Best practice for benchmarking injection moulding simulation

Injection moulding simulation benchmarking is the comparison of predicted and actual process and quality parameters. Best practice requires that the inputs and outputs from an injection moulding simulation agree to the actual conditions of a real life moulding machine, as closely as possible. The accuracy of injection moulding simulation is influenced by many factors such as: the modelling of the part geometry, runner and nozzle, model mesh type and density, mathematical finite element solution, material data, and process settings. Validation of injection moulding simulation requires good quality process measurements from a range of transducers, measuring process pressure and temperatures at different locations and including movement of the reciprocating screw to infer flow rate and accurate and repeatable measurement methods for part deflection. The objective of this paper is to give the reader an appreciation of the important issues, to ensure the inputs for an injection moulding simulation match the actual conditions of the real life moulding machine. The inputs for injection moulding simulation are reviewed in detail, firstly considering machine performance issues and secondly considering the simulations issues. This will provide the reader with knowledge and understanding to improve benchmarking procedures.