Moldflow Analysis Report Part Name 产品名称: 579524ROH & 579525ROH Mold Number 模具编号: W579524-25-H Prepared by 报告制作: Gavin Zhang Date Prepared 日期: Oct. 19th 2015 Version 版本 : Rev.1

Project Summary 分析要求 Analysis Purpose Validate potential problem after the part and mold design 验证可能存在的问题在产品和模具设计完成后 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: 1+1 Number of cavity analysis 分析时出模数: 1+1 Part Material 塑胶材料: PA66+30%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 PA66+30%GF (Ultramid A3WG6 from BASF) Melt Temperature Range (℃) 280~300 Solid Density (g/cm3) 1.38 Mold Temperature Range (℃) 80~90 Maximum Shear Rate (1/s) 60000 Ejection Temperature (℃) 195 Maximum Shear Stress (MPa) 0.5 Absolute Maximum Melt Temperature (℃) 320 MFR (g/10min) ( 270 ℃/ 5 Kg) 47.8 Recommended Melt Temperature (℃) 290 Filler 30%GF Recommended Mold Temperature (℃) 85 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 579524ROH & 579525ROH CAD File / Version/ Date 模型格式和版本 579524ROH & 579525ROH /stp/2015.10.8 Part Volume 产品体积 528 cm^3 (1+1) Nominal Wall Thickness 产品平均厚度 3 mm Tool Description 出模数 1+1 Cavities Injection machine Tonnage 注塑机台 / Process Setup 成型设置 Material 塑胶材料 PA66+30%GF (Ultramid A3WG6 from BASF) Injection time 注塑时间 3.0 s Material temp 材料温度 290 [deg.c] Mold temp 模具温度 85 [deg.c] Velocity/Pressure Transfer (% volume) 转保压体积 98 % Packing Pressure/Time 保压压力/时间 60% filling pressure /6 s, 50% filling pressure /4 s, Project Area 产品投影面积 893 cm^2 (1+1)

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 mm. 平均厚度 3 mm Total part weight = 695 g (1+1), the cold runners weight = 50 g 产品重量 695 g (1+1), 冷流道重量 50 g

Gate Location and size 流道布局 Cold runner Sub. gate Dia. 2 mm Dia. 8 mm 流道布局基于DFM报告, 用冷流道和潜水填充这个产品 The mold is the cold runner and sub. gate. The runner layout was based on the DFM report.

Simulation results list 分析结果项目 Fill time (Animate) 填充时间 ( 动态) Flow Front Temperature 前端温度 Pressure at the V/P switchover 转保压压力 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 Fiber orientation 纤维定向 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: 2.8 sec. Shift+F5, you will see the animated flow

Temperature at flow front 前端温度分布 Above figure showed the temperature at the part. Melt enters cavity at 290 C The polymer recommended temperature range: 280~300 C From above plot we can see that the temperature drop on the part are in this polymer recommend rang

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.

Injection pressure 压力XY曲线图 The maximum value is 72 Mpa, Injection pressure specified at Packing is 57.8 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 (72 Mpa). Packing profile plot

Clamp force 锁模力XY曲线图 The maximum clamp force is 322 Tons. 最大锁模力为 322 tonne.

Weld lines locations 熔接线位置 熔接线出现在表面上是可见的，熔接线位置加排气 The weld lines is visible, adding the vent at the weld lines position. Above figure shows the location of weld-line on the part. The weld lines form less than 75 degree of the two melt were expected have a bad quality. (No the temperature at flow front)

Air trapped area-1 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.

Air trapped area-2 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. 困气位置大部分在流动和骨位末端，没有严重困气存在，流动末端加排气。 Air traps locations mark in red color. Most of the air trapped appear at the edge of part and the tip of ribs 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30 s内 95%冷却, 流道冷却60%需要30 s The time to reach ejection temperature is about 30 s for 95 % melt volume freezed, the cold runner is about 30 s for 60 % melt volume freezed

Volumetric shrinkage at ejection 产品体积收缩 轻微的缩痕可能出现在产品表面 Slight sink marks appear on the surface, the thick wall result in the defect. The maximum shrinkage at ejection is 7.4 %.The minimum shrinkage at ejection is 2.3 %.

Fiber orientation 纤维定向分布 The fiber orientation result provides the final results of fiber orientation, at the end of the analysis. Inconsistent alignment/orientation of fibers. There should be a high probability of fiber alignment in the first principal direction. The fiber orientation result in the large deformation defect, 纤维定向直接作用者产品的变形

Deflection-All 产品整体收缩+变形，放大1倍 Note : warpage shape magnified 1X for display purposes. (The undeformed part display transparent) 产品整体最大变形 +缩水在红色区域 3.4 mm, The maximum shrinkage and deflection value is about 3.4 mm.

X-deflection 产品X方向变形，放大1倍 Note : warpage shape magnified 1X 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 -1.4~1.58 mm, The black arrow indicates the shrinkage and deflection moved inward about 1.4 mm. The red arrow indicates the shrinkage and deflection moved inward about 1.58 mm.

Y-deflection 产品Y方向变形，放大1倍 Note : warpage shape magnified 1X 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 -0.98~0.96 mm, The black arrow indicates the shrinkage and deflection moved inward about 0.98 mm. The red arrow indicates the shrinkage and deflection moved inward about 0.96 mm.

Z –deflection 产品Z方向变形，放大1倍 Note : warpage shape magnified 1X 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 -1.58~3.33 mm, The black arrow indicates the shrinkage and deflection moved downward about 1.58 mm. The red arrow indicates the shrinkage and deflection moved upward about 3.33 mm.

Conclusions &Suggestions From the above analysis The cycle time is about: 3.0 (filling) + 30.0 (cooling + packing ) + 20.0 (open & eject) =53.0 sec This part will not have filling problem due to the pressure are within the moldflow recommend range. Visible weld lines were expected appear at this part. (refer page 13) Most of the air trapped appear at the edge of part and the tip of ribs that is easy to vent. (refer page 14~15) Slight sink mark appear at the surface of part. (refer page 17) This part have large uneven shrinkage at the X,Y,Z deflection, the different fiber orientation result in the defect. Fill time Injection pressure Volumetric shrinkage 3.0 sec 72 Mpa 2.3~7.4 % Deflection: X Component Y Component Z Component -1.4~1.58 mm -0.98~0.96 mm -1.58~3.33 mm Next pages: we try to move gate to improve the large warpage.