i ntroduction to nautilus 7 m old q ualification and d esign of e xperiments s oftware for i...

INTRODUCTION TO

NAUTILUS 7

MOLD QUALIFICATION AND

DESIGN OF EXPERIMENTS SOFTWAREFOR

INJECTION MOLDING

SUHAS KULKARNI FIMMTECH 1-760-525-9053

NAUTILUS IS A PROGRAM THAT HELPS IN THE

EVALUATION, ANALYSIS, DEVELOPMENT AND

DOCUMENTATION OF THE INJECTION MOLDING

PROCESS.

THE SOFTWARE ALSO HAS A COMPLETE DESIGN

OF EXPERIMENTS MODULE THAT IS CUSTOMIZED

FOR INJECTION MOLDING


BENEFITS OF USING THE TECHNIQUES:

• ESTABLISHED PROCESS IS ROBUST

• PROCESS WILL BE A ‘NO OR LITTLE ATTENTION

REQUIRED’ PROCESS

• WILL DETERMINE THE FASTEST CYCLE TIME POSSIBLE

• LESS SCRAP AT STARTUP

• LESS SCRAP DURING PRODUCTION

• IMPROVED PART QUALITY AND PROCESS CAPABILITY

ABOVE FACTORS INCREASE THE BOTTOM LINE PROFITS!


3 CASE STUDIES


CASE STUDY 1 – CONSUMER PRODUCTPart and Mold Irrigation Body – 32 Cavity Hot Runner

Status • Diameter closer to LSL with CpK < 1.0• Length closer to LSL• Cycle Time = 46 seconds

Target • Diameter to be closer nominal • Length to be closer to nominal• Diameter and Length CpK ≥ 2.0• Cycle time = 38 seconds

Analysis • Via Scientific Molding and DOE it was found that higher pack pressures helped increase the dimensions• Machine tonnage was not sufficient to prevent flash• DOE showed cooling time did not have significant effect on the part dimensions.

Actions • Mold moved to a higher tonnage machine• Process re-established using Scientific Molding and DOE

Achievements • Diameter and Length in spec and closer to nominal• Diameter and Length CpK>2.0• Cycle Time = 35 seconds

CASE STUDY 2 – AUTOMOTIVE PRODUCTPart and Mold Automotive Connector – 4 Cavity Mold

Status • Shroud Dimension in the center lower than LSL• Shroud Walls not parallel to each other• Cycle time was 38 seconds

Target • Shroud Dimension to be at nominal• Shroud walls to be parallel to each other• Cycle time of 32 seconds

Analysis • Shroud was closer to the end of fill • Shroud thickness was relatively smaller compared to the rest of the part.• Shroud was not sufficiently packed out

Actions • A Gate seal study using Scientific Molding showed the gate froze off too quick. The gate was opened up.• DOE showed the shroud dimension could be improved up to half of what was required. The steel in the shroud area was contoured to compensate for the warp

Achievements • Shroud dimension and parallelism were in spec• Cycle Time of 32 seconds was achieved• Based on the DOE results, a new molding screw with a different design was installed and cycle time of 29 sec was achieved

CASE STUDY 3 – MEDICAL PRODUCTPart and Mold Surgical Clip – 16 Cavity Hot Runner Mold

Status • Part Length was over the LSL• Mold was not steel safe• Cycle time = 24 seconds• Black streaks were found on the molded part

Target • Part Length to be closer to Nominal• Cycle Time = 15 seconds• No Black Streaks

Analysis • Part was too thick, needed extra time to cool• Residence time in hot runner was too high

Actions • Scientific Molding and DOE was done to understand the effect of the process on the part quality• Part was cored out to reduce the thick section.• Scientific Molding and DOE were redone.

Achievements • New thinner part thickness helped to run the mold at lower cooling times therefore achieving a cycle time of 12 seconds• Part length was closer to nominal with CpK values = ~ 4.0• With faster cycle, the residence time in the hot runner manifold reduced and the black specs were eliminated.

THE SOFTWARE


FOLLOWING ARE SOME OF THE FEATURES OF THE SOFTWARE:

MATERIAL, MOLD AND MACHINE DATABASES

MOLD – MACHINE COMPATIBILITY REPORT

SCIENTIFIC MOLDING WORKSHEETS (6-STEP STUDY)

• VISCOSITY STUDY

• PRESSURE DROP STUDY

• CAVITY BALANCE STUDY

• PROCESS WINDOW STUDY

• GATE SEAL STUDY

• COOLING TIMESUHAS KULKARNI FIMMTECH 1-760-525-9053

DESIGN OF EXPERIMENTS MODULE

• TORNADO CHARTS – WHAT IS THE MOST SIGNIFICANT FACTOR?

