Moldflow Analysis Report              Part name :BASE & COVERObjective : Moldflow Analysis of ‘ BASE & COVER’ with 1+1 too...
Who                    We                    Arewww.polysmart.com
Project Details Product                    : BASE & COVER Material                   : PA6 – 20% Glass-filled. Grade      ...
Feed System DetailsCOVER                        BASE               Hot sprue details                                      ...
Feed System Details                      BASE    COVER
Material Details                                                    Shear Rate Vs ViscosityShear rate plot shows that when...
Zone PlotComments: The Zone plot gives us the idea of preliminary process-setting &then further it is optimized.
Process Parameters              Packing Profile
Flow Analysis Results
Fill Time PlotComments: Part is filling completely in 2.42s & with flow rate of 46CC/s.Minorimbalance is observed in the f...
Fill Time Interval Plot       Fill @ 25%                         Fill @ 50%                    Plot Shows the             ...
Pressure At Injection Location                    80.3Mpa                                           72MpaComments:Comments...
Frozen Layer FractionComments: The plot shows the frozen layer fraction for the component, thecomponent gets completely fr...
Temperature At Flow FrontDuring Cavity FillingComments: This plot shows temperature flow front for the component. Rise int...
Fiber Orientation PlotComments: The plot shows the movement of fibers during the injection moldingprocess, averaged over t...
Volumetric Shrinkage AtEjectionComments : The Plot shows the volumetric shrinkage across the component.Higher values are o...
Shear RateComments : The max shear rate value observed is 86591 1/s which is withinthe recommended limit of which is speci...
Clamp Tonnage Plot Comments : Maximum clamp tonnage required is 224 tonnes based on thecalculations done by Moldflow.
Air Trap PlotComments : The observed air-trap can be vented out by providing air-vents in themold. If proper venting is no...
Weldline PlotComments : The temperature when weldline were formed is high (263.7°C),hence the weld strength will be good &...
Sink Marks PlotComments : Max sink marks depth observed is 0.04mm.As per the guidelines,for the normal surfaces the max li...
Cooling Analysis Results
Cooling Circuit EfficiencyPlot                                                        Circuit Coolant    Circuit heat     ...
Coolant Flow Rate &Reynolds Number.       Coolant Flow-Rate.                         Circuit Reynolds Number.Comments : Th...
Average Temperature Part.Comments : The Plot shows the average temperature of the part at the end ofthe cooling time. High...
Temperature Maximum Part.Comments : The plot shows the maximum temperature in the part at the endof the cooling time. The ...
Warpage Analysis Results
Deflection in X-Direction                                                         Component Shrinking                     ...
Deflection in Y-Direction              Component Shrinking              downwards                                         ...
Deflection in Z-Direction                                                                  Component Warping              ...
Recommended ProcessingParameters.Injection Time: - 2s                                       Case1                  Case2 (...
Conclusion  Component gets filled completely with no flow related problem except minor flowimbalance, but that can be negl...
POLYSMART TECHNOLOGIES PVT LTD                              LTD.94,Bombay Talkies Compound,                       Shreenat...
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Sample Moldflow Analysis Report For Automotive Part

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Sample Moldflow Analysis Report For Automotive Part.

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Sample Moldflow Analysis Report For Automotive Part

  1. 1. Moldflow Analysis Report Part name :BASE & COVERObjective : Moldflow Analysis of ‘ BASE & COVER’ with 1+1 tool layout. Toidentify the optimized process-parameters & to list down the findings bydoing Cool+Fill+Pack+Warp Analysis.
  2. 2. Who We Arewww.polysmart.com
  3. 3. Project Details Product : BASE & COVER Material : PA6 – 20% Glass-filled. Grade : Akulon K222-KGV4(DSM) Processing Conditions : Mold temperature – 80O C Melt temperature – 262O C Injection time – 2s Objective : Moldflow Analysis of ‘BASE & COVER with 1+1 tool layout. To BASE COVER’ layout identify the optimized process-parameters & to list down the findings by doing Cool+Fill+Pack+Warp Analysis.
