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Top cover_soft part

Top cover_soft part

2020-06-18


           Moldflow Analysis Report

Top cover_soft part

Mold Number:16033

Prepared by:Gavin Zhang

Date Prepared:July 5th 2019

Version:Rev.1




           Project Summary

Analysis Purpose

Validate potential problem after the part and mold design

Check the fill balance pattern, weld line, air traps, and predict the needed clamp force and 

injection pressure, warpage.

Input Model Description

The runner system is simulated as the mold design.

Result Required 

Filling result

Warpage result 

Actual of cavities

1+1

Number of cavity analysis 

1+1

Part Material

 TPE 

Type of analyses

Flow + Warp


Material Data


■ The material datas are from supplier is in moldflow database and shown in the pictures below


Material Property

TPE (Thermolast K TP7VCZ from KRAIBURG )

Melt  Temperature Range (℃)

175~230

Solid Density (g/cm3)

1.05

Mold  Temperature Range (℃)

5~60

Maximum Shear Rate (1/s)

100006

Ejection Temperature (℃)

102

Maximum Shear Stress (MPa)

1

Absolute Maximum Melt Temperature (℃)

250

MFR (g/10min) (  ℃/  Kg)

/

Recommended Melt Temperature (℃)

200

Filler

Unfilled

Recommended Mold Temperature (℃)

30


Rheology:

           
PVT properties:

           


Part、Tool、Setup

Part Details and Tool Description

Part Name

Top cover_soft part

 CAD File / Version/ Date

16033_nrgkick_dsgn_asm_190627 /stp

Part Volume 

11 (1*1) cm^3

 Nominal Wall Thickness 

2 mm

Tool Description 

1*1  Cavity

Injection machine Tonnage 

/

Process Setup

Material 

TPE (Thermolast K TP7VCZ from KRAIBURG )

Injection time 

1.0 s

Material temp 

200 [deg.c]

Mold temp 

30 [deg.c]

Velocity/Pressure Transfer (% volume) 

98 %

Packing Pressure/Time

80% filling pressure /8 s, 60% filling pressure /4 s

Project Area 

41 (1*1 ) cm^2


Wall thickness

This above plot used different color to show the thickness of this part.

 We can see that: the average thickness of this part is 2 mm. 

 Total part weight =11 g (1*1 ) ,   the cold runners weight = 6 g 

             

Gate Location and size


The mold is the cold runner and point gate. 

 The runner layout was based on the 3D drawing.

             

Simulation results list

Fill time (Animate & Contour) 

Pressure at the V/P switchover 

Injection pressure

Clamp Force  

Weld lines 

Air Traps 

Time to freeze 

Volumetric shrinkage at ejection

Deflection  

Conclusions and suggestions 



Fill result – Fill animate

This result shows how the melt flows through the cavity.      Fill time is about:  1.3 sec.

Shift+F5,  you will see the animated flow

           

Fill result – Fill Contour

The area with dense lines in the above picture represents the area with lower flow velocity; and the area with sparse lines represents the area with higher flow velocity. 

           


Pressure at V/P switchover

 Above figure shows the pressure distribution through the flow path inside the mold, at the V/P switchover of the filling phase. 

           

Clamp force

 The maximum clamp force is 8.4 Tons.

           


Injection pressure
The maximum value is 88.8 Mpa, Injection pressure specified at Packing is 30.5 Mpa
The filling pressure are within moldflow recommend value which can acceptable.
           
Clamp force
The maximum clamp force is 8.4 Tons.
           


Weld lines locations

No weld lines appear on the surface



           

Air trapped area

 The result shows areas of the cavity that may require additional venting, it should be viewed in combination with the filling 
pattern result. Air traps locations mark in red color.
 Most of the air trapped appear at the edge of part and the tip of ribs that is easy to vent

           


Time to freeze

 The result shows the amount of time taken for all of the elements in the part to freeze to ejection temperature.  Air traps locations mark in red color.

 The time to reach ejection temperature is about 12 s for 95 % melt volume freezed, the cold runner is about 12 s for 60 % melt 

volume freezed 

           

Volumetric shrinkage at ejection

Visible sink marks appear on the wall surface. 

 The maximum shrinkage at ejection is 6.3 %.The minimum shrinkage at ejection is 1 %.

           


Deflection-All

 Note : warpage shape magnified 3X for display purposes.  (The undeformed  part display transparent). The maximum shrinkage and deflection value is about 0.14 mm. 

           

X-deflection

 Note : warpage shape magnified 3X for display purposes.  (The undeformed  part display transparent)

 The black arrow indicates the shrinkage and deflection moved inward about 0.12 mm.

 The red arrow indicates the shrinkage and deflection moved inward about 0.12 mm.

           


Y-deflection

Note : warpage shape magnified 3X for display purposes.  (The undeformed  part display transparent)

 The black arrow indicates the shrinkage and deflection moved inward about 0.08mm.

 The red arrow indicates the shrinkage and deflection moved inward about 0.08 mm.

           

Z –deflection

Note : warpage shape magnified 3X for display purposes.  (The undeformed  part display transparent)

 The black arrow indicates the shrinkage and deflection moved downward about 0.09mm.

 The red arrow indicates the shrinkage and deflection moved upward about 0.09 mm.

                    


Conclusions & Suggestions

From the above analysis

 ■The cycle time is about:1.0 (filling) + 12.0 (cooling + packing ) + ? (open & eject) = ? sec

 ■ This part will not have filling problem due to the pressure are within the moldflow recommend range.

 ■ Visible weld lines were expected appear at this part. (refer page 14)

 ■ Most of the air trapped appear at the edge of part and the tip of ribs that is easy to vent, some serious air traps appear on the surface. (refer page 15)

 ■ Visible sink mark may appear at the surface of part. (refer page 16)

 ■ This part have large uneven shrinkage at the X, Y, Z deflection, the different volumetric shrinkage (different wall thickness) result in the defect.


  • Fill time
    1.0 sec
  • Injection pressure
    38.1 Mpa
  • Volumetric shrinkage
    1~6.3 %
  • Shrinkage and deflection :
    X Component
    -0.12~0.12 mm
  • Shrinkage and deflection :
    Y Component
    -0.08~0.08 mm
  • Shrinkage and deflection :
    Z Component
    -0.09~0.09 mm
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