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Moldflow Analysis Report

CASE AL3909 _ 20170606


2017.06
2017.06
ANALYSIS AIMS
To analysis original design, cooling and check flow , warp.
Plastic Material Introduction
PC Lexan SLX1432 : SABIC Innovative Plastics US, LLC
In software can’t find the grade of material, so we choose a near material.
1. Melt Density 1.0969 g/cu.cm 7. Melt Temperature Minimum 295.0 deg.C
2. Solid Density 1.0319 g /cu.cm 8. Melt Temperature Maximum 315.0 deg.C
3. Ejection Temperature 125 deg.C 9. Mold Temperature Minimum 70.0 deg.C
4. Recommended Mold Temperature 80 deg.C 10. Mold Temperature Maximum 95.0 deg.C
5. Recommended Melt Temperature 305 deg.C 11. Maximum Shear Rate 40000.00 1/s
6. Absolute Max. Melt Temperature 355 deg.C 12. Maximum Shear Stress 0. 500 MPa

PVT profile

Viscosity model
P a r t I n t r o d u c t i o n

The mostly wall thickness of part is imbalance shown by picture.


Feed System Design

Cold sprue 4-+mm

Cold runner 6mm

sub gate 1.5mm


Cold runner 6mm

1x1 cavities, two plates mold, Cold runner +sub gate, the size is shown by picture.
Cooling System Design

The cooling system is shown by picture, the diameter of channel is 10mm, the diameter of bafflers is 13
mm.
Processing conditions

Filling Conditions : Packing Profile :


Mold temperature : 80.00 deg.C
Melt temperature : 305.00 deg.C
Injection time 1.6sec

Cooling Conditions:
Coolant Temperature(Cavity) 80 deg.C
Coolant Temperature(Core) 80 deg.C PRESSURE [MPa] STEP DURATION [sec]
94.5 0.0
94.5 10.0
Circuit coolant Temperature

The circuit coolant temperature of part is balance shown by picture.


Temperature (bottom), part

• The temperature variation over each mold face should be more than 10°C, because the part is
too deep. Otherwise it may bring negative effect on deflection.
• The distribution of temperature over mold faces is uneven, It is under of the range .
Fill time

Shown by picture the fill time is 1.6s and the flow status is
balance.
Fill time

Shown by picture the fill time is 1.6s and the flow status is
balance.
Fill time series
Pressure at V/P switchover

• The result shows the pressure distribution through the flow path inside the mold at the switchover point from
velocity to pressure control.
• The filling is balance and the pressure at V/P switchover is about 114.4 MPA. The main pressure losing is
through the runner , about 53.9 MPA .Considering the part is not a small one, both pressure value are low and
acceptable.
.
Temperature at flow front

Temperature at flow front is balance shown by picture.


Air traps

• The air trap shown in purple plots and occur in the end of filling. Vents or inserts are
required near the air trap location to avoid part quality issues.
Air traps

• The air trap shown in purple plots and occur in the end of filling. Vents or inserts are
required near the air trap location to avoid part quality issues.
Weld lines

The color lines are possible weld lines.


Weld lines

The color lines are possible weld lines.


Volumetric shrinkage

Volumetric shrinkage is imbalance show by picture, please attention the setting of pac
king.
Sink marks estimate

• The sink marks may be visible when the estimate value>0.07mm. The sink marks is not
obvious. Adjust the packing time and packing pressure may improve the sink marks.
Injection Pressure & Clamp Force

Max.: 114.4MPa Max.: 61.2tonne

Pressure at injection location Clamp Force


Frozen series

Finish cooling, close cycle.


Deflection – All direction

Deflection of All direction is imbalance, possible cause warp.


Deflection – X direction

0.2mm

0.3mm

Deflection of X direction is imbalance, possible cause warp.


Deflection – X direction

0.2mm

0.3mm

Deflection of X direction is imbalance, possible cause warp.


Deflection – Y direction

Deflection of Y direction is balance, cause warp is little.


Deflection – Y direction

Deflection of Y direction is balance, cause warp is little.


Deflection – Z direction

Deflection – Z direction is balance, cause warp is little.


Deflection – Z direction

Deflection – Z direction is balance, cause warp is little.


S u m m a r y

The results::
The flow status is balance, the injection and packing pressure is normal.
The volumetric shrinkage is imbalance, please attention the setting of packi
ng.
Deflection of Y&Z direction is balance, cause warp is little. Deflec
tion of X direction is imbalance, possible cause warp.
The project cycle time: 1.6 (filling)+ 24.4(cooling + packing) + 5.0 (open & eject & c
lose) =31.0 sec.