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Cool, Flow & Warp Analysis Of Small base P art

Cool, Flow & Warp Analysis Of Small base P art. Contents. Summary. ANALYSIS AIMS To study the flow and predict the cy cle 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.

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Cool, Flow & Warp Analysis Of Small base P art

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  1. Cool, Flow & Warp Analysis OfSmall base Part

  2. Contents

  3. Summary ANALYSIS AIMS To study the flow and predict the cycle time of theA1309-2part. 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).

  4. Material : PP Similar Material Trade Name: Polypropylene PPC 5660Manufacturer : 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

  5. Part thickness Use different color to show the thickness.

  6. Part thickness Use different color to show the thickness.

  7. 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

  8. Filling Pattern Fig 1 Fig 2 The last filling area Fig 3 Fig 4

  9. Filling Time(Flash)

  10. Filling Time(Flash)

  11. Pressure drop A pressure drop of 15MPa is expected across the system, this indicated that the material is easy to fill this part.

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

  14. Air traps The air traps (pink mark ) location are as show.

  15. 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 exceed0.66C, this indicate the cooling channels are efficient. Cavity Core cooling

  16. Cooling Channels : Temperature Rise Slider cooling

  17. 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

  18. Warpage in X direction

  19. Warpage in Y direction

  20. Warpage in Z direction

  21. Warpage in Z direction The main warpage area Z direction 3 gates, the warpage of Z direction just reduce about 0.1mm compare to 1 gate.

  22. END

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