Sample Moldflow Report

1. Moldflow Report
BTI Logo
Performed by: Beaumont Technologies
Requested by: Customer

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• To analyze the BTI Logo part in order to determine an optimal gate location.
• To thoroughly evaluate the filling progression in an attempt to discover any potential molding
concerns.
• To detail warpage based upon cooling line placement, volumetric shrinkage, and fiber
orientation effects.
Objective

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The following parameters were used to run the analysis:
Material: Zytel PLS90G30DR BK099: PA66, DuPont Performance Polymers [30% Glass Fiber Filled]
Melt Temperature = 554°F
Water Temperature = 190°F
Injection time = 1.5 - 2.0 seconds based on DOE study
V/P Switchover = 98% Full Part
Pack Profile = 8,000 psi until gate seal
Process Set-up for Analysis

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Dimensional Diagnostics
Part wall thickness = 0.080” – 0.160”

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Material Information

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Gate Locations
Iteration 1- Center Gate
Iteration 2- End Gate

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Analysis Set-Up – Iteration 1 (Center Gate)
Tab Gate:
0.130” X 0.065”
Sprue:
Inlet = Ø 0.156”
Standard 1.2° Taper
Length = 2.5”
Ø 0.156”

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Analysis Set-Up – Iteration 2 (End Gate)
Tab Gate:
0.130” X 0.065”
Sprue:
Inlet = Ø 0.156”
Standard 1.2° Taper
Length = 2.5”
Ø 0.156”
Ø 0.156”

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Injection Time- DOE Results, Center Gate
A DOE study was run to evaluate the effect of injection time on pressure and flow front temperature distribution. This gives
an indication of the overall processing window and preferred fill time.

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Injection Time- DOE Results, End Gate
A DOE study was run to evaluate the effect of injection time on pressure and flow front temperature distribution. This gives
an indication of the overall processing window and preferred fill time.

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Injection Time DOE – Comparison Results
Iteration 1
Iteration 2

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Fill Time
Activate “Slide Show” (F5) to
view animation
The mold was filled using an injection time of 1.5 – 2.0 seconds. The black lines represent the location of the weld lines.
Iteration 1
Iteration 2

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Filling Progression
The Fill time result shows the position of the flow front at regular intervals as the cavity fills. The result is dark blue at the
start of the injection, and the last areas to fill are red.
Iteration 1
Iteration 2

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Filling Progression
Air Trap
Slight hesitation
through thin regions
Iteration 1
Iteration 2

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Filling Progression
Slight hesitation
through thin regions
Weld Line
Iteration 1
Iteration 2

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Filling Progression
Slight hesitation
through thin regions
Iteration 1
Iteration 2

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Filling Progression
Slight hesitation
through thin regions
Weld Line
Iteration 1
Iteration 2
Air Trap

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Filling Progression
Slight hesitation
through thin regions
Weld Line
Weld Line
Slight race tracking
effect due to thicker
rim geometry
Iteration 1
Iteration 2

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Filling Progression
Slight hesitation
through thin regions
Weld Line
Slight race tracking
effect due to thicker
rim geometry
Iteration 1
Iteration 2

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Filling Progression
Slight hesitation
through thin regions
Weld Line
Air Trap
Weld Line
Air Trap
Air Trap
Iteration 1
Iteration 2

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Filling Progression
Slight hesitation
through thin regions
Air Trap
Weld Line Weld Line
Hesitation
Iteration 1
Iteration 2

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Filling Progression
Slight hesitation
through thin regions
Weld Line Weld Line
Weld Line
Hesitation
Iteration 1
Iteration 2

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Filling Progression
Slight hesitation
through thin regions
Weld Line Weld Line
Weld Line/ Air Trap
Hesitation
Iteration 1
Iteration 2

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Filling Progression
Slight hesitation
through thin regions
Weld Line Weld Line
Slight race tracking
effect due to thicker
rim geometry
Iteration 1
Iteration 2

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Filling Progression
Weld Lines/ Air Traps
Slight race tracking effect due
to thicker rim geometry
Weld Line/ Air Trap
Iteration 1
Iteration 2

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Filling Progression
End of Fill
Weld Line
End of Fill
Weld Line
Air Trap
98% Full V/P
Switchover
Iteration 1
Iteration 2
Slight race tracking effect due
to thicker rim geometry

