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Moldflow Analysis Report

For
P/Ns 902866 + 902867

Prepared by CEPS Inc.

5-20-2009
Best Gate Location Analysis Page 2
The best gate location is in or around the dark blue areas.

902866 902867
Gate Location Page 3
Based on the Best Gate Location results shown on page 2, edge gates feeding the parts
centrally were designed in for this analysis.
 This analysis indicates the best molding parameters to
Molding Windows use for this part geometry with an ABS type material

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Process Settings Page 5
Material : ABS
Filling time = 0.92 sec
Melt temperature = 217
Mold temperature cavity and core side = 25
Filling / packing switch volume = 99 %
Packing time = 4s
Cycle time = 20s
Filling Time Page 6

This analysis predicts that it will take

approximately 0.9 secs to fill the parts.
The colors indicate we have even flow
throughout both parts.
Temperature at Flow Front Page 7

The maximum variance of the

temperature is less than 1°C
which means that we have good
filling throughout the part. Any
weld lines formed will be of good
quality and should not be a
detriment to the functional
integrity of the part.
Air Traps Page 8
The Air Traps, indicated by pink circles, are
prominent around the Finger Indent areas. This is
due to the thicker wall section at the
intersections. To avoid these Air Traps we can do
a number of things;
1. Decrease the internal fillet radii from 0.030” to
0.005”
2. Add venting at the part
line.
3. Create the internal
geometry of this area
using a core insert that
Can be vented.
 THIS ANALYSIS INDICATES WHERE WE CAN EXPECT TO SEE WELD LINES AND GIVES THE

Welding Lines DESIGNER AN INSIGHT AS TO WHERE POTENTIAL FRACTURES COULD OCCUR IF HEAVY
LOADS WERE APPLIED. THE POSITION OF WELD LINES CAN BE SHIFTED BY RE-
POSITIONING THE GATE OR GATES.

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Volumetric Shrinkage
Suggest to reduce the internal .030” fillet radii on
the core side to reduce wall thicknesses.
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On the underside of these parts, the
shrinkage of the long rib, indicated in dark
blue, is different from the wall. This
indicates that some warpage could occur.
(See page 12)
The volumetric shrinkage of the parts is evenly
distributed which indicates that warpage will be
minimized, except the thicker section as indicated on
page 8 and in the diagram on the left where Air Traps
occur is higher.

Cooling Quality Page 11

When designing into the analysis

the proposed water circuits for
cooling these parts, we can see that
the cooling quality is 100%.
Sink Marks For Part # 902866 Page 12

The predicted Sink Marks Estimate results show that the maximum sink will be 0.0395mm which
occurs on the under-side of this part where the thick wall section is, due to the 0.030” fillet radii.
This further indicates that this fillet radius needs to be reduced. The estimated sink on the seen
surface is around 0.02mm where the internal ribs are.
Sink Marks For Part # 902867 Page 13

The predicted Sink Marks estimate for this part shows a maximum of .0343mm, indicated by the
red color on the part which occurs in a few spots. The rest of the sink is around .020mm.
Warpage Indicator Results For 902867

The results above, indicate where we would expect to see warpage and the percentage. As we can
see, differential shrinkage is the cause of the warpage. The area in red is where the long rib on
the underside was indicating a difference in volumetric shrinkage, as shown on page 10.
The “Warpage Indicator, All Effects” results are defined below:
Green color area (97.5%) is <0.15mm; yellow color area(2.5%) = 0.15mm; red color area is >0.15mm

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 Warpage Indicator Results For 902866

The results above for part #902866 indicate that the small amount of warpage (3.69%) that occurs is again
due to differential shrinkage. This is caused by the thick wall sections around the finger grip area as
indicated on page 8. Reducing the .030” fillet radii to .005” will improve this.
The “Warpage Indicator, All Effects” results are defined below;
Green color area(96.1%) <0.08mm; yellow color area(3.69%) = 0. 08mm; red color area(0.0%) >0.08mm

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 Conclusion: Page 16

1. The parts will fill with uniformity.

2. The cooling quality is excellent.

3. The temperature at the flow front variance is less than 1º C indicating

that there will be minimal warpage.

4. Air traps can be alleviated with part-line venting, vented core pins and
if required a vented core insert for the finger grip area where there is
presently two areas of thick wall section.

5. Warpage on both parts is very minimal and can be improved if not

eliminated on part #902866 if the .030” fillet radii is reduced to .005”
thinning the wall section in those areas.

6. The warpage is not significant enough to be detrimental in the areas

that are critical when the parts are mated together.