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1 Part Name : Base Bracket Mold Number : M3281.9-9 Prepared by : Engineering Date Prepared : Jan 5, 2019 Version : Rev.6 Moldflow Analysis Report

Moldflow Analysis Report - Sun Molding

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Text of Moldflow Analysis Report - Sun Molding

Mold Flow ReportVersion : Rev.6
2
n The material datas are from supplier is in moldflow database and shown in the pictures below
Material Data
PVT properties:Rheology:
Material Property
PP+PE+10%Talc (Finalloy ST-210 from TOTAL substitute RR62G )
Melt Temperature Range () 200~270
Solid Density (g/cm3) 0.97 Mold Temperature Range () 15~70
Maximum Shear Rate (1/s) 100000 Ejection Temperature () 110
Maximum Shear Stress (MPa) 0.25 Absolute Maximum Melt Temperature () 310
MFR (g/10min) ( 230 / 2.16 Kg) 22 Recommended Melt Temperature () 235
Filler 10%Talc Recommended Mold Temperature () 40
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Process Setup
Part Volume 86 (1*1) cm^3
Nominal Wall Thickness 2.5 mm
Tool Description 1*1 Cavity
Injection machine Tonnage 280 T
Material PP+PE+10%Talc (Finalloy ST-210 from TOTAL)
Injection time 1.5 s
Material temp 230 [deg.c]
Mold temp 30 [deg.c]
Velocity/Pressure Transfer (% volume) 98 %
Packing Pressure/Time 80% filling pressure /6 s, 60% filling pressure /4 s
Project Area 214 (1*1) cm^2
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Wall thickness
n This above plot used different color to show the thickness of this part. n We can see that: the average thickness of this part is about 2.5 mm. n Total part weight = 78 g (1*1), the cold runners weight = 8 g
The ribs is too thick Sink mark risk
The wall is too thick Sink mark risk
5
Gate Location and size
n The mold is the cold runner and cashew, sub. gate. n The runner layout was based on the drawing.
Cashew gate Dia. 1.2 mm
T-shape Width 6 * height 5 mm
Cashew gate Width 3 * height 1.5 mm
T-shape Width 4.5 * height 3.5 mm
6n Coolant was specified as water 30 C, Cooling time as 20 s
Cooling Layout
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n This result shows how the melt flows through the cavity.
Fill result
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Air trapped area n The result shows areas of the cavity that may require additional venting, it should be viewed in combination with the filling pattern result.
n Air traps locations mark in red color spot. n Most of the air trapped appear at the edge of part and the tip of ribs that is easy to vent n The serious air traps may appear in the depth blue circle
Adding vent
From the above analysis
Ü The cycle time is about: 1.5 (filling) + 24.0 (cooling + packing ) + 12.0 (open & eject) =37.5 sec
Ü This part will not have filling problem due to the pressure are within the moldflow recommend range.
Ü Visible weld lines were expected appear at this part. (refer page 13)
Ü Most of the air trapped appear at the edge of part and the tip of ribs that is easy to vent, some serious air traps may appear on the surface. (refer page 14)
Ü This part have minimal uneven shrinkage at the X, Y, Z direction.
Fill time Injection pressure
1.5 sec 23.7 Mpa
22
From the above analysis
Ü The cycle time is about: 1.5 (filling) + 24.0 (cooling + packing ) + 12.0 (open & eject) =37.5 sec
Ü This part will not have filling problem due to the pressure are within the moldflow recommend range.
Ü Visible weld lines were expected appear at this part. (refer page 13)
Ü Most of the air trapped appear at the edge of part and the tip of ribs that is easy to vent, some serious air traps may appear on the surface. (refer page 14)
Ü This part have minimal uneven shrinkage at the X, Y, Z direction.
Fill time Injection pressure
1.5 sec 23.7 Mpa