DESIGN OF EXPERIMENTS SOFTWARE INJECTION MOLDING

DESIGN OF EXPERIMENTS SOFTWARE INJECTION MOLDING
INTRODUCTION TO NAUTILUS 7 MOLD QUALIFICATION AND DESIGN OF EXPERIMENTS SOFTWARE FOR INJECTION MOLDING SUHAS KULKARNI FIMMTECH

SUHAS KULKARNI FIMMTECH 1-760-525-9053
NAUTILUS IS A PROGRAM THAT HELPS IN THE EVALUATION, ANALYSIS, DEVELOPMENT AND DOCUMENTATION OF THE INJECTION MOLDING PROCESS. THE SOFTWARE ALSO HAS A COMPLETE DESIGN OF EXPERIMENTS MODULE THAT IS CUSTOMIZED FOR INJECTION MOLDING SUHAS KULKARNI FIMMTECH

BENEFITS OF USING THE TECHNIQUES: ESTABLISHED PROCESS IS ROBUST PROCESS WILL BE A ‘NO OR LITTLE ATTENTION REQUIRED’ PROCESS WILL DETERMINE THE FASTEST CYCLE TIME POSSIBLE LESS SCRAP AT STARTUP LESS SCRAP DURING PRODUCTION IMPROVED PART QUALITY AND PROCESS CAPABILITY ABOVE FACTORS INCREASE THE BOTTOM LINE PROFITS! SUHAS KULKARNI FIMMTECH

3 CASE STUDIES SUHAS KULKARNI FIMMTECH

CASE STUDY 1 – CONSUMER PRODUCT
Part and Mold Irrigation Body – 32 Cavity Hot Runner Status Diameter closer to LSL with CpK < 1.0 Length closer to LSL Cycle Time = 46 seconds Target Diameter to be closer nominal Length to be closer to nominal Diameter and Length CpK ≥ 2.0 Cycle time = 38 seconds Analysis Via Scientific Molding and DOE it was found that higher pack pressures helped increase the dimensions Machine tonnage was not sufficient to prevent flash DOE showed cooling time did not have significant effect on the part dimensions. Actions Mold moved to a higher tonnage machine Process re-established using Scientific Molding and DOE Achievements Diameter and Length in spec and closer to nominal Diameter and Length CpK>2.0 Cycle Time = 35 seconds Suhas Kulkarni - FIMMTECH

CASE STUDY 2 – AUTOMOTIVE PRODUCT
Part and Mold Automotive Connector – 4 Cavity Mold Status Shroud Dimension in the center lower than LSL Shroud Walls not parallel to each other Cycle time was 38 seconds Target Shroud Dimension to be at nominal Shroud walls to be parallel to each other Cycle time of 32 seconds Analysis Shroud was closer to the end of fill Shroud thickness was relatively smaller compared to the rest of the part. Shroud was not sufficiently packed out Actions A Gate seal study using Scientific Molding showed the gate froze off too quick. The gate was opened up. DOE showed the shroud dimension could be improved up to half of what was required. The steel in the shroud area was contoured to compensate for the warp Achievements Shroud dimension and parallelism were in spec Cycle Time of 32 seconds was achieved Based on the DOE results, a new molding screw with a different design was installed and cycle time of 29 sec was achieved Suhas Kulkarni - FIMMTECH

CASE STUDY 3 – MEDICAL PRODUCT
Part and Mold Surgical Clip – 16 Cavity Hot Runner Mold Status Part Length was over the LSL Mold was not steel safe Cycle time = 24 seconds Black streaks were found on the molded part Target Part Length to be closer to Nominal Cycle Time = 15 seconds No Black Streaks Analysis Part was too thick, needed extra time to cool Residence time in hot runner was too high Actions Scientific Molding and DOE was done to understand the effect of the process on the part quality Part was cored out to reduce the thick section. Scientific Molding and DOE were redone. Achievements New thinner part thickness helped to run the mold at lower cooling times therefore achieving a cycle time of 12 seconds Part length was closer to nominal with CpK values = ~ 4.0 With faster cycle, the residence time in the hot runner manifold reduced and the black specs were eliminated. Suhas Kulkarni - FIMMTECH

THE SOFTWARE SUHAS KULKARNI FIMMTECH

FOLLOWING ARE SOME OF THE FEATURES OF THE SOFTWARE: MATERIAL, MOLD AND MACHINE DATABASES MOLD – MACHINE COMPATIBILITY REPORT SCIENTIFIC MOLDING WORKSHEETS (6-STEP STUDY) VISCOSITY STUDY PRESSURE DROP STUDY CAVITY BALANCE STUDY PROCESS WINDOW STUDY GATE SEAL STUDY COOLING TIME SUHAS KULKARNI FIMMTECH

DESIGN OF EXPERIMENTS MODULE TORNADO CHARTS – WHAT IS THE MOST SIGNIFICANT FACTOR? PROCESS SENSITIVITY CHARTS COSMETIC PROCESS WINDOW DYNAMIC PROCESS WINDOW VISUAL PREDICTION EQUATION MOLD TRIAL AND QUALIFICATION PROGRESS REPORT WATER LINE DIAGRAMS AND MOLD TEMPERATURE MAPS MOLD SETUP AND OPERATION DOCUMENTATION SUHAS KULKARNI FIMMTECH

QUALITY MODULE FULL DIMENSIONAL ANALYSIS STATISTICAL ANALYSIS POST MOLDING SHRINKAGE REPORT DOCUMENTATION OF QUALITY INSPECTION PLAN MOLD DESIGN AND PART DESIGN CHECKLISTS CALCULATION WORKSHEETS COMMONLY USED IN MOLDING SUHAS KULKARNI FIMMTECH

