Moldflow翹曲原因分析总结

WELCOMETotheMF/WARPTrainingCourseUnit1SolvingWarpageProblemsAnalysisProcedureFastFillingAnalysisCoolingAnalysisMulti-laminateFillingandPackingAnalysisConstrainModelforWarpagePredictTypeofWarpageUnstableWarpage(PartBuckles&Warps)IsolatetheCauseofWarpage(BucklingSingleVariantAnalysis)IdentifyVariantwithLargestSensitivityFactorStableWarpage(PartWarpslinearly)IsolatetheCauseofWarpage(SmallDeflectionSingleVariantAnalysis)IdentifyVariantCausingLargestPercentageofDeflectionReduceWarpageDetermineWhetherPartMeetsDesignTolerances翹曲的因素在塑膠件中產生收縮變化收縮變化的種類在塑膠件中不同區域的收縮變化沿厚度方向的收縮變化在分子排列平行及垂直方向的收縮變化影響收縮的因素EquilibriumPVT(pressure/volume/temperature)冷卻速率不同結晶度不同由於流動產生的方向性平行和垂直方向的收縮不同模具的約束在厚度方向溫度不同導致彎曲效應Moldflow‘sShrinkageModel考慮下列因素體積收縮因塑膠性質所產生的收縮由EquilibriumPVTdata計算結晶度由結晶動力學計算評估結晶度對體積收縮的影響結晶度越大收縮越大Moldflow’sShrinkageModel模具的約束塑膠的移動受模穴中外型的約束在厚望的方向可以正常收縮塑件頂出後應力的釋放依照溫度變化的情形流在模穴的時間方向性由在凝固時的shearstress來決定考慮應力的釋放流動的平行及垂直方向的收縮不均ShrinkageData計算的因素塑料的方向性平行流動方向的收縮垂直流動方向的收縮不同冷卻速度導致的彎曲應力輸入資料保壓結果冷卻結果解決翹曲問題

主要方法塑件設計

肉厚

肉厚變化(劇烈的變化)

設計的形狀模具設計

澆口位置流道及澆口的設計冷卻系統的設計頂出系統的設計解決翹曲問題

主要方法

成型條件

料溫

模溫

射出時間

保壓時間及壓力

冷卻時間塑料

結晶度

分子結構

添加物如色素翹曲的因素冷卻不均公母模模面冷卻速率不同收縮不均在塑膠件中不同區域的收縮變化分子方向性效應在分子排列平行及垂直方向的收縮變化翹曲的因素冷卻不均沿厚度方向收縮不均的結果由於;模穴表面溫度不均

溫度沿厚度方向變化

模具的熱性質凝固與收縮MFC09張力翹曲的因素收縮不均(又稱區域收縮)整個塑件收縮分佈不均的結果由於;

厚度不均

澆口位置

冷卻系統的設計或冷卻參數

成型條件翹曲的因素

highTRAIN54lowTRAIN53highlow中間進澆的收縮不均現象在中央的區域有較大的收縮時在中央的區域收縮較小時翹曲的因素分子方向性效應流動平行及垂直方向收縮量不同的結果由於;

方向性分子方向性玻纖方向澆口位置冷卻系統的設計或冷卻參數成型條件翹曲的因素TRAIN55

TRAIN56平行收縮較大時垂直收縮較大時中間進澆的分子方向性效應翹曲的種類穩定的翹曲不穩定的翹曲穩定的翹曲無挫曲現象（Un-buckled）不穩定的翹曲有挫曲現象（Buckled）解決翹曲問題tasktoolTW1P12IsolateWarpageCausePredictWarpageBucklingAnalysisSmallDeflectionAnalysisLargeDeflectionAnalysisBucklingAnalysisSmallDeflectionAnalysisQUESTIONS?Unit2AimsofMF/WARPMF/WARP的目的

決定:

塑件是否翹曲

分辨翹曲的因素

如何降低翹曲量MF/WARP的分析程序MF/FLOWMF/FLOWMF/COOLMF/WARP冷卻分析計算散熱Fastfillinganalysis,計算有少熱量必須散失流動及保壓分析,分析整個循環預測及降低翹曲QUESTIONS?Unit3ConstrainingaPartforWarpageAnalysisConstrainingaPartforMF/WARP

