By using MAGMA5, Wagner AG significantly reduced the number of sampling trials per die.
For the design of hybrid components, Wagner saw the advantages of simulating the second production step, covering the cast metal as an insert during plastic injection molding, using SIGMASOFT®.
To simulate the production of the thermoplastic component, the cavity and tool geometries, as well as the precise definition of the injection molding process (melt temperature, injection profile, dwell pressure, cooling time, etc.) are required. In addition, both the thermal and the mechanical properties of the cast insert had to be considered.
The simulation allowed the detection of potential weaknesses in the hybrid part at an early stage in the development process. Simple questions such as the ability to fill the cavity could be answered, in addition to addressing complex relationships between shear stresses and polymer degradation. By specifically influencing the injection profile, material damage could be reduced to a minimum. As with MAGMA5, tracer particles could be used to trace the material history. If weld lines, which are areas of potentially weakened material, are not thoroughly intermixed, the resulting mechanical properties of the component would be reduced significantly. The tracer particles were used to display the level of intermixture. As a result of information from simulation, important conclusions could be made regarding the component properties resulting from the injection molding process.
The solidification simulation of the part provides insight into how long the dwell pressure can be effectively applied in the cavity. The impact of this holding pressure is an important factor for the part quality. The results showed that the connection between the two thin-walled areas solidified early, meaning that the regions farther from the gate were no longer supplied with the dwell pressure. Therefore, the thermal contraction could not be compensated for by the flow of additional plastic. Here, sink marks were expected to affect the surface quality of the part significantly.