ANALYSIS AND IMPROVEMENTS OF PHONECASE MOLD CAVITY USING MOLDFLOW SOFTWARE

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ABDUL SYAKIR BIN ABDUL MUBIN KEC080001 MOHAMMAD IZZUDDIN BIN MOHAMED ROSLI KEC080010 MOHD HIDAYAT BIN MOHD HAMBALI KEC080012
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Product

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Analy sis 3 Runner layout design

H- runner layout

X-runner layout

Y-runner layout

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Analysis
The analysis has been developed using Autodesk Moldflow Adviser 2011 The product chose is an iphone 4 case made of polypropylene (PP). It is observed and its dimension is measured. A CAD model of the phone case is designed by using ProE software. It is then saved as a stl format so that it can be exported to Autodesk Moldflow for further design process. Three alternate cavity layout designss are made with improvements based on the software analysis. The best cavity layout design is then chosen by comparing the analysis. 5/5/12

RESULTS GENERAL SUMMARY

Material trade name: Generic PP Melt temperature: 240.0 (C) Mold temperature: 40.0 (C) Injection locations: 4 Max. machine injection pressure: 180.000 (MPa)

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H X Y Runne Runne Runne r r r

0.67 0.66 62.003 63.711 303.876 302.203 46.698 47.293 98.14 0.65 9.82 34.274 51.5303 44.4924 7.0379 38.414 153.655 230.483 98.04 0.64 9.81 34.733 51.0048 44.4924 6.5124 39.225 157.019 235.528

Actual filling time: (s) 0.67 Actual injection pressure: (MPa) 66.977 Clamp force area: (cm^2) 303.082 Max. clamp force during filling: (tonne) 48.159 Velocity/pressure switch-over at % volume: (%) 97.96 Velocity/pressure switch-over at time: (s) 0.65 Estimated cycle time: (s) 9.82 Total part weight: (g) 34.731 Shot volume: (cm^3) 51.2808 Cavity volume: (cm^3) 44.4924 Runner system volume: (cm^3) 6.7884 Clamp force estimate during packing using: 20% of the injection pressure: (tonne) 41.387 80% of the injection pressure: (tonne) 165.547 248.321 120% of the injection pressure: (tonne) 5/5/12

Fill time

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Confidence of fill

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Quality prediction

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Pressure at end of fill

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Pressure drop

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Temperature at flow front

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Orientation at skin

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Average temperature

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Time to reach ejection temperature

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Frozen layer fraction at end of fill

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Air traps

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Weld lines

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Discussion

Material selected for the phone case is polypropylene (PP) due to its properties; durability, light weight, variations of colour selection and lower production cost. The best cavity layout design can be evaluated by comparing the cost, time and product quality. The idea of best design is when all these parameters are optimized, ideally if the design has the lowest cost and time production with the fewest product defects.

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It is found that the fill time and cycle time for Y runner system is the lowest compared to the other two, meaning less material consumption for production, resulting it to have the lowest cost between them. All three cavity layout designs possess the same weld line and air trap location. It is due to the same gate location placed at all three designs, which is an edge/tab gate. The projected area affects the clamping forces such that the more area is projected, the more clamping pressure needed to hold the product during pecking time. It explains why Y runner system with lowest projected area has the lowest clamping force among all three designs.

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Conclusion

Y runner is the best design Because it has lowest cycle time, lowest clamping pressure, lowest shot volume, lowest runner system volume.

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