Why?PreventsrigidbodymotionAllowswarpagetobedeterminedHow?IdentifyareferenceplaneConstrainreferenceplaneCheckforproperconstraintsCreateaboundaryconditionfile.exlfile了解座標系統GlobalCoordinatesystemLocalCoordinatesystemIdentifyPositionofReferencePlaneUnderstandCoordinateSystemConstrainReferencePlaneCheckConstraintsSaveConstraintBoundaryConditionsLocalCoordinateSystemxyzglobalcoordinatesTW001P02X21Y2720ZFirstnodedefined(20)istheorigin,Secondnode(21)definesthelocalXdirectionThirdnode(27)thelocalYdirectionThelocalZfollowstherighthandruleUsedtodefinethereferenceplaneReferencePlaneCreatedbyconstrainingthelocalcoordinatesystemUsedasareferencewhenlookingatwarpageresultsSimplifiesinterpretationofresultsLocateineasytovisualizeareaBaseofpartFeetofpartMatingsurfaceDeflectionsbasedonconstraintsformingreferenceplaneConstrainingaPartSame3nodesusedtodefinethelocalcoordinatesystemareusedtoconstrainthepart6degreesoffreedom(DOF)mustbeconstrainedforawarpageanalysisAllnodeshave6DOFLocalXtranslationandrotationLocalYtranslationandrotationLocalZtranslationandrotationGUIforReferencePlane&ConstraintsNotation&Commands

forConstraintsXtYtZtXrYrZr

XYZtranslation,XYZrotationFforFree,CforconstrainedCommandsBOUNDXtYtZtXrYrZr

NodeNo.constrainsanyorallDOFBOUNDFCCFFFNodeNoPINconstrainsalltranslationsEqualtoBOUNDCCCFFFNodeNoXZYXZYConstrainingaPartzxyzGlobalCoordinates202534ReferencePlaneLocalCoordinatesPIN20BOUNDFCCFFF25BOUNDFFCFFF34TW001P09xyViewingConstraintsTypeBOUNDtodisplayconstraintsintabularformTypeBOUNDDtographicallydisplayconstraintsTypeBOUND0toclearallconstraints.

BoundaryConditions:Nodedof1dof2dof3dof4dof5dof6====================================================37CCCFFF(Local)199FFCFFF(Local)287FCCFFF(Local)SaveConstraintsFromtheMenuFile>SaveBoundaryConditions>WarpageEnterafilenameFromthecommandlinewrbcstressfilenameConstrainingaPartSummaryReadinanddisplaypartmodelDecideonpositionofreferenceplaneConstrainthereferenceplaneusingGUIChecktheconstraintsSavetheboundaryfileQUESTIONS?Unit5DeterminingtheTypeofWarpageDetermineTypeofWarpage

Why?MustknowwhetherwarpageacceptableornotStableorunstableisthesameasNon-buckledorbuckledDetermineshowtoproceedwithanalysisLinearorbucklinganalysisHow?RunashrinkageanalysisfrompackingresultsRunFENASbucklinganalysistodetermineloadfactorwithshrinkageresultsDoneinonestepDetermineTypeofWarpageTW1P13ExamineresultsMFVIEWRunbucklinganalysisBoundaryconditionfileCoolingelementalresultsfilePartmodelnameShrinkagedatasourceMaterialsupplier&gradecodeMechanicaldatasourceAnalysisGUIforBuckling,PCFenasAnalysisTypes

SmalldeflectionanalysisUsedtoinvestigatelinearwarpageproblems

LinearbucklinganalysisUsedtoidentifytypeofwarpage

Stableorunstable(linearornonlinear)ThisistheoneusedinthisUnitLargedeflectionanalysisUsedtocheckdeflectionsofunstablewarpageLinearBucklingAnalysis計算loadfactors(Eigenvalues)用來決定

warpagestabilityLoadfactors可能是正數或負數正數-收縮(shrinkage)負數-擴張(expansion)

選擇最小的正數

loadfactor(Eigenvalues)LowestpositiveloadfactoristhecriticalloadfactorIfcr<1partbuckles(unstablewarpage)Ifcr>1partdoesnotbuckle(stablewarpage)LoadFactors(Eigenvalues)