MAIN SCREEN: SUHAS KULKARNI FIMMTECH

VISUAL HELP MENU IS AVAILABLE IN EACH SCREEN
SUHAS KULKARNI FIMMTECH

DATABASES: MATERIAL – MOLD – MACHINE SUHAS KULKARNI FIMMTECH

MOLD MACHINE COMPATIBILITY REPORT: SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 1: IN MOLD RHEOLOGY SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 2: CAVITY BALANCE STUDY SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 3: PRESSURE DROP STUDY SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 4: PROCESS WINDOW SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 5: GATE SEAL STUDY SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 6: COOLING STUDY SUHAS KULKARNI FIMMTECH

WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS

INPUTS WORKSHEETS FOR DOE:

TORNADO CHARTS GIVES YOU INFO ON THE FACTOR THAT MOST IMPACTS THE PART QUALITY (POSITIVE FACTORS ABOVE THE LINE, AND NEGATIVE BELOW THE LINE) SUHAS KULKARNI FIMMTECH

PROCESS SENSITIVITY GRAPH GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE PROCESS SUHAS KULKARNI FIMMTECH

COMPOSITE PROCESS SENSITIVITY GRAPH GIVES YOU A QUICK SNAP SHOT OF HOW ALL THE DIMENSION WAS AFFECTED BY THE PROCESS (ALL ON ONE SCREEN) SUHAS KULKARNI FIMMTECH

DYNAMIC PROCESS WINDOW GREEN CONTOURS – PARTS IN DIMENSION RED – PARTS OUT OS SPEC YOU CAN DRAW A BOX AS SHOWN TO DETERMINE ALARM AND TOLERANCE SETTINGS SUHAS KULKARNI FIMMTECH

PREDICTION EQUATION SUHAS KULKARNI FIMMTECH

VISUAL PREDICTION EQUATION THE DIMENSION CAN GO OUT OF SPEC USL LSL Cavity No → EXTENT TO WHICH THE DIMENSION CAN BE INFLUENCED BETWEEN THE EXTREMES OF THE DOE PARAMETERS USL LSL Cavity No → SUHAS KULKARNI FIMMTECH

VISUAL PREDICTION EQUATION THE DIMENSION CAN GO OUT OF SPEC USL LSL Cavity No → STABLE DIMENSION – WILL ALWAYS BE IN SPEC USL LSL LSL Cavity No → SUHAS KULKARNI FIMMTECH

VISUAL PREDICTION EQUATION PROCESS GOLD SPOT - BEST PROCESS TO BRING ALL DIMENSIONS CLOSEST TO NOMINAL USL LSL Cavity No → STABLE DIMENSION – WILL ALWAYS BE IN SPEC USL LSL Cavity No → SUHAS KULKARNI FIMMTECH

VISUAL PREDICTION EQUATION SIMULATED PROCESS USL LSL Cavity No → USL Cavity No → SUHAS KULKARNI FIMMTECH

DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED CAVITIES AND DIMENSIONS SUHAS KULKARNI FIMMTECH

CONFIDENCE RATINGS SUHAS KULKARNI FIMMTECH

PRINTING: SELECTION SCREEN

PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS

MOLD SPECIFIC TROUBLE SHOOTING GUIDE

WATER LINE DOCUMENTATION: SUHAS KULKARNI FIMMTECH

MOLD TEMPERATURE DOCUMENTATION: SUHAS KULKARNI FIMMTECH

CAVITY LAYOUT DOCUMENTATION: SUHAS KULKARNI FIMMTECH

QUALIFICATION DOCUMENTATION: SUHAS KULKARNI FIMMTECH

CHECKLIST SUHAS KULKARNI FIMMTECH

FULL DIMENSIONAL ANALYSIS: SUHAS KULKARNI FIMMTECH

STATISTICAL ANALYSIS : SUHAS KULKARNI FIMMTECH

ATTRIBUTE DATA ANALYSIS : SUHAS KULKARNI FIMMTECH

INJECTION SPEED LINEARITY : SUHAS KULKARNI FIMMTECH

SHOT TO SHOT REPEATABILITY TEST : SUHAS KULKARNI FIMMTECH

LOAD SENSITIVITY TEST : SUHAS KULKARNI FIMMTECH

FREQUENTLY USED MOLDING CALCULATIONS: SUHAS KULKARNI FIMMTECH

WATER FLOW CALCULATION: SUHAS KULKARNI FIMMTECH

PROCESS TRANSFER BETWEEN MACHINES WORKSHEET: SUHAS KULKARNI FIMMTECH

SHOT SIZE ESTIMATION WORKSHEET: SUHAS KULKARNI FIMMTECH

HOPPER SIZE CALCULATION WORKSHEET: SUHAS KULKARNI FIMMTECH

REGRIND CALCULATIONS: SUHAS KULKARNI FIMMTECH

COST OF THE SOFTWARE: $2295 PER COMPUTER WITH A 10% MAINTENANCE CHARGE EVERY YEAR. AN EXAMPLE OF THE RETURN ON INVESTMENT IS GIVE IN THE NEXT PAGE. YOU CAN PERFORM YOUR OWN ANALYSIS ON THE SLIDE AFTER THE EXAMPLE. SUHAS KULKARNI FIMMTECH

PERFORM YOUR OWN ANALYSIS NEXT ….. SUHAS KULKARNI FIMMTECH

CONTACT INFO: SUHAS KULKARNI SUHAS KULKARNI FIMMTECH

DESIGN OF EXPERIMENTS SOFTWARE INJECTION MOLDING

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