DESIGN OF EXPERIMENTS SOFTWARE INJECTION MOLDING

DESIGN OF EXPERIMENTS SOFTWARE INJECTION MOLDING
INTRODUCTION TO NAUTILUS 8 MOLD QUALIFICATION AND DESIGN OF EXPERIMENTS SOFTWARE FOR INJECTION MOLDING SUHAS KULKARNI FIMMTECH

SUHAS KULKARNI FIMMTECH 1-760-525-9053
Nautilus is a program that helps in the evaluation, analysis, development and documentation of the injection molding process. The software also has a complete design of experiments module that is customized for injection molding Once a process has been established on one machine, the software will calculate the processes for all the machines in the shop. The process can now be transferred and ‘starting from scratch’ will not be necessary on the other machines SUHAS KULKARNI FIMMTECH

Benefits Of Using The Techniques: Established process is robust Process will require ‘no or little attention’ Will determine the fastest cycle time possible Less scrap at startup Zero scrap during production Improved part quality and process capability Above factors increase the bottom line profits! SUHAS KULKARNI FIMMTECH

THE SOFTWARE SUHAS KULKARNI FIMMTECH

Following are some of the features of the software: Material, Mold and Machine databases Mold – Machine Compatibility report Scientific Molding Worksheets (6-step study) Viscosity study Pressure drop study cavity balance study Process window study Gate seal study cooling time SUHAS KULKARNI FIMMTECH

Design Of Experiments Module Tornado Charts Process Sensitivity Charts Cosmetic Process Window Dynamic Process Window Visual Prediction Equation Mold trial and qualification progress report water line diagrams and mold temperature maps Mold setup and operation documentation SUHAS KULKARNI FIMMTECH

Quality module Full dimensional analysis Statistical analysis Post molding shrinkage report Documentation of quality inspection plan Calculation worksheets commonly used in molding User privileges Choice of units Network/concurrent versions SUHAS KULKARNI FIMMTECH

SUMMARY OF ADDITIONS TO VERSION 8: Process – Machine compatibility Add a plastic process sheet for a given mold Generate the plastic process sheet for any given machine Determine the machines in the shop that are compatible and capable of running the mold based on plastic variables Units management – Select between metric, english or a combination Auto convert on demand Once units for a given machine are saved all process sheets are generated in the machine units SUHAS KULKARNI FIMMTECH

SUMMARY OF ADDITIONS TO VERSION 8: User Access Levels Determine who can and cannot change databases and documents Custom read/write access Ability to create family molds and run them through 6-step study, for example: determine cavity imbalances between family parts Doe, select the processes for family molds Optimize for all family parts Miscellaneous: All studies/documents for a given mold under one tab Additional fields added to all databases SUHAS KULKARNI FIMMTECH

MAIN SCREEN: SUHAS KULKARNI FIMMTECH

DATABASES: MATERIAL – MOLD – MACHINE SUHAS KULKARNI FIMMTECH

Mold Machine Compatibility Report: Criteria based on Required tonnage % Shot size used Residence time of the material in the barrel Physical size of the mold and the machine specs SUHAS KULKARNI FIMMTECH

Process – Machine Compatibility Add a plastic process sheet for a given mold SUHAS KULKARNI FIMMTECH

Process – Machine Compatibility Generate the plastic process sheet for any given machine in the database Determine if the machines are capable of running the mold based on plastic variables Established Process Calculated Process Sheets For Other Machines NOT ACCEPTABLE ACCEPTABLE SUHAS KULKARNI FIMMTECH

Process – Machine Compatibility Once the target machine is selected, select the process sheet from the drop down list and click on ‘generate process sheet’ to print the process sheet for the machine SUHAS KULKARNI FIMMTECH

Mold Qualification Part 1: 6-step Study (Aka: Scientific Molding)
SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 1: IN MOLD RHEOLOGY SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 2: CAVITY BALANCE STUDY SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 3: PRESSURE DROP STUDY SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 4: COSMETIC PROCESS WINDOW SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 5: GATE SEAL STUDY – COLD RUNNER SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 5: GATE SEAL STUDY – HOT RUNNER SUHAS KULKARNI FIMMTECH

WORKSHEET NO. 6: COOLING STUDY SUHAS KULKARNI FIMMTECH

WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS

MOLD QUALIFICATION PART 2:
DESIGN OF EXPERIMENTS SUHAS KULKARNI FIMMTECH

Key features: No prior math or statistics experience required With 4 easy steps you will be able to design a doe and run the experiments. The data will visually show you what you can and cannot mold as far as the dimensions of the part are concerned. No guesswork: data driven decisions for all changes in mold steel and/or nominal - specifications Adjust the steel with confidence and leave the process alone! SUHAS KULKARNI FIMMTECH

