Page 1

Moldflow Analysis Report

For

P/Ns 902866 + 902867

Prepared by CEPS Inc. 5-20-2009

Best Gate Location Analysis

The best gate location is in or around the dark blue areas. 902866 902867

Page 2

Gate Location

Page 3

Based on the Best Gate Location results shown on page 2, edge gates feeding the parts centrally were designed in for this analysis.

Molding Windows

This analysis indicates the best molding parameters to use for this part geometry with an ABS type material

Page 4

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

Page 5

Filling Time

Page 6

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

Temperature at Flow Front

Page 7

The maximum variance of the temperature is less than 1C 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.

Air Traps

Page 8
The 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 part line. 3. Create the internal geometry of this area using a core insert that Can be vented.

Welding Lines

THIS 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 REPOSITIONING THE GATE OR GATES.

Page 9

Volumetric Shrinkage

Page 10
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)

Suggest to reduce the internal .030 fillet radii on the core side to reduce wall thicknesses.

The volumetric shrinkage of the parts is evenly distributed which indicates that warpage will be minimized, except the thicker section as indicated on page 8 and in the diagram on the left where Air Traps occur is higher.

Cooling Quality

Page 11

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

Sink Marks For Part # 902866

Page 12

The predicted Sink Marks Estimate results show that the maximum sink will be 0.0395mm which occurs on the under-side of this part where the thick wall section is, due to the 0.030 fillet radii. This further indicates that this fillet radius needs to be reduced. The estimated sink on the seen surface is around 0.02mm where the internal ribs are.

Sink Marks For Part # 902867

Page 13

The predicted Sink Marks estimate for this part shows a maximum of .0343mm, indicated by the red color on the part which occurs in a few spots. The rest of the sink is around .020mm.

Warpage Indicator Results For 902867

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. 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

Page 14

Warpage Indicator Results For 902866

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. 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

Page 15

Conclusion:
1. The parts will fill with uniformity. 2. The cooling quality is excellent.

Page 16

3. The temperature at the flow front variance is less than 1 C indicating that there will be minimal warpage. 4. Air traps can be alleviated with part-line venting, vented core pins and if required a vented core insert for the finger grip area where there is presently two areas of thick wall section. 5. Warpage on both parts is very minimal and can be 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 detrimental in the areas that are critical when the parts are mated together.