ETS CAPABILITIES IN MOLDFLOW ANALYSIS

MOLDFLOW
SUPPORT

TROUBLE SHOOTING

NEW PRODUCT DEVELOPMENT

CHANGE IN COMPONENT DESIGN

CHANGE IN MOLDING PROCESS

CHANGES IN MOLD DESIGN

CHANGES IN COMPONENT DESIGN

TROUBLE SHOOTING

Case:
Core Shift Analysis for Insert Molding
Metal Insert made of Spring Steel

Molding made of PA6 30% GF

Results of the Fill analysis with existing Molding conditions:

Filling Pattern

Deformation Pattern

Final Distortion

Possible solutions suggested:

Change of Gate Location Providing better anchor to the metal insert Changing the material of the metal insert so that it

can with-stand the Injection pressures

Results of Analysis with change in the gating location:

Filling Pattern

Deformation Pattern

Final Distortion

Note: It can be seen by changing the gating location we can reduce the deformation by almost half

Case:
Changing the Product design to avoid warpage
Material(used) Machine(used) AKULON K224 G6 HTW 900

EXISTING COMPONENT

PROPOSED COMPONENT

OLD

NEW

Filling Pattern
NOTE: The flow pattern is improved to a large extent in New Case, hence avoiding the over-packing of the Limb of the Cam.

OLD

NEW

Total Deflection in Y direction

NOTE: Similarly, the deflection in Y direction due to Warpage in Old Case is 0.55 mm and in New Case is 0.15mm; the Angular deflection is also reduced.

Case:
Changing the Gate Location to avoid the breaking of the component in the highlighted region

Material(used) Machine(used)

ZYTEL 70G33L SP 30

CASE 1 The Core Pin deflects the Flow, creating a Turbulent flow, which is desired.

CASE 2

No obstacle in front of the Flow Front, hence the Flow is Laminar.

Filling Pattern

CASE 1 The Shear Modulus of the Part in this zone is within the Limit.

CASE 2

The Shear Modulus of the Part in this zone is exceeding the Max. Shear Modulus of the material (2371.84 MPa). Shear Modulus(Fiber)

Case:
Changing the type of gate and size of opening to avoid the warpage

Note: The results show that the Part is uniformly thick and the Gate is selected in one of the Thickest Zones of the Component.

Feed system

Note: A Submarine Gate is selected with a modified trapezoidal runner and inclined sprue.

Processing conditions
1. Molding Material: Akulon K222-D (PA6)

2. Mold Material: OS
3. Machine: Windsor SP30 4. Melt Temperature: 260 C 20 C 5. Mold Temperature: 65 C 15 C 6. Cooling Time: 20-30 sec 7. Max. Injection Pressure: 13.66-20 MPa 8. Holding Pressure: 10.93 MPa

9. Filling Time: 1.88-3 sec

Fill analysis

GATE OPENING =1.2mm

Note: The filling pattern shows a hesitation during filling of the Cavity in this zone and hence non-uniform filling.

Case:
Family Mold with components with different filling time

Processing conditions using Molding Window Analysis

Mold Temperature= 100-120 C Melt Temperature= 300-320 C Injection Time = 0.6-0.8 sec

Proposed changes in the Feed system

PRODUCT DEVELOPMENT

Component: SHROUD
Component from SDDC

Material Machine

Akulon K225KS (PA6)

SP 130

Submarine Gates on Ejector Pin.

Best Gate Location

23

FEW ITERATIONS...

Old Component: Total Deflection (ABS)

Old Component: Filling with Sprue Gate(PA6)

Modified Component: The Walls were given Z type skirting features (PA6).

Due to Rigidity provided by the Vertical Walls, these Corners are Inducing Warpage, and hence a Twisting Effect on the Side Walls.

Y
The Total Deformation Pattern shows that, in the X & Z directions, Deflection is mainly due to Shrinkage; whereas in Y direction the deflection is due to both Shrinkage+Warpage

Old Component: Total Deflection

25

The Total Deformation Pattern shows that, in the X & Z directions, Deflection is mainly due to Shrinkage; whereas in Y direction the deflection is due to both Shrinkage+Warpage

Old Component: Total Deflection (PA6)

26

Final Suggestion by ETS

Total No. of Iterations carried out Iterations by changing gate Location and Types Iterations by changing the Material Iterations by imparting changes in the product design

24

12

The Warpage at these corners is Appox. 0.7mm per side

OLD

The Warpage at these corners is Appox. 0.15-0.2mm per side

NEW

Total Deflection in Y direction