Simulation

Jayesh Modi

Managing Director, Ultra Cool 3D

[email protected]

+61 410 095 160

ULTRACOOL3D_MO VX1 ANALYSIS

mailto:[email protected]

Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com

UltraCool3D_MO VX1 Analysis

Process Parameters

Here you will note we have designed for Three thicknesses. Machine parameters your moulding expert can provide, inject time, machine movements- fastest possible. Our algorithm may work out lower coolant temperature.

Resulting in best possible cycle time.

http://www.ultracool3d.com/


1. Please note cool time starts

with end of inject and overlaps

with packing stage.

2. RTC temperature achieved

within overall cycle time.

3. Cool time estimated for

process driven maximum

temperature.


Process Parameters

Moulding Material PC HF1130

Cycle time 19.69 Sec.

Position Point A Point C Point E

Part thickness, mm. 3 2.8 2.5

Mold wall distance, lm mm. 6 6 6

Cooling channel width, Ch(W) mm. 6 6 6

Cooling channel height, Ch(H) mm. 15 15 15

Distance between cooling channels, W mm. 16 16 16

Coolant temperature, Tc Deg. C 20 20 20

Coolant flow rate, Q L/Min 6 6 6

Sec. 2.5

Cool time Sec. 10.19

M/c open time Sec. 2.2

Eject , part removal and load insert Sec. 3

M/c close time, including dwell to heat tool Sec. 1.8

High pressure water heating temp. Deg. C 200

Temp reached_A Deg. C 138

Inject (Including compression time exclude

normal pack time, it overlaps with cool time.)

Note: Switch to heating mode as soon as machine starts to open till it is closed completely.

Switch to cool as soon as inject cycle completed.




Design Rules Compliance

Here you will note our algorithm has analysed for uniformity of cooling. warpage in a linear function. sufficiency of cooling. Part thickness average temperature. Mould deflection above cooling channel– skin and ensured we were safe with tool strength.





Design Rules Compliance

Cycle time sec 19.69Design Rule 4.1 τ < cycle time sec 9 9 9

Design Rule 4.2 Coolent pressure drop kg/cm^2 0.09 0.09 0.09

Design Rule 4.3 Design for coolant temperature uniformityDegC 0.38 0.36 0.32

Design Rule 4.4_1_T

part center < GT for Thickness averaged eject temp.< Material eject.DegC Safe ejection Safe ejection Safe ejection

Design Rule 4.4_2_T

thickness averaged

T<T eject for material

Part central temperature < Glass transition temp.DegC Safe GT Safe GT Safe GT Max

Design Rule 4.5 Design for uniform cooling DegC 3.04 3.07 3.04 25.64

Differential shrinkage (causing warpage) mm 0.0287 0.0290 0.0288 0.2423

No. Of mold shots to tool stabilsation (Delta T < 0.1) 4 4 4

Design Rule 4.6 Design for Mold Strength (for conformal being closest to mold surface)

Maximum tensile stress Mpa 112

Maximum shear stress Mpa 118

Maximum mold deflection Micron 1



Here you will note our algorithm has analysed for Mould stabilisation temperature. Part thickness average temperature as well as Mid plane temperature.

That is the power we give you in understanding your moulding cycle.


Temperature Distribution




Temperature Distribution



Here is the graphic view of temperature profile through the part. Power of this one graphic is more than most simulations and books of results you have seen till date. This single graphic will help you optimise….



Temperature Profile Through Part Thickness




Temperature Profile Through Part Thickness



RTC(Rapid Thermal Response) tooling With conformally laid channels close to mould wall, you will get to higher temperature in less time.



Temperature Response Rapid Heating




Temperature Response Rapid Heating



Seen mountain of scrap before tool produces satisfactory parts? With conformal cooling you will reach tool stabilisation in matter of 3 shots, that is the power to produce good parts within minutes of startup.



Time to Tool Stabilisation




Time to Tool Stabilisation




Reference Drawing for study points

IMPORTANT DISCLAIMER: Because of the multiplicity of possible effects during the processing and use of different

brand resins, the information herein does not free the processor from carrying his own validation tests and experiments.

Our calculation does not provide legally binding assurances of specific performance or of suitability for a particular

application.



We have condensed published research from MIT and many notable

researchers to produce this plastics tool cooling evaluation algorithm.

Hope you gathered from this sample report that our proprietary software

produces most powerful, easy to understand and most practical plastics

simulation. This simulation is developed to help tool designers and process

personnel get the cooling design right, accurately predict cycle time with

eye for uniformity of cooling, sufficient cooling, stress-free part and

accurate prediction of shrinkage. This algorithm is equally accurate in

predicting temperature rise for Rapid Thermal Cycling tooling, demanded

by today’s most demanding moulding applications. All in one neat

package. Will love to here from you with your most demanding application.


Powerful, Simple, Practical.



Confidentiality Note: Intellectual property protection is sought for various stages of our products, they are protected under various patents in various stages of application.

No part of this presentation or technologies described herein may be copied, reproduced without express written permission of its proprietors.


Good Cooling Is Not Optional !


Simulation

Documents

cool time

compression time

overall cycle time

mo vx1 analysis confidential

best possible cycle

rtc temperature

maximum temperature

mc open time