Examples

cr=0.25means;part受25%ofshrinkageload時會發生buckle

cr=3means;part受3倍shrinkageload時才會發生buckle判斷這個質是非常重要的BucklingModeShapes每一個loadfactor計算一個modeshapeModeshape顯示相關loadfactor所呈現的變型狀況Modeshape0isalinearresult假如criticalloadfactor大於1則modeshape可輸入0但每個modeshapes的變形量是無意義的

FindingCriticalLoadFactor******************************LOWEST2EIGENVALUE(S)******************************

CONVERGENCEREACHEDFOREPS=0.1000E-04NUMBEROFITERATIONSUSED=7NUMBEROFSHIFTSUSED=0

EIGENVALUELAMBDA1=0.1639222637E+00EIGENVALUELAMBDA2=-0.1729038342E+00ERRORNORMSONTHEEIGENPROBLEM

FORMODE1D(1)=0.4199906959E-04FORMODE2D(2)=0.1426574922E-04Criticalloadfactor,Modeshape1ExaminingResults使用ProjectManager選擇要檢視結果的node在按summary的Icon選擇要檢視結果的node在按view的Icon將results及model讀入view輸入modeshapenumber檢視contourplot及element的變型結果

Setdefl.1scalesdeflectionresultssetcol1ds;deBucklingresult其變型量會介於0to100mm之間,這值是沒有意義的但變形趨勢是可以重要的判斷Shrinkagedata的正確性比較分析的shrinkage結果和收縮測試的差異結果必須相近

不然會影響的warpage分析的正確性CheckforwarningsinthetermsofthemodelCheckfordistancetothecentroidoftheparallelandperpendicularmodels若有問題產生可能是保壓分析不正確或成型條件不良判斷Shrinkagedata的正確性讀入shrinkage的結果File>ReadResult(shrinkage)顯示summaryfileShow>Results>ResultsSummaryLookforwarningmessagesabouttermsintheshrinkagemodelNowarningshouldbeover50%LookforrelativedistancetocentroidintheparallelandperpendicularmodelsThisvalueshouldbeunder1ShrinkageSummaryFile**SummaryofShrinkageValues.MaximumVolumetricShrinkage:6.72[%]InElement:1003MinimumVolumetricShrinkage:1.69[%]InElement:722MaximumIsotropicShrinkage:1.52[%]InElement:1003MinimumIsotropicShrinkage:0.95[%]InElement:613MaximumPerpendicularShrinkage:0.83[%]InElement:1003MinimumPerpendicularShrinkage:0.47[%]InElement:613MaximumParallelShrinkage:0.69[%]InElement:1003MinimumParallelShrinkage:0.46[%]InElement:460

**WARNING:TheORIENTATIONterminthePERPENDICULARshrinkagemodelhadvalueswhichweretooHIGHin5.81%ofplateelements(volumefraction).TheUPPERLIMIThasbeenusedfortheseelements.ForthePARALLELshrinkagemodel,therelativedistancetothecentroidofexperimentalmeasurementsis0.3822ForthePERPENDICULARshrinkagemodel,therelativedistancetothecentroidofexperimentalmeasurementsis0.3968ShrinkageOutputFiles.sev記載element的收縮結果.sec記載收縮熱傳係數.ssuShrinkagesummaryfileFENASOutputFiles.DOCfile對分析的結果或訊息做簡短的敘述.OUTfile記載分析結果供MFVIEW顯示.JSUfileJobsummaryfileSummary進行FENASlinearbucklinganalysis

檢查結果決定criticalloadfactor,ie.

<1unstablewarpage(partbuckles)>1stablewarpage(nobuckling)顯示相對於美每個criticalloadfactor的modeshape結果檢視shrinkagesummary判斷shrinkagedata的正確性QUESTIONS?Unit6DeterminingtheCauseofWarpage決定翹曲的因素

Why?決定造成翹曲的主要原因.如此解決翹曲方法可被固定

How?

