mold flow analysys project

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  • J.M. Keerthi Bandara.

    SOAP BOX [MOLD FLOW ANALYSED REPORT]

    19 April 2017

  • PAGE 1

    Statement of the problem.

    1. Select a suitable injection molding machine for the soap

    box production process.

    2. Select a suitable material feeding mechanism for

    injection mold to get high quality product. (Pinpoint

    gate & Submarine gate)

  • PAGE 2

    Material & Method.

    Material Detail

    Polypropylene (PP)

    Melt temperature 180 c0- 260 c0

    Density 905 kgm-3

    Software

    Solidworks 2015.

    Autodesk Moldflow Adviser 2016.

  • PAGE 3

    Product Detail.

  • PAGE 4

    Results.

    Table 1:- Submarine Gate.( Runner diameter 1.76 mm balanced)

    Maximum clamp force during cycle

    16.021 (tonne)

    Max. wall shear stress

    0.231 (MPa)

    Total part weight

    25.794 (g)

    Cooling time

    0.80 (s)

    Cycle time

    16.86 (s)

    Table 2 :- Pinpoint Gate (Runner diameter 2.64 mm and 2.79mm

    balanced)

    Maximum clamp force during cycle

    19.395 (tonne)

    Max. wall shear stress

    0.288 (MPa)

    Total part weight

    24.947 (g)

    Cooling time

    0.00 (s)

    Cycle time

    16.09 (s)

    Both runner systems are balanced by Mold Flow 2016 software.

  • PAGE 5

    Flow Analysis Result

    Figure 1: Confidence of fill.

    Figure 2: Fill time.

  • PAGE 6

    Figure 3: Injection pressure.

    Figure 4: Quality Prediction.

  • PAGE 7

    Figure 5 : Temperature at flow front.

    Figure 6 : Time to reach ejection temperature.

  • PAGE 8

    Figure 7: Volumetric Shrinkage at ejection.

  • PAGE 9

    Conclusion.

    According to Table 1 and Table 2, clamp force of the pin point gate product higher

    than the submarine gate product. Part weight of pin point gate product lower than

    the submarine gate product.

    Machine Selection,

    According to clamp force,

    For submarine gate product = 16.021 x 1.5 = 24.03 tone.

    For pinpoint gate product= 19.395 x 1.5 = 29. o9 tone.

    According to part weight,

    For submarine gate product = 25.794 x 1.2 = 30.95 g.

    For pinpoint gate product= 24.947 x 1.2 = 29. 93 g.

    According to flow analysis results, the pin point gate product quality is higher than

    the other. But according to Figure 7, the pin point gate product has higher

    volumetric shrinkage it will be creating sum sink problems (yellow area).

    According Figure 5 this product needs some modifications to reduce the

    difference of the temperature at flow front to building up high quality and durable

    product.

  • PAGE 10