INPUTS WORKSHEETS FOR DOE:
STEP 1: SELECT THE FACTORS FROM A DROPDOWN LIST SUHAS KULKARNI FIMMTECH

STEP 2: ENTER THE UNITS, HIGH AND LOWS FOR THE STUDIES THE HIGHS AND LOWS ARE DETERMENIED FROM THE COSMETIC PROCESS WINDOW. SUHAS KULKARNI FIMMTECH

STEP 3: ENTER THE NOMINALS AND TOLERANCES SUHAS KULKARNI FIMMTECH

STEP 3: SOFTWARE GENERATES THE EXPERIMENTAL MATRIX MOLD THE PARTS, ENTER DATA AND CLICK ON THE ANALYSIS BUTTON TO VIEW THE RESULTS SUHAS KULKARNI FIMMTECH

TORNADO CHARTS GIVES YOU INFO ON THE FACTOR THAT MOST IMPACTS THE PART QUALITY (POSITIVE FACTORS ABOVE THE LINE, AND NEGATIVE BELOW THE LINE) SUHAS KULKARNI FIMMTECH

PROCESS SENSITIVITY GRAPH GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE DOE PROCESS RUN SUHAS KULKARNI FIMMTECH

DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED CAVITIES AND DIMENSIONS SUHAS KULKARNI FIMMTECH

DIMENSIONAL PROCESS WINDOW GREEN CONTOURS – PARTS IN DIMENSION RED – PARTS OUT OS SPEC YOU CAN DRAW A BOX AS SHOWN TO DETERMINE ALARM AND TOLERANCE SETTINGS DIMENSIONAL PROCESS WINDOW SUHAS KULKARNI FIMMTECH

DIMENSIONAL PROCESS WINDOW MOLD PARTS BETWEEN THE PROCESS WINDOWS TO MAINTAIN THE PARTS WITHIN THE DIMENSIONS. DIMENSIONAL PROCESS WINDOW SUHAS KULKARNI FIMMTECH

DIMENSIONAL PROCESS WINDOW WITH A DIMENSIONAL PROCESS WINDOW AS SHOWN IT WILL BE IMPOSSIBLE TO MOLD PARTS CONSISTENTLY TO THE REQUIRED DIMENSIONS. IT WILL BE IMPOSSIBLE TO OBTAIN GOOD CpKs TIME TO MAKE A DATA DRIVEN DECISION! SUHAS KULKARNI FIMMTECH

VISUAL PREDICTION EQUATION THE DIMENSION CAN GO OUT OF SPEC USL LSL Cavity No → EXTENT TO WHICH THE DIMENSION CAN BE INFLUENCED BETWEEN THE EXTREMES OF THE DOE PARAMETERS USL LSL Cavity No → SUHAS KULKARNI FIMMTECH

VISUAL PREDICTION EQUATION THE DIMENSION CAN GO OUT OF SPEC USL LSL Cavity No → STABLE DIMENSION – WILL ALWAYS BE IN SPEC USL LSL LSL Cavity No → SUHAS KULKARNI FIMMTECH

VISUAL PREDICTION EQUATION PROCESS GOLD SPOT - BEST PROCESS TO BRING ALL DIMENSIONS CLOSEST TO NOMINAL USL LSL Cavity No → STABLE DIMENSION – WILL ALWAYS BE IN SPEC USL LSL Cavity No → SUHAS KULKARNI FIMMTECH

VISUAL PREDICTION EQUATION SIMULATED PROCESS: CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES (SEE NEXT SLIDE) USL LSL Cavity No → USL Cavity No → SUHAS KULKARNI FIMMTECH

VISUAL PREDICTION EQUATION SIMULATED PROCESS: CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES SUHAS KULKARNI FIMMTECH

NUMERICAL PREDICTION EQUATION USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY SUHAS KULKARNI FIMMTECH

Target Seeker The user can select any one cavity and any one dimension and input the required target and the software will predict the process to achieve the target. In some cases, the target is not achievable because of the high and low limits. The difference is displayed. The user can select the Nominal, LSL, USL or enter their own value.

Max Dimensional Acceptance:
The user can select any of the dimensions and the cavities and the software will predict the process where those dimensions will be as close to bringing within the specifications. Please see the slide towards the end of the presentation to better understand the difference between the Gold Spot and Max Dimensional Acceptance.