使用單一因素分析來決定DifferentialCoolingDifferentialShrinkageOrientation如此可以判斷那一個因素是造成翹曲的主要原因.決定翹曲的因素IsolatethewarpagecauseusingsmalldeflectionanalysisExaminethedeflectionsinMFVIEWforeachvariantVariantwiththelargestdeflectionsisthedominantcauseofwarpageDominantcauseofwarpageidentifiedVariantwiththelargestpositivesensitivityfactorisdominantcauseofwarpageComparethesensitivityfactorsforeachvariantin.JSUfileIsolatethewarpage

causeusingabucklinganalysisDidthepartBuckle?StartNOYES決定翹曲的因素假如發生挫曲(buckle)進行Isolatewarpage-bucklinganalysis進行shrinkanalysis將各種因素導致的影響區分出來進行bucklinganalysis計算敏感因素（sensitivityfactor）儲存在.JSUfile的最尾端數質最高的敏感因素就是對翹曲貢獻最多的因素IsolateWarpage-BucklingGUI,PC敏感因素（SensitivityFactors）在summaryfile,列出敏感因素.這因素是造成翹曲的主要原因.以上的結果不須讀入

MF/VIEWLINEAR-BUCKLINGSINGLE-VARIATEORTHOTROPICWARPAGE==================================================SensitivityFactorAnalysisResultsSensitivityfor1(DifferentialCooling)=-0.5900Sensitivityfor2(DifferentialShrinkage=-2.8669Sensitivityfor3(OrientationEffects)=1.0601決定翹曲的因素假如沒有挫曲(buckle)

進行

Isolatewarpage

分析-

smalldeflectionanalysis進行shrinkanalysis將各種因素導致的影響區分出來對各種因素進行smalldeflectionanalysis在MF/VIEW中觀察各各種因素的線性變形的結果在node的

totaldeflection是三個因素的變形總合而X,Y,andZdeflections,不是

total(DEFL)決定翹曲的因素假如沒有挫曲(buckle)將warpage的結果讀入MF/VIEW三次每種因素一次Loadcase1isDifferentialCooling(DC)Loadcase2isDifferentialShrinkage(DS)Loadcase3isOrientationEffects(OE)比較每一個變形結果的特定方向如”Z“方向選出造成變形的主要原因QUESTIONS?Unit7ReducingtheWarpageProblemReducingWarpage

Why?AimtoreducewarpagetowithindesigntolerancesNotpracticaltoreducewarpagetozeroHow?ApplyMoldflow’swarpagephilosophytoreducetheeffectofthedominantvariant(s)UseMF/WARPdiagnostictoolstoinvestigatesolutionsReducingWarpageReducedominantvariantseffectsConfirmthatdeflectionsarewithindesigntolerancesReduceothervariableseffectsasnecessaryRecalldominantcauseofWarpageIsWarpageSufficientlyReduced?ENDStartYesNoReducingWarpage

Warpagecanbereducedby:ChangingfactorswhichreduceavariantsaffectAddstiffeningfeaturesChangematerialReducingWarpageOrientationMoldingConditionsRunconstantshrinkanalysistodetermineeffectIforientationeffectisworsechangingconditionswillnothelpIfwillhelp,increasemoldand/ormelttemperaturesanddecreaseinjectiontimePartThicknessIncreaseinthicknesswillreduceorientationGatelocationsPositionandnumberofgate(s)PositiontogetflatterflowfrontReducingWarpageDifferentialShrinkageEffectsPackingProfilesObtainuniformdistributionofvolumetricshrinkagePartthicknessReducethicknessvariationsImproveCoolingAdjustwaterconditions,temperaturesorflowratesRevisecoolinglinesAddInsertsProfiledConstantReducingWarpage

DifferentialCoolingCoolinglinedesignProvideuniformheatextractionCoolingParametersControlrateofheatextractionviaflowrateandwatertemperatureMoldInsertsInsertsallowuniformcoolingrateBeCutoincreaseheatextractionStainlesssteeltoreduceheatextractionReducingOrientationEffectsDetermineifchangingprocessingconditionswillreduceorientationeffectsRunConstantShrinkageanalysisFindlowestvalueoforientation(SHPA-SHPE)forgeneralpartthickness,notePA&PEshrinkageRunconstantshrinkageanalysisRunbucklinganalysisbasedonconstantshrinkageoutputObtainminimumpositiveloadfactorif<actualloadfactorprocessingconditionswillnothelpif>actualloadfactorprocessingconditionsmayhelpShrinkageSummaryReport

