1. DESIGN OF EXPERIMENTS SOFTWARE INJECTION MOLDING
INTRODUCTION TO
NAUTILUS 8
MOLD QUALIFICATION
AND
DESIGN OF EXPERIMENTS SOFTWARE
FOR
INJECTION MOLDING
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2. 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
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3. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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!
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4. SUHAS KULKARNI FIMMTECH 1-760-525-9053
THE SOFTWARE
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5. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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
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6. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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
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7. SUHAS KULKARNI FIMMTECH 1-760-525-9053
QUALITY MODULE
FULL DIMENSIONAL ANALYSIS
STATISTICAL ANALYSIS
POST MOLDING SHRINKAGE REPORT
DOCUMENTATION OF QUALITY INSPECTION PLAN
CALCULATION WORKSHEETS COMMONLY USED IN MOLDING
USER PREVILAGES
CHOICE OF UNITS
NETWORK/CONCURRENT VERSIONS
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8. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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
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9. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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
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10. SUHAS KULKARNI FIMMTECH 1-760-525-9053
MAIN SCREEN:
NEW LOOK IN VER 8
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11. SUHAS KULKARNI FIMMTECH 1-760-525-9053
DATABASES: MATERIAL – MOLD – MACHINE
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12. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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
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13. SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW IN
VER 8
PROCESS – MACHINE COMPATIBILITY
ADD A PLASTIC PROCESS SHEET FOR A GIVEN MOLD
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14. SUHAS KULKARNI FIMMTECH 1-760-525-9053
PROCESS – MACHINE COMPATIBILITY
NEW IN
VER 8
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
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15. SUHAS KULKARNI FIMMTECH 1-760-525-9053
PROCESS – MACHINE COMPATIBILITY
NEW IN
VER 8
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
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16. MOLD QUALIFICATION PART 1: 6-STEP STUDY (AKA: SCIENTIFIC MOLDING)
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17. SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 1: IN MOLD RHEOLOGY
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18. FAMILY MOLDS OPTION NEW IN
WORKSHEET NO. 2: CAVITY BALANCE STUDY
FAMILY MOLDS OPTION NEW IN
VER 8
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19. SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 3: PRESSURE DROP STUDY
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20. SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 4: COSMETIC PROCESS WINDOW
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21. SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 5: GATE SEAL STUDY – COLD RUNNER
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22. SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 5: GATE SEAL STUDY – HOT RUNNER
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23. SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 6: COOLING STUDY
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24. WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS
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25. MOLD QUALIFICATION PART 2:
DESIGN OF EXPERIMENTS
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26. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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 CONFICDENCE AND LEAVE THE PROCESS ALONE!
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27. INPUTS WORKSHEETS FOR DOE:
STEP 1: SELECT THE FACTORS FROM A DROPDOWN LIST
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28. SUHAS KULKARNI FIMMTECH 1-760-525-9053
STEP 2: ENTER THE UNITS, HIGH AND LOWS FOR THE STUDIES
THE HIGHS AND LOWS ARE DETERMENIED FROM THE COSMETIC PROCESS WINDOW.
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29. SUHAS KULKARNI FIMMTECH 1-760-525-9053
STEP 3: ENTER THE NOMINALS AND TOLERANCES
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30. SUHAS KULKARNI FIMMTECH 1-760-525-9053
STEP 3: SOFTWARE GENERATES THE EXPERIMENTAL MATRIX MOLD THE PARTS, ENTER DATA AND CLICK ON THE ANALYSIS BUTTON TO VIEW THE RESULTS
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31. SUHAS KULKARNI FIMMTECH 1-760-525-9053
TORNADO CHARTS
GIVES YOU INFO ON THE FACTOR THAT MOST IMPACTS THE PART QUALITY
(POSITIVE FACTORS ABOVE THE LINE, AND NEGATIVE BELOW THE LINE)
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32. SUHAS KULKARNI FIMMTECH 1-760-525-9053
PROCESS SENSITIVITY GRAPH
GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE DOE PROCESS RUN
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33. SUHAS KULKARNI FIMMTECH 1-760-525-9053
DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED CAVITIES AND DIMENSIONS
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34. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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
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35. SUHAS KULKARNI FIMMTECH 1-760-525-9053
DIMENSIONAL PROCESS WINDOW
MOLD PARTS BETWEEN THE PROCESS WINDOWS TO MAINTAIN THE PARTS WITHIN THE DIMENSIONS.
DIMENSIONAL PROCESS WINDOW
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36. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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!
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37. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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 →
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38. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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 →
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39. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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 →
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40. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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

41. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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
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42. SUHAS KULKARNI FIMMTECH 1-760-525-9053
NUMERICAL PREDICTION EQUATION
USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY
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43. SUHAS KULKARNI FIMMTECH 1-760-525-9053
ACHIEVING DIMENSIONS:
MAKING STEEL AND/OR NOMINAL – TOLERANCE CHANGES
NEW IN
VER 8
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
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44. SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW IN
VER 8
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
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45. SUHAS KULKARNI FIMMTECH 1-760-525-9053
CONFIDENCE RATINGS
USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY
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46. PRINTING: SELECTION SCREEN
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47. PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS
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48. MOLD SPECIFIC TROUBLE SHOOTING GUIDE
NEW IN
VER 8
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49. SUHAS KULKARNI FIMMTECH 1-760-525-9053
QUALITY MODULE:
FULL DIMENSIONAL ANALYSIS:
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50. SUHAS KULKARNI FIMMTECH 1-760-525-9053
QUALITY MODULE: STATISTICAL ANALYSIS :
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51. SUHAS KULKARNI FIMMTECH 1-760-525-9053
MACHINE QUALIFICATION: INJECTION SPEED LINEARITY :
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52. SUHAS KULKARNI FIMMTECH 1-760-525-9053
MACHINE QUALIFICATION:
SHOT TO SHOT REPEATABILITY TEST :
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53. SUHAS KULKARNI FIMMTECH 1-760-525-9053
MACHINE QUALIFICATION:
LOAD SENSITIVITY TEST :
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54. SUHAS KULKARNI FIMMTECH 1-760-525-9053
FREQUENTLY USED MOLDING CALCULATIONS:
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55. SUHAS KULKARNI FIMMTECH 1-760-525-9053
WATER FLOW CALCULATION:
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56. SUHAS KULKARNI FIMMTECH 1-760-525-9053
PROCESS TRANSFER BETWEEN MACHINES WORKSHEET:
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57. SUHAS KULKARNI FIMMTECH 1-760-525-9053
SHOT SIZE ESTIMATION WORKSHEET:
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58. SUHAS KULKARNI FIMMTECH 1-760-525-9053
HOPPER SIZE CALCULATION WORKSHEET:
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59. SUHAS KULKARNI FIMMTECH 1-760-525-9053
REGRIND CALCULATIONS (CLOSED LOOP SYSTEMS)
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60. MISCELLANEOUS FEATURES
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61. SUHAS KULKARNI FIMMTECH 1-760-525-9053
NEW IN
VER 8
UNITS MANAGEMENT
UNITS MANAGEMENT –
SELECT BETWEEN METRIC, ENGLISH OR A COMBINATION
AUTO CONVERT ON DEMAND
SUHAS KULKARNI FIMMTECH

62. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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

63. SUHAS KULKARNI FIMMTECH 1-760-525-9053
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

64. SUHAS KULKARNI FIMMTECH 1-760-525-9053
FAMILY MOLDS
NEW IN
VER 8
ABILITY TO CREATE FAMILY MOLDS IN THE DATABASE
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65. SUHAS KULKARNI FIMMTECH 1-760-525-9053
FAMILY MOLDS
NEW IN
VER 8
ABILITY TO QULAIFY FAMILY MOLDS IN 6-STEP AND DOE MODULE
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66. SUHAS KULKARNI FIMMTECH 1-760-525-9053
CONTACT INFO:
SUHAS KULKARNI
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