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Filling Progression
This plot shows the filling progression in contours. The contours are evenly spaced and indicate the speed at which the
polymer is flowing. Widely-spaced contours indicate rapid flow (race tracking), narrow contours indicate hesitation.
Iteration 1 shows a higher degree of hesitation throughout the part compared to Iteration 2.
Flow HesitationFlow Hesitation
Iteration 1
Iteration 2

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Potential Gas Traps
This plot shows the potential location of gas traps. These areas should be investigated to determine adequate venting.
Iteration 1
Iteration 2

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Temperature at Flow Front
Melt Temperature = 554°F
Delta T= 9.6°F
The plot below shows the temperature of the polymer at the flow front. Large changes may indicate that the material is
either shear heating or cooling excessively (areas of hesitation). Optimal injection times will results in smaller variations.
Delta T= 26.1°F
Iteration 1
Iteration 2

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Pressure at V/P Switchover
This plot shows the predicted pressure at V/P switchover (98% full parts). The pressure shown does not include pressure
losses through the machine nozzle and screw conveyance losses. Studies have shown pressure losses of around 4,000 psi
would be typical.
Moldflow Pressure = 7,151 psi
Estimated +4,000 psi for machine
and nozzle losses = 11,151 psi
Moldflow Pressure = 15,115 psi
Estimated +4,000 psi for machine
and nozzle losses = 19,115 psi
Iteration 1 Iteration 2

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Weld Line Temperature Formation
Weld lines will form where flow fronts converge during filling. Weld lines forming at higher temperatures and pressures will
have increased integrity. The plot below indicates the predicted location of potential weld lines and the corresponding
temperature at which they form.
Placing a vent in the areas of the weld line will
also help remove potential air traps.
Iteration 1
Iteration 2
Melt Temperature = 554°F

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Weld Line Pressure Formation
Weld lines will form where flow fronts converge during filling. Weld lines forming at higher temperatures and pressures will
have increased integrity. The plot below indicates the predicted location of potential weld lines and the corresponding
pressure at which they form.
The quality of a weld line can be improved by
increasing melt temperature, injection speed or
packing pressure.
Iteration 1
Iteration 2

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Shear Rate Maximum
The maximum shear rate
through the gate is ~7,226 1/s
The shear rate is a measure of how quickly the layers of plastic are sliding past each other. If this happens too fast, the
polymer chains may break and the material degrades. The maximum shear rate limit for this particular grade is 60,000 1/s.
Iteration 1 Iteration 2
The maximum shear rate
through the gate is ~10,602 1/s

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Pressure at Injection Location
The pressure at injection location plot shows the pressure development at the injection location over time.
Iteration 1 Iteration 2
System Pressure = 7,151 psi
Cold Runner = 3,138 psi
Part Pressure = 4,013 psi
System Pressure = 15,115 psi
Cold Runner = 9,326 psi
Part Pressure = 5,789 psi

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Clamp Force: XY Plot
This plot shows the maximum clamp tonnage to mold this part. Note: The max clamp tonnage is during the packing phase.
(Pack pressure = 8,000 psi)
Clamp Force:
Filling- 5.3 Tons
Packing- 25.6 Tons
Iteration 1 Iteration 2
Clamp Force:
Filling- 13.1 Tons
Packing- 25.7 Tons

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Temperature
This plot shows the material scaled to the specific transition temperature (438.8°F). The simulation uses this temperature
to define when the material transitions from a molten state to a frozen state. The material in green is at or above the
transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray).
The plot shows the part at ~2.16 seconds. The filling phase has
ended. Note: Portions of the part have already begun to freeze off.
The plot shows the part at ~1.58 seconds. The filling phase has
ended. Note: Portions of the part have already begun to freeze off.
Iteration 1
Iteration 2

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Temperature
This plot shows the material scaled to the specific transition temperature (438.8°F). The simulation uses this temperature
to define when the material transitions from a molten state to a frozen state. The material in green is at or above the
transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray).
The plot shows the part at ~4.5 seconds. The thin
walls and nominal walls have begun to freeze.
The plot shows the part at ~3.8 seconds. The thin
walls and nominal walls have begun to freeze.
Iteration 1
Iteration 2

