iPhone4 case analysis using Autodesk Moldflow Software

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    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

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    Product

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    3 Runner layout design

    Analysis

    X-runner

    layout

    Y-runnerlayout

    H- runnerlayout

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    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.

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    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

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    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

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    Fill time

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    Confidence of fill

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    Quality prediction

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    Pressure at end of fill

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    Pressure drop

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    Temperature at flow front

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    Orientation at skin

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    Average temperature

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    Time to reach ejectiontemperature

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    Frozen layer fraction at end offill

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    Air traps

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    Weld lines

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    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.

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    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.

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    Conclusion

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

    lowest clamping pressure, lowest

    shot volume, lowest runner systemvolume.