Moldflow Report Beaumont Logo Performed by: Beaumont Technologies Requested by: Customer
Objective To analyze the BTI Logo part in order to determine an optimal gate location. To thoroughly evaluate the filling progression in an attempt to discover any potential molding concerns. To detail warpage based upon cooling line placement, volumetric shrinkage, and fiber orientation effects.
Process Set-up for Analysis The following parameters were used to run the analysis: Material: Zytel PLS90G30DR BK099: PA66, DuPont Performance Polymers [30% Glass Fiber Filled] Melt Temperature = 554 F Water Temperature = 190 F Injection time = 1.5-2.0 seconds based on DOE study V/P Switchover = 98% Full Part Pack Profile = 8,000 psi until gate seal
Dimensional Diagnostics Part wall thickness = 0.080 0.160
Material Information
Gate Locations - Center Gate - End Gate
Analysis Set-Up (Center Gate) Tab Gate: 0.130 X 0.065 Ø 0.156 Sprue: Inlet = Ø 0.156 Standard 1.2 Taper Length = 2.5
Analysis Set-Up (End Gate) Tab Gate: 0.130 X 0.065 Sprue: Inlet = Ø 0.156 Standard 1.2 Taper Length = 2.5 Ø 0.156 Ø 0.156
Injection Time- DOE Results, Center Gate A DOE study was run to evaluate the effect of injection time on pressure and flow front temperature distribution. This gives an indication of the overall processing window and preferred fill time.
Injection Time- DOE Results, End Gate A DOE study was run to evaluate the effect of injection time on pressure and flow front temperature distribution. This gives an indication of the overall processing window and preferred fill time.
Injection Time DOE Comparison Results
Fill Time The mold was filled using an injection time of 1.5 2.0 seconds. The black lines represent the location of the weld lines.
Filling Progression The Fill time result shows the position of the flow front at regular intervals as the cavity fills. The result is dark blue at the start of the injection, and the last areas to fill are red.
Filling Progression Slight hesitation through thin regions Air Trap
Filling Progression Weld Line Slight hesitation through thin regions
Filling Progression Slight hesitation through thin regions
Filling Progression Weld Line Air Trap Slight hesitation through thin regions
Filling Progression Weld Line Weld Line Slight race tracking effect due to thicker rim geometry Slight hesitation through thin regions
Filling Progression Weld Line Slight race tracking effect due to thicker rim geometry Slight hesitation through thin regions
Filling Progression Weld Line Air Trap Air Trap Weld Line Air Trap Slight hesitation through thin regions
Filling Progression Hesitation Weld Line Weld Line Air Trap Slight hesitation through thin regions
Filling Progression Hesitation Weld Line Weld Line Weld Line Slight hesitation through thin regions
Filling Progression Hesitation Weld Line Weld Line Weld Line/ Air Trap Slight hesitation through thin regions
Filling Progression Slight race tracking effect due to thicker rim geometry Weld Line Weld Line Slight hesitation through thin regions
Filling Progression Weld Lines/ Air Traps Weld Line/ Air Trap Slight race tracking effect due to thicker rim geometry
Filling Progression 98% Full V/P Switchover Air Trap End of Fill Weld Line End of Fill Weld Line Slight race tracking effect due to thicker rim geometry
Filling Progression This plot shows the filling progression in contours. The contours are evenly spaced and indicate the speed at which the polymer is flowing. Widely-spaced contours indicate rapid flow (race tracking), narrow contours indicate hesitation. shows a higher degree of hesitation throughout the part compared to. Flow Hesitation Flow Hesitation
Potential Gas Traps This plot shows the potential location of gas traps. These areas should be investigated to determine adequate venting.
Temperature at Flow Front The plot below shows the temperature of the polymer at the flow front. Large changes may indicate that the material is either shear heating or cooling excessively (areas of hesitation). Optimal injection times will results in smaller variations. Delta T= 26.1 F Delta T= 9.6 F Melt Temperature = 554 F
Pressure at V/P Switchover This plot shows the predicted pressure at V/P switchover (98% full parts). The pressure shown does not include pressure losses through the machine nozzle and screw conveyance losses. Studies have shown pressure losses of around 4,000 psi would be typical. Moldflow Pressure = 7,151 psi Estimated +4,000 psi for machine and nozzle losses = 11,151 psi Moldflow Pressure = 15,115 psi Estimated +4,000 psi for machine and nozzle losses = 19,115 psi
Weld Line Temperature Formation Weld lines will form where flow fronts converge during filling. Weld lines forming at higher temperatures and pressures will have increased integrity. The plot below indicates the predicted location of potential weld lines and the corresponding temperature at which they form. Melt Temperature = 554 F Placing a vent in the areas of the weld line will also help remove potential air traps.
