Moldflow Analysis ReportFor

P/Ns 902866 + 902867P/Ns 902866 + 902867

Prepared by CEPS Inc.

5-20-2009

Page 1

Best Gate Location AnalysisBest Gate Location AnalysisThe best gate location is in or around the dark The best gate location is in or around the dark The best gate location is in or around the dark The best gate location is in or around the dark blue areas.

902867902866

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Gate Location Based on the Best Gate Location results shown on page 2, edge gates feeding the parts

centrally were designed in for this analysis.

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Molding Windows This analysis indicates the best molding parameters to

use for this part geometry with an ABS type material

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Process Settings Material : ABS

Filling time = 0.92 sec

Melt temperature = 217

Mold temperature cavity and core side = 25

Filling / packing switch volume = 99 %

Packing time = 4s

Cycle time = 20s

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Filling Time Filling Time

This analysis predicts that it will take This analysis predicts that it will take This analysis predicts that it will take This analysis predicts that it will take approximately 0.9 approximately 0.9 approximately 0.9 approximately 0.9 secssecssecssecs to fill the parts. to fill the parts. to fill the parts. to fill the parts. The colors indicate we have even flow The colors indicate we have even flow The colors indicate we have even flow The colors indicate we have even flow throughout both parts.throughout both parts.throughout both parts.throughout both parts.

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Temperature at Flow Front Temperature at Flow Front Temperature at Flow Front Temperature at Flow Front Temperature at Flow Front Temperature at Flow Front Temperature at Flow Front Temperature at Flow Front

The maximum variance of the

temperature is less than 1°C which means that we have good filling throughout the part. Any weld lines formed will be of good quality and should not be a detriment to the functional

integrity of the part.

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Air TrapsAir TrapsAir TrapsAir TrapsAir TrapsAir TrapsAir TrapsAir TrapsThe Air Traps, indicated by pink circles, are prominent around the Finger Indent areas. This is due to the thicker wall section at the intersections. To avoid these Air Traps we can do a number of things;

1. Decrease the internal fillet radii from 0.030” to 0.005”

2. Add venting at the partline.

3. Create the internalgeometry of this area using a core insert thatCan be vented.

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Welding LinesWelding LinesWelding LinesWelding LinesWelding LinesWelding LinesWelding LinesWelding LinesTHIS ANALYSIS INDICATES WHERE WE CAN EXPECT TO SEE WELD LINES AND GIVES THE DESIGNER AN INSIGHT AS TO WHERE POTENTIAL FRACTURES COULD OCCUR IF HEAVY LOADS WERE APPLIED. THE POSITION OF WELD LINES CAN BE SHIFTED BY RE-POSITIONING THE GATE OR GATES.

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Volumetric ShrinkageVolumetric ShrinkageVolumetric ShrinkageVolumetric ShrinkageVolumetric ShrinkageVolumetric ShrinkageVolumetric ShrinkageVolumetric Shrinkage

The volumetric shrinkage of the parts is evenly The volumetric shrinkage of the parts is evenly The volumetric shrinkage of the parts is evenly The volumetric shrinkage of the parts is evenly distributed which indicates that distributed which indicates that distributed which indicates that distributed which indicates that warpagewarpagewarpagewarpage will be will be will be will be minimized, except the thicker section as indicated on minimized, except the thicker section as indicated on minimized, except the thicker section as indicated on minimized, except the thicker section as indicated on page 8 and in the diagram on the left where Air Traps page 8 and in the diagram on the left where Air Traps page 8 and in the diagram on the left where Air Traps page 8 and in the diagram on the left where Air Traps occur is higher.occur is higher.occur is higher.occur is higher.Suggest to reduce the internal .030” fillet radii on

the core side to reduce wall thicknesses.

On the underside of these parts, the shrinkage of the long rib, indicated in dark blue, is different from the wall. This indicates that some warpage could occur. (See page 12)

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� Cooling Quality

When designing into the analysis the proposed water circuits for cooling these parts, we can see that the cooling quality is 100%.

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Sink Marks For Part # 902866

The predicted Sink Marks Estimate results show that the maximum The predicted Sink Marks Estimate results show that the maximum sink will be 0.0395mm which sink will be 0.0395mm which

occurs on the underoccurs on the under--side of this part where the thick wall section is, due to the 0.side of this part where the thick wall section is, due to the 0.030030”” fillet radii.fillet radii.

This further indicates that this fillet radius needs to be reducThis further indicates that this fillet radius needs to be reduced. The estimated sink on the seen ed. The estimated sink on the seen

surface is around 0.02mm where the internal ribs are.surface is around 0.02mm where the internal ribs are.

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Sink Marks For Part # 902867Sink Marks For Part # 902867

The predicted Sink Marks estimate for this part shows a maximum The predicted Sink Marks estimate for this part shows a maximum of .0343mm, indicated by the of .0343mm, indicated by the

red color on the part which occurs in a few spots. The rest of tred color on the part which occurs in a few spots. The rest of the sink is around .020mm. he sink is around .020mm.

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WarpageWarpageWarpageWarpageWarpageWarpageWarpageWarpage Indicator Results ForIndicator Results ForIndicator Results ForIndicator Results ForIndicator Results ForIndicator Results ForIndicator Results ForIndicator Results For 902867902867902867902867902867902867902867902867

The “Warpage Indicator, All Effects” results are defined below:

Green color area (97.5%) is <0.15mm; yellow color area(2.5%) = 0.15mm; red color area is >0.15mm

The results above, indicate where we would expect to see warpage and the percentage. As we can

see, differential shrinkage is the cause of the warpage. The area in red is where the long rib on

the underside was indicating a difference in volumetric shrinkage, as shown on page 10.

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WarpageWarpageWarpageWarpageWarpageWarpageWarpageWarpage Indicator Results For 902866Indicator Results For 902866Indicator Results For 902866Indicator Results For 902866Indicator Results For 902866Indicator Results For 902866Indicator Results For 902866Indicator Results For 902866

The “Warpage Indicator, All Effects” results are defined below;

Green color area(96.1%) <0.08mm; yellow color area(3.69%) = 0. 08mm; red color area(0.0%) >0.08mm

The results above for part #902866 indicate that the small amount of warpage (3.69%) that occurs is again

due to differential shrinkage. This is caused by the thick wall sections around the finger grip area as

indicated on page 8. Reducing the .030” fillet radii to .005” will improve this.

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Conclusion:

1. The parts will fill with uniformity.

2. The cooling quality is excellent.

3. The temperature at the flow front variance is les s than 1º C indicating that there will be minimal warpage.

4. Air traps can be alleviated with part-line ventin g, vented core pins and if required a vented core insert for the finger gri p area where there is presently two areas of thick wall section.

5. Warpage on both parts is very minimal and can b e improved if not eliminated on part #902866 if the .030” fillet radii is reduced to .005”thinning the wall section in those areas.

6. The warpage is not significant enough to be detr imental in the areas that are critical when the parts are mated together .

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