INTRODUCTION
TO
NAUTILUS 8
MOLD QUALIFICATION
AND
DESIGN
OF
EXPERIMENTS SOFTWARE
FOR
INJECTION MOLDING
SUHAS KULKARNI FIMMTECH 1-760-525-9053
NAUTILUS IS A PROGRAM THAT HELPS IN THE EVALUATION,
ANALYSIS, DEVELOPMENT AND DOCUMENTATION OF THE
INJECTION MOLDING PROCESS.
THE SOFTWARE ALSO HAS A COMPLETE DESIGN OF EXPERIMENTS
MODULE THAT IS CUSTOMIZED FOR INJECTION MOLDING
ONCE A PROCESS HAS BEEN ESTABLISHED ON ONE MACHINE, THE
SOFTWARE WILL CALCULATE THE PROCESSES FOR ALL THE
MACHINES IN THE SHOP. THE PROCESS CAN NOW BE
TRANSFERRED
AND ‘STARTING FROM SCRATCH’ WILL NOT BE
NECESSARY ON THE OTHER MACHINES
SUHAS KULKARNI FIMMTECH 1-760-525-9053
BENEFITS OF USING THE TECHNIQUES:
• ESTABLISHED PROCESS IS ROBUST
• PROCESS WILL REQUIRE ‘NO OR LITTLE ATTENTION’
• WILL DETERMINE THE FASTEST CYCLE TIME POSSIBLE
• LESS SCRAP AT STARTUP
• ZERO SCRAP DURING PRODUCTION
• IMPROVED PART QUALITY AND PROCESS CAPABILITY
ABOVE FACTORS INCREASE THE BOTTOM LINE PROFITS!
SUHAS KULKARNI FIMMTECH 1-760-525-9053
THE SOFTWARE
SUHAS KULKARNI FIMMTECH 1-760-525-9053
FOLLOWING ARE SOME OF THE FEATURES OF THE SOFTWARE:
 MATERIAL, MOLD AND MACHINE DATABASES
 MOLD – MACHINE COMPATIBILITY REPORT
 SCIENTIFIC MOLDING WORKSHEETS (6-STEP STUDY)
• VISCOSITY STUDY
• PRESSURE DROP STUDY
• CAVITY BALANCE STUDY
• PROCESS WINDOW STUDY
• GATE SEAL STUDY
• COOLING TIME
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DESIGN OF EXPERIMENTS MODULE
• TORNADO CHARTS
• PROCESS SENSITIVITY CHARTS
• COSMETIC PROCESS WINDOW
• DYNAMIC PROCESS WINDOW
• VISUAL PREDICTION EQUATION
 MOLD TRIAL AND QUALIFICATION PROGRESS REPORT
 WATER LINE DIAGRAMS AND MOLD TEMPERATURE MAPS
 MOLD SETUP AND OPERATION DOCUMENTATION
SUHAS KULKARNI FIMMTECH 1-760-525-9053
 QUALITY MODULE
• FULL DIMENSIONAL ANALYSIS
• STATISTICAL ANALYSIS
• POST MOLDING SHRINKAGE REPORT
• DOCUMENTATION OF QUALITY INSPECTION PLAN
 CALCULATION WORKSHEETS COMMONLY USED IN MOLDING
 USER PREVILAGES
 CHOICE OF UNITS
 NETWORK/CONCURRENT VERSIONS
SUHAS KULKARNI FIMMTECH 1-760-525-9053
SUMMARY OF ADDITIONS TO VERSION 8:
• PROCESS – MACHINE COMPATIBILITY
• ADD A PLASTIC PROCESS SHEET FOR A GIVEN MOLD
• GENERATE THE PLASTIC PROCESS SHEET FOR ANY GIVEN MACHINE
• DETERMINE THE MACHINES IN THE SHOP THAT ARE COMPATIBLE AND
CAPABLE OF RUNNING THE MOLD BASED ON PLASTIC VARIABLES
• UNITS MANAGEMENT –
• SELECT BETWEEN METRIC, ENGLISH OR A COMBINATION
• AUTO CONVERT ON DEMAND
• ONCE UNITS FOR A GIVEN MACHINE ARE SAVED ALL PROCESS SHEETS
ARE GENERATED IN THE MACHINE UNITS
SUHAS KULKARNI FIMMTECH 1-760-525-9053
SUMMARY OF ADDITIONS TO VERSION 8:
• USER ACCESS LEVELS
• DETERMINE WHO CAN AND CANNOT CHANGE DATABASES AND DOCUMENTS
• CUSTOM READ/WRITE ACCESS
• ABILITY TO CREATE FAMILY MOLDS AND RUN THEM THROUGH
• 6-STEP STUDY, FOR EXAMPLE: DETERMINE CAVITY IMBALANCES
