Bti Overview For Linkedin

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©Beaumont Technologies, Inc. The information within may not be reproduced without BTI’s written consent. Presents: Products and Services Overview & RCS Technical Review

description

Short overview on how Beaumont Technologies can help solve problems that develop during Plastic Injection Molding

Transcript of Bti Overview For Linkedin

  • 1. Presents: Products and Services Overview & RCS Technical Review

2.

  • Beaumont Technologies:
  • APlastics engineering firm and technology supplier to the Injection Molding Industry
  • Focus on polymer flow and rheology:
    • Drives our own internal development of patented products and innovative services
    • Provide our clients with a unique perspective during development or troubleshooting
  • Our goal is to increase our clients profits by improving part quality and manufacturing efficiencies.
  • Passion for Success-Unique Solutions-From Development To Production
  • If you've got questions, we've got ANSWERS.

Where the INDUSTRY Goes for ANSWERS Company Overview: 3.

  • BTI was founded on April 17th, 1998
  • Headquarters located in Erie, PAUnited States of America
  • Company Mission:
    • Optimization of the part design, mold design, and process
    • Educate our clients through day-to-day correspondence andformal training
    • Become an extension of our clients engineering department

Where were located 4. Who we are...

  • Consultants with in-depth understanding of plastic flow, which allows us to offer solutions that others can not offer
  • 65 years of experience with various CAE packages, product development, mold & part design, processing

5. BTI Partners

      • Incoe(Michigan, USA)
      • CoreTech Systems Co., Ltd.(Taiwan, Korea, Vietnam)
      • SimpaTec Simulation & Technology Consulting GmbH(Germany, France, Belgium, Netherlands, Luxembourg, Austria)
      • REP International(Thermoset Rubbers, Lyon Corbas, France; global representation)
    • Global
    • Partnerships

6. BTI Products and Services

  • Rheological Control Systems
    • SRC Inserts
    • iMARC Inserts
    • Opti-Flo Hot Runner Systems
    • MeltFlipper & MAX Design/Consulting Service
  • 5 Step Process Software
    • Systematic Mold Balance Analysis
    • Mold Filling & Part Quality Diagnostics
  • CAE Mold Filling Simulation Services
    • Mold Filling/Packing/Shrink/Warp/Cool Analysis
    • Part Design Optimization
    • Veri-flo Material Verification Service
  • Pro-Series Training Seminars
    • PlasticsPro - From Pellets to Parts
    • FillPro - Diagnosing Mold Filling & Part Quality Variations
  • Development, Engineering & Consulting Services
    • Mold & Part Troubleshooting
    • Mold & Part Design / Development

More Than 7. I. Engineering Consultant Services: BTI provides adeeper and uniquelook into your molding problems with or without CAE 8. II. Filling Simulation Services:

        • Ensure Fill & Pack
        • Control Shrink and Warp
        • Identify Air Traps
        • Strategically Position Weld Lines
      • Optimize part geometry and gate location(s)
      • Optimize the runner layout
      • Optimize the runner sizes

Engineer the Part and Melt Delivery System 9. Flow Analysis vs. Real World: Rheological Control Systems can help ensure accurate filling patterns that CAE predicts How do we know that the CAE simulation is providing accurate results? 10. Veriflo Material Verification Services

  • CAE+ (Veriflo Analysis)
    • Proprietary Simulation Verification Capabilities
    • Collect real-world data and compare to simulation results

Another BTIInnovation! Confirm the accuracy of the material dataand solver, and provide more reliable results to our customer. 11. Veri-flo Material Verification Services

  • CAE results may not be accurate for several reasons:
  • Improper rheological characterization
  • Use of equivalent materials
  • Therefore the simulation will then over/under estimate pressure predictions
  • Will the part fill
  • Runner sizing
  • Veri-flo Service:
  • Send 15-20lbs of material
  • Study the material in our proprietary mold
  • Collect data and compare results

Confirm the accuracy of the material data in the software, and provide more reliable results to our customer. 12. Everyone needs to be talking the same language

  • PlasticsPro SM From Pellets to Parts
    • 2 day seminar
    • Plastic flow and rheology (shrink, warp)
    • Part design
    • Designing and optimizing melt delivery systems
  • FillProSM - Diagnosing Mold Filling & Part Quality Variations
    • 1 day seminar
    • Understanding the Flow Group methodology
    • Process troubleshooting, mold maintenance, and QC

III. Pro Series Training: Being Profitable During a Slow Economy * Held periodically at BTI, in-house, or local to your facilities 13. Root Cause Analysis Basics of 5 Step Diagnostic Software The Underlying Causes The Root Below the surface(not obvious) Hard to identify until

  • Not utilizing all cavities
  • Short shots
  • Out of tolerance parts
  • Warped parts
  • Flash on some parts
  • Sink on others
  • Separate Shear & Steel Variations
  • Develop accurate game plans to solve variations
  • Leads to faster mold commissioning time
  • Customers will be happier
  • Get paid sooner
  • Lower mold maintenance cost

Symptom of the problem The Weed Above the surface(obvious) 14. IV.5Step Process Software Systematic Mold Balance Analysis Software 15.

  • Isolates and SeparatesSteelandRheologicalfactors so the user canfocus on the root cause

How the 5 Step Process Works...