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Temperature
This plot shows the material scaled to the specific transition temperature (438.8°F). The simulation uses this temperature
to define when the material transitions from a molten state to a frozen state. The material in green is at or above the
transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray).
The plot shows the part at ~6.4 seconds. The gate has just frozen off from the part.
The thicker regions remain above the transition temperature and will continue to
freeze without compensational pack. Sinks or voids maybe present in these regions.
The plot shows the part at ~5.6 seconds. The nominal walls have frozen off at this point in time. The
thicker outer rim geometry is still molten and the gate is providing compensational pack to this region.
Iteration 1
Iteration 2

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Temperature
This plot shows the material scaled to the specific transition temperature (438.8°F). The simulation uses this temperature
to define when the material transitions from a molten state to a frozen state. The material in green is at or above the
transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray).
The plot shows the part at ~8.3 seconds. The thicker regions are still above the
transition temperature and will continue to freeze without compensational pack
The plot shows the part at ~8.4 seconds. The gate is frozen off from the part. The thicker regions are
still above the transition temperature and will continue to freeze without compensational pack
Iteration 1
Iteration 2

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Temperature
This plot shows the material scaled to the specific transition temperature (438.8°F). The simulation uses this temperature
to define when the material transitions from a molten state to a frozen state. The material in green is at or above the
transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray).
The plot shows the part at ~18.0 seconds. The part and runner system are
completely solidified at the point in time. The cycle has ended.
Iteration 1
Iteration 2

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Average Volumetric Shrinkage
Gate
Gate
Iteration 1
Iteration 2
High shrinkage values could indicate sink marks or voids inside the part. Volumetric shrinkage should be uniform across the
whole part to reduce warpage.

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Average Volumetric Shrinkage
Gate
Gate
Iteration 1
Iteration 2
High shrinkage values could indicate sink marks or voids inside the part. Volumetric shrinkage should be uniform across the
whole part to reduce warpage.

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Sink Marks Estimate
The Sink marks estimate result displays simulated sink marks on the part. This result indicates the presence and location of
sink marks likely to be caused by features on the opposite face of the surface. The result does not indicate sink marks
caused by locally thick regions.
Iteration 1
Iteration 2

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Fiber Orientation
The Fiber orientation tensor result shows the orientation tensor (degree of orientation) at the end of the injection molding process.
This result shows the probability of fiber alignment in the principal direction. A high probability of fiber alignment in the principal
direction will be indicated by a value of close to 1 on the result scale, whereas a low probability is indicated by a value close to 0.
Iteration 1
Iteration 2

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Cooling Set-up
This plot shows cooling set-up for the BTI_Logo part. The cooling is identical for Iteration 1&2.
Iteration 1
Iteration 2

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Circuit Coolant Temperature
Water Temperature: 190°F. Depending on the configuration of the coolant lines, over all mold temperatures are expected
to rise. The plot below indicates temperature rise during the molding cycle.
Water Temperature: 190°F. This result shows the temperature of the coolant inside the cooling circuit. The inlet to outlet
temperature rise should be no more than 5-6°F. Depending on the configuration of the coolant lines, overall mold
temperatures are expected to rise.
Iteration 1
Iteration 2

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Circuit Flow Rate
This plots show the flow rate required to achieve turbulence in each circuit.
Iteration 1
Iteration 2

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Circuit Reynolds Number
This plots show the Reynolds number of the coolant in the cooling circuit. The ideal Reynolds number to achieve is 10,000.

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Mold Temperature
Gate
Gate
Iteration 1
Iteration 2
This plot shows the cycle averaged temperature of the mold side of the plastic/mold interface during the cycle.

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Mold Temperature
Gate
Gate
Iteration 1
Iteration 2
This plot shows the cycle averaged temperature of the mold side of the plastic/mold interface during the cycle.

