mold flow from hi precision

Moldflow Analysis ReportMoldflow Analysis Report

Reported by: Tom

Moldflow Analysis Moldflow Analysis ReportReport

HOUSINGHOUSING_UPPER_UPPER

2005.03


Reported by: Tom

Analysis the product’s flow, cooling , warpage conditions according to customer’s design .So as to we can achieve the reasonable process via good design of cooling and runner system.

ANALYSIS AIMS


Reported by: Tom

Outline dimension （ 458.6 X 288.8X50.5 ）

Part Model Introduction

Thickness distribution is indicated as figure. The base thickness is 2.5mm.

50.5mm

288.8mm

458.6 mm


Reported by: Tom

1. Melt Density 0.91818 g/cu.cm2. Solid Density 1.0215 g/cu.cm3. Ejection Temp. 100.0 deg.C4. Recommended Mold Temp. 44.0 deg.C5. Recommended Melt Temp. 235.0 deg.C6. Absolute Max. Melt Temp. 300.0 deg.C

7. Min melt temp. 200.0 deg.C 8. Max melt Temp. 270.0 deg.C 9. Min mould temp. 33.0 deg.C10. Max mould temp. 55.0 deg.C11. Max shear rate 40000.00 1/s12. Max shear stress 0.30 MPa

Plastic Material Introduction

Viscosity profiles

PVT profiles

HIPS HIPS Styron H9152T: Styron H9152T: Dow Dow Chemical USAChemical USA


Reported by: Tom

Feeding System Design

Feeding system is created according to the customer’s design.


Reported by: Tom

Cooling System design

Cooling system is created according to customer’s design.

Φ10mmBaffleΦ25mm

Φ10mm

Cavity side

Core side


Reported by: Tom

9 20.0 t(s)

P(MPa)

84.5

Processing conditions

Filling Conditions :

Mold temperature : 44.00 deg.C

Melt temperature : 235.00 deg.C

Injection time : 2.2 sec

Cooling Conditions:

Coolant Temperature(Cavity) 34 deg.C

Coolant Temperature(Core) 34 deg.C PRESSURE[MPa] STEP DURATION [sec]

84.5 0.0

84.5 9

Packing is 80% max injection pressure

Packing profile :


Reported by: Tom

Fill time


Reported by: Tom

Fill time series

Last filled area


Reported by: Tom

Distribution of flow front temperature is mostly even,but in some rib area （ circle area, indicated in picture ） the temperature decreased a lot. Because hesitation occurred in this area for the relative thin ribs.

Temperature at flow front


Reported by: Tom

Part totally frozen ， runner has frozen 60%.

Frozen layer fraction

Gate frozen, Packing stopped.


Reported by: Tom

Temperature distribution is indicated as the figure.

Temperature (top) , part


Reported by: Tom

Temperature (bottom) , part

Temperature at core side is some high in some ribs and boss area.


Reported by: Tom

Weld lines

Weld line may occurred at the black-line locations in the figure.


Reported by: Tom

Air traps

Air traps may occurred at pink circle area as the figure shows.


Reported by: Tom

Sink mark depth

Original

Improved

Sink mark depth can be decreased via packing profile adjusting.

P(MPa)

95

Increasing packing pressure so as to decrease the sink mark

6 9 20.0 t(s)


Reported by: Tom

Injection pressure & clamping force

Injection pressure

clamping force

Max.: 105.7 MPa

Max.: 496.5 ton


Reported by: Tom

Shape in the picture has been scaled 10 times 。

Introflexion

Totally Deflection

IntroflexionIntroflexion


Reported by: Tom

Deflection’s differential influence

Warpage are caused by uneven cooling and uneven shrinkage.

Cooling shrinkage

Orientation


Reported by: Tom

Deflection , caused by uneven cool （ original ）

Water inlet

34 deg.C

introflexion

0.81mm

0.50mm

Cooling result is better in left side compared to the right 。

Original

introflexion


Reported by: Tom

Water inlet

20 deg.C

0.68mm

A better cooling conditions on right side will decrease the side introflexion 。

Deflection , caused by uneven cool （ improved ）

Improved

0.45mm

introflexion

introflexion


Reported by: Tom

Original injection profile

The shrinkage are not so even ， the two side indicated in the figure are trend to protrude outside 。

Deflection , caused by uneven shrinkage （ original ）

Original


Reported by: Tom

The shrinkage towards inside are even , and the shrinkage value has been compensated via material’s shrinkage.

Deflection , caused by uneven shrinkage （ improved ）

Improved injection profileImproved


Reported by: Tom

Conclusion & Comment

Gets from the results ： The flow pattern is mostly balanced; Be care those locations that may occur weld line

or air trap 。 There will be some warpage on the molding

part. The sink mark would occurred on the part

surface, We could make it better via good packing condition .

mold flow from hi precision

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