Moldflow Analysis Report Please press shift+F5 to look at the report Part Name 产品名称: H-LAMELLEN_BFS&FS_LL_T6_AUSSTROEMER_VW Mold Number 模具编号: EBT-01097(O169) Prepared by 报告制作: Larry Xu Date Prepared 日期: Apr. 4th 2014 Version 版本 : Rev.1

Project Summary 分析要求 Analysis Purpose Validate potential problem after the part design 验证可能存在的问题在产品设计完成后 Check the fill balance pattern, weld line, air traps, and predict the needed clamp force and injection pressure, warpage. 指出流动模式，熔接线位置，困气位置，所需锁模力和注塑压力，产品变形 Estimate cycle time 评估周期 Input Model Description The runner system is simulated as the mold design. 根据模具设计建立流道为分析 Result Required Filling result 流动结果 Cycle time result 周期结果 Warpage result 变形结果 Actual of cavities 实际出模数: 10 parts Number of cavity analysis 分析时出模数: 10 parts Part Material 塑胶材料: PA6+50%GF Type of analyses 分析类型: Flow + Warp

Material Data 材料描述 The material datas are from supplier is in moldflow database and shown in the pictures below Material Property PA6+50%GF (Ultramid B3WG10 from BASF) Melt Temperature Range (℃) 270~290 Solid Density (g/cm3) 1.59 Mold Temperature Range (℃) 80~90 Maximum Shear Rate (1/s) 60000 Ejection Temperature (℃) 165 Maximum Shear Stress (MPa) 0.5 Absolute Maximum Melt Temperature (℃) 290 MFI (g/10min) ( ℃/ Kg) / Recommended Melt Temperature (℃) 280 Filler 50% GF Recommended Mold Temperature (℃) 80 Rheology: PVT properties:

Part、Tool、Setup 产品信息及成型参数设置 Process Setup 成型设置 Part Details and Tool Description 产品和模具描述 Part Name:产品名称 H-LAMELLEN_BFS&FS_LL_T6_AUSSTROEMER_VW CAD File / Version/ Date 模型格式和版本 H-LAMELLEN_BFS&FS_LL_T6_AUSSTROEMER_VW /stp/2014.3.21 Part Volume 产品体积 51 cm^3 Nominal Wall Thickness 产品平均厚度 3.2 mm Tool Description 出模数 10 Cavities Injection machine Tonnage 注塑机台 / Process Setup 成型设置 Material 塑胶材料 PA6+50%GF (Ultramid B3WG10 from BASF) Injection time 注塑时间 1.5 s Material temp 材料温度 280 [deg.c] Mold temp 模具温度 80 [deg.c] Velocity/Pressure Transfer (% volume) 转保压体积 98 % Packing Pressure 保压压力 80% filling pressure / 8 s, 80% filling pressure / 4 s Project Area 产品投影面积 204 cm^2

Wall thickness 产品厚度 This above plot used different color to show the thickness of this part. We can see that: the average thickness of this part is about 3.2 mm. 平均厚度 3.2 mm Total part weight = 78 g, the cold runners weight = 18 g 产品重量 78 g, 冷流道重量 18 g

Gate Location and size 流道布局 Hot runner system Dia. 2 mm Edge gate (typical 10) Dia. 1.5 mm No. Diameter (mm) Depth blue 3.5 Yellow 6 Pink 5.5 Green 4.5 Blue 4 Edge gate (typical 10) Dia. 1 mm 流道布局基于DFM报告, 用热流道和边入水填充这个产品 The mold is the hot runner system and edge gate. The runner layout was based on the DFM report.

Preprocess and Mesh statistics 网格统计 Specification: the type of model used for this analysis are dual-Domain and 3D meshes 双层面网格质量一般，使用双层面和3d分析

Simulation results list 分析结果项目 Fill time (Animate & Contour) 填充时间 ( 动态+轮廓) Flow Front Temperature 前端温度 Pressure at the V/P switchover 转保压压力 Pressure at the end of fill 填充末端压力 Injection pressure 注塑压力 Clamp Force 锁模力 Weld lines 熔接线 Air Traps 困气 Time to freeze 产品冷却时间 Volumetric shrinkage at ejection 顶出时体积收缩 Deflection 变形 Conclusions and suggestions 结论和建议

Fill result – Fill animate 动态流动 This result shows how the melt flows through the cavity. Fill time is about: 1.2 sec. Shift+F5, you will see the animated flow

Fill result – Filling Contour 流动轮廓图 The area with dense lines in the above picture represents the area with lower flow velocity; and the area with sparse lines represents the area with higher flow velocity.

