Moldflow Analysis Report - Valuable Mold Flow Analysis …€¦ · · 2011-10-21Moldflow Analysis Report ... To be sure that the design reasonable and injection molding feasible,

Confidential Slide 1

Moldflow Analysis Report

Description: 3 D dimension of this part is 160.58mmX86.63mmX53.49 mm

Volume of this part is 35.22 cm^3

To be sure that the design reasonable and injection molding feasible, we used Moldflow

MPI6.1 to analyze


Material Property:

The material is specified as GE cycolac C6200 by customer, it can be selected in moldflow

material database directly, property of the material is as below.

1. Melt Density 0.98129 g/cm^3

2. Solid Density 1.1161 g/cm^3

3. Recommended Mold Temperature 71℃

4. Recommended Melt Temperature 267℃

5. Absolute Max. Melt Temperature 325℃

6. Ejection Temperature 87 ℃

7. Melt Temperature Minimum 248 ℃8. Melt Temperature Maximum 285 ℃9. Mold Temperature Minimum 60 ℃10.Mold Temperature Maximum 82 ℃11.Maximum Shear Rate 40000 1/s12.Maximum Shear Stress 0.4 Mpa

PVT graph Viscosity graph


Mesh Statistics:

Fusion mesh will be used according to shape of the part ,the Match percentage is 91.8% and

the Reciprocal percentage is 90.8%, so the mesh can completely meet the requirement of

cool + flow + warp analyze .

Thickness of the mesh is mostly equal to the wall thickness of the part, in order to ensure the

accuracy of analysis results.


Mold Design Scheme : Mold type: 2 plates, submarine gate, cav1*1, moldbase 3035

Runner system and cooling circuit will be determined by moldflow engineer

Note: It is recommended that a gate location analysis should be run before runner system has been designed to determine the best gate location.

gate location result dimension of runner system

Cold runner:φ5

Cold sprue:

φ4+1°taper

Submarine gate:

Φ1.0


Note: Cooling circuits were designed by moldflow engineer , only for reference, and it will be different from actual mold

Top view Left view


Front viewCooling circuits layout

Work piece

Cooling channel Φ8


Process condition :

The optimum fill time is about 1.5s

Note: It is recommended that a molding window analysis should be run before process setting, in order to determine the optimum fill time. The optimum fill time zone is where the injection pressure and maximum shear rate and maximum shear stress are lowest together, green zone in pictures as follows.


Details of process setting

Fill time：1.5s

Injection+packing+cooling time：30s

Mold temperature：71℃

Melt temperature：267 ℃

Coolant inlet temperature of cavity side cooling circuit：60 ℃

Coolant inlet temperature of core side cooling circuit：40 ℃

V/P switch-over by %volume filled at: 98%

Holding pressure：

time（s） pressure（Mpa）

0 65

2 65

5 0

Water 40 ℃

Water 60 ℃

Water 60 ℃


Results explain : Fill time


Note:These pictures showed the filling step, the parts will be filled entirety.


AnimationAnimation


Temperature at flow front

Note:

Temperature at flow front varied from 259.9℃ to 268.8 ℃, and not be out of the material’s melt temperature

range (248 ℃ ~285 ℃).


Weld lineWeld line

Warning:Weld lines will be occured at area marked by red arrow, change the gate location if necessary.


Note:Most of air traps will be occured at the top of rib, it is necessary to vent at that area to avoid burning or

short shot .

Air trapsAir traps


Pressure distributionPressure distribution

Note :

Pressure in cavity is not uniform, maximum pressure is 44.39Mpa, pressure lost in runner system is about 20.6Mpa.


Pressure Pressure (Animation)(Animation)


Injection pressure graph

Note:

Pressure is measured at start of runner system, pressure in barrel is not taken account


Clamp force

Note:

Maximum clamp force is 30.70 tonne, so injection machine of 120 tonnage is adequate.


Temperature, mold

Note:Temperature of mold surface is not uniform, there are two hot spots on the part, so it will need an excess cooling

time to cool the part, then cycle time will be longer.


Temperature, part

Note:Temperature of part surface is not uniform, but under the transition temperature(144 ℃) entirely.


Frozen layer fraction

Note:Gates had been frozen at 8.7s, so 7s packing time is adequate.

animation


Volumetric shrinkage at ejectionVolumetric shrinkage at ejection Sink indexSink index

Note:

Volumetric shrinkage at ejection and Sink index are uniform at mVolumetric shrinkage at ejection and Sink index are uniform at most of the part, but there are larger ost of the part, but there are larger value at two area marked by red arrow, sink mark will be arise pvalue at two area marked by red arrow, sink mark will be arise possibly. ossibly.


Deflection, All EffectDeflection, All Effect


Deflection, X component, isolate cause of Deflection, X component, isolate cause of warpagewarpage


Deflection, Y component, isolate cause of Deflection, Y component, isolate cause of warpagewarpage


Detail view

Note:

To view the exact value of warpage, we define a datum plane to measure, the results are relative to datum plane.

Datum plane


Deflection, Z component, isolate cause of Deflection, Z component, isolate cause of warpagewarpage


Detail view

Note:

To view the exact value of warpage, we define a datum plane to measure, the results are relative to datum plane.

Datum plane


Conclusion And Advice:

It is known from the analysis results that:

The part will be full filled easily, and injection machine of 120 tonnage is adequate;

Weld lines will be arised at part surface, this will cause an unexpected influence to

the quality, change the gate location to avoid or improve weld lines if necessary ;

Warpage value is high, Diff Shrinkage are the primary cause of warpage.


Case2 (revised): Mold type: 2 plates, submarine gate, cav1*1, moldbase 3035

Runner system and cooling circuit will be determined by moldflow engineer

Note: change the gate location to avoid or improve weld lines

Original case Revised case

Add a rib here if possible, then place gate on the rib.


Results compare : Fill time


Note:These pictures showed the filling step, the parts will be filled entirety.


AnimationAnimation


Weld lineWeld line

Note:

Weld lines move to corner of the part after gate location had been changed


Pressure distributionPressure distribution

Note :

Pressure is little high than original case.


Pressure Pressure (Animation)(Animation)


Volumetric shrinkage at ejectionVolumetric shrinkage at ejection Sink indexSink index

Note:

Volumetric shrinkage at ejection and Sink index are uniform at mVolumetric shrinkage at ejection and Sink index are uniform at most of the part, but there are larger ost of the part, but there are larger value at two area marked by red arrow, sink mark will get worse.value at two area marked by red arrow, sink mark will get worse.


Deflection, All EffectDeflection, All Effect


Deflection, X component, isolate cause of Deflection, X component, isolate cause of warpagewarpage


Deflection, Y component, isolate cause of Deflection, Y component, isolate cause of warpagewarpage


Deflection, Z component, isolate cause of Deflection, Z component, isolate cause of warpagewarpage


Conclusion And Advice:

END

It is known from the analysis results that:

The part will be full filled easily, and injection machine of 120 tonnage is adequate;

Weld lines has been moved to corner of the part compared to original case, but sink mark

will get worse due to unbalance fill

Maximum injection pressure and maximum clamp force are little high than original case;

There is no more affect on warpage even the gate location had been changed.

Documents

Moldflow Analysis Report - Valuable Mold Flow Analysis …€¦ · · 2011-10-21Moldflow Analysis Report ... To be sure that the design reasonable and injection molding feasible,