BETWEEN FAMILY PARTS
• DOE, SELECT THE PROCESSES FOR FAMILY MOLDS
• OPTIMIZE FOR ALL FAMILY PARTS
• MISCELLANEOUS:
• ALL STUDIES/DOCUMENTS FOR A GIVEN MOLD UNDER ONE TAB
• ADDITIONAL FIELDS ADDED TO ALL DATABASES
SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW LOOK
IN VER 8
MAIN SCREEN:
SUHAS KULKARNI FIMMTECH 1-760-525-9053
DATABASES: MATERIAL – MOLD – MACHINE
SUHAS KULKARNI FIMMTECH 1-760-525-9053
MOLD MACHINE COMPATIBILITY REPORT:
CRITERIA BASED ON
• REQUIRED TONNAGE
• % SHOT SIZE USED
• RESIDENCE TIME OF THE MATERIAL IN THE BARREL
• PHYSICAL SIZE OF THE MOLD AND THE MACHINE SPECS
SUHAS KULKARNI FIMMTECH 1-760-525-9053
PROCESS – MACHINE COMPATIBILITY
•
ADD A PLASTIC PROCESS SHEET FOR A GIVEN MOLD
SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW IN
VER 8
PROCESS – MACHINE COMPATIBILITY
• GENERATE THE PLASTIC PROCESS SHEET FOR ANY GIVEN MACHINE IN THE DATABASE
NEW IN
VER 8
• DETERMINE IF THE MACHINES ARE CAPABLE OF RUNNING THE MOLD BASED ON PLASTIC VARIABLES
ESTABLISHED
PROCESS
CALCULATED PROCESS SHEETS FOR OTHER MACHINES
NOT ACCEPTABLE
SUHAS KULKARNI FIMMTECH 1-760-525-9053
ACCEPTABLE
PROCESS – MACHINE COMPATIBILITY
• ONCE THE TARGET MACHINE IS SELECTED, SELECT THE PROCESS SHEET FROM THE DROP
NEW IN
VER 8
DOWN
LIST AND CLICK ON ‘GENERATE PROCESS SHEET’ TO PRINT THE PROCESS SHEET FOR THE
MACHINE
SUHAS KULKARNI FIMMTECH 1-760-525-9053
MOLD QUALIFICATION PART 1: 6-STEP STUDY
(AKA: SCIENTIFIC MOLDING)
SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 1: IN MOLD RHEOLOGY
SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 2: CAVITY BALANCE STUDY
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FAMILY MOLDS
OPTION NEW IN
VER 8
WORKSHEET NO. 3: PRESSURE DROP STUDY
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WORKSHEET NO. 4: COSMETIC PROCESS WINDOW
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WORKSHEET NO. 5: GATE SEAL STUDY – COLD RUNNER
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WORKSHEET NO. 5: GATE SEAL STUDY – HOT RUNNER
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WORKSHEET NO. 6: COOLING STUDY
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WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS
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MOLD QUALIFICATION PART 2:
DESIGN OF EXPERIMENTS
SUHAS KULKARNI FIMMTECH 1-760-525-9053
KEY FEATURES:
• NO PRIOR MATH OR STATISTICS EXPERIENCE REQUIRED
• WITH 4 EASY STEPS YOU WILL BE ABLE TO DESIGN A DOE
AND RUN THE EXPERIMENTS.
• THE DATA WILL VISUALLY SHOW YOU WHAT YOU CAN AND
CANNOT MOLD AS FAR AS THE DIMENSIONS OF THE PART
ARE CONCERNED.
• NO GUESSWORK: DATA DRIVEN DECISIONS FOR ALL CHANGES
IN MOLD STEEL AND/OR NOMINAL - SPECIFICATIONS
• ADJUST THE STEEL WITH CONFICDENCE AND LEAVE THE
PROCESS ALONE!
