Post on 21-Apr-2017
J.M. Keerthi Bandara.
SOAP BOX [MOLD FLOW ANALYSED REPORT]
19 April 2017
PAGE 1
Statement of the problem.
1. Select a suitable injection molding machine for the soap
box production process.
2. Select a suitable material feeding mechanism for
injection mold to get high quality product. (Pinpoint
gate & Submarine gate)
PAGE 2
Material & Method.
Material Detail
Polypropylene (PP)
Melt temperature 180 c0- 260 c0
Density 905 kgm-3
Software
Solidworks 2015.
Autodesk Moldflow Adviser 2016.
PAGE 3
Product Detail.
PAGE 4
Results.
Table 1:- Submarine Gate.( Runner diameter 1.76 mm balanced)
Maximum clamp force during cycle
16.021 (tonne)
Max. wall shear stress
0.231 (MPa)
Total part weight
25.794 (g)
Cooling time
0.80 (s)
Cycle time
16.86 (s)
Table 2 :- Pinpoint Gate (Runner diameter 2.64 mm and 2.79mm
balanced)
Maximum clamp force during cycle
19.395 (tonne)
Max. wall shear stress
0.288 (MPa)
Total part weight
24.947 (g)
Cooling time
0.00 (s)
Cycle time
16.09 (s)
Both runner systems are balanced by Mold Flow 2016 software.
PAGE 5
Flow Analysis Result
Figure 1: Confidence of fill.
Figure 2: Fill time.
PAGE 6
Figure 3: Injection pressure.
Figure 4: Quality Prediction.
PAGE 7
Figure 5 : Temperature at flow front.
Figure 6 : Time to reach ejection temperature.
PAGE 8
Figure 7: Volumetric Shrinkage at ejection.
PAGE 9
Conclusion.
According to Table 1 and Table 2, clamp force of the pin point gate product higher
than the submarine gate product. Part weight of pin point gate product lower than
the submarine gate product.
Machine Selection,
According to clamp force,
For submarine gate product = 16.021 x 1.5 = 24.03 tone.
For pinpoint gate product= 19.395 x 1.5 = 29. o9 tone.
According to part weight,
For submarine gate product = 25.794 x 1.2 = 30.95 g.
For pinpoint gate product= 24.947 x 1.2 = 29. 93 g.
According to flow analysis results, the pin point gate product quality is higher than
the other. But according to Figure 7, the pin point gate product has higher
volumetric shrinkage it will be creating sum sink problems (yellow area).
According Figure 5 this product needs some modifications to reduce the
difference of the temperature at flow front to building up high quality and durable
product.
PAGE 10