ShrinkageMoldingSummaryTableStartMeltMoldFlowRamThicknessHoldHoldCoolingPtTemp.TempRateTravelPresTimeTimepar/perpDegC.DegC.cu.cm/smmmmMPaSecSec1/1 228.5 62.1 13.1 48.9 2.0/0 30.8 15 205/5 228.9 63.3 19.1 50.1 2.0/0 30.8 15 209/9 228.6 63.6 26.9 49.7 2.0/0 30.9 15 2013/13 228.4 63.7 8.2 49.9 2.0/0 30.5 15 2017/17 228.3 63.6 2.2 49.6 2.0/0 28.5 15 2021/21 228.4 63.0 12.9 49.5 2.0/0 30.7 15 3025/25 226.9 62.1 12.9 49.0 2.0/0 30.3 15 4029/29 227.4 62.5 12.9 47.5 2.0/0 39.8 15 2033/33 227.4 62.5 12.5 48.3 2.0/0 53.6 15 2037/37 225.6 61.7 12.3 50.8 2.0/0 64.4 15 2041/41 228.0 64.3 17.7 49.0 2.0/0 64.7 15 2045/45 227.7 65.3 25.3 48.6 2.0/0 64.7 15 2049/49 227.9 64.3 7.9 50.9 2.0/0 64.4 15 2053/53 227.2 64.2 2.3 51.0 2.0/0 61.7 15 2057/57 228.4 64.4 12.6 50.8 2.0/0 64.6 15 3061/61 226.3 62.3 12.6 49.5 2.0/0 64.2 15 4065/65 228.0 79.8 15.8 49.7 2.0/0 64.8 15 2069/69 227.3 78.3 13.2 48.9 2.0/0 30.3 15 2073/73 258.3 63.1 12.9 49.9 2.0/0 64.9 15 2077/77 257.7 61.9 13.0 49.7 2.0/0 30.6 15 2081/81 196.4 62.5 12.6 48.7 2.0/0 64.4 15 2085/85 197.1 63.6 12.8 48.7 2.0/0 30.3 15 2089/- 197.3 47.7 21.8 68.2 5.0/0 73.1 20 3093/89 197.1 46.8 23.0 67.6 5.0/0 37.5 20 3097/93 197.5 43.7 17.2 61.1 3.0/0 73.6 20 30101/97 196.4 43.6 16.7 59.3 3.0/0 24.2 20 30105/101 257.9 64.9 7.0 42.4 1.0/2 74.0 15 20113/106 256.7 63.1 6.8 41.8 1.0/2 24.7 15 20ShrinkageSummaryReport

ShrinkageDesignDataTableStartThicknessHoldAvgAvgPar.MaxPtPresMeasMeasMinusPred.volpar/perpmmMPaPar.Perp.Perp.Shrink1/1 2.0/0 30.8 0.01782 0.01684 0.00098 0.046635/5 2.0/0 30.8 0.01695 0.01694 0.00001 0.046899/9 2.0/0 30.9 0.01661 0.01661 0.00000 0.0471613/13 2.0/0 30.5 0.01843 0.01659 0.00185 0.0456517/17 2.0/0 28.5 0.01979 0.01440 0.00539 0.0415921/21 2.0/0 30.7 0.01794 0.01665 0.00129 0.0467225/25 2.0/0 30.3 0.01738 0.01694 0.00089 0.0470629/29 2.0/0 39.8 0.01673 0.01484 0.00189 0.0400133/33 2.0/0 53.6 0.01513 0.01326 0.00187 0.0311537/37 2.0/0 64.4 0.01410 0.01197 0.00214 0.0252741/41 2.0/0 64.7 0.01363 0.04201 0.00162 0.0250545/45 2.0/0 64.7 0.01325 0.01178 0.00147 0.0255749/49 2.0/0 64.4 0.01435 0.01203 0.00232 0.0246453/53 2.0/0 61.7 0.01682 0.01076 0.00606 0.0234657/57 2.0/0 64.6 0.01388 0.01190 0.00197 0.0250861/61 2.0/0 64.2 0.01336 0.01159 0.00176 0.0254765/65 2.0/0 64.8 0.01401 0.01192 0.00209 0.0256469/69 2.0/0 30.3 0.01838 0.01653 0.00186 0.0464173/73 2.0/0 64.9 0.01223 0.01124 0.01124 0.0242177/77 2.0/0 30.6 0.01636 0.01632 0.00004 0.0456681/81 2.0/0 64.4 0.01605 0.01168 0.00438 0.0258785/85 2.0/0 30.3 0.02030 0.01592 0.00438 0.0478489/- 5.0/0 73.1 0.01377 0.01707 -0.00330 0.0614093/89 5.0/0 37.5 0.01766 0.02146 -0.00380 0.0581197/93 3.0/0 73.6 0.01211 0.01078 0.00133 0.01638101/97 3.0/0 24.2 0.01615 0.01621 -0.00006 0.04223105/101 1.0/2 74.0 0.01696 0.01090 0.00606 0.02889113/106 1.0/2 24.7 0.02062 0.01550 0.00550 0.06527ConstantShrinkageAnalysisGUI,PCConstantShrinkageAnalysisResultsLoadfactorsfromtheconstantshrinkagebucklinganalysis(Traymlcs)