Temperature at flow front 前端温度分布 Above figure showed the temperature at the part. Melt enters cavity at 280 C The polymer recommended temperature range: 270~290 C From above plot we can see that the temperature drop on the part are out of this polymer recommend rang and indicate flow relate problem were expected appear on this part, we suggest to injection this part by slow speed.

Pressure at V/P switchover 转保压压力 Above figure shows the pressure distribution through the flow path inside the mold, at the V/P switchover of the filling phase.

Pressure at the end of fill 填充完成时压力 显示填充完时的压力分布情况。 Above figure shows the pressure distribution through the flow path inside the mold, at the of the filling phase.

Injection pressure 压力XY曲线图 The maximum value is 38.8 Mpa, Injection pressure specified at Packing is 31.3 Mpa The filling pressure are within moldflow recommend value which can acceptable. 压力分布结果表明:射胶压力在MF推荐范围内 (38.8 Mpa). Packing profile plot

Clamp force 锁模力XY曲线图 The maximum clamp force is 61.8 Tons. 最大锁模力为 61.8 tonne.

Weld lines locations 熔接线位置 没有熔接线出现在表面。 No weld lines appear on the surface.

Air trapped area 困气位置 The result shows areas of the cavity that may require additional venting, it should be viewed in combination with the filling pattern result. Adding vent 困气位置大部分在流动末端，不存在严重困气，流动末端加排气。 Air traps locations mark in depth blue color. Most of the air trapped appear at the edge of part that is easy to vent.

Time to freeze 产品冷却时间 The result shows the amount of time taken for all of the elements in the part to freeze to ejection temperature. 产品冷却大部分在18 s内 95%冷却, 流道冷却60%需要12 s The time to reach ejection temperature is about 18 s for 95 % melt volume freezed, the cold runner is about 12 s for 60 % melt volume freezed

Volumetric shrinkage at ejection 产品体积收缩 没有的缩痕出现在产品表面 No sink marks appear at the surface. The maximum shrinkage at ejection is 7.3 %.The minimum shrinkage at ejection is 1.6 %.

Deflection-All 产品整体收缩+变形，放大3倍 Note : warpage shape magnified 3X for display purposes. (The undeformed part display transparent) 产品整体最大变形 +缩水在红色区域 0.09 mm, The maximum shrinkage and deflection value is about 0.09 mm.

X-deflection 产品X方向变形，放大3倍 Note : warpage shape magnified 3X for display purposes. (The undeformed part display transparent) 产品X方向最大变形 +缩水在红色和深蓝色区域 -0.09~0.07 mm, The black arrow indicates the shrinkage and deflection moved inward about 0.09 mm. The red arrow indicates the shrinkage and deflection moved inward about 0.07 mm.

Y-deflection 产品Y方向变形，放大3倍 Note : warpage shape magnified 3X for display purposes. (The undeformed part display transparent) 产品Y方向最大变形 +缩水在红色和深蓝色区域 -0.06~0.08 mm, The black arrow indicates the shrinkage and deflection moved inward about 0.06 mm. The red arrow indicates the shrinkage and deflection moved inward about 0.08 mm.

Z –deflection 产品Z方向变形，放大3倍 Note : warpage shape magnified 3X for display purposes. (The undeformed part display transparent) 产品Z方向最大变形 +缩水在红色和深蓝色区域 -0.03~0.03 mm, The black arrow indicates the shrinkage and deflection moved downward about 0.03 mm. The red arrow indicates the shrinkage and deflection moved upward about 0.03 mm.

Conclusions &Suggestions From the above analysis The cycle time is about: 1.5 (filling) + 18.0 (cooling + packing ) + 8.0 (open & eject) =27.5 sec This part will not have filling problem due to the pressure are within the moldflow recommend range. No weld lines were expected appear at this part. (refer page 16) Most of the air trapped appear at the edge of part that is easy to vent. (refer page 17) No sink mark appear at the surface of part. (refer page 19) This part have minimal uneven shrinkage at the X,Y,Z deflection. Fill time Injection pressure Volumetric shrinkage 1.5 sec 38.8 Mpa 1.6~7.3 % Deflection: X Component Y Component Z Component -0.09~0.07 mm -0.06~0.08 mm -0.03~0.03 mm