  4. 4. Feed System DetailsCOVER BASE Hot sprue details Dia: - 10mm Height - 60mmRunner detailsTop Width: – 6.0mm Runner detailsBottom Width: - 4.0mm Top Width: – 5.0mmHeight: - 4 5mm 4.5mm Bottom Width: - 3.5mm Height: - 4.0mm Edge Gate details Width: - 5.0mm Depth: - 1.5mm
  5. 5. Feed System Details BASE COVER
  6. 6. Material Details Shear Rate Vs ViscosityShear rate plot shows that when the shear rate isincreased, the material flows easily. Increasingshear rate by gate dimensions and injection ratecan help material to flow easily.PVT graph indicates that below 215° C melttemperature, packing pressure would not havemuch impact on shrinkage. PVT
  7. 7. Zone PlotComments: The Zone plot gives us the idea of preliminary process-setting &then further it is optimized.
  8. 8. Process Parameters Packing Profile
  9. 9. Flow Analysis Results
  10. 10. Fill Time PlotComments: Part is filling completely in 2.42s & with flow rate of 46CC/s.Minorimbalance is observed in the filling which can be neglected as it is not affecting thequality of the component. Overall Contour plot shows uniform spacing between thecontour lines (95% of the component) which indicates that there is no flow relatedproblem occurring during filling of the component.
  11. 11. Fill Time Interval Plot Fill @ 25% Fill @ 50% Plot Shows the Filling of the component at Fill @ 100% Fill @ 75% various intervals intervals.
  12. 12. Pressure At Injection Location 80.3Mpa 72MpaComments:Comments This plot shows pressure at injection location Packing press re sho s press re location. pressuregiven is initially 90% of filling pressure for 8s & then in 1s it decays to zero.Total packing given in 8+1=9s
  13. 13. Frozen Layer FractionComments: The plot shows the frozen layer fraction for the component, thecomponent gets completely frozen in 20s.
  14. 14. Temperature At Flow FrontDuring Cavity FillingComments: This plot shows temperature flow front for the component. Rise intemperature observed is up to 2o C due to shear heating & drop in temperatureis observed is up to 15o C (Melt temperature is 262oC).Therefore the flow fronttemperature range is within the acceptable limit.
  15. 15. Fiber Orientation PlotComments: The plot shows the movement of fibers during the injection moldingprocess, averaged over the thickness.
  16. 16. Volumetric Shrinkage AtEjectionComments : The Plot shows the volumetric shrinkage across the component.Higher values are observed in the thick walled areas marked in the plot. Thevolumetric shrinkage ranges in between 1.4% to 7.9%.*Volumetric shrinkage and the linear shrinkage are different.
  17. 17. Shear RateComments : The max shear rate value observed is 86591 1/s which is withinthe recommended limit of which is specified by Material Manufacturer.
  18. 18. Clamp Tonnage Plot Comments : Maximum clamp tonnage required is 224 tonnes based on thecalculations done by Moldflow.
  19. 19. Air Trap PlotComments : The observed air-trap can be vented out by providing air-vents in themold. If proper venting is not provided at end of fill areas then it may lead to short shot orburn marks on the component.
  20. 20. Weldline PlotComments : The temperature when weldline were formed is high (263.7°C),hence the weld strength will be good & area near the weldline will bestructurally strong.
  21. 21. Sink Marks PlotComments : Max sink marks depth observed is 0.04mm.As per the guidelines,for the normal surfaces the max limit is 0.04mm,if it exceeds therecommended limit then it will leave a visible mark onto the surface. In thiscase the values are just within the acceptable limit.
  22. 22. Cooling Analysis Results
  23. 23. Cooling Circuit EfficiencyPlot Circuit Coolant Circuit heat Temperature. removal Efficiency.Comments : The plot shows the cooling circuit efficiency.
  24. 24. Coolant Flow Rate &Reynolds Number. Coolant Flow-Rate. Circuit Reynolds Number.Comments : The plot shows the circuit flow rate & reynolds number.
  25. 25. Average Temperature Part.Comments : The Plot shows the average temperature of the part at the end ofthe cooling time. Higher values are observed in the thick walled areas whichare marked in the plot.