SUHAS KULKARNI FIMMTECH 1-760-525-9053
INPUTS WORKSHEETS FOR DOE:
STEP 1: SELECT THE FACTORS FROM A DROPDOWN LIST
SUHAS KULKARNI FIMMTECH 1-760525-9053
STEP 2: ENTER THE UNITS, HIGH AND LOWS FOR THE STUDIES
THE HIGHS AND LOWS ARE DETERMENIED FROM THE
COSMETIC PROCESS WINDOW.
SUHAS KULKARNI FIMMTECH 1-760525-9053
STEP 3: ENTER THE NOMINALS AND TOLERANCES
SUHAS KULKARNI FIMMTECH 1-760525-9053
STEP 3: SOFTWARE GENERATES THE EXPERIMENTAL MATRIX
MOLD THE PARTS, ENTER DATA AND CLICK ON THE ANALYSIS BUTTON TO
VIEW THE RESULTS
SUHAS KULKARNI FIMMTECH 1-760525-9053
TORNADO CHARTS
GIVES YOU INFO ON THE FACTOR THAT MOST IMPACTS THE PART QUALITY
(POSITIVE FACTORS ABOVE THE LINE, AND NEGATIVE BELOW THE LINE)
SUHAS KULKARNI FIMMTECH 1-760-525-9053
PROCESS SENSITIVITY GRAPH
GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE
DOE PROCESS RUN
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DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED
CAVITIES AND DIMENSIONS
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DIMENSIONAL PROCESS WINDOW
GREEN CONTOURS – PARTS IN DIMENSION
RED – PARTS OUT OS SPEC
YOU CAN DRAW A BOX AS SHOWN TO DETERMINE ALARM AND TOLERANCE SETTINGS
DIMENSIONAL PROCESS WINDOW
SUHAS KULKARNI FIMMTECH 1-760-525-9053
DIMENSIONAL PROCESS WINDOW
MOLD PARTS BETWEEN THE PROCESS WINDOWS TO MAINTAIN THE PARTS WITHIN THE
DIMENSIONS.
DIMENSIONAL PROCESS WINDOW
SUHAS KULKARNI FIMMTECH 1-760-525-9053
DIMENSIONAL PROCESS WINDOW
WITH A DIMENSIONAL PROCESS WINDOW AS SHOWN IT WILL BE IMPOSSIBLE
TO MOLD PARTS CONSISTENTLY TO THE REQUIRED DIMENSIONS.
IT WILL BE IMPOSSIBLE TO OBTAIN GOOD CpKs
TIME TO MAKE A DATA DRIVEN DECISION!
SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL PREDICTION EQUATION
THE DIMENSION CAN
GO OUT OF SPEC
USL
LSL
Cavity No
→
USL
EXTENT TO
WHICH
THE DIMENSION CAN BE
INFLUENCED BETWEEN
THE EXTREMES OF THE
DOE PARAMETERS
LSL
Cavity No
→
SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL PREDICTION EQUATION
THE DIMENSION CAN
GO OUT OF SPEC
USL
LSL
Cavity No
→
USL
STABLE DIMENSION –
WILL
ALWAYS BE IN SPEC
LSL
Cavity No
→
SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL PREDICTION EQUATION
PROCESS GOLD SPOT - BEST
PROCESS TO BRING ALL
DIMENSIONS CLOSEST TO
NOMINAL
USL
LSL
Cavity No
→
USL
STABLE DIMENSION –
WILL
ALWAYS BE IN SPEC
LSL
Cavity No
→
SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL PREDICTION EQUATION
SIMULATED PROCESS:
CHANGE THE PROCESS AND
SEE WHAT IT DOES TO
THE PART DIMENSIONS.
THE BLACK X WILL MOVE
WITH PROCESS CHANGES
(SEE NEXT SLIDE)
USL
LSL
Cavity No
→
USL
Cavity No
→
SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL PREDICTION EQUATION
SIMULATED PROCESS:
CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART
DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES
SUHAS KULKARNI FIMMTECH 1-760-525-9053
NUMERICAL PREDICTION EQUATION
USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON
THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY
SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW IN
ACHIEVING DIMENSIONS:
VER 8
MAKING STEEL AND/OR NOMINAL – TOLERANCE CHANGES
GOOD Cp BUT A BAD CpK??? YOUR CHOICES ARE
• MODIFY THE STEEL DIMENSION AND/OR
• MODIFY THE NOMINAL – SPEC LIMITS
ROBUST PROCESS
MODIFY MOLD AND/OR
NOMINAL-SPEC
LIMITS BY THIS
NUMBER TO HIT THE
MOMINAL VALUE
SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW IN
VER 8
CAPABILITY NOT A REQUIREMENT?
