MOLDFLOW ANALYSIS REPORT 20038 BATTERY COVER David Deng 2005/05/29 CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 1
MOLDFLOW ANALYSIS REPORT Contents 1. Plastic Material Introduction -------------------------------- 3 2. Product Model Introduction----------------------------- 4 3. Cooling System Design 4. Feed System Design -------------------------------- 5 --------------------------------6 5. Analysis Indication --------------------------7 6. Processing Conditions -----------------------------8 7. Analysis Results ---------------------- 9~27 8. Conclusions & Suggestions ------------------------------- 28 CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 2
MOLDFLOW ANALYSIS REPORT Material introduction PP POLYPROPYLENES 1. Conductivity 2. Specific heat 3. Melt density 4. Max. shear stress 5. Max. shear rate CM 1171 0. 170000 W/m/ deg. C 3100. 000000 J/kg/ deg. C 774. 7500000 kg/cu. m 0. 260000 MPa 24000. 000000 1/s CYPRESS CHINA CAE/CAD/CAM TECH CENTER Taiwan PP VI(245)84 OCT-08 -2002 JUL 93 8. Ejection temperature 9. Min. melt temperature 10. Max. melt temperature 11. Min. mold temperature 12. Max. mold temperature 2005/05/29 93. 000000 deg. C 200. 000000 deg. C 280. 000000 deg. C 20. 000000 deg. C 80. 000000 deg. C 20038 Page 3
MOLDFLOW ANALYSIS REPORT Product model introduction Thickness distribution is not even. Min. wall thickness is about 0. 64 mm, Max. wall thickness is about 5. 00 mm. As shown below the plot, the blue is the thinner region, and the red is the thicker region(include injection and cooling system). 210 51 87 Max. contour dimension(mm) CYPRESS CHINA CAE/CAD/CAM TECH CENTER Thickness distribution 2005/05/29 20038 Page 4
MOLDFLOW ANALYSIS REPORT Cooling System Design Ø 10 Cooing network Cooling system have 20 circuits. Core have 12 circuits and cavity have 8 circuits. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 5
MOLDFLOW ANALYSIS REPORT Feed System Design Gate location 9 Gate 2. 2 Ø 5 Ø 8 Ø 4. 15 16 124 2 The mold is cold feed system, two cavities, one banana gate. The dimension of the gate is shown in top plot. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 6
MOLDFLOW ANALYSIS REPORT Analysis Indication Ø Moldflow CAE analysis includes Flow, Cooling and Warp results, aimed to optimize the feed system, the cooling system of the mold. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 7
MOLDFLOW ANALYSIS REPORT Processing Conditions Packing profile: Filling Conditions: Mold temperature: 50. 00 deg. C Melt temperature: 230. 00 deg. C Injection time ﹕ MPa 3. 8 sec 30 Total Volume (cavity): 170. 00 cu. cm Part Volume : 165. 00 cu. cm 10 Sprue/runner/gate volume: 5. 00 cu. cm Total Weight : Runner Weight﹕ Pressure [MPa] 137. 4 g 2005/05/29 0. 0 30 Cooling Conditions: Temp : 25. 0 deg. C Circuit Inlet CYPRESS CHINA CAE/CAD/CAM TECH CENTER Time [sec] 30 3. 5 g s 10. 0 20038 Page 8
MOLDFLOW ANALYSIS REPORT Gate Analysis Results Best Gate Location The best gate location lie in the marked region. It is difficult to design mold, so can’t be accepted in fact. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 9
MOLDFLOW ANALYSIS REPORT Flow Analysis Results Fill Time Fill time is about 3. 8 sec, and the filling pattern is satisfied. The marked region is filled last. The below plot is the scene of filling 99%(V/P switch over). Click for animation CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 10
MOLDFLOW ANALYSIS REPORT Flow Analysis Results Fill Time Fill time is about 3. 8 sec, and the filling pattern is satisfied. The marked region is filled last. The below plot is the scene of filling 99%(V/P switch over). Click for animation CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 11
MOLDFLOW ANALYSIS REPORT Flow Analysis Results Injection Pressure Max. injection pressure is 33 Mpa (V/P switch over). CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 12
MOLDFLOW ANALYSIS REPORT Flow Analysis Results Injection Pressure The pressure drop in runner system is about 24 MPa, which is 72. 7% of injection pressure. The below plot is the pressure distribution of filling 99%(V/P switch over). CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 13
MOLDFLOW ANALYSIS REPORT Flow Analysis Results Flow Front Temperature Gate CYPRESS CHINA CAE/CAD/CAM TECH CENTER The flow front temperature is from 221 to 230. 6 deg. C, and the distribution is not very uniform. The minimum temperature is shown in the marked region. Pay attention to the weldlines in this area. 2005/05/29 20038 Page 14
MOLDFLOW ANALYSIS REPORT Flow Analysis Results Weld Lines Main weld lines are shown as red lines. Pay more attention to the weldlines in this area. Gate CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 15
MOLDFLOW ANALYSIS REPORT Flow Analysis Results Air Traps Air traps locations are shown by small pink balls. Most of them lie in the last filling or the interface area, so can be vented easily. Gate CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 16
MOLDFLOW ANALYSIS REPORT Flow Analysis Results Sink Index Pay attention to the Sink Mark in marked region. Gate CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 17
MOLDFLOW ANALYSIS REPORT Flow Analysis Results Clamp Force Centroid locates in the center of mold. Clamp Force(Max. =61. 3 Ton) Variation curve of pressure&clamp force in cycle time shown by above figure. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 18
MOLDFLOW ANALYSIS REPORT Cool Analysis Results Coolant Temp Coolant temp difference is very small, so the number of circuits is enough. Temp difference(Max. =0. 23 deg. C) CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 19
MOLDFLOW ANALYSIS REPORT Cool Analysis Results Temp (part) The distribution of temp is not very uniform. Pay more attention for the cooling in marked region. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 20
MOLDFLOW ANALYSIS REPORT Cool Analysis Results Temp (part) Pay more attention for the cooling in marked region. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 21
MOLDFLOW ANALYSIS REPORT Cool Analysis Results Frozen Time(part) Click for animation. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 22
MOLDFLOW ANALYSIS REPORT Cool Analysis Results Frozen Time(part) The frozen time is non-uniform. The frozen time of most area is about 23 S, 6. 1 S in gate area. Pay more attention for the cooling in marked region. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 23
MOLDFLOW ANALYSIS REPORT Cool Analysis Results Frozen Time(gate) The frozen time of gate is about 6. 45 S, less than the frozen time of most area in the part, which will do harm to packing. Design larger gate. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 24
MOLDFLOW ANALYSIS REPORT Warp Analysis Results X Deflection The X direction belongs to natural shrinkage basically. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 25
MOLDFLOW ANALYSIS REPORT Warp Analysis Results Y Deflection in Y direction is shown in the left plot, belongs to natural shrinkage basically. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 26
MOLDFLOW ANALYSIS REPORT Z Deflection Warp Analysis Results Deflection in Z direction is uniform. 0. 58 0. 42 0. 41 Gate CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 27
MOLDFLOW ANALYSIS REPORT Conclusions&Suggestions From the above analysis: ØSome weld lines maybe affect the strength of molding part, and air traps are vented easily. Ø The packing effect is the main cause of sink mark, deflection. Deflection is very uniform, improve packing will get small deflection. Ø The distribution of temp is not very uniform. Suggestions: Ø To use baffle, bubbler and inserts to improve cooling effect. Ø To design larger gate. CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 20038 Page 28
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