Moldflow Reports sampl

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    Confidential Slide 1

    Moldflow Analysis ReportDescription:

    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

    Confidential Slide 2

    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/s

    12.Maximum Shear Stress 0.4 Mpa

    PVT graph Viscosity graph

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    Confidential Slide 3

    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.

    Confidential Slide 4

    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

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    Confidential Slide 5

    Note: Cooling circuits were designed by moldflow engineer ,

    only for reference, and it will be different from actual mold

    Top view Left view

    Confidential Slide 6

    Front viewCooling circuits layout

    Work piece

    Cooling channel

    Φ8

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    Confidential Slide 7

    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 todetermine 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.

    Confidential Slide 8

    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℃ 

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    Confidential Slide 9

    Results explain :

    Fill time

    Confidential Slide 10

    Note:

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

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    Confidential Slide 11

     Ani mati on Ani mati on

    Confidential Slide 12

    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℃ ).

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    Confidential Slide 13

    Weld lineWeld line

    Warning:

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

    Confidential Slide 14

    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 traps Air traps

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    Confidential Slide 15

    Pressure distributionPressure distribution

    Note :

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

    Confidential Slide 16

    PressurePressure (Animation)(Animation)

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    Confidential Slide 17

    Injection pressure graph

    Note:

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

    Confidential Slide 18

    Clamp force

    Note:

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

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    Confidential Slide 19

    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.

    Confidential Slide 20

    Temperature, part

    Note:

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

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    Confidential Slide 21

    Frozen layer fraction

    Note:

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

    animation

    Confidential Slide 22

    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 m ost of the part, but there are largerost 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 p ossibly.ossibly.

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    Confidential Slide 23

    Deflection, All EffectDeflection, All Effect

    Confidential Slide 24

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

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    Confidential Slide 25

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

    Confidential Slide 26

    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

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    Confidential Slide 27

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

    Confidential Slide 28

    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

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    Confidential Slide 29

    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.

    Confidential Slide 30

    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.

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    Confidential Slide 31

    Results compare :

    Fill time

    Confidential Slide 32

    Note:

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

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    Confidential Slide 33

     Ani mati on Ani mati on

    Confidential Slide 34

    Weld lineWeld line

    Note:

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

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    Confidential Slide 35

    Pressure distributionPressure distribution

    Note :

    Pressure is little high than original case.

    Confidential Slide 36

    PressurePressure (Animation)(Animation)

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    Confidential Slide 37

    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 m ost of the part, but there are largerost 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.

    Confidential Slide 38

    Deflection, All EffectDeflection, All Effect

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    Confidential Slide 39

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

    Confidential Slide 40

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

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    Confidential Slide 41

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

    Confidential Slide 42

    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.