1. Moldflow Analysis Report Page 1AG10-07, 07 JULY 2010 Cool, Flow & Warp Analysis Of Small base Part

2. Moldflow Analysis Report Page 2AG10-07, 07 JULY 2010 Contents 1.Summary03 2.Material Properties04 3.Part thickness05 -06 4.Processing Condition & Runner Layout07 5.Results08 - 21

3. Moldflow Analysis Report Page 3AG10-07, 07 JULY 2010 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). Summary

4. Moldflow Analysis Report Page 4AG10-07, 07 JULY 2010 PVT Plot Viscosity Plot 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

5. Moldflow Analysis Report Page 5AG10-07, 07 JULY 2010 Part thickness Use different color to show the thickness.

6. Moldflow Analysis Report Page 6AG10-07, 07 JULY 2010 Part thickness Use different color to show the thickness.

7. Moldflow Analysis Report Page 7AG10-07, 07 JULY 2010 Hot Gate size: Ф2.5mm 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 Processing Condition & Runner Layout

8. Moldflow Analysis Report Page 8AG10-07, 07 JULY 2010 Filling Pattern Fig 3 Fig 1 Fig 4 Fig 2 The last filling area

9. Moldflow Analysis Report Page 9AG10-07, 07 JULY 2010 Filling Time (Flash)

10. Moldflow Analysis Report Page 10AG10-07, 07 JULY 2010 Filling Time (Flash)

11. Moldflow Analysis Report Page 11AG10-07, 07 JULY 2010 Pressure drop A pressure drop of 15MPa is expected across the system, this indicated that the material is easy to fill this part.

12. Moldflow Analysis Report Page 12AG10-07, 07 JULY 2010 Temperature at flow front The plastics material enters the runners at 230 C. The overall temperature drop is about 1.2C, which is acceptable.

13. Moldflow Analysis Report Page 13AG10-07, 07 JULY 2010 Weld Lines The weld lines (color curve) might be visible to eye, due to the zero degree of the two melts.

14. Moldflow Analysis Report Page 14AG10-07, 07 JULY 2010 Air traps The air traps (pink mark ) location are as show.

15. Moldflow Analysis Report Page 15AG10-07, 07 JULY 2010 Cavity Core cooling 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. Cooling Channels : Temperature Rise

16. Moldflow Analysis Report Page 16AG10-07, 07 JULY 2010 Cooling Channels : Temperature Rise Slider cooling

17. Moldflow Analysis Report Page 17AG10-07, 07 JULY 2010 Cavity side Mould Surface Temperature Total Cycle time: 105 sec. ( Auto Injection + Packing + Cooling Times = 100 sec. Mold open time = 5 sec.) Hot spot Core side Slider

18. Moldflow Analysis Report Page 18AG10-07, 07 JULY 2010 Warpage in X direction

19. Moldflow Analysis Report Page 19AG10-07, 07 JULY 2010 Warpage in Y direction

20. Moldflow Analysis Report Page 20AG10-07, 07 JULY 2010 Warpage in Z direction

21. Moldflow Analysis Report Page 21AG10-07, 07 JULY 2010 Warpage in Z direction Z direction 3 gates, the warpage of Z direction just reduce about 0.1mm compare to 1 gate. The main warpage area

22. Moldflow Analysis Report Page 22AG10-07, 07 JULY 2010 END