Short overview on how Beaumont Technologies can help solve problems that develop during Plastic Injection Molding
- 1. Presents: Products and Services Overview & RCS Technical
Review
2.
- APlastics engineering firm and technology supplier to the
Injection Molding Industry
- Focus on polymer flow and rheology:
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- Drives our own internal development of patented products and
innovative services
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- Provide our clients with a unique perspective during
development or troubleshooting
- Our goal is to increase our clients profits by improving part
quality and manufacturing efficiencies.
- Passion for Success-Unique Solutions-From Development To
Production
- If you've got questions, we've got ANSWERS.
Where the INDUSTRY Goes for ANSWERS Company Overview: 3.
- BTI was founded on April 17th, 1998
- Headquarters located in Erie, PAUnited States of America
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- Optimization of the part design, mold design, and process
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- Educate our clients through day-to-day correspondence andformal
training
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- Become an extension of our clients engineering department
Where were located 4. Who we are...
- Consultants with in-depth understanding of plastic flow, which
allows us to offer solutions that others can not offer
- 65 years of experience with various CAE packages, product
development, mold & part design, processing
5. BTI Partners
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- CoreTech Systems Co., Ltd.(Taiwan, Korea, Vietnam)
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- SimpaTec Simulation & Technology Consulting GmbH(Germany,
France, Belgium, Netherlands, Luxembourg, Austria)
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- REP International(Thermoset Rubbers, Lyon Corbas, France;
global representation)
6. BTI Products and Services
- Rheological Control Systems
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- Opti-Flo Hot Runner Systems
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- MeltFlipper & MAX Design/Consulting Service
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- Systematic Mold Balance Analysis
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- Mold Filling & Part Quality Diagnostics
- CAE Mold Filling Simulation Services
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- Mold Filling/Packing/Shrink/Warp/Cool Analysis
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- Veri-flo Material Verification Service
- Pro-Series Training Seminars
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- PlasticsPro - From Pellets to Parts
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- FillPro - Diagnosing Mold Filling & Part Quality
Variations
- Development, Engineering & Consulting Services
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- Mold & Part Troubleshooting
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- Mold & Part Design / Development
More Than 7. I. Engineering Consultant Services: BTI provides
adeeper and uniquelook into your molding problems with or without
CAE 8. II. Filling Simulation Services:
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- Strategically Position Weld Lines
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- Optimize part geometry and gate location(s)
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- Optimize the runner layout
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- Optimize the runner sizes
Engineer the Part and Melt Delivery System 9. Flow Analysis vs.
Real World: Rheological Control Systems can help ensure accurate
filling patterns that CAE predicts How do we know that the CAE
simulation is providing accurate results? 10. Veriflo Material
Verification Services
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- Proprietary Simulation Verification Capabilities
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- Collect real-world data and compare to simulation results
Another BTIInnovation! Confirm the accuracy of the material
dataand solver, and provide more reliable results to our customer.
11. Veri-flo Material Verification Services
- CAE results may not be accurate for several reasons:
- Improper rheological characterization
- Use of equivalent materials
- Therefore the simulation will then over/under estimate pressure
predictions
- Send 15-20lbs of material
- Study the material in our proprietary mold
- Collect data and compare results
Confirm the accuracy of the material data in the software, and
provide more reliable results to our customer. 12. Everyone needs
to be talking the same language
- PlasticsPro SM From Pellets to Parts
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- Plastic flow and rheology (shrink, warp)
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- Designing and optimizing melt delivery systems
- FillProSM - Diagnosing Mold Filling & Part Quality
Variations
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- Understanding the Flow Group methodology
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- Process troubleshooting, mold maintenance, and QC
III. Pro Series Training: Being Profitable During a Slow Economy
* Held periodically at BTI, in-house, or local to your facilities
13. Root Cause Analysis Basics of 5 Step Diagnostic Software The
Underlying Causes The Root Below the surface(not obvious) Hard to
identify until
- Not utilizing all cavities
- Separate Shear & Steel Variations
- Develop accurate game plans to solve variations
- Leads to faster mold commissioning time
- Customers will be happier
- Lower mold maintenance cost
Symptom of the problem The Weed Above the surface(obvious) 14.
IV.5Step Process Software Systematic Mold Balance Analysis Software
15.
- Isolates and SeparatesSteelandRheologicalfactors so the user
canfocus on the root cause
How the 5 Step Process Works...
