Plastic Omnium Tank

shell
Udaybhan Rana | June 17, 2016
Contents
• Warpage in upper tank
• Warpage in lower tank
• Warpage mismatch analysis
• CPCL
• Root Cause Analysis
• Recommendations
• Conclusion

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 Warpage in Upper Tank

Dimensional reading are taken from white light scan test. In above graphs
mean is the average of the offset of each point from the nominal 3-D.
Microsoft Office
Similarly, maximum and minimum are the maximum and minimum offset Excel 97-2003 Worksheet
respectively..
For details, please see the embedded document.

3
Warpage in Lower Tank

Plastic Omnium is requested to make decision to provide the tolerance

Lower tank
concession. 97-2003 Worksheet
For details, please see the embedded document.
4
 Warpage mismatch analysis

• The corresponding dimensions of upper and lower tank that have mismatch in warpage
will be difficult to fit/align together.
• The points (PT, WS, PRF) that have mismatch have been discussed in the further slides.

PT Points:

Upper Tank

Lower Tank

 PT points are measured approximately on corresponding locations

on lower and upper tank.
 The points highlighted in the drawings have mismatch in warpage.
 The maximum mismatch in warpage of PT is approximately
8 units. 5
WS Points
4
3
2
1
0
Lower tank warp
Dev-13D
-2 Upper tank warp
-3
-4
-5
-6

 WS points are
approximately on
corresponding
locations on lower
and upper tank.

 Warpage of both the

tanks are plotted in
the above graph.

 By observing the
graph we see the
mismatch at the
locations shown in
the adjacent table.

 The maximum
mismatch in
warpage of WS is
approximately 5
mms (as 6
6
highlighted in
PRF Points
10
8
6
4
2 Upper tank warp
0 Lower tank warp
-2
-4
-6
-8

 PRF points are

approximately on
corresponding
locations on lower
and upper tank.

 Warpage of both the

tanks are plotted in
the above graph.

 By observing the
graph we see the
mismatch at the
locations shown in
the adjacent table.

 The maximum
mismatch in
warpage of PRF
is approximately
7
9 mm (as 7
CPCL
• The dimensions for the tank have been checked for 30 random samples. The
inspection is done according to attached balloon drawings.

• Conclusion of the inspection:

i. Upper Tank: 14 dimensions out of 38 inspected dimensions were good for Adobe Acrobat Microsoft Office
DocumentExcel 97-2003 Worksheet

all samples. The dimensions are highlighted in green.

ii. Lower Tank: 5dimensions out of 31 inspected dimensions were good for all Lower Microsoft Office

samples. The dimensions are highlighted in green. Excel 97-2003 Worksheet

•. The inspected readings are recorded in the attached file. The readings
highlighted in red color are out of customer specification limits. Please review
the attached file.

8
 Root Cause Analysis
MACHINE

Improper expansion Poor gate design

factor in tool for
approved material
Poor mold design

Plastic omnium
tank shell
Improper thermal warpage
expansion material
molded in High melt temp Low injection
approved mold velocity
High mold temp
Low Hold time
Material is not
compatible Low Pack pressure
with injection
molding
Uneven cooling
process
MATERIAL METHOD

9
Recommendations
• Material should be changed, present material is compatible with
blow molding.
• We should look for water circuit design around the mold.
• Better coolant should be used.
• Uniform cooling should be maintained around the mold.
• Ensure temperature in both mold halves is equal.
• Increase cooling time , injection hold time.
• Monitor part ejection from mold, relocate ejector pins if needed.
• Part design problem, rib should be as shown. This helps in
reducing stresses.

• Not allowing the part to cool on the fixture long enough.

• Thermal expansion of tool and molded material should be
checked.

10
10
Conclusion

• The corresponding locations of upper and lower tank having

mismatch in warpage can not be fit together properly. Therefore,
QMI will work according to the recommendations to eliminate the
mismatch.

• Similarly, the corresponding locations of upper and lower tank

having equal warpage can be fit together properly. Therefore,
plastic omnium is requested to provide tolerance concession on
those locations.

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Thank you.

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