Moldflow Tutorial – Warpage

Warpage Overview
Design Influences on Warpage
Review of units
Warpage Analysis Process
Determine the Magnitude of Warpage
Determine the Cause of Warpage
Reducing Warpage

Warpage Analysis Process
First optimize Cooling, Filling and Packing
Analyze the part warpage
Type stable or unstable, Midplane only
Magnitude net shape and magnitude
Cause DC, DS, OE
Reduce warpage
Final Check

Reducing Warpage
Aim should be to reduce warpage to within design tolerances
Need to have well defined criteria for measuring warpage
It is generally not practical/possible to reduce warpage to zero

Take measures to reduce the effect of the dominant warpage contributor
Add stiffing features to the part
Change the material
Use analysis results to help determine how to reduce the warpage.

Determine the Cause of Warpage
Warpage is caused by variations in shrinkage across the part. The principle causes of shrinkage variations are: Differential shrinkage Differential orientation Differential cooling
For midplane models, the procedure for determining the cause of warpage depends on whether or not buckling has been predicted
For Fusion models, procedure assumes no buckling

Determine the Magnitude of Warpage
Stable warpage — Warpage (deflection) is linearly proportional to applied shrinkage stress
Unstable warpage — In-plane stresses increase membrane stress to the point of instability Conversion of in-plane membrane energy to bending energy results in large deformations

Design Influences on Warpage
Part Design — Wall thickness Wall thickness variations (abrupt changes) Part stiffness / shape
Mold Design — Gate location(s) Runner and gate design Cooling system configuration Ejection system

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