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REM3D® - Overview

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REM3D® is a 3D simulation software. Thanks to this simulation tool, you can test your innovations and analyse the influence of process parameters. Therefore, optimize your process to increase your productivity and to improve the quality and the in-use properties of your components.

 

With REM3D®:

  • Optimize your chemical foaming process
    How? → For example:  Determine with REM3D® the minimum mass to fill and consequently reduce the loss of material at the vents.
  • Analyze your filling defects
    How? → For example: Use REM3D® to simulate the filling of a complex mold in 3 dimensions and/or with major variations of thickness.
  • Reduce mold design time
    How? → For example: With  REM3D®, determine the best position for gates and coolers and/or heating cartridges.
  • Reduce cycle time
    How? → For example: Use REM3D® to determine the optimum packing time for minimum warpage.

 

Thanks to REM3D® you can simulate your standard injection processes but also more complex processes.

Do not hesitate to inquire our experts who will provide valuable recommendations to simulate your processes by taking into account all their specifities.

  • Water-assisted injection molding
     
  • Gas-assisted injection molding
     
  • Bi-injection, co-injection, overmolding
     
  • Sequential injection with multiple melts
    (no limit on the number of pin points or materials)
     
  • Injection of fiber-reinforced polymers
    (possibility of exporting results for mechanical computation with Digimat-RP)
     
  • Injection-Expansion of polyurethane foams
    (module co-developed with and validated by DOW Chemical Company)
     
  • Injection of thermosetting materials
     
  • Injection-Compression : SMC - BMC
    (sheet molding compound / bulk molding compound)
     
  • Flow balancing in extrusion die
     
  • Injection of highly viscous and filled fluids
    (SAFRAN Herakles Applications, concrete, ...)
   
 

Injection of fiber-reinforced polymers - Courtesy of Solvay

   
    Injection-Expansion of polyurethane foams - Courtesy of DOW

 

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Chemical foaming with polyurethane foams

With REM3D® you can simulate the complete injection expansion process. The thermo-rheological-kinetic coupling of the resolution allows a high level of prediction for the results. This modile has been validated by our industrial partners and more specifically by the company DOW. It allows the user to etimate the minimum mass required for injection in order to perfectly fill the part. It also enables to predict the filling defects and to optimize the vents & inserts location needed to the equilibrium of the expansion. Finally, thanks to its volumic sensors, REM3D® allows to analyse the final density in every zone of the part.

 

Fluid-assisted injection

With a global consideration of the rheological behaviors and the thermal phenomena during the injection cycle,   c une prise en compte globale des rhéologies et des phénomènes thermiques durant le cycle d'injection, REM3D® enables to know precisely the residial polymer thickness. On the example here below, we can observe the polymer injection (inorange) and later on the gas injection (in blue).

 

Temperature field by the end of the gas injection phase and prior to the packing and cooling stages. We can note that the injected gas allows not only to hollow the part, but also to cool it from the inside, which contributes the reduction of the injectino cycle.

 

Reinforced plastics

With REM3D®, it is possible to determine the fibers orientation during the filling stage and after cooling. Therefore, you can easily observe the orientation tensor during the injection phase in an ellipsoid form (export for structural analysis with Digimat-RP from e-Xstream is possible).
 

Courtesy of Solvay

 

 

Shrinkage and warpage

Shrinkage and warpage of an injected part is higly dependent of the residual stresses. These ones are calculated with a high accuracy in REM3D®, therefore allowing an easy prediction of the shrinkage and the warpage after complete cooling of the part.


 

 



Shrinkage after complete cooling

 

Fully automatic self-adaptive meshing!

With REM3D® : no more painful initial meshing operation!
Hence, thanks to a fully automatic adaptive tehcnology for anisotropic mesh, the user obtains results of a very high accuracy without being an expert in meshing techniques. Furthermore, as the re-meshing stage is fully integrated into the computation, it is parallelized which brings to very competitive calculation time in 3D.

Thanks to this unique automatic re-meshing capability, REM3D® enables to observe very sharp defects or complex phenomena such as "jet buckling" or "fluid buckling" which are undetectable with 2.5D software-type, but critical fo rthe final appearnace of the components.


Automatic mesh adaptation during the calculation along the jet: the number of nodes and therefore the computation time remain low. However the results accuracy is high and it is possible to observe torroidal oscillations characteristic of a viscous fluid flowing on a plane surface.

This technique, based on a-priori error minimization, has been developped by a scientific research laboratory at the leading adge of numerical methodology: this is the CEMEF , laboratory of the Ecole des Mines de Paris specialized in material forming.

 

A fully coupled resolution

Thanks to a fully coupled resolution, you can analyse the influence of material & process parameters on the final component. The sketch here after represents all steps for the resolution of the analysis. The re-meshing stage is included into the resolution and therefore totally handled by the computation which will adapt the mesh depending on the needs to observe as accurately as possible any filling defects.

Courtesy of Solvay

This resolution method is suitable for a very accurate 3-dimensional representation of the polymer front(s) during the filling stage, as shown in this industrial example:

 

 

 

REM3D® also means

Like all TRANSVALOR software, REM3D® this is:

  • High levels of performance and modularity based on multi-core processing for greater accuracy of simulation and/or a larger number of simulations, or so as to obtain data relevant for the simulation of later manufacturing stages;
  • Fully parallelizable computations, tested on a large number of cores (>64) and on a variety of platforms: Windows x64 and Linux;

.

  • Use of unlimited Pre-and Postprocessors with a new graphical user interface allowing an effective use of the software.
  • An international technical support & training staff;
  • Customer requests matter a lot to determine the forthcoming evolutions of our software.

 

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