Transcript Slide 1
I
NTRODUCTION
TO
NAUTILUS 7 D M
OLD ESIGN OF
E Q
UALIFICATION
AND
XPERIMENTS
FOR
S
OFTWARE
I
NJECTION
M
OLDING
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 SUHAS KULKARNI FIMMTECH 1-760-525-9053
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!
SUHAS KULKARNI FIMMTECH 1-760-525-9053
3 CASE STUDIES SUHAS KULKARNI FIMMTECH 1-760-525-9053
CASE STUDY 1 – CONSUMER PRODUCT
Part and Mold Status Target Analysis Actions Achievements
Irrigation Body – 32 Cavity Hot Runner • • • • • • • Diameter closer to LSL with CpK < 1.0
Length closer to LSL Cycle Time = 46 seconds • • • Diameter to be closer nominal Length to be closer to nominal Diameter and Length CpK ≥ 2.0
Cycle time = 38 seconds • • • 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.
Mold moved to a higher tonnage machine Process re-established using Scientific Molding and DOE Diameter and Length in spec and closer to nominal Diameter and Length CpK>2.0
Cycle Time = 35 seconds
CASE STUDY 2 – AUTOMOTIVE PRODUCT
Part and Mold Status Target Analysis Actions Achievements
Automotive Connector – 4 Cavity Mold • • • • • • Shroud Dimension in the center lower than LSL Shroud Walls not parallel to each other Cycle time was 38 seconds Shroud Dimension to be at nominal Shroud walls to be parallel to each other Cycle time of 32 seconds • • 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 • • 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 • • • 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 PRODUCT
Part and Mold Status Target Analysis Actions Achievements
Surgical Clip – 16 Cavity Hot Runner Mold • • • • • • • Part Length was over the LSL Mold was not steel safe Cycle time = 24 seconds Black streaks were found on the molded part Part Length to be closer to Nominal Cycle Time = 15 seconds No Black Streaks • • Part was too thick, needed extra time to cool Residence time in hot runner was too high • 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.
• 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 SUHAS KULKARNI FIMMTECH 1-760-525-9053
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 TIME SUHAS 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 SUHAS KULKARNI FIMMTECH 1-760-525-9053
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 SUHAS KULKARNI FIMMTECH 1-760-525-9053
MAIN SCREEN:
SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL HELP MENU IS AVAILABLE IN EACH SCREEN
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DATABASES: MATERIAL – MOLD – MACHINE
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MOLD MACHINE COMPATIBILITY REPORT:
SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 1: IN MOLD RHEOLOGY
SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 2: CAVITY BALANCE STUDY
SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 3: PRESSURE DROP STUDY
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WORKSHEET NO. 4: PROCESS WINDOW
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WORKSHEET NO. 5: GATE SEAL STUDY
SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET NO. 6: COOLING STUDY
SUHAS KULKARNI FIMMTECH 1-760-525-9053
WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS
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INPUTS WORKSHEETS FOR DOE:
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TORNADO CHARTS
GIVES YOU INFO ON THE FACTOR THAT MOST IMPACTS THE PART QUALITY (POSITIVE FACTORS ABOVE THE LINE, AND NEGATIVE BELOW THE LINE) SUHAS KULKARNI FIMMTECH 1-760-525-9053
PROCESS SENSITIVITY GRAPH
GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE PROCESS SUHAS KULKARNI FIMMTECH 1-760-525-9053
COMPOSITE PROCESS SENSITIVITY GRAPH
GIVES YOU A QUICK SNAP SHOT OF HOW ALL THE DIMENSION WAS AFFECTED BY THE PROCESS (ALL ON ONE SCREEN) SUHAS KULKARNI FIMMTECH 1-760-525-9053
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 SUHAS KULKARNI FIMMTECH 1-760-525-9053
PREDICTION EQUATION
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VISUAL PREDICTION EQUATION THE DIMENSION CAN GO OUT OF SPEC USL LSL
Cavity No →
USL EXTENT TO WHICH THE DIMENSION CAN BE INFLUENCED BETWEEN THE EXTREMES OF THE DOE PARAMETERS LSL
Cavity No → SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL PREDICTION EQUATION THE DIMENSION CAN GO OUT OF SPEC USL LSL
Cavity No →
USL STABLE DIMENSION – WILL ALWAYS BE IN SPEC
Cavity No → SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL PREDICTION EQUATION PROCESS GOLD SPOT - BEST PROCESS TO BRING ALL DIMENSIONS CLOSEST TO NOMINAL USL LSL
Cavity No →
USL STABLE DIMENSION – WILL ALWAYS BE IN SPEC LSL
Cavity No → SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL PREDICTION EQUATION SIMULATED PROCESS USL LSL
Cavity No →
USL
Cavity No → SUHAS KULKARNI FIMMTECH 1-760-525-9053
DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED CAVITIES AND DIMENSIONS
SUHAS KULKARNI FIMMTECH 1-760-525-9053
CONFIDENCE RATINGS
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PRINTING: SELECTION SCREEN
SUHAS KULKARNI FIMMTECH 1-760-525-9053
PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS
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MOLD SPECIFIC TROUBLE SHOOTING GUIDE
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WATER LINE DOCUMENTATION:
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MOLD TEMPERATURE DOCUMENTATION:
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CAVITY LAYOUT DOCUMENTATION:
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QUALIFICATION DOCUMENTATION:
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CHECKLIST
SUHAS KULKARNI FIMMTECH 1-760-525-9053
FULL DIMENSIONAL ANALYSIS:
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STATISTICAL ANALYSIS :
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ATTRIBUTE DATA ANALYSIS :
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INJECTION SPEED LINEARITY :
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SHOT TO SHOT REPEATABILITY TEST :
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LOAD SENSITIVITY TEST :
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FREQUENTLY USED MOLDING CALCULATIONS:
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WATER FLOW CALCULATION:
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PROCESS TRANSFER BETWEEN MACHINES WORKSHEET:
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SHOT SIZE ESTIMATION WORKSHEET:
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HOPPER SIZE CALCULATION WORKSHEET:
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REGRIND CALCULATIONS:
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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. SUHAS KULKARNI FIMMTECH 1-760-525-9053
SUHAS KULKARNI FIMMTECH 1-760-525-9053
PERFORM YOUR OWN ANALYSIS NEXT …..
SUHAS KULKARNI FIMMTECH 1-760-525-9053
DOUBLE CLICK THE TABLE TO PERFORM YOUR OWN ROI ITEM
MACHINE DRYER MOLD SETUP PROCESS TECH OPERATOR QA INSPECTOR
RATE per HOUR or LB HOURS/LBS SPENT
MATERIAL (LBS) MISC EXPENSES
GRAND TOTAL
COST OF THE SOFTWARE = 2295
ONE MOLD TRIAL EQUALS =
THEREFORE REDUCING ONLY
ONE
MOLD TRIAL IN THE
LIFE
OF YOUR
0.0
0.0
TOTAL COST
0 0 0 0 0 0 0 0
0 copies of the software
INSTALLTIONS
CONTACT INFO:
SUHAS KULKARNI [email protected]
1-760-525-9053 WWW.FIMMTECH.COM
WWW .I
NJECTION M OLDING O NLINE .
COM SUHAS KULKARNI FIMMTECH 1-760-525-9053