Moldflow Analysis Report

Cool, Flow & Warp Analysis Of Small base Part

AG10-07, 07 JULY 2010 Page 1

 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

AG10-07, 07 JULY 2010 Page 2

 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).

AG10-07, 07 JULY 2010 Page 3

 Moldflow Analysis Report
Material : PP
Similar Material

Trade Name: Polypropylene PPC 5660 Manufacturer : TOTAL Petrochemicals

Material Family: PP
Recommend processing temperature
Melt : 200C – 260C Mold : 20 C – 60 C
Characteristics : Amorphous Material Viscosity Index : VI(240)0111
others: Melt mass –Flow Rate(MFR)(230C/2.16kg) 7.0g/10min
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
PVT Plot
Viscosity Plot

AG10-07, 07 JULY 2010 Page 4

 Moldflow Analysis Report
Part thickness
Use different color to show the thickness.

AG10-07, 07 JULY 2010 Page 5

 Moldflow Analysis Report
Part thickness
Use different color to show the thickness.

AG10-07, 07 JULY 2010 Page 6

 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

AG10-07, 07 JULY 2010 Page 7

 Moldflow Analysis Report
Filling Pattern
Fig 1 Fig 2

The last filling area

Fig 3 Fig 4

AG10-07, 07 JULY 2010 Page 8

 Moldflow Analysis Report
Filling Time (Flash)

AG10-07, 07 JULY 2010 Page 9

 Moldflow Analysis Report
Filling Time (Flash)

AG10-07, 07 JULY 2010 Page 10

 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.

AG10-07, 07 JULY 2010 Page 11

 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.

AG10-07, 07 JULY 2010 Page 12

 Moldflow Analysis Report
Weld Lines
The weld lines (color curve) might be visible to
eye, due to the zero degree of the two melts.

AG10-07, 07 JULY 2010 Page 13

 Moldflow Analysis Report
Air traps
The air traps (pink mark ) location are as show.

AG10-07, 07 JULY 2010 Page 14

 Moldflow Analysis Report
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

AG10-07, 07 JULY 2010 Page 15

 Moldflow Analysis Report
Cooling Channels : Temperature Rise

Slider cooling

AG10-07, 07 JULY 2010 Page 16

 Moldflow Analysis Report
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 Slider

AG10-07, 07 JULY 2010 Page 17

 Moldflow Analysis Report
Warpage in X direction

AG10-07, 07 JULY 2010 Page 18

 Moldflow Analysis Report
Warpage in Y direction

AG10-07, 07 JULY 2010 Page 19

 Moldflow Analysis Report
Warpage in Z direction

AG10-07, 07 JULY 2010 Page 20

 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.

AG10-07, 07 JULY 2010 Page 21

 Moldflow Analysis Report

END

AG10-07, 07 JULY 2010 Page 22