Moldflow翹曲原因分析總結(jié)

WELCOMETotheMF/WARPTrainingCourseUnit1SolvingWarpageProblemsAnalysisProcedureFastFillingAnalysisCoolingAnalysisMulti-laminateFillingandPackingAnalysisConstrainModelforWarpagePredictTypeofWarpageUnstableWarpage(PartBuckles&Warps)IsolatetheCauseofWarpage(BucklingSingleVariantAnalysis)IdentifyVariantwithLargestSensitivityFactorStableWarpage(PartWarpslinearly)IsolatetheCauseofWarpage(SmallDeflectionSingleVariantAnalysis)IdentifyVariantCausingLargestPercentageofDeflectionReduceWarpageDetermineWhetherPartMeetsDesignTolerances翹曲的因素在塑膠件中產(chǎn)生收縮變化收縮變化的種類在塑膠件中不同區(qū)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(jié)晶度不同由於流動(dòng)產(chǎn)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(dǎo)致彎曲效應(yīng)Moldflow‘sShrinkageModel考慮下列因素體積收縮因塑膠性質(zhì)所產(chǎn)生的收縮由EquilibriumPVTdata計(jì)算結(jié)晶度由結(jié)晶動(dòng)力學(xué)計(jì)算評(píng)估結(jié)晶度對(duì)體積收縮的影響結(jié)晶度越大收縮越大Moldflow’sShrinkageModel模具的約束塑膠的移動(dòng)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(yīng)力的釋放依照溫度變化的情形流在模穴的時(shí)間方向性由在凝固時(shí)的shearstress來(lái)決定考慮應(yīng)力的釋放流動(dòng)的平行及垂直方向的收縮不均ShrinkageData計(jì)算的因素塑料的方向性平行流動(dòng)方向的收縮垂直流動(dòng)方向的收縮不同冷卻速度導(dǎo)致的彎曲應(yīng)力輸入資料保壓結(jié)果冷卻結(jié)果解決翹曲問(wèn)題

主要方法塑件設(shè)計(jì)

肉厚

肉厚變化(劇烈的變化)

設(shè)計(jì)的形狀模具設(shè)計(jì)

澆口位置流道及澆口的設(shè)計(jì)冷卻系統(tǒng)的設(shè)計(jì)頂出系統(tǒng)的設(shè)計(jì)解決翹曲問(wèn)題

主要方法

成型條件

料溫

模溫

射出時(shí)間

保壓時(shí)間及壓力

冷卻時(shí)間塑料

結(jié)晶度

分子結(jié)構(gòu)

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(qū)域的收縮變化分子方向性效應(yīng)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(jié)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(zhì)凝固與收縮MFC09張力翹曲的因素收縮不均(又稱區(qū)域收縮)整個(gè)塑件收縮分佈不均的結(jié)果由於;

厚度不均

澆口位置

冷卻系統(tǒng)的設(shè)計(jì)或冷卻參數(shù)

成型條件翹曲的因素

highTRAIN54lowTRAIN53highlow中間進(jìn)澆的收縮不均現(xiàn)象在中央的區(qū)域有較大的收縮時(shí)在中央的區(qū)域收縮較小時(shí)翹曲的因素分子方向性效應(yīng)流動(dòng)平行及垂直方向收縮量不同的結(jié)果由於;

方向性分子方向性玻纖方向澆口位置冷卻系統(tǒng)的設(shè)計(jì)或冷卻參數(shù)成型條件翹曲的因素TRAIN55

TRAIN56平行收縮較大時(shí)垂直收縮較大時(shí)中間進(jìn)澆的分子方向性效應(yīng)翹曲的種類穩(wěn)定的翹曲不穩(wěn)定的翹曲穩(wěn)定的翹曲無(wú)挫曲現(xiàn)象（Un-buckled）不穩(wěn)定的翹曲有挫曲現(xiàn)象（Buckled）解決翹曲問(wèn)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(jì)算散熱Fastfillinganalysis,計(jì)算有少熱量必須散失流動(dòng)及保壓分析,分析整個(gè)循環(huán)預(yù)測(cè)及降低翹曲QUESTIONS?Unit3ConstrainingaPartforWarpageAnalysisConstrainingaPartforMF/WARP

Why?PreventsrigidbodymotionAllowswarpagetobedeterminedHow?IdentifyareferenceplaneConstrainreferenceplaneCheckforproperconstraintsCreateaboundaryconditionfile.exlfile了解座標(biāo)系統(tǒng)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(jì)算loadfactors(Eigenvalues)用來(lái)決定

warpagestabilityLoadfactors可能是正數(shù)或負(fù)數(shù)正數(shù)-收縮(shrinkage)負(fù)數(shù)-擴(kuò)張(expansion)

選擇最小的正數(shù)

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

Examples

cr=0.25means;part受25%ofshrinkageload時(shí)會(huì)發(fā)生buckle

cr=3means;part受3倍shrinkageload時(shí)才會(huì)發(fā)生buckle判斷這個(gè)質(zhì)是非常重要的BucklingModeShapes每一個(gè)loadfactor計(jì)算一個(gè)modeshapeModeshape顯示相關(guān)loadfactor所呈現(xiàn)的變型狀況Modeshape0isalinearresult假如criticalloadfactor大於1則modeshape可輸入0但每個(gè)modeshapes的變形量是無(wú)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(jié)果的node在按summary的Icon選擇要檢視結(jié)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(jié)果

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

不然會(huì)影響的warpage分析的正確性CheckforwarningsinthetermsofthemodelCheckfordistancetothecentroidoftheparallelandperpendicularmodels若有問(wèn)題產(chǎn)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(jié)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(jié)果.sec記載收縮熱傳係數(shù).ssuShrinkagesummaryfileFENASOutputFiles.DOCfile對(duì)分析的結(jié)果或訊息做簡(jiǎn)短的敘述.OUTfile記載分析結(jié)果供MFVIEW顯示.JSUfileJobsummaryfileSummary進(jìn)行FENASlinearbucklinganalysis

檢查結(jié)果決定criticalloadfactor,ie.

<1unstablewarpage(partbuckles)>1stablewarpage(nobuckling)顯示相對(duì)於美每個(gè)criticalloadfactor的modeshape結(jié)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(lái)決定DifferentialCoolingDifferentialShrinkageOrientation如此可以判斷那一個(gè)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(fā)生挫曲(buckle)進(jìn)行Isolatewarpage-bucklinganalysis進(jìn)行shrinkanalysis將各種因素導(dǎo)致的影響區(qū)分出來(lái)進(jìn)行bucklinganalysis計(jì)算敏感因素（sensitivityfactor）儲(chǔ)存在.JSUfile的最尾端數(shù)質(zhì)最高的敏感因素就是對(duì)翹曲貢獻(xiàn)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(jié)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(méi)有挫曲(buckle)

進(jìn)行

Isolatewarpage

分析-

smalldeflectionanalysis進(jìn)行shrinkanalysis將各種因素導(dǎo)致的影響區(qū)分出來(lái)對(duì)各種因素進(jìn)行smalldeflectionanalysis在MF/VIEW中觀察各各種因素的線性變形的結(jié)果在node的

totaldeflection是三個(gè)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(méi)有挫曲(buckle)將warpage的結(jié)果讀入MF/VIEW三次每種因素一次Loadcase1isDifferentialCooling(DC)Loadcase2isDifferentialShrinkage(DS)Loadcase3isOrientationEffects(OE)比較每一個(gè)變形結(jié)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