mold flow analysis report - upmold technology limited

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Mold Flow Analysis ReportAutomotive Radiator Grille Injection Mold

Video Hyperlink:http://upmold.com/Product/automotive-grille-mold-flow-analysis-report/

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2

Product

Automotive grille of Audi car

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Reliable Creative SolutionsMaterials

Manufacturer Bayer MaterialScience

Trade name Makroblend DP 7645

Family abbreviation PC+PET

Mold temp. 70 (60-80) ℃

Melt temp. 270 (260-280) ℃

Max. shear stress 0.4 MPa

Max. shear rate 40000 1/s

Density Melt 1.0492

g/cm^3Solid 1.2303

Ejection temp. 125 ℃

Transition temp. 222 ℃

Absolute max. melt temp. 320 ℃

MFR --- ---

Mold flow Viscosity Index VI(270)0214

E1 2100 Mpa

E2 2100 Mpa

Shrinkage Model Uncorrected residual stress

Parallel Shrinkage 0.6851 %

Perpendicular Shrinkage 0.8864 %

PVT Plot

Viscosity Plot

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Reliable Creative SolutionsMesh

4

The 3D model is suplied by the customer , the mesh model is Dual-Domain

3DModel& Mesh Model Mesh Date

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Reliable Creative SolutionsThickness

The size of the part : 218.8 mm * 1075.0 mm * 435.7mmVolume of the part : 1578.6 cm^3 The global thickness of the part : 2.7mm

thin

thickness

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Case-1 Case-2 Case-3

7 hot nozzles with valve gate 10 hot nozzles with valve gate 9 hot nozzles with valve gate

Solutions

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Reliable Creative SolutionsFill time(Contour)

7


Hesitation Hesitation

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Pressure at injection location XY Plot


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Pressure at V/P switchover


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Volumetric shrinkage at ejection


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We got the conclusion as below Base on the analyzing validation. case-1：the case have hesitation and pressure is high；Case-2： the case have hesitation, but the pressure is OK; Case-3：best than case 1 and case 2

So we suggest use case3 and we did it in details as following pages.

Conclusion

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Injection System

G1(72,0)

Hot runner Series Synventive

Valve No. NOZZLE DUCT (mm)

Pin(mm)

GATE (mm)

G1~G9 22 7 5

G2(-142,-132)G3(-142,132)

G6(-60,292) G7(-60,-292)

G5(-195,-283)G4(-195,283)

G8(130,265) G9(130,-265)

Valve gate control :The nozzle Open time

G1~3 0s

G4~9 2.83s

Case-3

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Injection System

G1

G2G3

G4

G5

G6

G7

G8

G9

Cold gate 12*1.5mm

Cold runner

Case-3

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Reliable Creative SolutionsFill time(Contour)

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The contours are evenly spaced and indicate the speed at which the polymer is flowing. Widely-spaced contours indicate rapid flow; narrow contours indicate that the part is filling slowly. The fill time is 4.38s.

Case-3

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The fill time is 4.38s ,the V/P switch-over is starting when the filling volume is 99%.

Fill time

G1

G2

G1~G3 0s G4~G9 open at 2.83s volume is 63%

100%90%

G8

G5G4

G6G7

G3

Case-3

G9

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Fill time(Dynamic)Click“shift+F5”Play

Case-3

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The holding pressure (About 76% of the Max. pressure)

The Max. pressure

Pressure at injection location XY PlotWe notice that maximum pressure is reached at 2.8 sec during filling, it is 76.4Mpa, and the holding pressure is about 58Mpa (About 76% of the Max. pressure).

Case-3

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Reliable Creative SolutionsClamp force XY Plot

Clamp force in packing phase

Clamp force in filling phase

The result depends on projected surface of the part and the injection pressure. A good clamp force history result should show that the maximum clamp force applied is less than approximately 80% of the machine limit, allowing the remaining about 20% as a safety factor.

The max clamp force is 1576tonne.

Case-3

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The flow front Temp. is 272.1~281.7℃ ,the difference of Temp. is 9.6℃,No hesitation ,No short shot, No deflection .

Temperature at flow front

★:Melt Temp. Setting：270 ℃;Melt Temp. Range(Recommended)：260℃~280℃

Case-3

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Air trapsThe air traps is at the end of the flow fronts and between two or more converging flow fronts , please consider to select appropriate locations for air vents .

Case-3

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21

Weld linesWe don’t observe any critical and brittle weld lines during filling for this part . All visible weld lines are located in corner and less visible areas with good quality.

Case-3

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Weld linesWe don’t observe any critical and brittle weld lines during filling for this part . All visible weld lines are located in corner and less visible areas with good quality.

熔接线成型温度较高,熔接线质量较好

Case-3

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23

Shear rate, bulkThe bulk shear rate should not exceed the maximum value(40000 1/s) recommended for the material in the material database. Exceeding this value would likely lead to polymer degradation.

Case-3

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Shear stress at wallThe shear stress should be less than the maximum recommended for the material in the material database(0.4Mpa). The shear stress can be compared directly with the values stored in the material database. Regions above this limit could be subject due to stress-cracking during ejection or in service.

Case-3

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Injection PressureDuring cycle time, pressure dynamic distributionClick“shift+F5”Play

Case-3

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Pressure at V/P switchoverThe Pressure at V/P switchover result shows the pressure distribution through the flow path inside the mold at the switchover point from velocity to pressure control. The packing is started when the filling volume is 99%, the pressure is 72.2Mpa in at entrance point on the part, the time is 4.29s.

Case-3

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Reliable Creative SolutionsPressure, in cavity Case-3

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Volumetric shrinkage at ejectionThis plot shows the distribution of the volumetric shrinkage at ejection. It is high near the Gate point area. The target is to reach a homogeneous profile.

Case-3

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Sink marks estimate Case-3

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Reliable Creative SolutionsThroughputThe plot shows the throughput for each runner and we can know its efficiency .

Case-3

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Frozen layer fraction (Dynamic)The Frozen layer fraction result shows the thickness of the frozen layer as a fraction of the part thickness. Ideally the part freezes uniformly and as quickly as possible.

Case-3

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Conclusions

1. The fill time is 4.38s; the V/P switchover start at 4.29s, when the part volume is filled at 99% of the volume ,The V/P pressure is 72.2MPa. And Max pressure is 76.4MPa;

2. The Max. clamp force is 1576tonne during the packing phase ;3. The air traps is at the end of the flow fronts and between two or more converging

flow fronts , please consider to select appropriate locations for air vents . (P19) 4. The weld lines is between two or more converging flow fronts , Please check

it .(P20~21)

Case-3

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Thank you

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mold flow analysis report - upmold technology limited

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