Moldflow Analysis Report

Description:
3 D dimension of this part is 160.58mmX86.63mmX53.49 mm
Volume of this part is 35.22 cm^3
To be sure that the design reasonable and injection molding feasible, we used Moldflow
MPI6.1 to analyze

Slide 1

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Material Property:
The material is specified as GE cycolac C6200 by customer, it can be selected in moldflow
material database directly, property of the material is as below.
1. Melt Density
0.98129 g/cm^3
2. Solid Density 1.1161 g/cm^3
3. Recommended Mold Temperature
4. Recommended Melt Temperature
5. Absolute Max. Melt Temperature
6. Ejection Temperature

7. Melt Temperature Minimum

71
267
325
87

248

8. Melt Temperature Maximum

285

9. Mold Temperature Minimum

60

10.Mold Temperature Maximum

11.Maximum Shear Rate
12.Maximum Shear Stress

82
40000 1/s
0.4 Mpa

PVT graph

Viscosity graph

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Slide 2

Mesh Statistics:
Fusion mesh will be used according to shape of the part ,the Match percentage is 91.8% and
the Reciprocal percentage is 90.8%, so the mesh can completely meet the requirement of
cool + flow + warp analyze .
Thickness of the mesh is mostly equal to the wall thickness of the part, in order to ensure the
accuracy of analysis results.

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Mold Design Scheme :

Mold type: 2 plates, submarine gate, cav1*1, moldbase 3035
Runner system and cooling circuit will be determined by moldflow engineer
Note: It is recommended that a gate location analysis should be run before
runner system has been designed to determine the best gate location.
Cold sprue:

4+1taper

Submarine gate:
1.0

Cold runner:5
gate location result

dimension of runner system

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Slide 4

Note: Cooling circuits were designed by moldflow engineer ,

only for reference, and it will be different from actual mold

Left view

Top view

Slide 5

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Cooling channel
8

Front view

Work piece

Cooling circuits layout

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Slide 6

Process condition :
Note: It is recommended that a molding window analysis should be run before process setting, in order to
determine the optimum fill time. The optimum fill time zone is where the injection pressure and maximum shear
rate and maximum shear stress are lowest together, green zone in pictures as follows.

The optimum fill

time is about 1.5s

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Details of process setting

Fill time1.5s
Injection+packing+cooling time30s
Mold temperature71
Melt temperature267
Coolant inlet temperature of cavity side cooling circuit60
Coolant inlet temperature of core side cooling circuit40
V/P switch-over by %volume filled at: 98%
Holding pressure
times

pressureMpa

65

65

0
Water
40

Water
60
Water
60

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Slide 8

Results explain :
Fill time

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Slide 9

Note:
These pictures showed the filling step, the parts will be filled entirety.

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Slide 10

Animation

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Slide 11

Temperature at flow front

Note:
Temperature at flow front varied from 259.9 to 268.8 , and not be out of the materials melt temperature
range (248 ~285 ).

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Slide 12

Weld line

Warning:
Weld lines will be occured at area marked by red arrow, change the gate location if necessary.

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Air

Slide 13

traps

Note:
Most of air traps will be occured at the top of rib, it is necessary to vent at that area to avoid burning or
short shot .

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Slide 14

Pressure distribution

Note :
Pressure in cavity is not uniform, maximum pressure is 44.39Mpa, pressure lost in runner system is about 20.6Mpa.

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Slide 16

Pressure (Animation)

Injection pressure graph

Note:
Pressure is measured at start of runner system, pressure in barrel is not taken account

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Slide 17

Clamp force

Note:
Maximum clamp force is 30.70 tonne, so injection machine of 120 tonnage is adequate.

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Slide 18

Temperature, mold

Note:
Temperature of mold surface is not uniform, there are two hot spots on the part, so it will need an excess cooling
time to cool the part, then cycle time will be longer.

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Slide 19

Temperature, part

Note:
Temperature of part surface is not uniform, but under the transition temperature(144 ) entirely.

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Slide 20

Frozen layer fraction

animation

Note:
Gates had been frozen at 8.7s, so 7s packing time is adequate.

Slide 21

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Volumetric shrinkage at ejection

Sink index

Note:
Volumetric shrinkage at ejection and Sink index are uniform at most
most of the part, but there are larger
value at two area marked by red arrow, sink mark will be arise possibly.
possibly.

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Slide 22

Deflection, All Effect

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Slide 23

Deflection, X component, isolate cause of warpage

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Slide 24

Deflection, Y component, isolate cause of warpage

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Slide 25

Note:
To view the exact value of warpage, we define a datum plane to measure,
the results are relative to datum plane.

Datum
plane

Detail view

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Slide 26

Deflection, Z component, isolate cause of warpage

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Slide 27

Note:
To view the exact value of warpage, we define a datum plane to measure,
the results are relative to datum plane.

Datum plane

Detail view

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Slide 28

Conclusion And Advice:

It is known from the analysis results that:
The part will be full filled easily, and injection machine of 120 tonnage is adequate;
Weld lines will be arised at part surface, this will cause an unexpected influence to

the quality, change the gate location to avoid or improve weld lines if necessary ;

Warpage value is high, Diff Shrinkage are the primary cause of warpage.

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Case2 (revised):
Mold type: 2 plates, submarine gate, cav1*1, moldbase 3035
Runner system and cooling circuit will be determined by moldflow engineer
Note: change the gate location to avoid or improve weld lines

Add a rib here if possible,

then place gate on the rib.

Original case

Revised case

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Slide 30

Results compare :
Fill time

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Slide 31

Note:
These pictures showed the filling step, the parts will be filled entirety.

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Slide 32

Animation

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Slide 33

Weld line

Note:
Weld lines move to corner of the part after gate location had been changed

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Slide 34

Pressure distribution

Note :
Pressure is little high than original case.

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Slide 35

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Slide 36

Pressure (Animation)

Volumetric shrinkage at ejection

Sink index

Note:
Volumetric shrinkage at ejection and Sink index are uniform at most
most of the part, but there are larger
value at two area marked by red arrow, sink mark will get worse.

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Slide 38

Deflection, All Effect

Deflection, X component, isolate cause of warpage

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Slide 39

Deflection, Y component, isolate cause of warpage

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Slide 40

Deflection, Z component, isolate cause of warpage

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Slide 41

Conclusion And Advice:

It is known from the analysis results that:
The part will be full filled easily, and injection machine of 120 tonnage is adequate;
Weld lines has been moved to corner of the part compared to original case, but sink mark

will get worse due to unbalance fill

Maximum injection pressure and maximum clamp force are little high than original case;
There is no more affect on warpage even the gate location had been changed.

END
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