iPhone4 case analysis using Autodesk Moldflow Software

Embed Size (px)

Text of iPhone4 case analysis using Autodesk Moldflow Software

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    1/21

    Click to edit Master subtitle style

    5/5/12

    ANALYSIS AND

    IMPROVEMENTS OF

    PHONECASE MOLD CAVITYUSING M

    OLDFLOW

    SOFTWARE

    ABDUL SYAKIR BIN ABDUL MUBINKEC080001

    MOHAMMAD IZZUDDIN BIN MOHAMED ROSLI

    KEC080010

    MOHD HIDAYAT BIN MOHD HAMBALI

    KEC080012

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    2/21

    5/5/12

    Product

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    3/21

    5/5/12

    3 Runner layout design

    Analysis

    X-runner

    layout

    Y-runnerlayout

    H- runnerlayout

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    4/21

    5/5/12

    Analysis

    The analysis has been developed using AutodeskMoldflow Adviser 2011

    The product chose is an iphone 4 case made of

    polypropylene (PP). It is observed and itsdimension is measured.

    A CAD model of the phone case is designed byusing ProE software. It is then saved as a stl formatso that it can be exported to Autodesk Moldflow forfurther design process.

    Three alternate cavity layout designss are madewith improvements based on the softwareanalysis. The best cavity layout design is then

    chosen by comparing the analysis.

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    5/21

    5/5/12

    GENERAL

    Material trade name: Generic PP Melt temperature: 240.0 (C)

    Mold temperature: 40.0 (C) Injection locations: 4 Max. machine injection pressure:180.000 (MPa)

    RESULTS

    SUMMARY

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    6/21

    5/5/12

    H

    Runne

    r

    X

    Runne

    r

    Y

    Runne

    r

    Actual filling time: (s) 0.67 0.67 0.66

    Actual injection pressure: (MPa) 66.977 62.003 63.711 Clamp force area:(cm^2) 303.082 303.876 302.203 Max. clamp force during filling: (tonne) 48.159 46.698 47.293 Velocity/pressure switch-over at % volume:(%) 97.96 98.14 98.04 Velocity/pressure switch-over at time: (s) 0.65 0.65 0.64 Estimated cycle time:(s) 9.82 9.82 9.81 Total part weight: (g) 34.731 34.274 34.733 Shot volume: (cm^3) 51.2808 51.5303 51.0048 Cavity volume: (cm^3) 44.4924 44.4924 44.4924 Runner system volume: (cm^3) 6.7884 7.0379 6.5124Clamp force estimate during packing using: 20% of the injection pressure: (tonne) 41.387 38.414 39.225 80% of the injection pressure: (tonne) 165.547 153.655 157.019

    120% of the injection pressure: (tonne) 248.321 230.483 235.528

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    7/21

    5/5/12

    Fill time

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    8/21

    5/5/12

    Confidence of fill

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    9/21

    5/5/12

    Quality prediction

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    10/21

    5/5/12

    Pressure at end of fill

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    11/21

    5/5/12

    Pressure drop

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    12/21

    5/5/12

    Temperature at flow front

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    13/21

    5/5/12

    Orientation at skin

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    14/21

    5/5/12

    Average temperature

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    15/21

    5/5/12

    Time to reach ejectiontemperature

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    16/21

    5/5/12

    Frozen layer fraction at end offill

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    17/21

    5/5/12

    Air traps

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    18/21

    5/5/12

    Weld lines

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    19/21

    5/5/12

    Discussion

    Material selected for the phone case is polypropylene(PP) due to its properties; durability, light weight,variations of colour selection and lower production cost.

    The best cavity layout design can be evaluated by

    comparing the cost, time and product quality. The ideaof best design is when all these parameters areoptimized, ideally if the design has the lowest cost andtime production with the fewest product defects.

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    20/21

    5/5/12

    It is found that the fill time and cycle time for Y runner

    system is the lowest compared to the other two,meaning less material consumption for production,resulting it to have the lowest cost between them.

    All three cavity layout designs possess the same weldline and air trap location. It is due to the same gate

    location placed at all three designs, which is anedge/tab gate.

    The projected area affects the clamping forces suchthat the more area is projected, the more clampingpressure needed to hold the product during pecking

    time. It explains why Y runner system with lowestprojected area has the lowest clamping force among allthree designs.

  • 8/3/2019 iPhone4 case analysis using Autodesk Moldflow Software

    21/21

    5/5/12

    Conclusion

    Y runner is the best design Because it has lowest cycle time,

    lowest clamping pressure, lowest

    shot volume, lowest runner systemvolume.