Sample Moldflow Analysis Report For Automotive Part.

1. Moldflow Analysis Report
Part name :BASE & COVER
Objective : Moldflow Analysis of ‘ BASE & COVER’ with 1+1 tool layout. To
identify the optimized process-parameters & to list down the findings by
doing Cool+Fill+Pack+Warp Analysis.

2. Who
We
Are
www.polysmart.com

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. Feed System Details
COVER BASE Hot sprue details
Dia: - 10mm
Height - 60mm
Runner details
Top Width: – 6.0mm Runner details
Bottom Width: - 4.0mm Top Width: – 5.0mm
Height: - 4 5mm
4.5mm Bottom Width: - 3.5mm
Height: - 4.0mm
Edge Gate details
Width: - 5.0mm
Depth: - 1.5mm

5. Feed System Details
BASE
COVER

6. Material Details
Shear Rate Vs Viscosity
Shear rate plot shows that when the shear rate is
increased, the material flows easily. Increasing
shear rate by gate dimensions and injection rate
can help material to flow easily.
PVT graph indicates that below 215° C melt
temperature, packing pressure would not have
much impact on shrinkage. PVT

7. Zone Plot
Comments: The Zone plot gives us the idea of preliminary process-setting &
then further it is optimized.

8. Process Parameters
Packing Profile

9. Flow Analysis Results

10. Fill Time Plot
Comments: Part is filling completely in 2.42s & with flow rate of 46CC/s.Minor
imbalance is observed in the filling which can be neglected as it is not affecting the
quality of the component. Overall Contour plot shows uniform spacing between the
contour lines (95% of the component) which indicates that there is no flow related
problem occurring during filling of the component.

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. Pressure At Injection Location
80.3Mpa
72Mpa
Comments:
Comments This plot shows pressure at injection location Packing press re
sho s press re location. pressure
given is initially 90% of filling pressure for 8s & then in 1s it decays to zero.
Total packing given in 8+1=9s

13. Frozen Layer Fraction
Comments: The plot shows the frozen layer fraction for the component, the
component gets completely frozen in 20s.

14. Temperature At Flow Front
During Cavity Filling
Comments: This plot shows temperature flow front for the component. Rise in
temperature observed is up to 2o C due to shear heating & drop in temperature
is observed is up to 15o C (Melt temperature is 262oC).Therefore the flow front
temperature range is within the acceptable limit.

15. Fiber Orientation Plot
Comments: The plot shows the movement of fibers during the injection molding
process, averaged over the thickness.

16. Volumetric Shrinkage At
Ejection
Comments : The Plot shows the volumetric shrinkage across the component.
Higher values are observed in the thick walled areas marked in the plot. The
volumetric shrinkage ranges in between 1.4% to 7.9%.
*Volumetric shrinkage and the linear shrinkage are different.

17. Shear Rate
Comments : The max shear rate value observed is 86591 1/s which is within
the recommended limit of which is specified by Material Manufacturer.

18. Clamp Tonnage Plot
Comments : Maximum clamp tonnage required is 224 tonnes based on the
calculations done by Moldflow.

19. Air Trap Plot
Comments : The observed air-trap can be vented out by providing air-vents in the
mold. If proper venting is not provided at end of fill areas then it may lead to short shot or
burn marks on the component.

20. Weldline Plot
Comments : The temperature when weldline were formed is high (263.7°C),
hence the weld strength will be good & area near the weldline will be
structurally strong.

21. Sink Marks Plot
Comments : 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 the
recommended limit then it will leave a visible mark onto the surface. In this
case the values are just within the acceptable limit.

22. Cooling Analysis Results

23. Cooling Circuit Efficiency
Plot
Circuit Coolant
Circuit heat Temperature.
removal Efficiency.
Comments : The plot shows the cooling circuit efficiency.

24. Coolant Flow Rate &
Reynolds Number.
Coolant Flow-Rate. Circuit Reynolds Number.
Comments : The plot shows the circuit flow rate & reynolds number.

25. Average Temperature Part.
Comments : The Plot shows the average temperature of the part at the end of
the cooling time. Higher values are observed in the thick walled areas which
are marked in the plot.

26. Temperature Maximum Part.
Comments : The plot shows the maximum temperature in the part at the end
of the cooling time. The max temperature observed is 180°C which is just
within the limit of Ejection temperature.

27. Warpage Analysis Results

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).The
observed shrinkage value is 0.96%. While setting the mould dimensions it is
g g
essential 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. 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
upwards
Comments : Shrinkage observed in Y- direction is (+1.62mm, -1.74mm). The observed
shrinkage 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. 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. Recommended Processing
Parameters.
Injection Time: - 2s Case1 Case2 (Optimized)
Mold Temp 80°C Mold Temp 80°C
Melt Temperature: - 262°C
262 C
Melt Temp 260°C Melt Temp 262°C
Mold Temperature: - 80°C
V/P Switchover V/P Switchover
Packing 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. Conclusion
Component gets filled completely with no flow related problem except minor flow
imbalance, 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 which
is just within the recommended limit
limit.
Mold temperature & Melt temperature needs to be precisely control, to control
sink 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 t
to prevent the component sticking into the cavity.
It recommended to give air-vents at the end of fill areas to prevent short shot or
burn mark on th component.
b k the t
It is recommended, that if warpage in the molded component observed is high
after molding then finally it is recommended to use cooling fixture to control
warpage.
warpage

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:- +91-22-28820629
Website:-
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.
******************************************************************************