Dashboard Injection Mould

1 Moulding Process

Injection pressure 80~200MPa; Preheat 130°c for 4H; Suggested barrel temperature: front 260~290 °c, middle 250~280 °c and end 230~240 °c; Shot time 30~90s, cooling 30~60s, molding 70~160s; To use screw type injection machine with rotation rate of 28r/min is suggested; Post-treatment using infrared light heating glycerol, 150 °c for 1~4H.

2 Draft Angle

To click “check Regions” of “Molded Part Validation” at analysis menu bar, pick “keep existing” under “Calculate” and then click the icon of draft angle to have “Z axis” as draft angle following with “OK”s. Input “0” at “Draft Angle Limit” under “Face” and then click “Select Color of All Faces”, you will find part surface color changes which helps to check which faces molded in cavity side or core side, which haven’t been processed draft and where there are undercuts.

3 Mold Flow Analysis

Purpose: to determine the gate positions and check filling state, air trap and weld line positions and deformation.

Scheme: Molding window analysis, filling analysis, filling & packing analysis, filling & packing & warp analysis. Cooling analysis should be taken after the dashboard tool structure design.

Suggestion: Before analysis simplify model that to leave out small fillets, bosses and ribs which is not effective so that the analysis time can be saved.

3.1 Model Import

Import the product data file into “Mold-flow” and choose “Double Domain” for mesh type, then create project name and saving directory.

3.2 Mesh Create and Statistics

Click “Mesh” and “Generate Mesh”, then define mesh size, for the initial suggest to use default value. Check “Preview” and as the size is defined, click “Mesh Now”.

Under “Mesh Statistics” choose “triangle” as element type and then click “Show”.

Notes: average aspect ratio should be <3; max. ratio could be 8~20 according to part structure; free edges, manifold edges, not oriented elements, intersecting elements and overlapping elements should be set “o” value; matching ratio should be over 85%.

3.3 Mesh Repair

First to do intersecting elements diagnostic to modify them. Open “Overlapping Elements Diagnostics” at “Mesh Diagnostics”, select “Place Results in Diagnostics” and then “Display”. Right click at “Diagnostic Results” to open “Expand” layer dialog and input 2 then “OK”, you will get figure (left bellow): Delete intersecting mesh elements and find “Fill Hole” command to get it fixed.

3.4 Aspect Ratio Diagnostic

Click “Aspect Ratio Diagnostic” icon, input 20 as Min. Value, select “Place Results in Diagnostics” and then “Display”. After modified mesh elements with big aspect ratio, launch mesh statistics again to check, if no errors, go on for runner unit creation, as soon as the process parameters are set, the mold flow analysis for dashboard injection mould can be started.

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