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Cool, Flow & Warp Analysis Of The Small Base P art. Contents. Summary. ANALYSIS AIMS To study the flow and to predict the cy cle time of the A1309-2 part. ANALYSIS APPROACH The cavity and the cold runner sections are modeled. A Fusion Cool + Flow + Warp analysis was conducted. - PowerPoint PPT Presentation
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Moldflow Analysis Report
Page 1AG10-07, 07 JULY 2010
Cool, Flow & Warp Analysis Of The Small Base Part
Moldflow Analysis Report
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Contents
1. Summary 03
2. Material Properties 04
3. Part thickness 05 -06
4. Processing Condition & Runner Layout 07
5. Results 08 - 23
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ANALYSIS AIMSTo study the flow and to predict the cycle time of the A1309-2 part.
ANALYSIS APPROACHThe cavity and the cold runner sections are modeled.A Fusion Cool + Flow + Warp analysis was conducted.The specified material is PP (grade is specified BP RPP 2009 GK BLK, which is not listed in the moldflow database, so we used Polypropylene PPC 5660 from TOTAL Petrochemicals) to run the analysis .This may effect the actual values obtained in the analysis (e.g. shrinkage values, pressure requirements), but it can still be used to observe the general trends in the results (e.g. filling pattern, warpage shape etc).
CONCLUSIONA pressure drop of 15MPa is expected across the system which indicates this material can easily fill this part.The overall melt front temperature drop is 1.2 C across the part, which is acceptable.The weld lines might be visible to the eye due to zero degrees of two melts. The part is expected to have warpage in X,Y,Z direction. Please refer to the data of the particular warpage on page 19 to 22.
The hot spots in the slider side are due to the placement of the cooling channel. These areas need cooling circuit or beryllium insert added to them if possible (refer to page 18).
Summary
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Similar Material
Trade Name: Polypropylene PPC 5660 Manufacturer : TOTAL Petrochemicals
Material Family: PP
Recommend processing temperatureMelt : 200C – 260C Mold : 20 C – 60 CCharacteristics : Amorphous Material Viscosity Index : VI(240)0111others: Melt mass –Flow Rate(MFR)(230C/2.16kg) 7.0g/10minConductivity : 0.1762 W/m/C (at 230C)Specific Heat : 2618.6 J/kg/ C (at 230 C)Melt Density : 0.74577 g/cm^3Absolute Max Temp : 300 CEjection Temperature : 95C Max Shear Stress : 0.25MPaMax Shear Rate : 100,000 l/s
Material : PP
PVT PlotViscosity Plot
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Part thickness
Use different color to show the thickness.
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Part thickness
Use different color to show the thickness.
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Processing Condition & Runner Layout
Gate size:
Ф7.8mm
The Processing Conditions used was as follows:
Filling Time : Auto, 4.6 sec.
Mold Temperature : 40 C
Melt Temperature : 230 C
Velocity/Pressure switchover at 98.5% volume fill
Packing Pressure : 80% of Max Injection Pressure
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Filling Pattern
Fig 3
Fig 1
Fig 4
Fig 2
The last filling area
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Filling Time (Flash)
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Filling Time (Flash)
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Pressure drop
A pressure drop of 15MPa is expected across the system, this indicated that the material is easy to fill this part.
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Temperature at flow front
The plastics material enters the runners at 230 C. The overall temperature drop is about 1.2C, which is acceptable.
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Weld Lines
The weld lines (color curve) might be visible to the eye, due to the zero degrees of the two melts.
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Air traps
The air traps (pink marks ) location are as show.
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Cavity cooling
The coolant is specified as water at 25 C, and with turbulent flow in each channels (Reynold Number = 10,000). The outlet temperature of each channels exceeds 0.66C, this indicates the cooling channels are efficient.
Cooling Channels : Temperature Rise
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Core cooling
The coolant is specified as water at 25 C, and with turbulent flow in each channels (Reynold Number = 10,000). The outlet temperature of each channels exceeds 0.8C, this indicates the cooling channels are efficient.
Cooling Channels : Temperature Rise
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Cooling Channels : Temperature Rise
Slider cooling
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Cavity side
Mould Surface TemperatureTotal Cycle time: 105 sec. ( Auto Injection + Packing + Cooling Times = 100 sec. Mold open time = 5 sec.)
Hot spot
Core side
Slider Slider
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Warpage in X direction
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Warpage in Y direction
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Warpage in Z direction
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Warpage in Z direction
Z direction
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• The conclusions
• 1) This product was analyzed by using Moldflow software. The directions of the shrinkage is due to structure of the product.
• 2)There’s not enough cooling of the slide and core. Suggestions: to improve this, use the Heat Pipes on the slide area instead and increase water cooling system on the core area, But these are just some minor adjustments, the deformation will still be prominent.
• 3) The large base mold has the same problems.
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The End