Weld Line Pressure Formation Weld lines will form where flow fronts converge during filling. Weld lines forming at higher temperatures and pressures will have increased integrity. The plot below indicates the predicted location of potential weld lines and the corresponding pressure at which they form. The quality of a weld line can be improved by increasing melt temperature, injection speed or packing pressure.
Shear Rate Maximum The shear rate is a measure of how quickly the layers of plastic are sliding past each other. If this happens too fast, the polymer chains may break and the material degrades. The maximum shear rate limit for this particular grade is 60,000 1/s. The maximum shear rate through the gate is ~10,602 1/s The maximum shear rate through the gate is ~7,226 1/s
Pressure at Injection Location The pressure at injection location plot shows the pressure development at the injection location over time. System Pressure = 7,151 psi Cold Runner = 3,138 psi Part Pressure = 4,013 psi System Pressure = 15,115 psi Cold Runner = 9,326 psi Part Pressure = 5,789 psi
Clamp Force: XY Plot This plot shows the maximum clamp tonnage to mold this part. Note: The max clamp tonnage is during the packing phase. (Pack pressure = 8,000 psi) Clamp Force: Filling- 5.3 Tons Packing- 25.6 Tons Clamp Force: Filling- 13.1 Tons Packing- 25.7 Tons
Temperature This plot shows the material scaled to the specific transition temperature (438.8 F). The simulation uses this temperature to define when the material transitions from a molten state to a frozen state. The material in green is at or above the transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray). The plot shows the part at ~1.58 seconds. The filling phase has ended. Note: Portions of the part have already begun to freeze off. The plot shows the part at ~2.16 seconds. The filling phase has ended. Note: Portions of the part have already begun to freeze off.
Temperature This plot shows the material scaled to the specific transition temperature (438.8 F). The simulation uses this temperature to define when the material transitions from a molten state to a frozen state. The material in green is at or above the transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray). The plot shows the part at ~3.8 seconds. The thin walls and nominal walls have begun to freeze. The plot shows the part at ~4.5 seconds. The thin walls and nominal walls have begun to freeze.
Temperature This plot shows the material scaled to the specific transition temperature (438.8 F). The simulation uses this temperature to define when the material transitions from a molten state to a frozen state. The material in green is at or above the transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray). The plot shows the part at ~5.6 seconds. The nominal walls have frozen off at this point in time. The thicker outer rim geometry is still molten and the gate is providing compensational pack to this region. The plot shows the part at ~6.4 seconds. The gate has just frozen off from the part. The thicker regions remain above the transition temperature and will continue to freeze without compensational pack. Sinks or voids maybe present in these regions.
Temperature This plot shows the material scaled to the specific transition temperature (438.8 F). The simulation uses this temperature to define when the material transitions from a molten state to a frozen state. The material in green is at or above the transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray). The plot shows the part at ~8.4 seconds. The gate is frozen off from the part. The thicker regions are still above the transition temperature and will continue to freeze without compensational pack The plot shows the part at ~8.3 seconds. The thicker regions are still above the transition temperature and will continue to freeze without compensational pack
Temperature This plot shows the material scaled to the specific transition temperature (438.8 F). The simulation uses this temperature to define when the material transitions from a molten state to a frozen state. The material in green is at or above the transition temperature and once the material drops below this temperature it is no longer shown on the color plot (gray). The plot shows the part at ~18.0 seconds. The part and runner system are completely solidified at the point in time. The cycle has ended.
Average Volumetric Shrinkage High shrinkage values could indicate sink marks or voids inside the part. Volumetric shrinkage should be uniform across the whole part to reduce warpage. Gate Gate
Average Volumetric Shrinkage High shrinkage values could indicate sink marks or voids inside the part. Volumetric shrinkage should be uniform across the whole part to reduce warpage. Gate Gate
Sink Marks Estimate The Sink marks estimate result displays simulated sink marks on the part. This result indicates the presence and location of sink marks likely to be caused by features on the opposite face of the surface. The result does not indicate sink marks caused by locally thick regions.
Fiber Orientation The Fiber orientation tensor result shows the orientation tensor (degree of orientation) at the end of the injection molding process. This result shows the probability of fiber alignment in the principal direction. A high probability of fiber alignment in the principal direction will be indicated by a value of close to 1 on the result scale, whereas a low probability is indicated by a value close to 0.
Cooling Set-up This plot shows cooling set-up for the BTI_Logo part. The cooling is identical for &2.