• PROCESS SENSITIVITY CHARTS

• COSMETIC PROCESS WINDOW

• DYNAMIC PROCESS WINDOW

• VISUAL PREDICTION EQUATION

MOLD TRIAL AND QUALIFICATION PROGRESS REPORT

WATER LINE DIAGRAMS AND MOLD TEMPERATURE MAPS

MOLD SETUP AND OPERATION DOCUMENTATION


QUALITY MODULE

• FULL DIMENSIONAL ANALYSIS

• STATISTICAL ANALYSIS

• POST MOLDING SHRINKAGE REPORT

• DOCUMENTATION OF QUALITY INSPECTION PLAN

MOLD DESIGN AND PART DESIGN CHECKLISTS

CALCULATION WORKSHEETS COMMONLY USED IN

MOLDING


MAIN SCREEN:



VISUAL HELP MENU IS AVAILABLE IN EACH SCREEN

DATABASES: MATERIAL – MOLD – MACHINE


MOLD MACHINE COMPATIBILITY REPORT:


WORKSHEET NO. 1: IN MOLD RHEOLOGY


WORKSHEET NO. 2: CAVITY BALANCE STUDY


WORKSHEET NO. 3: PRESSURE DROP STUDY


WORKSHEET NO. 4: PROCESS WINDOW


WORKSHEET NO. 5: GATE SEAL STUDY


WORKSHEET NO. 6: COOLING STUDY



WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS


INPUTS WORKSHEETS FOR DOE:


TORNADO CHARTS

GIVES YOU INFO ON THE FACTOR THAT MOST IMPACTS THE PART QUALITY(POSITIVE FACTORS ABOVE THE LINE, AND NEGATIVE BELOW THE LINE)


PROCESS SENSITIVITY GRAPH

GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE PROCESS


COMPOSITE PROCESS SENSITIVITY GRAPH

GIVES YOU A QUICK SNAP SHOT OF HOW ALL THE DIMENSION WAS AFFECTED BY THE PROCESS (ALL ON ONE SCREEN)


DYNAMIC PROCESS WINDOW

GREEN CONTOURS – PARTS IN DIMENSION RED – PARTS OUT OS SPEC

YOU CAN DRAW A BOX AS SHOWN TO DETERMINE ALARM AND TOLERANCE SETTINGS


PREDICTION EQUATION


VISUAL PREDICTION EQUATION

USL

LSL

USL

LSL

EXTENT TO WHICH THE DIMENSION CAN BE INFLUENCED BETWEEN THE EXTREMES OF THE DOE PARAMETERS

THE DIMENSION CAN GO OUT OF SPEC

Cavity No →

Cavity No →



USL

LSL

USL

LSL

STABLE DIMENSION – WILL ALWAYS BE IN SPEC

LSL

THE DIMENSION CAN GO OUT OF SPEC

Cavity No →

Cavity No →



USL

LSL

USL

STABLE DIMENSION – WILL ALWAYS BE IN SPEC

LSL

PROCESS GOLD SPOT - BEST PROCESS TO BRING ALL DIMENSIONS CLOSEST TO NOMINAL

Cavity No →

Cavity No →



USL

LSL

USL

SIMULATED PROCESS

Cavity No →

Cavity No →


DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED CAVITIES AND DIMENSIONS


CONFIDENCE RATINGS


PRINTING: SELECTION SCREEN


PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS


MOLD SPECIFIC TROUBLE SHOOTING GUIDE

WATER LINE DOCUMENTATION:


MOLD TEMPERATURE DOCUMENTATION:


CAVITY LAYOUT DOCUMENTATION:


QUALIFICATION DOCUMENTATION:


CHECKLIST


FULL DIMENSIONAL ANALYSIS:


STATISTICAL ANALYSIS :


ATTRIBUTE DATA ANALYSIS :


INJECTION SPEED LINEARITY :


SHOT TO SHOT REPEATABILITY TEST :


LOAD SENSITIVITY TEST :


FREQUENTLY USED MOLDING CALCULATIONS:


WATER FLOW CALCULATION:


PROCESS TRANSFER BETWEEN MACHINES WORKSHEET:


SHOT SIZE ESTIMATION WORKSHEET:


HOPPER SIZE CALCULATION WORKSHEET:


REGRIND CALCULATIONS:



COST OF THE SOFTWARE: $2295 PER COMPUTER

WITH A 10% MAINTENANCE CHARGE EVERY YEAR.

AN EXAMPLE OF THE RETURN ON INVESTMENT IS

GIVE IN THE NEXT PAGE.

YOU CAN PERFORM YOUR OWN ANALYSIS ON THE

SLIDE AFTER THE EXAMPLE.


PERFORM YOUR OWN ANALYSIS NEXT …..


ITEMRATE per HOUR

or LB HOURS/LBS SPENT TOTAL COST

MACHINE 0

DRYER 0

MOLD SETUP 0

PROCESS TECH 0

OPERATOR 0

QA INSPECTOR 0

MATERIAL (LBS) 0

MISC EXPENSES 0

0

2295

0.0copies of the software

0.0 INSTALLTIONSTHEREFORE REDUCING ONLY ONE MOLD TRIAL IN THE LIFE OF YOUR

SHOP WILL PAY FOR

GRAND TOTAL

DOUBLE CLICK THE TABLE TO PERFORM YOUR OWN ROI

ONE MOLD TRIAL EQUALS =

COST OF THE SOFTWARE =


CONTACT INFO:

SUHAS KULKARNI

[email protected]

1-760-525-9053

WWW.FIMMTECH.COM

WWW.INJECTIONMOLDINGONLINE.COM

i ntroduction to nautilus 7 m old q ualification and d esign of e xperiments s oftware for i...

Documents

nominal cycle time

lsl cycle time

spec cycle time

seconds slide

seconds analysis shroud

length closer

cooling time

extra time