  • Different solutions are required for each root cause
  • Optimize the mold based on a scientific approach
    • Therefore
      • variationswithina Flow Group = Steel Variations ( l, r)
      • variationsbetweenFlow Groups = Shear Imbalance ( )
  • Explanation...
    • If the Pressure Drop is the same to all cavities, then the parts should fill & weigh the same
    • Parts within the same Flow Group have the same flow path and experience the same shear history and material conditions ( )

16. 5 Step Process vs. Traditional MBA Traditional Method =50.8% Imbalance Steel Imbalances: Quadrants A & D are always heavier, & on the same side of the sprue 5 6 7 13 14 15 1 3 9 11 12 2 10 4 16 8 5 Step Process = Steel Imbalances: Flow 1 = 19% Flow 2 = 34% Flow 3 = 37% Flow 4 = 34% Shear Imbalances: Max Shear Imbalance = 31.6% Flows 1&2 vs. Flows 3&4 = 20.8% Flows 1&4 vs. Flows 2&3 = 15.1% Diagnosis: Primary runner diameters varied by0.006 (0.152mm) 17. IV.5Step Process Software

  • Updates to the Software Include:
  • Scalable Reports
    • Easy to compare before & after
  • Shot Manager Feature
    • Compare averages or shot-to-shot
  • New Layouts
    • 16-cavity layouts
    • 32-cavity layouts

18. Primary Root Causes of Imbalances: II. Rheological Variations ( ) I. Mold Steel Variations ( l, r) How do solve these issues? Solution: Rheological Control Systems Solution: Mold Makers 19.

  • Rheological Control Systems

Reduce Cycle TimeBalance Filling Improve Dimensions Eliminate Scrap Hot Runner and Cold Runner Solutions 20.

  • Two Rotation Types:
      • Single-Axis Symmetry
      • Multi-Axis Symmetry

Rheological Control Systems (Cold Runners)

  • Overview:
    • Manage flow to and within the cavities
    • Static and dynamic control
    • Mold inserts and design & license services
  • Three Control System Types:
      • Static (SRC Inserts)
      • Dynamic (iMARC Inserts)
      • Design Service w/ License

21.

  • Rheological Control Systems
  • Previously only available through design and license services
  • Now available for quote as Static Rheological Control inserts

Optimize the material conditions to and within the cavities for Plastic and Rubber materials 22. What is an Intra-Cavity Imbalance? Common Molding Problems: Warp Gas traps Race tracking Cosmetic blemishes Core shift Weld lines Non-fills / short shots Yes, even within a Single Cavity Mold!! The Filling Pattern So when do you use Single-Axis vs. Multi-Axis intra-cavity flow control? 23. RCS: Single-Axis Intra-Cavity Flow

  • Rotates high sheared material around the perimeter of the part to:
        • create symmetrical flow across the part

24. RCS: Multi-Axis Intra-cavity Flow

  • Rotates high sheared material throughout the cross-section of the part to:
        • enhance part characteristics and flow to a particular part geometry
        • re-create symmetrical material properties (i.e.. round parts)
        • more effective for improving some cosmetic defects vs. single-axis control

25. RCS: SRC vs. iMARC

  • iMARC Inserts: Adjustable Rheological Control
      • Optimize balance and fill pattern
      • Adjustments made from parting line without taking the mold out of the machine.

Conventional Adjustment 1 Adjustment 2 Adjustment 3

  • SRC Inserts: Static Rheological Control
      • Optimize balance and fill pattern
      • Adjustments require the mold or inserts be taken out of the machine.

Conventional Static 26.

  • Part Description
    • 4-cavity, 3-plate mold
    • Delphi Automotive component for HVAC
    • Mineral filled nylon
  • Problems
    • 75 % cavitationat bestdue to short shots
    • Intra-Cavity imbalance
    • Short shots with48% scrap
    • Equals high Machine time, material, and labor costs

Reducing Scrap and Short Shots Customer: Cav 1 Cav 2 Cav 4 Cav 3 $114,000 in Savings

  • Benefits / Savings
    • 100 % Cavity Utilization
    • Scrap Reduced to 5%
    • Short Shots Eliminated

Cav 1 Cav 2 Cav 3 Cav 4 High sheared laminates feeding different locations between cavities Equal distribution of high sheared material with MeltFlipper Technology 27. Melt Rotation: Intra-Cavity Control, Concentricity

  • Mold Layout

Effective Melt Temperature Concentricity Conventional Melt Rotation Conventional Melt Rotation Avg. T = 39.3F Avg. T = 4.8F 28.

  • From Prototype to Production
    • Implemented into prototype molds; adapt into production molds = shorter lead-times
    • Ability to change the filling pattern
    • Optimize part dimensions; control/minimize warp; enhance weld-line strength

Conventional Runner iMARC Runner iMARC Optimizing Fill Patterns and Weld Lines 29.

  • Increasing Weld Line Strength
    • Controlling rheology within the part to optimize weld-line strength
    • Customer: Siemon Corporation
    • Moldmaker/Processor: Tech Tool & Molded Plastics

iMARC Optimizing Fill Patterns and Weld Lines LCP Avg. Force (N) PC+ABS Avg. Force (N) 16% increase 20% increase 30. Beaumont Technologies, Inc. Controlled Melt Rotation for Eliminating Shear Induced Flow Imbalance

  • Reduced Set Up and Overall Cycle Time
  • Geometrically & Rheologically Balanced Manifold
  • Increased Process Capability without Flow Restriction or Pressure Loss
  • Outstanding Part Quality and Cavity Consistency

Rheological Control Systems (Hot Runners) BTI and Incoe can be your one-stop-shop for your Hot Runner & Cold Runner Needs DF Gold Series &QuickFlow Series 31. For more information Contact Kevin Rottinghaus 715.821.8444 direct line [email_address]