WANT TO BE ONLY IN SPEC??
ROBUST PROCESS
MODIFY MOLD AND/OR
NOMINAL-SPEC
LIMITS BY THIS
NUMBER TO HIT BE
INSIDE THE USL OR
LSL
0
SUHAS KULKARNI FIMMTECH 1-760-525-9053
CONFIDENCE RATINGS
USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON
THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY
SUHAS KULKARNI FIMMTECH 1-760-525-9053
PRINTING: SELECTION SCREEN
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PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS
SUHAS KULKARNI FIMMTECH 1-760-525-9053
MOLD SPECIFIC TROUBLE SHOOTING GUIDE
SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW IN
VER 8
QUALITY MODULE:
FULL DIMENSIONAL ANALYSIS:
SUHAS KULKARNI FIMMTECH 1-760-525-9053
QUALITY MODULE:
STATISTICAL ANALYSIS :
SUHAS KULKARNI FIMMTECH 1-760-525-9053
MACHINE QUALIFICATION:
INJECTION SPEED LINEARITY :
SUHAS KULKARNI FIMMTECH 1-760-525-9053
MACHINE QUALIFICATION:
SHOT TO SHOT REPEATABILITY TEST :
SUHAS KULKARNI FIMMTECH 1-760-525-9053
MACHINE QUALIFICATION:
LOAD SENSITIVITY TEST :
SUHAS KULKARNI FIMMTECH 1-760-525-9053
FREQUENTLY USED MOLDING CALCULATIONS:
SUHAS KULKARNI FIMMTECH 1-760-525-9053
WATER FLOW CALCULATION:
SUHAS KULKARNI FIMMTECH 1-760-525-9053
PROCESS TRANSFER BETWEEN MACHINES WORKSHEET:
SUHAS KULKARNI FIMMTECH 1-760-525-9053
SHOT SIZE ESTIMATION WORKSHEET:
SUHAS KULKARNI FIMMTECH 1-760-525-9053
HOPPER SIZE CALCULATION WORKSHEET:
SUHAS KULKARNI FIMMTECH 1-760-525-9053
REGRIND CALCULATIONS (CLOSED LOOP SYSTEMS)
SUHAS KULKARNI FIMMTECH 1-760-525-9053
MISCELLANEOUS FEATURES
SUHAS KULKARNI FIMMTECH 1-760-525-9053
UNITS MANAGEMENT
•
UNITS MANAGEMENT –
•
SELECT BETWEEN METRIC, ENGLISH OR A COMBINATION
•
AUTO CONVERT ON DEMAND
SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW IN
VER 8
USER ACCESS LEVELS
•
USER ACCESS LEVELS
•
DETERMINE WHO CAN AND CANNOT CHANGE DATABASES AND DOCUMENTS
•
CUSTOM READ/WRITE ACCESS
SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW IN
VER 8
NEW IN
VER 8
FAMILY MOLDS
•
ABILITY TO CREATE FAMILY MOLDS AND RUN THEM THROUGH
•
6-STEP STUDY, FOR EXAMPLE: DETERMINE CAVITY IMBALANCES BETWEEN FAMILY PARTS
•
DOE, SELECT THE PROCESSES FOR FAMILY MOLDS
•
OPTIMIZE FOR ALL FAMILY PARTS
SUHAS KULKARNI FIMMTECH 1-760-525-9053
FAMILY MOLDS
NEW IN
VER 8
• ABILITY TO CREATE FAMILY MOLDS IN THE DATABASE
SUHAS KULKARNI FIMMTECH 1-760-525-9053
FAMILY MOLDS
NEW IN
VER 8
• ABILITY TO QULAIFY FAMILY MOLDS IN 6-STEP AND DOE MODULE
SUHAS KULKARNI FIMMTECH 1-760-525-9053
CONTACT INFO:
SUHAS KULKARNI
suhas@fimmtech.com
1-760-525-9053
WWW.FIMMTECH.COM
WWW .I NJECTION M OLDING O NLINE . COM
SUHAS KULKARNI FIMMTECH 1-760-525-9053