Ets Capabilities

8/3/2019 Ets Capabilities

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ETS CAPABILITIES

IN

MOLDFLOW

ANALYSIS


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MOLDFLOW

SUPPORT

TROUBLESHOOTING

CHANGE INCOMPONENT

DESIGN

CHANGE INMOLDINGPROCESS

NEW PRODUCTDEVELOPMENT

CHANGES INMOLD DESIGN

CHANGES INCOMPONENT

DESIGN


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TROUBLE SHOOTING


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Case:Core Shift Analysis for Insert Molding

Metal Insert madeof Spring Steel

Molding made ofPA6 30% GF


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Results of the Fill analysis with existing Molding conditions:

Filling Pattern Deformation Pattern

Final Distortion


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Possible solutions suggested:

Change of Gate Location

Providing better anchor to the metal insert

Changing the material of the metal insert so that itcan with-stand the Injection pressures


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Results of Analysis with change in the gating location:

Filling Pattern Deformation Pattern

Final Distortion

Note: It can be seen by changing the gating location we can reduce the deformation by almost half


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Material(used) AKULON K224 G6

Machine(used) HTW 900

EXISTING COMPONENT PROPOSED COMPONENT

Case:Changing the Product design to avoid warpage


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Filling Pattern

NOTE:

The flow pattern is improved to a large extent in New Case, hence avoiding the over-packing ofthe Limb of the Cam.

OLD NEW


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NOTE:Similarly, the deflection in Y direction due to Warpage in Old Case is 0.55 mm andin New Case is 0.15mm; the Angular deflection is also reduced.

Total Deflection in Y direction

OLD NEW


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Material(used) ZYTEL 70G33L

Machine(used) SP 30

Case:Changing the Gate Location to avoid the breaking of the

component in the highlighted region


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Filling Pattern

CASE 1

CASE 2

No obstacle in front of theFlow Front, hence the Flowis Laminar.

The Core Pin deflects theFlow, creating a Turbulentflow, which is desired.


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Shear Modulus(Fiber)

CASE 1

CASE 2

The Shear Modulus of the

Part in this zone is exceedingthe Max. Shear Modulus ofthe material (2371.84 MPa).

The Shear Modulus of thePart in this zone is withinthe Limit.


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Note:The results show that the Part is uniformly thick and the Gate is selected in one of

the Thickest Zones of the Component.

Case:Changing the type of gate and size of opening to

avoid the warpage


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Feed system

Note:

A Submarine Gate is selected with a modified trapezoidal runner and inclinedsprue.


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Processing conditions

1. Molding Material: Akulon K222-D (PA6)

2. Mold Material: OS

3. Machine: Windsor SP30

4. Melt Temperature: 260 C 20 C

5. Mold Temperature: 65 C 15 C

6. Cooling Time: 20-30 sec

7. Max. Injection Pressure: 13.66-20 MPa

8. Holding Pressure: 10.93 MPa

9. Filling Time: 1.88-3 sec


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Fill analysis

Note:

The filling pattern shows a hesitation during filling of the Cavity in this zoneand hence non-uniform filling.

GATE OPENING =1.2mm


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Case:Family Mold with components with different filling time


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Processing conditions using Molding Window

Analysis

Mold Temperature= 100-120 CMelt Temperature= 300-320 C

Injection Time = 0.6-0.8 sec


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Proposed changes in the Feed system


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PRODUCT DEVELOPMENT


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Component: SHROUD

MaterialAkulon

K225KS (PA6)

Machine SP 130

Component from SDDC


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Submarine Gates onEjector Pin.

Best Gate Location

23


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Old Component: Total Deflection (ABS)

FEW ITERATIONS...

Old Component: Filling with Sprue Gate(PA6)

Modified Component: The Walls were given Z type skirting features (PA6).


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Old Component: Total Deflection

Due to Rigidity provided by the Vertical Walls,these Corners are Inducing Warpage, andhence a Twisting Effect on the Side Walls.

The Total DeformationPattern shows that, in theX & Z directions, Deflectionis mainly due to Shrinkage;whereas in Y direction thedeflection is due to bothShrinkage+Warpage

Y

25

X


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Old Component: Total Deflection (PA6)

The Total DeformationPattern shows that, in theX & Z directions, Deflectionis mainly due to Shrinkage;whereas in Y direction thedeflection is due to bothShrinkage+Warpage

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Total No. of Iterationscarried out

24

Iterations by changinggate Location and Types

6

Iterations by changing the

Material 6

Iterations by impartingchanges in the product

design12

Final Suggestion by ETS


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OLD

NEW

Total Deflection in Y direction

The Warpage at these corners isAppox. 0.7mm per side

The Warpage at these corners isAppox. 0.15-0.2mm per side

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