New Tab: Lowest Cooling Time Process:
Keeping the lowest time at the lowest possible value – what is the process where all the dimensions are as close as possible to the nominal? Select the cavities and the dimensions and click on ‘Seek Process’ and the software will predict the process

Difference between ‘Gold Spot’ and ‘Max Part Acceptance’
Original Process Gold Spot Max part Acceptance Dimensions are as close as possible to nominal A process is predicted to bring the parts within specifications X Y Reqd change Reqd change X Y X Y Dimension A Dimension B Please note at these predictions the parts may not be in spec. The software runs an analysis to predict the process each process.

Achieving Dimensions: Making Steel And/Or Nominal – Tolerance Changes Good Cp but a bad Cpk??? Your Choices Are Modify The Steel Dimension And/Or Modify The Nominal – Spec Limits ROBUST PROCESS MODIFY MOLD AND/OR NOMINAL-SPEC LIMITS BY THIS NUMBER TO HIT THE MOMINAL VALUE SUHAS KULKARNI FIMMTECH

Capability not a requirement? Want to be only in spec?? ROBUST PROCESS MODIFY MOLD AND/OR NOMINAL-SPEC LIMITS BY THIS NUMBER TO HIT BE INSIDE THE USL OR LSL SUHAS KULKARNI FIMMTECH

CONFIDENCE RATINGS Use the arrows to change the process and see the effect on the dimensions. Dimensions are displayed numerically SUHAS KULKARNI FIMMTECH

PRINTING: SELECTION SCREEN

PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS

MOLD SPECIFIC TROUBLE SHOOTING GUIDE

QUALITY MODULE: FULL DIMENSIONAL ANALYSIS: SUHAS KULKARNI FIMMTECH

QUALITY MODULE: STATISTICAL ANALYSIS : SUHAS KULKARNI FIMMTECH

MACHINE QUALIFICATION: INJECTION SPEED LINEARITY : SUHAS KULKARNI FIMMTECH

MACHINE QUALIFICATION: SHOT TO SHOT REPEATABILITY TEST : SUHAS KULKARNI FIMMTECH

MACHINE QUALIFICATION: LOAD SENSITIVITY TEST : SUHAS KULKARNI FIMMTECH

FREQUENTLY USED MOLDING CALCULATIONS: SUHAS KULKARNI FIMMTECH

WATER FLOW CALCULATION: SUHAS KULKARNI FIMMTECH

PROCESS TRANSFER BETWEEN MACHINES WORKSHEET: SUHAS KULKARNI FIMMTECH

SHOT SIZE ESTIMATION WORKSHEET: SUHAS KULKARNI FIMMTECH

HOPPER SIZE CALCULATION WORKSHEET: SUHAS KULKARNI FIMMTECH

REGRIND CALCULATIONS (CLOSED LOOP SYSTEMS) SUHAS KULKARNI FIMMTECH

MISCELLANEOUS FEATURES

NEW IN VER 8 UNITS MANAGEMENT UNITS MANAGEMENT – SELECT BETWEEN METRIC, ENGLISH OR A COMBINATION AUTO CONVERT ON DEMAND SUHAS KULKARNI FIMMTECH

NEW IN VER 8 USER ACCESS LEVELS USER ACCESS LEVELS DETERMINE WHO CAN AND CANNOT CHANGE DATABASES AND DOCUMENTS CUSTOM READ/WRITE ACCESS SUHAS KULKARNI FIMMTECH

NEW IN VER 8 FAMILY MOLDS ABILITY TO CREATE FAMILY MOLDS AND RUN THEM THROUGH 6-STEP STUDY, FOR EXAMPLE: DETERMINE CAVITY IMBALANCES BETWEEN FAMILY PARTS DOE, SELECT THE PROCESSES FOR FAMILY MOLDS OPTIMIZE FOR ALL FAMILY PARTS SUHAS KULKARNI FIMMTECH

FAMILY MOLDS NEW IN VER 8 ABILITY TO CREATE FAMILY MOLDS IN THE DATABASE SUHAS KULKARNI FIMMTECH

FAMILY MOLDS NEW IN VER 8 ABILITY TO QULAIFY FAMILY MOLDS IN 6-STEP AND DOE MODULE SUHAS KULKARNI FIMMTECH

CONTACT INFO: SUHAS KULKARNI SUHAS KULKARNI FIMMTECH

DESIGN OF EXPERIMENTS SOFTWARE INJECTION MOLDING

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