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Moldflow Analysis Report

Cool, Flow & Warp Analysis Of The Small Base Part

AG10-07, 07 JULY 2010

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Moldflow Analysis Report


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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Moldflow Analysis Report


Summary
ANALYSIS AIMS
To study the flow and to predict the cycle 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.
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).

CONCLUSION
A 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).
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Moldflow Analysis Report


Material :

PP

Similar Material
Trade Name: Polypropylene PPC 5660
Material Family: PP

Manufacturer : TOTAL Petrochemicals

Recommend processing temperature


Melt : 200C 260C
Characteristics : Amorphous Material
others:
Conductivity : 0.1762 W/m/C (at 230C)
Specific Heat :
2618.6 J/kg/ C (at 230 C)
Melt Density : 0.74577 g/cm^3
Absolute Max Temp : 300 C
Ejection Temperature :
95C
Max Shear Stress :
0.25MPa
Max Shear Rate :
100,000 l/s
Viscosity Plot

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Mold : 20 C 60 C
Viscosity Index : VI(240)0111
Melt mass Flow Rate(MFR)(230C/2.16kg)

7.0g/10min

PVT Plot

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Moldflow Analysis Report


Part thickness
Use different color to show the thickness.

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Moldflow Analysis Report


Part thickness
Use different color to show the thickness.

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Moldflow Analysis Report


Processing Condition & Runner Layout
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

Gate size:
7.8mm

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Moldflow Analysis Report


Filling Pattern
Fig 1

Fig 3

Fig 2

The last filling area

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Fig 4

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Moldflow Analysis Report


Filling Time (Flash)

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Moldflow Analysis Report


Filling Time (Flash)

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Moldflow Analysis Report


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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Moldflow Analysis Report


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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Moldflow Analysis Report


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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Moldflow Analysis Report

Air traps
The air traps (pink marks ) location are as show.

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Moldflow Analysis Report


Cooling Channels : Temperature Rise
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.

Cavity cooling

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Moldflow Analysis Report


Cooling Channels : Temperature Rise
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.

Core cooling

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Moldflow Analysis Report


Cooling Channels : Temperature Rise
Slider cooling

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Moldflow Analysis Report

Mould Surface Temperature


Total Cycle time: 105 sec.
( Auto Injection + Packing + Cooling Times = 100 sec. Mold open time = 5 sec.)
Core side
Cavity side

Hot spot

Slider
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Slider
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Moldflow Analysis Report


Warpage in X direction

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Moldflow Analysis Report


Warpage in Y direction

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Moldflow Analysis Report


Warpage in Z direction

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Moldflow Analysis Report


Warpage in Z direction
Z direction

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Moldflow Analysis Report

The conclusions

1) This product was analyzed by using Moldflow software. The


directions of the shrinkage is due to structure of the product.

2)Theres 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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Moldflow Analysis Report

The End

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