  26. 26. Temperature Maximum Part.Comments : The plot shows the maximum temperature in the part at the endof the cooling time. The max temperature observed is 180°C which is justwithin the limit of Ejection temperature.
  27. 27. Warpage Analysis Results
  28. 28. Deflection in X-Direction Component Shrinking inward. Deflection pattern is scaled 5 times to understand the shape of the component after deflection.Comments : Shrinkage observed in X- direction is (+0.73mm, -0.56mm).Theobserved shrinkage value is 0.96%. While setting the mould dimensions it is g gessential to note the shrinkage in that area. Please note that the calculated deflection value may not be the same as actual conditions. However, warpage results can be used to understand the deflection pattern of the component.
  29. 29. Deflection in Y-Direction Component Shrinking downwards Deflection pattern is scaled 5 times to understand the shape of the component after deflection. deflection Component Sh i ki C t Shrinking upwardsComments : Shrinkage observed in Y- direction is (+1.62mm, -1.74mm). The observedshrinkage value i 0 95% hi k l is 0.95%. Please note that the calculated deflection value may not be the same as actual conditions. However, warpage results can be used to understand the deflection pattern of the component.
  30. 30. Deflection in Z-Direction Component Warping Upward Component Warping Downward Component Warping Upward Deflection pattern is scaled 5 times to understand the shape of the component after deflection.Comments : Deflection observed in Z- direction is (+1.27mm, -0.74mm). Please note that the calculated deflection value may not be the same as actual conditions. However, warpage results can be used to understand the deflection pattern of the component.
  31. 31. Recommended ProcessingParameters.Injection Time: - 2s Case1 Case2 (Optimized) Mold Temp 80°C Mold Temp 80°CMelt Temperature: - 262°C 262 C Melt Temp 260°C Melt Temp 262°CMold Temperature: - 80°C V/P Switchover V/P SwitchoverPacking Profile:P ki P fil - 97% of Filling 96% of Filling Packing Pressure Packing Pressure 90% of Filling 90% of Filling Pressure. Pressure. Clamp Force 266T Clamp Force 224T Disclaimer: The analysis has been carried out as per the material database available in Moldflow. If the viscosity of the material differs than what is considered in database, the results would vary. i it f th t i l diff th h ti id di d t b th lt ld Polysmart accepts no responsibility for the results obtained on shop floor. The process conditions are simulated and the results obtained are reproduced in the report. ******************************************************************************
  32. 32. Conclusion Component gets filled completely with no flow related problem except minor flowimbalance, but that can be neglected as it is not affecting the quality of component. Weldlines in the component are formed at higher temperature (i e near to melt (i.e.temperature). This indicates that the area near weldlines will be structurally strong. In the sinkmark plot the max sink mark depth observed is around 0.04mm whichis just within the recommended limit limit. Mold temperature & Melt temperature needs to be precisely control, to controlsink marks. It is recommended t give sufficient draft for proper ejection of the component & i d d to i ffi i t d ft f j ti f th tto prevent the component sticking into the cavity. It recommended to give air-vents at the end of fill areas to prevent short shot orburn mark on th component.b k the t It is recommended, that if warpage in the molded component observed is highafter molding then finally it is recommended to use cooling fixture to controlwarpage.warpage
  33. 33. POLYSMART TECHNOLOGIES PVT LTD LTD.94,Bombay Talkies Compound, Shreenath Chambers, 3rd Floor,Malad (West) B-66 & 67, Gyaneshwar Paduka Chowk,Mumbai:- 400064 Ferguson College Road,India. Pune: - 411005.Tel:- +91-22-28824448, e 9 88 8, Tel: - +91-020-25520311 / 312 +91 020 25520311 312. +91-22-28823241,91-22-28813508.Fax:- +91-22-28820629Website:-W b it www.polysmart.com l t Disclaimer: The analysis has been carried out as per the material database available in Moldflow. If the viscosity of the material differs than what is considered in database, the results would vary. Polysmart accepts no responsibility for the results obtained on shop floor. The process conditions are simulated and the results obtained are reproduced in the report. ******************************************************************************

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