mold-flow-checklist-解释说明

1%Valuegenerallyshouldbebetween95%and99%.Consequences:Iftheswitchoverislessthan95%,thepartmaynotfillwithpacking.Iftheswitchoverismorethan99%,thepartmayflash.Enterfill/packswitchoverpercentage.•Enterfill/packswitchoverpercentageforeachscenario•填充/保压转换时填充百分率Thisplotshowsthepressuredistributionat97%switchoverbyvolume.Pressuretofill–8,675psi.97%JES3.2—AnalyzeMoldFlowandSelectOptimalScenario通过模流分析选择最佳方案2psiEnterfirststageinjectionpressure.Ingeneral,thevalueshouldbeamaximumof10,000psi.Consequences:Iftherequiredpressureismorethan10,000psi,thepartmayflash,haveundesirableresidualstresses,ormaynotfill.•Entermaximumpressureatendoffillforeachscenario•第一阶段注射压力Thisplotshowsthepressuredistributionat97%switchoverbyvolume.Pressuretofill–8,675psi.8675.63•Reviewpressuredistributionandbalanceatendoffillforeachscenario•压力分布及填充平衡•Avoid•Good•Partispoorlybalancedandhaslargedistributionofpressure•产品填充不平衡且压力差较大•Partisverywellbalancedandhassmalldistributionofpressure•产品填充平衡且压力分布均匀Consequences:Unevenpressuredistributioncanresultinlessconsistentmaterialshrink,higherresidualstresses,andareasofoverpackorunderpackconditions.压力分布不均会导致材料收缩不一致，残余应力高并且有些地方可能出现断层情况。4Enterflowfronttemperaturevariation.Deg.FThevariationshouldbelessthan30degreesF.Consequences:Largevariationsintemperaturecanleadtoresidualstresses,whichcanleadtowarpage.•Enterflowfronttemperaturevariationatendoffillforeachscenario•前端温差551.5-548.9=2.651/secTheshearrateinthegateshouldnotexceedresinmaterialmaximumlimit(TPO-100,000;ASA,ABS-50,000).Consequences:Exceedingtheshearrateofthematerialcancauseittodegradeandthereforenotperformasanticipated.Enterthebulkshearrateingate.•Enterbulkshearrateingateforeachscenario•浇口处剪切率~60,000流体的流动速相对圆流道半径的变化速率—剪切速率(shearrate)6psiTheshearstressinthepartshouldnotexceedtheresinmaterialmaximumlimit(TPO-73psi;ASA,ABS-43psi).Consequences:Excessiveshearstressesinthepartcanleadtosurfacequalityissues.Enterthe95thpercentileshearstressatthewallattheendoffillinginthepart.•Entershearstressinthepartforeachscenario•填充末端（95%时）壁上剪切力~257•Reviewweldlinesandincludetemperatureatflowfrontforeachscenario•熔界线位置和长度包括熔接线位置的前端温度GUIDELINES:Minimizethelengthofallknitlines.Wherepossible,horizontallinesarepreferredtoverticalknitlines.Also,reviewtheflowfronttemperatureattheweldlines.使熔接线长度最小化。可能的话，水平的熔接线比垂直的好。同时要审核熔接线处的前端温度。CONSEQUENCES:Lowertemperaturesmayindicatethatitwillbedifficulttocontroltheappearanceoftheweldline.Thestrengthofthecoolerweldlinesmayalsobelessthanhighertemperatureweldlines.温度低会使得熔接线外观难于控制。温度低的熔接线处强度比温度高的差。8•Reviewairtrapsforeachscenario•气泡•Avoid•VentGUIDELINES:Forceallairtrapstoedgesofpart.Airtrapslocatedattheedgesofthepartshouldbevented.Airtrapsthatareonthesurfaceofthepartshouldbeavoided.将所有气泡赶到产品边缘。位于产品边缘的气泡可以排气。避免产品表面气泡。CONSEQUENCES:Airtrapsthatarenotproperlyventedcancausegasburnsinthoselocations.不能排气的气泡可能导致该区域气体灼伤。9Entersecondstagepressure.Asastartingpoint,thisshouldbegreaterthanorequalto80%ofinjectionpressure.Consequences:Notmeetingtheminimumvaluecanresultinunderpackedpartswhichcanresultinpoorappearance.psi•Enterpackandholdpressureforeachscenario•第二阶段压力6,400(80%of8,000)6,4008,00010•Reviewinjectionpressureatnozzleversustimeforeachscenario•喷嘴处压力/时间图GUIDELINES:Optimaldesignshavenearlyequalspikesatfillingandswitchoverpoints.最好是尖点位于转换点。CONSEQUENCES:Unevenspikesareanindicationofunbalancedparts,whichcanleadtoresidualstresses.若不然会导致产品不平衡，产生残余应力。11Thistimeshouldbegreaterthanorequaltothe100%gatefreezetime.Consequences:Iftimeislessthanthegatefreezetime,partmaybeunderpackedresultinginpoorsurfacequality.Iftimeismorethanthegatefreezetime,partcannotbefurtherpackedsoextratimeisnotrequired.secEntersecondstage(pack+hold)time.•Enterpackandholdtimeforeachscenario•第二阶段（保压）时间20–5=15GateFreezeat~20sec.20512•Entermaximumclamptonnagerequiredforeachscenario•最大锁模力tonThisvalueshouldnotexceedthepresstonnageofthemachinebeingusedforproduction.Consequences:Planningforamachinethatissmallerthantherequiredtonnagecanresultinpartsthatareflashed.Enterclamptonnagepeak.160013•Reviewandentervolumetricshrinkageatejectionforeachscenario•顶出时的体积收缩量%Thetargetvalueis3timesthetoolshrinkagerate.Forexample,fortoolthathas0.8%shrinkage,volumetricshrinkageis0.8%*3=2.4%.Consequences:Ifthevalueisgreaterthan3timesitcouldleadtoundesirablepartwarpage,anditshouldbeevaluatedingreaterdetailwithwarpageanalysis.Entervolumetricshrinkageatejection.4.0614•Entersinkmarkdepthvalueforeachscenario•最大缩印深度值0.12Thetargetvalueis0.1mm.Consequences:Ifthevalueisgreaterthan0.1mm,asinkmarkisexpectedtobeseenonanungrainedpart.mmEntermaximumsinkmarkdepthvalue.15•Entercavityandcorecoolantflowraterequiredforturbulenceforeachscenario•型腔及型芯冷却水流动速率，保证是湍流水111Ensurethesupplier'sequipmentiscapableofrequiredflowrate.Also,confirmflowrateinanycircuitislessthan5timesaveragecircuit.Consequences:Ifequipmentnotcapable,moldmaynotcoolproperlyresultingindimensionalstabilityissues.Ifflowrateinanycircuitismorethan5timesaveragecircuit,systemmaynotperformasdesired.GPMEnterthecavitycoolantflowratetoensureturbulence.16•Entercavityandcoremoldwalltemperaturerang