1. Moldflow Analysis Report Page 1AG10-07, 07 JULY 2010 Cool, Flow & Warp Analysis Of The Small Base Part

2. Moldflow Analysis Report Page 2AG10-07, 07 JULY 2010 Contents 1.Summary03 2.Material Properties04 3.Part thickness05 -06 4.Processing Condition & Runner Layout07 5.Results08 - 23

3. Moldflow Analysis Report Page 3AG10-07, 07 JULY 2010 ANALYSIS AIMS To study the flow and to predict the cycle time of the A1309-2 part. ANALYSIS APPROACH The cavity and the cold runner sections are modeled. A Fusion Cool + Flow + Warp analysis was conducted. The specified material is PP (grade is specified BP RPP 2009 GK BLK, which is not listed in the moldflow database, so we used Polypropylene PPC 5660 from TOTAL Petrochemicals) to run the analysis. This may effect the actual values obtained in the analysis (e.g. shrinkage values, pressure requirements), but it can still be used to observe the general trends in the results (e.g. filling pattern, warpage shape etc). CONCLUSION A pressure drop of 15MPa is expected across the system which indicates this material can easily fill this part. The overall melt front temperature drop is 1.2 C across the part, which is acceptable. The weld lines might be visible to the eye due to zero degrees of two melts. The part is expected to have warpage in X,Y,Z direction. Please refer to the data of the particular warpage on page 19 to 22. The hot spots in the slider side are due to the placement of the cooling channel. These areas need cooling circuit or beryllium insert added to them if possible (refer to page 18). Summary

4. Moldflow Analysis Report Page 4AG10-07, 07 JULY 2010 Similar Material Trade Name: Polypropylene PPC 5660 Manufacturer : TOTAL Petrochemicals Material Family: PP Recommend processing temperature Melt : 200C – 260C Mold : 20 C – 60 C Characteristics : Amorphous Material Viscosity Index : VI(240)0111 others: Melt mass –Flow Rate(MFR)(230C/2.16kg) 7.0g/10min Conductivity : 0.1762 W/m/C (at 230C) Specific Heat : 2618.6 J/kg/ C (at 230 C) Melt Density : 0.74577 g/cm^3 Absolute Max Temp : 300 C Ejection Temperature : 95C Max Shear Stress : 0.25MPa Max Shear Rate : 100,000 l/s Material : PP PVT Plot Viscosity Plot

5. Moldflow Analysis Report Page 5AG10-07, 07 JULY 2010 Part thickness Use different color to show the thickness.

6. Moldflow Analysis Report Page 6AG10-07, 07 JULY 2010 Part thickness Use different color to show the thickness.

7. Moldflow Analysis Report Page 7AG10-07, 07 JULY 2010 Processing Condition & Runner Layout Gate size: Ф7.8mm The Processing Conditions used was as follows: Filling Time : Auto, 4.6 sec. Mold Temperature : 40 C Melt Temperature : 230 C Velocity/Pressure switchover at 98.5% volume fill Packing Pressure : 80% of Max Injection Pressure

8. Moldflow Analysis Report Page 8AG10-07, 07 JULY 2010 Filling Pattern Fig 3 Fig 1 Fig 4 Fig 2 The last filling area

9. Moldflow Analysis Report Page 9AG10-07, 07 JULY 2010 Filling Time (Flash)

10. Moldflow Analysis Report Page 10AG10-07, 07 JULY 2010 Filling Time (Flash)

11. Moldflow Analysis Report Page 11AG10-07, 07 JULY 2010 Pressure drop A pressure drop of 15MPa is expected across the system, this indicated that the material is easy to fill this part.

12. Moldflow Analysis Report Page 12AG10-07, 07 JULY 2010 Temperature at flow front The plastics material enters the runners at 230 C. The overall temperature drop is about 1.2C, which is acceptable.

13. Moldflow Analysis Report Page 13AG10-07, 07 JULY 2010 Weld Lines The weld lines (color curve) might be visible to the eye, due to the zero degrees of the two melts.

14. Moldflow Analysis Report Page 14AG10-07, 07 JULY 2010 Air traps The air traps (pink marks ) location are as show.

15. Moldflow Analysis Report Page 15AG10-07, 07 JULY 2010 Cavity cooling The coolant is specified as water at 25 C, and with turbulent flow in each channels (Reynold Number = 10,000). The outlet temperature of each channels exceeds 0.66C, this indicates the cooling channels are efficient. Cooling Channels : Temperature Rise

16. Moldflow Analysis Report Page 16AG10-07, 07 JULY 2010 Core cooling The coolant is specified as water at 25 C, and with turbulent flow in each channels (Reynold Number = 10,000). The outlet temperature of each channels exceeds 0.8C, this indicates the cooling channels are efficient. Cooling Channels : Temperature Rise

17. Moldflow Analysis Report Page 17AG10-07, 07 JULY 2010 Cooling Channels : Temperature Rise Slider cooling

18. Moldflow Analysis Report Page 18AG10-07, 07 JULY 2010 Cavity side Mould Surface Temperature Total Cycle time: 105 sec. ( Auto Injection + Packing + Cooling Times = 100 sec. Mold open time = 5 sec.) Hot spot Core side Slider

19. Moldflow Analysis Report Page 19AG10-07, 07 JULY 2010 Warpage in X direction

20. Moldflow Analysis Report Page 20AG10-07, 07 JULY 2010 Warpage in Y direction

21. Moldflow Analysis Report Page 21AG10-07, 07 JULY 2010 Warpage in Z direction

22. Moldflow Analysis Report Page 22AG10-07, 07 JULY 2010 Warpage in Z direction Z direction

23. Moldflow Analysis Report Page 23AG10-07, 07 JULY 2010 The conclusions 1) This product was analyzed by using Moldflow software. The directions of the shrinkage is due to structure of the product. 2)There’s not enough cooling of the slide and core. Suggestions: to improve this, use the Heat Pipes on the slide area instead and increase water cooling system on the core area, But these are just some minor adjustments, the deformation will still be prominent. 3) The large base mold has the same problems.

24. Moldflow Analysis Report Page 24AG10-07, 07 JULY 2010 The End