3D simulation techniques of injection-molding and related processes

CAE (Computer-Aided Engineering) has been widely adopted and proved to be an important tool for part and mold designers. Design and process variables of design are evaluated on computer before the mold is actually constructed. In this manner, potential defects are identified and eliminated in the design phase. In addition to this, design can be refined and even be optimized according to the simulation results, this makes concurrent engineering can be implemented in a cost-efficient way. With the advancement of hardware and theoretical modeling, it's possible now to simulate injection molding process in a more realistic way. In this paper, true three-dimensional simulation techniques are proposed for injection molding and related processes (Gas-assisted injection molding, IC packaging encapsulation process). Filling/Cooling dynamics are simulated by the proposed approach for benchmarking. model and practical parts. Special techniques developed for handling 3D simulation problems are also addressed. Numerical experiments indicated the proposed tool is reliable and efficient for the true 3D simulation of injection molding and related processes.