Circuit Coolant Temperature Water Temperature: 190 F. This Depending result shows on the the configuration temperature of of the the coolant lines, inside over the all cooling mold temperatures circuit. The inlet are to expected outlet to temperature rise. The plot rise below should indicates be no more temperature than 5-6 F. rise Depending during the on molding the configuration cycle. of the coolant lines, overall mold temperatures are expected to rise.
Circuit Flow Rate This plots show the flow rate required to achieve turbulence in each circuit.
Circuit Reynolds Number This plots show the Reynolds number of the coolant in the cooling circuit. The ideal Reynolds number to achieve is 10,000.
Mold Temperature This plot shows the cycle averaged temperature of the mold side of the plastic/mold interface during the cycle. Gate Gate
Mold Temperature This plot shows the cycle averaged temperature of the mold side of the plastic/mold interface during the cycle. Gate Gate
Warpage / Deflection: All Effects This plot shows the warpage caused by all effects. All effects include differential shrinkage, orientation effects and differential cooling. *Plot scaled 3X
Warpage / Deflection: All Effects X Components This plot shows the warpage caused by all effects in the X direction. *Plot scaled 3X +X -X
Warpage / Deflection: All Effects Y Components This plot shows the warpage caused by all effects in the Y direction. *Plot scaled 3X -Y +Y
Warpage / Deflection: All Effects Z Components This plot shows the warpage caused by all effects in the Z direction. *Plot scaled 3X -Z -Z +Z
Warpage / Deflection: All Effects Z Components This plot shows the warpage caused by all effects in the Z direction. *Plot scaled 3X -Z -Z +Z
Warpage / Deflection: All Effects Differential Cooling This plot shows the deflection (warpage) at each node attributable to differential cooling. Differential cooling effects are defined as warpage caused by shrinkage differences through the thickness (cavity to core). *Plot scaled 3X
Warpage / Deflection: All Effects Differential Shrinkage This plot shows the deflection (warpage) at each node attributable to differential shrinkage or natural shrinkage. Differential shrinkage effects are defines as shrinkage differences from region to region in the part (example: gate to end of fill; part geometry, thin versus thick areas). *Plot scaled 3X
Warpage / Deflection: All Effects Orientation Effects This plot shows the deflection (warpage) at each node attributable to orientation effects. Orientation effects are defined as shrinkage differences parallel and perpendicular to the material orientation direction. *Plot scaled 3X
Summary/Recommendations The following parameters were used to run the analysis: Material: Zytel PLS90G30DR BK099: PA66, DuPont Performance Polymers [30% Glass Fiber Filled] Melt Temperature = 554 F Water Temperature = 190 F Injection time = 1.5-2.0 seconds based on DOE study V/P Switchover = 98% Full Part Pack Profile = 8,000 psi Pressure Through Runner System (psi) Pressure Through Part (psi) Pressure V/P Switchover (psi) Pressure V/P Switchover +4,000 psi Clamp Tonnage (US Tons) 3,138 4,013 7,151 11,151 5.3-25.6 9,326 5,789 15,115 19,115 13.1-25.7 Weld Line Weld Line Temperature at Shear Rear Average Volumetric Temperature ( F) Pressure (psi) Flow Front ( F) Maximum (1/s) Shrinkage (%) Sink Mark Estimate (in) 533.7 558.4 2,679-6,848 533.0 559.1 10,602 2.694 9.201 0.0083 556.5 562.8 1,562 3,298 554.0 563.6 7,226 2.833 9.312 0.0060 Warpage all Effects Warpage all Effects X Warpage all Effects Y Warpage all Effects Z max min + - + - + - 0.0460 0.0046 0.0211-0.0200 0.0091-0.0049 0.0248-0.0426 0.0332 0.0066 0.0146-0.0265 0.0242 +0.0049 0.0140-0.0152
Beaumont Technologies MORE than simulation MeltFlipper Patented Runner System Options Eliminate imbalances Fix Cosmetic Defects Therma-Flo State of the Art Plastics Material Characterization Method (If you deal with MFI in any way, check this out!) Injection Molding Services ISO-ASTM Test Specimen Molding Mold sampling and qualification Production Runs Process debugging Injection Molding Training and Education Certification Program Development Courses Autodesk Moldflow Courses
Schedule your web meeting Have questions on this report? Schedule a web meeting with Beaumont to get the most of your simulation. To schedule a web meeting contact David Corsi at dcorsi@beaumontinc.com
CAE Disclaimer Any and all analysis results provided are believed to be reliable but are not to be construed as providing a warranty, including any warranty of merchantability or fitness for purpose, or representation for which BTI assumes legal responsibility. Users should undertake sufficient verification and testing to determine the suitability for their own particular purpose of any information presented herein. Nothing herein is to be taken as permission, inducement, or recommendation by BTI to practice any patented invention without a license or in any way infringe upon the intellectual property rights of any other party.