EIGENVALUELAMBDA1=0.1190806631E+00EIGENVALUELAMBDA2=-0.1296485721E+00Loadfactorsfromtheoriginalbucklinganalysis(Trayml)EIGENVALUELAMBDA1=0.1639222637E+00EIGENVALUELAMBDA2=-0.1729038342E+00CriticalloadfactorsSincethecriticalloadfactorfromtheconstantshrinkageanalysisislessthantheoriginalbucklinganalysis,theorientationwillnotbeimprovedchangingthemoldingconditions.ALookattheProcessBucklinganalysisSinglevariantanalysisConstantshrinkageanalysisOrientationEffectsontheOriginalPartRange2.07:2.71d=0.64Range1.27:2.21d=0.94IncreasetheWallThickness'Originalmodel(tray)Firstrevision(tray15)Tray15WithOriginalPackingTime

GateDidNotFreeze,thePartBuckledEIGENVALUELAMBDA1=0.1639222637E+00EIGENVALUELAMBDA2=-0.1729038342E+00OriginalLoadfactors(trayml)EIGENVALUELAMBDA1=0.9485991215E+00EIGENVALUELAMBDA2=-0.2020005116E+01Firstrevisionfactors(tray15ml)SensitivityFactorAnalysisResultsSensitivityfor1(DifferentialCooling)=-6.7807

Sensitivityfor2(DifferentialShrinkage)=4.6613Sensitivityfor3(OrientationEffects)=-48.6124Firstrevisionconstantshrinkageanalysis(tray15mlsv)ShrinkagenowthedominantcauseofwarpageDifferentialCoolingDifferentialShrinkageOrientationEffectsAllEffectsRange-.088:.275d=0.363Range-.044:.286d=0.330Range-.114:.120d=0.234Range-.168:.459d=.627Singlevariantvsalleffects,Packingtimeincreasedfrom3to6seconds,coolingtimereduced3secondsTray15,SingleVariantAnalysis

WithRevisedPackingTime

GateDidFreeze,thePartDidNotBuckleOrientationEffects

OriginalVsFirstRevision,GateFrozenTRAYML.SEVTRAYML.SEVTRAYML.SEVTRAY15ML2.SEVTRAY15ML2.SEVRange2.073:2.707d=0.634Originalpartwithgatenotfrozentoprow,FirstrevisiongatefrozensecondrowRange1.271:2.206d=0.935Range1.318:2.593d=1.275Range1.431:2.280d=0.849OrientationEffects

OriginalvsfirstrevisionTRAY15ML2.SEVPARALLELMINUSPERP.[%]Range.389:1.056d=0.667Range-.323:.238d=0.561Range-.168:.459d=0.627Range-2.493:1.695d=4.188Upperplotsparallelminusperpendicularshrinkage,bottomplotsZdeflections,LeftTray,RightTray15TRAYML2.SEVPARALLELMINUSPERP.[%]ALookattheProcessBucklinganalysisSinglevariantanalysisPackinganalysiswithnewpackingtimeIncreasingtheSideWallThickness’Secondrevision(tray18)Firstrevision(tray15)AreaShrinkage

