Moldflow Analysis Report
Cool, Flow & Warp Analysis Of Small base Part
AG10-07, 07 JULY 2010
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Moldflow Analysis Report
Contents
1.
Summary
03
2.
Material Properties
04
3.
Part thickness
05 -06
4.
Processing Condition & Runner Layout
07
5.
Results
08 - 21
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Moldflow Analysis Report
Summary
ANALYSIS AIMS
To study the flow and predict the cycle time of the A1309-2 part.
ANALYSIS APPROACH
The cavity and the cold runner sections are modeled.
And a Fusion Cool + Flow + Warp analysis was conducted.
The specified material is PP (grade is specified BP RPP 2009 GK BLK, which is not listed in
the moldflow database, so we used Polypropylene PPC 5660 from TOTAL Petrochemicals) to
running the analysis .
This may effect the actual values obtained in the analysis (e.g. shrinkage values, pressure
requirements), but it can still be used to observe the general trends in the results (e.g. filling
pattern, warpage shape etc).
CONCLUSION
A pressure drop of 15MPa is expected across the system which indicating this material can
easy to fill this part.
The over all melt front temperature drop is C across the part, which is acceptable.
The weld lines might be visible to eye due to zero degree of two melt.
The part is expected to have warpage in X,Y,Z direction, the particular data of warpage please
refer to page 20 to 23.
The hot spots in the slider side due to the placement of the cooling channel, these area need
to add cooling circuit or beryllium insert if we can (refer to page 19).
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Moldflow Analysis Report
Material : PP
Similar Material
Trade Name: Polypropylene PPC 5660
Material Family: PP
Manufacturer : TOTAL Petrochemicals
Recommend processing temperature
Melt : 200C – 260C
Characteristics : Amorphous Material
others:
Conductivity : 0.1762 W/m/C (at 230C)
Specific Heat :
2618.6 J/kg/ C (at 230 C)
Melt Density : 0.74577 g/cm^3
Absolute Max Temp : 300 C
Ejection Temperature :
95C
Max Shear Stress :
0.25MPa
Max Shear Rate :
100,000 l/s
Viscosity Plot
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Mold : 20 C – 60 C
Viscosity Index : VI(240)0111
Melt mass –Flow Rate(MFR)(230C/2.16kg)
7.0g/10min
PVT Plot
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Moldflow Analysis Report
Part thickness
Use different color to show the thickness.
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Moldflow Analysis Report
Part thickness
Use different color to show the thickness.
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Moldflow Analysis Report
Processing Condition & Runner Layout
The Processing Conditions used was as
follows:
Filling Time : Auto, 4.6 sec.
Mold Temperature : 40 C
Melt Temperature : 230 C
Velocity/Pressure switchover at 98.5% volume fill
Packing Pressure : 80% of Max Injection Pressure
Hot Gate
size:
Ф2.5mm
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Moldflow Analysis Report
Filling Pattern
Fig 1
Fig 2
The last filling area
Fig 3
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Fig 4
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Moldflow Analysis Report
Filling Time (Flash)
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Moldflow Analysis Report
Filling Time (Flash)
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Moldflow Analysis Report
Pressure drop
A pressure drop of 15MPa is expected across the system,
this indicated that the material is easy to fill this part.
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Moldflow Analysis Report
Temperature at flow front
The plastics material enters the runners at 230 C.
The overall temperature drop is about 1.2C,
which is acceptable.
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Moldflow Analysis Report
Weld Lines
The weld lines (color curve) might be visible to
eye, due to the zero degree of the two melts.
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Moldflow Analysis Report
Air traps
The air traps (pink mark ) location are as show.
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Cooling Channels : Temperature Rise
The coolant is specified as water at 25 C, and with turbulent flow in each channels
(Reynold Number = 10,000).
The outlet temperature of each channels is exceed 0.66C, this indicate the cooling
channels are efficient.
Cavity Core cooling
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Moldflow Analysis Report
Cooling Channels : Temperature Rise
Slider cooling
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Mould Surface Temperature
Total Cycle time: 105 sec.
( Auto Injection + Packing + Cooling Times = 100 sec. Mold open time = 5 sec.)
Core side
Cavity side
Hot spot
Slider
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Slider
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Moldflow Analysis Report
Warpage in X direction
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Moldflow Analysis Report
Warpage in Y direction
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Moldflow Analysis Report
Warpage in Z direction
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Moldflow Analysis Report
Warpage in Z direction
Z direction
The main warpage area
3 gates, the warpage of Z direction just
reduce about 0.1mm compare to 1 gate.
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END
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