- Different solutions are required for each root cause
- Optimize the mold based on a scientific approach
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- variationswithina Flow Group = Steel Variations ( l, r)
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- variationsbetweenFlow Groups = Shear Imbalance ( )
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- If the Pressure Drop is the same to all cavities, then the
parts should fill & weigh the same
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- Parts within the same Flow Group have the same flow path and
experience the same shear history and material conditions ( )
16. 5 Step Process vs. Traditional MBA Traditional Method =50.8%
Imbalance Steel Imbalances: Quadrants A & D are always heavier,
& on the same side of the sprue 5 6 7 13 14 15 1 3 9 11 12 2 10
4 16 8 5 Step Process = Steel Imbalances: Flow 1 = 19% Flow 2 = 34%
Flow 3 = 37% Flow 4 = 34% Shear Imbalances: Max Shear Imbalance =
31.6% Flows 1&2 vs. Flows 3&4 = 20.8% Flows 1&4 vs.
Flows 2&3 = 15.1% Diagnosis: Primary runner diameters varied
by0.006 (0.152mm) 17. IV.5Step Process Software
- Updates to the Software Include:
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- Easy to compare before & after
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- Compare averages or shot-to-shot
18. Primary Root Causes of Imbalances: II. Rheological
Variations ( ) I. Mold Steel Variations ( l, r) How do solve these
issues? Solution: Rheological Control Systems Solution: Mold Makers
19.
- Rheological Control Systems
Reduce Cycle TimeBalance Filling Improve Dimensions Eliminate
Scrap Hot Runner and Cold Runner Solutions 20.
Rheological Control Systems (Cold Runners)
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- Manage flow to and within the cavities
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- Static and dynamic control
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- Mold inserts and design & license services
- Three Control System Types:
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- Design Service w/ License
21.
- Rheological Control Systems
- Previously only available through design and license
services
- Now available for quote as Static Rheological Control
inserts
Optimize the material conditions to and within the cavities for
Plastic and Rubber materials 22. What is an Intra-Cavity Imbalance?
Common Molding Problems: Warp Gas traps Race tracking Cosmetic
blemishes Core shift Weld lines Non-fills / short shots Yes, even
within a Single Cavity Mold!! The Filling Pattern So when do you
use Single-Axis vs. Multi-Axis intra-cavity flow control? 23. RCS:
Single-Axis Intra-Cavity Flow
- Rotates high sheared material around the perimeter of the part
to:
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- create symmetrical flow across the part
24. RCS: Multi-Axis Intra-cavity Flow
- Rotates high sheared material throughout the cross-section of
the part to:
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- enhance part characteristics and flow to a particular part
geometry
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- re-create symmetrical material properties (i.e.. round
parts)
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- more effective for improving some cosmetic defects vs.
single-axis control
25. RCS: SRC vs. iMARC
- iMARC Inserts: Adjustable Rheological Control
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- Optimize balance and fill pattern
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- Adjustments made from parting line without taking the mold out
of the machine.
Conventional Adjustment 1 Adjustment 2 Adjustment 3
- SRC Inserts: Static Rheological Control
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- Optimize balance and fill pattern
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- Adjustments require the mold or inserts be taken out of the
machine.
Conventional Static 26.
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- Delphi Automotive component for HVAC
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- 75 % cavitationat bestdue to short shots
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- Short shots with48% scrap
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- Equals high Machine time, material, and labor costs
Reducing Scrap and Short Shots Customer: Cav 1 Cav 2 Cav 4 Cav 3
$114,000 in Savings
Cav 1 Cav 2 Cav 3 Cav 4 High sheared laminates feeding different
locations between cavities Equal distribution of high sheared
material with MeltFlipper Technology 27. Melt Rotation:
Intra-Cavity Control, Concentricity
Effective Melt Temperature Concentricity Conventional Melt
Rotation Conventional Melt Rotation Avg. T = 39.3F Avg. T = 4.8F
28.
- From Prototype to Production
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- Implemented into prototype molds; adapt into production molds =
shorter lead-times
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- Ability to change the filling pattern
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- Optimize part dimensions; control/minimize warp; enhance
weld-line strength
Conventional Runner iMARC Runner iMARC Optimizing Fill Patterns
and Weld Lines 29.
- Increasing Weld Line Strength
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- Controlling rheology within the part to optimize weld-line
strength
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- Customer: Siemon Corporation
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- Moldmaker/Processor: Tech Tool & Molded Plastics
iMARC Optimizing Fill Patterns and Weld Lines LCP Avg. Force (N)
PC+ABS Avg. Force (N) 16% increase 20% increase 30. Beaumont
Technologies, Inc. Controlled Melt Rotation for Eliminating Shear
Induced Flow Imbalance
- Reduced Set Up and Overall Cycle Time
- Geometrically & Rheologically Balanced Manifold
- Increased Process Capability without Flow Restriction or
Pressure Loss
- Outstanding Part Quality and Cavity Consistency
Rheological Control Systems (Hot Runners) BTI and Incoe can be
your one-stop-shop for your Hot Runner & Cold Runner Needs DF
Gold Series &QuickFlow Series 31. For more information Contact
Kevin Rottinghaus 715.821.8444 direct line [email_address]