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March 16, 2020

Injection Molding Moldflow Case Analysis Report

Project Summary

1, Analyze Intention

To search best gate location

To predict flow issues

2, Input Model Description

Tentative runner system and cooling

Circuits are build for calculation

3, Result Required

Filling result (flow, pressure drop, deflection and so on.)

Analysis on geometrical deformations

Wall Thickness Analysis: That photo mean wall thickness is about 2.50mm

Material Property and Process Condition

Material Property
PC+ABS Cycoloy C1000HF Melt Temperature Range (℃) 260~290
Solid Density (g/cm3) 1.126 Mold Temperature Range(℃) 70~90
Maximum Shear Rate (1/s) 40000 Ejection Temperature(℃) 110
Maximum Shear Stress (MPa) 0.4 Absolute Maximum Melt Temperature(℃) 330
MFI (g/10 min)(℃/Kg) / Recommended Melt Temperature(℃) 275
Filler / Recommended Mold Temperature(℃) 80

 

Process Condition
Melt Temperature(℃) 275 Injection Time 1.2 sec
Mold Temperature(℃) 80 V/P Switch-over 98%
Coolant Temperature(℃) 75 Packing 80% filling pressure/10 s

Flow Animation: The part can not be full filled by one sub gate, short shot occur in the rib.

Flow Animation: The part can be full filled by two sub gate, but hesitation occur in the rib.

Pressure at V/P Switchover:

The max injection pressure of option 1 is about 33.2% higher than option 2.

High Pressure is not suitable for molding

Clamping Force Plot:

Show the pressure at the Clamping Force VS time

High clamping force is required for molding the part

Air Trap: The air trap is shown in black circle. Enough Vent should be set near the air trap location, or short shot, burn mark may occur.

Weld lines:The weld line locations are showing in black circles, venting should be set to improve the weld line quality

Volumetric Shrinkage at Ejection: The volumetric shrinkage is even, sink mark may not occur

Deflection, All Effects: Deflection

Show the deformation on all-component after the part is ejected and cooled down to room temperature

Deflection, All Effects: X Component

Show the deformation on X-component after the part is ejected and cooled down to room temperature

Deflection, All Effects: Y Component

Show the deformation on Y-component after the part is ejected and cooled down to room temperature

Deflection, All Effects: Z Component

Show the deformation on Z-component after the part is ejected and cooled down to room temperature

Conclusion

The part can be full filled by 2 sub gates, but hesitation flow occur.

The volumetric shrinkage is even, sink mark may not occur.

Venting will be set refer to the air trap and weld line results.

The part deflection of option 2 is lower than option 1, so we suggest to use option 2.

Injection Molding, Plastic Mold Case, Plastic Molding Design, Plastic Parts, Uncategorized
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