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20038 Page 1 2005/05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 David Deng 20038 BATTERY COVER.

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Presentation on theme: "20038 Page 1 2005/05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 David Deng 20038 BATTERY COVER."— Presentation transcript:

1 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER 2005/05/29 David Deng BATTERY COVER

2 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER 1.Plastic Material Introduction Product Model Introduction Cooling System Design Feed System Design Analysis Indication Processing Conditions Analysis Results ~27 8.Conclusions & Suggestions Contents

3 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER PP POLYPROPYLENES CM1171 Taiwan PP VI(245)84 OCT JUL93 1. Conductivity W/m/ deg.C 8. Ejection temperature deg.C 2. Specific heat J/kg/ deg.C 9. Min. melt temperature deg.C 3. Melt density kg/cu.m 10. Max. melt temperature deg.C 4. Max. shear stress MPa 11. Min. mold temperature deg.C 5.Max. shear rate /s 12. Max. mold temperature deg.C Material introduction

4 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER 210 Product model introduction Max. contour dimension(mm)Thickness distribution Thickness distribution is not even. Min. wall thickness is about 0.64mm, Max. wall thickness is about 5.00mm. As shown below the plot, the blue is the thinner region, and the red is the thicker region(include injection and cooling system)

5 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Cooling system have 20 circuits. Core have 12 circuits and cavity have 8 circuits. Cooling System Design Cooing network Ø10

6 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Feed System Design The mold is cold feed system, two cavities, one banana gate. The dimension of the gate is shown in top plot. 9 Gate location Ø 4.15 Ø Ø Gate

7 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Moldflow CAE analysis includes Flow,Cooling and Warp results,aimed to optimize the feed system, the cooling syst em of the mold. Analysis Indication

8 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Mold temperature: deg.C Melt temperature: deg.C Injection time 3.8 sec Total Volume (cavity): cu.cm Part Volume : cu.cm Sprue/runner/gate volume: 5.00 cu.cm Total Weight : g Runner Weight 3. 5 g Circuit Inlet Temp : 25.0 deg.C MPa s Processing Conditions Filling Conditions: Cooling Conditions: Packing profile: Pressure [MPa] Time [sec]

9 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Best Gate Location The best gate location lie in the marked region. It is difficult to design mold, so cant be accepted in fact. Gate Analysis Results\

10 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Flow Analysis Results\ Fill Time Click for animation Fill time is about 3.8sec, and the filling pattern is satisfied. The marked region is filled last.The below plot is the scene of filling 99%(V/P switch over).

11 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Fill Time Click for animation Fill time is about 3.8sec, and the filling pattern is satisfied. The marked region is filled last.The below plot is the scene of filling 99%(V/P switch over). Flow Analysis Results\

12 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Injection Pressure Max. injection pressure is 33 Mpa (V/P switch over). Flow Analysis Results\

13 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Injection Pressure The pressure drop in runner system is about 24MPa, which is 72.7% of injection pressure. The below plot is the pressure distribution of filling 99%(V/P switch over). Flow Analysis Results\

14 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Flow Front Temperature The flow front temperature is from 221 to deg.C, and the distribution is not very uniform. The minimum temperature is shown in the marked region.Pay attention to the weldlines in this area. Flow Analysis Results\ Gate

15 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Weld Lines Main weld lines are shown as red lines. Gate Pay more attention to the weldlines in this area. Flow Analysis Results\

16 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Air Traps Air traps locations are shown by small pink balls. Most of them lie in the last filling or the interface area, so can be vented easily. Gate Flow Analysis Results\

17 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Sink Index Pay attention to the Sink Mark in marked region. Gate Flow Analysis Results\

18 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Clamp Force(Max.=61.3Ton) Clamp Force Variation curve of pressure&clamp force in cycle time shown by above figure. Clamp Force Centroid locates in the center of mold. Flow Analysis Results\

19 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Temp difference (Max.=0.23 deg.C ) Coolant Temp Coolant temp differe nce is very small,so t he number of circuits is enough. Cool Analysis Results\

20 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Temp (part) The distribution of temp is not very uniform. Pay more attention for the cooling in marked region. Cool Analysis Results\

21 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Cool Analysis Results\ Temp (part) Pay more attention for the cooling in marked region.

22 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Click for animation. Frozen Time(part) Cool Analysis Results\

23 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER The frozen time is non-uniform. The frozen time of m ost area is about 23 S, 6.1S in gate area. Cool Analysis Results\ Frozen Time(part) Pay more attention for the cooling in marked region.

24 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER The frozen time of gate is about 6.45S,less tha n the frozen time of mo st area in the part,whic h will do harm to packin g. Design larger gate. Cool Analysis Results\ Frozen Time(gate)

25 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER X Deflection The X direction belongs to natural shrinkage basically. Warp Analysis Results

26 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Y Deflection Deflection in Y direction is shown in the left plot, belongs to natural shrinkage basically. Warp Analysis Results

27 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Z Deflection Warp Analysis Results Deflection in Z direction is uniform Gate

28 20038 Page /05/29 MOLDFLOW ANALYSIS REPORT CYPRESS CHINA CAE/CAD/CAM TECH CENTER Conclusions&Suggestions From the above analysis: Some weld lines maybe affect the strength of molding part, and air traps are vented easily. The packing effect is the main cause of sink mark,deflection. Deflection is very uniform,improve packing will get small deflection. The distribution of temp is not very uniform. Suggestions: To use baffle,bubbler and inserts to improve cooling effect. To design larger gate.


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