Revision1and2withandwithoutgatefreezeTRAY18ML2.SEVTRAY18ML.SEVRange3.038:4.946d=1.908Range2.764:4.815d=2.051Range2.893:4.865d=1.972Range3.208:4.946d=1.738Upperplotsfirstrevision(tray15),lowersecondrev.(tray18),leftgatenotfrozen,rightgatefrozenTRAY15ML2.SEVTRAY15ML.SEVDifferentialCoolingDifferentialShrinkageOrientationEffectsAllEffectsTray18,SingleVariantAnalysis

WithRevisedPackingTime

GateDidFreeze,thePartDidNotBuckleRange-.081:.232d=0.313Range-.053:.296d=0.349Range-.048:.036d=0.084Range-.112:.323d=0.435Singlevariantvsalleffects,Packingtimeincreasedfrom3to6seconds,coolingtimereduced3secondsIsitFlat,WhatistheProblem?DifferentialCoolingDifferentialShrinkageOrientationEffectsAllEffectsRange-.050:.233d=0.283Range-.054:.061d=0.115Range-.033:.037d=0.070Range-.112:.324d=0.436Singlevariantvsalleffects,Resultsscaledtojustthetopsurfacethatmustbeflat!ComparisonofDeflectionsRange-2.493:1.695d=4.188Range-.168:.459d=0.627Range-.112:.323d=0.435Range-.117:.332d=0.449OriginalmodelFirstiteration,gatefrozenSeconditeration,gatefrozenSeconditeration,LargedeflectionReducingDifferentialCooling

InvestigatechanginginletwatertemperaturestogetmoreuniformRun2additionalcoolinganalysesInlettemperature+/-4DegCDonotrerunMFLfillandpackanalysisUseoptiontore-analyzeshrinkage'swithnewcoolingresultsChangingWaterInletTemperaturesOriginalbaselineconditions,Uniform25deg.Ctemp.Cavitytemperaturelowered4deg.CCoretemperatureincreased4deg.CChangingWaterInletTemperaturesOriginalbaselineconditions,Uniform25deg.Ctemp.Cavitytemperaturelowered4deg.CCoretemperatureincreased4deg.CRange-17.278:-1.839d=15.439Range-14.099:.008d=14.107Range-19.380:-4.290d=15.090TemperaturedifferencebetweenthecavityandcoreduetothechangesinwatertemperatureWarpageDuetoTemperatureChangesOriginalbaselineconditions,Uniform25deg.Ctemp.Cavitytemperaturelowered4deg.CCoretemperatureincreased4deg.CRange-.649:.480d=1.129Range-.626:.513d=1.139Range-.647:.484d=1.131WarpageonthepartsduetothechangesinwatertemperatureChangingCoolingWarpageGUIALookattheProcessBucklinganalysisSinglevariantanalysisCoolinganalysiswithdifferentwatertempsSmalldeflectionanalysiswithnewcoolingReducingWarpage

SummaryReducetheeffectofeachvariantStartingwiththedominantvariantUsecomplimentarysolutionsBuildoneachvariantreductiontoarriveatanoverallacceptablewarpageLargeDeflectionAnalysisUsedtoverifyresultsofsmalldeflectionanalysisLargedeflectionwilldetectandpredictanonlinearproblemAfterfixingwarpage,thedeflectionMUSTbelinearDisplacementPlots0NonlinearStiffeningNonlinearSoftening(Buckling)DisplacementLoadLinearLargeDeflectionAnalysisGUIQUESTIONS?Unit8AdvancedWarpageTopicsMF/WARPAdvancedTopics

Why?:TounderstandhowtoapplyMF/WARPincomplexsituationsHow:LearnhowtoaccountforMulti-cavitymoldsPartswithstructuralbeamsFangatedpartsWarpageinterpretationindifficultareasModelingPartswith

StructuralBeamsUsedtodistinguishrunnersfromthepartforawarpag