Tom analyzed the molding process for a housing part according to the customer's design. The analysis examined flow, cooling, warpage conditions and optimized the runner and cooling systems. It determined processing parameters, identified potential weld lines and air traps, evaluated warpage and sink marks, and provided recommendations to improve the design.

1. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Moldflow AnalysisMoldflow Analysis
ReportReport
HOUSINGHOUSING_UPPER_UPPER
2005.03

2. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Analysis the product’s flow, cooling , warpage conditions
according to customer’s design .So as to we can achieve the
reasonable process via good design of cooling and runner
system.
ANALYSIS AIMS

3. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Outline dimension
（ 458.6 X
288.8X50.5 ）
Part Model
Introduction
Thickness distribution is indicated as
figure. The base thickness is 2.5mm.
50.5mm
288.8mm
458.6 mm

4. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
1. Melt Density 0.91818 g/cu.cm
2. Solid Density 1.0215 g/cu.cm
3. Ejection Temp. 100.0 deg.C
4. Recommended Mold Temp. 44.0 deg.C
5. Recommended Melt Temp. 235.0 deg.C
6. Absolute Max. Melt Temp. 300.0 deg.C
7. Min melt temp. 200.0 deg.C
8. Max melt Temp. 270.0 deg.C
9. Min mould temp. 33.0 deg.C
10. Max mould temp. 55.0 deg.C
11. Max shear rate 40000.00 1/s
12. Max shear stress 0.30 MPa
Plastic Material Introduction
Viscosity profiles
PVT profiles
HIPSHIPS Styron H9152T:Styron H9152T: DowDow
Chemical USAChemical USA

5. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Feeding System Design
Feeding system is created according to the customer’s design.

6. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Cooling System design
Cooling system is created according to customer’s
design.
Φ10mm
BaffleΦ25m
m
Φ10mm
Cavity
side
Core
side

7. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
9 20.0 t(s)
P(MPa
)
84.5
Processing conditions
Filling Conditions :
Mold temperature : 44.00 deg.C
Melt temperature : 235.00 deg.C
Injection time : 2.2 sec
Cooling Conditions:
Coolant Temperature(Cavity) 34 deg.C
Coolant Temperature(Core) 34 deg.C PRESSURE[MPa] STEP DURATION [sec]
84.5 0.0
84.5 9
Packing is 80% max
injection pressure
Packing profile :

8. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Fill time

9. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Fill time series
Last filled area

10. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Distribution of flow front
temperature is mostly
even,but in some rib
area （ circle area,
indicated in
picture ） the
temperature decreased
a lot. Because
hesitation occurred in
this area for the relative
thin ribs.
Temperature at flow front

11. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Part totally frozen ， runner has
frozen 60%.
Frozen layer fraction
Gate frozen, Packing
stopped.

12. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Temperature distribution is indicated as the
figure.
Temperature (top) , part

13. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Temperature (bottom) , part
Temperature at core side is some high in some ribs and
boss area.

14. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Weld lines
Weld line may occurred at the black-line locations in the figure.

15. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Air traps
Air traps may occurred at pink circle area as the figure shows.

16. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Sink mark depth
Original
Improved
Sink mark depth can be decreased via packing profile adjusting.
P(MPa)
95
Increasing packing pressure so
as to decrease the sink mark
6 9 20.0 t(s)

17. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Injection pressure &
clamping force
Injection pressure clamping force
Max.: 105.7 MPa
Max.: 496.5 ton

18. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Shape in the picture has been
scaled 10 times 。
Introflexion
Totally
Deflection
IntroflexionIntroflexion

19. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Deflection’s differential
influence
Warpage are caused by uneven
cooling and uneven shrinkage.
Cooling shrinkage
Orientation

20. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Deflection , caused by uneven cool
（ original ）
Water
inlet
34
deg.C
introflexio
n
0.81m
m
0.50m
m
Cooling result is better in left
side compared to the right 。
Original
introflexio
n

21. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Water
inlet
20
deg.C
0.68m
m
A better cooling conditions on right
side will decrease the side
introflexion 。
Deflection , caused by uneven cool
（ improved ）
Improved
0.45m
m
introflexio
n
introflexio
n

22. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Original injection profile
The shrinkage are not so even ， the two side
indicated in the figure are trend to protrude outside 。
Deflection , caused by uneven shrinkage
（ original ）
Original

23. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
The shrinkage towards inside are even , and the shrinkage
value has been compensated via material’s shrinkage.
Deflection , caused by uneven shrinkage
（ improved ）
Improved injection profile
Improved

24. Moldflow Analysis ReportMoldflow Analysis Report
Reported by: Tom
Conclusion & Comment
Gets from the results ：
 The flow pattern is mostly balanced;
 Be care those locations that may occur weld line or air
trap 。
 There will be some warpage on the molding part.
 The sink mark would occurred on the part surface, We
could make it better via good packing condition .