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Warpage / Deflection: All Effects
This plot shows the warpage caused by all effects. All effects include differential shrinkage, orientation effects and
differential cooling. *Plot scaled 3X
Iteration 1
Iteration 2

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Warpage / Deflection: All Effects X Components
This plot shows the warpage caused by all effects in the X direction. *Plot scaled 3X
-X
Iteration 1
Iteration 2
+X

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Warpage / Deflection: All Effects Y Components
This plot shows the warpage caused by all effects in the Y direction. *Plot scaled 3X
+Y
-YIteration 1
Iteration 2

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Warpage / Deflection: All Effects Z Components
This plot shows the warpage caused by all effects in the Z direction. *Plot scaled 3X
-Z
+Z
-Z
Iteration 1
Iteration 2

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Warpage / Deflection: All Effects Z Components
This plot shows the warpage caused by all effects in the Z direction. *Plot scaled 3X
+Z
-Z -Z

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Warpage / Deflection: All Effects Differential Cooling
Iteration 1
Iteration 2
This plot shows the deflection (warpage) at each node attributable to differential cooling. Differential cooling effects are
defined as warpage caused by shrinkage differences through the thickness (cavity to core). *Plot scaled 3X

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Warpage / Deflection: All Effects Differential Shrinkage
Iteration 2
This plot shows the deflection (warpage) at each node attributable to differential shrinkage or natural shrinkage.
Differential shrinkage effects are defines as shrinkage differences from region to region in the part (example: gate to end of
fill; part geometry, thin versus thick areas). *Plot scaled 3X
Iteration 1

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Warpage / Deflection: All Effects Orientation Effects
Iteration 1
Iteration 2
This plot shows the deflection (warpage) at each node attributable to orientation effects. Orientation effects are defined as
shrinkage differences parallel and perpendicular to the material orientation direction. *Plot scaled 3X

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Summary/Recommendations
Warpage all Effects Warpage all Effects X Warpage all Effects Y Warpage all Effects Z
max min + - + - + -
Iteration 1 0.0460” 0.0046” 0.0211” -0.0200” 0.0091” -0.0049” 0.0248” -0.0426”
Iteration 2 0.0332” 0.0066” 0.0146” -0.0265” 0.0242” +0.0049” 0.0140” -0.0152”
Weld Line
Temperature (°F)
Weld Line
Pressure (psi)
Temperature at
Flow Front (°F)
Shear Rear
Maximum (1/s)
Average Volumetric
Shrinkage (%)
Sink Mark Estimate (in)
Iteration 1 533.7 – 558.4 2,679 - 6,848 533.0 – 559.1 10,602 2.694 – 9.201 0.0083
Iteration 2 556.5 – 562.8 1,562 – 3,298 554.0 – 563.6 7,226 2.833 – 9.312 0.0060
Pressure Through Runner
System (psi)
Pressure Through Part
(psi)
Pressure V/P
Switchover (psi)
Pressure V/P
Switchover +4,000 psi
Clamp Tonnage
(US Tons)
Iteration 1 3,138 4,013 7,151 11,151 5.3 - 25.6
Iteration 2 9,326 5,789 15,115 19,115 13.1 - 25.7
The following parameters were used to run the analysis:
Material: Zytel PLS90G30DR BK099: PA66, DuPont Performance Polymers [30% Glass Fiber Filled]
Melt Temperature = 554°F
Water Temperature = 190°F
Injection time = 1.5 -2.0 seconds based on DOE study
V/P Switchover = 98% Full Part
Pack Profile = 8,000 psi

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Beaumont Technologies – MORE than simulation
MeltFlipper®
• Patented Runner System Options
• Eliminate imbalances
• Fix Cosmetic Defects
Therma-Flo™
State of the Art Plastics Material Characterization Method
(If you deal with MFI in any way, check this out!)
Injection Molding Services
• ISO-ASTM Test Specimen Molding
• Mold sampling and qualification
• Production Runs
• Process debugging
Injection Molding Training and Education
• Certification Program
• Development Courses
• Autodesk Moldflow Courses

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Schedule your web meeting
Have questions on this report?
Schedule a web meeting with Beaumont to get the most of your simulation.
To schedule a web meeting contact David Corsi at
dcorsi@beaumontinc.com

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CAE Disclaimer
Any and all analysis results provided are believed to be reliable but are not to
be construed as providing a warranty, including any warranty of merchantability
or fitness for purpose, or representation for which BTI assumes legal
responsibility.
Users should undertake sufficient verification and testing to determine the
suitability for their own particular purpose of any information presented herein.
Nothing herein is to be taken as permission, inducement, or recommendation
by BTI to practice any patented invention without a license or in any way
infringe upon the intellectual property rights of any other party.