INTRODUCTION TO

NAUTILUS 8

MOLD QUALIFICATION AND

DESIGN OF EXPERIMENTS SOFTWAREFOR

INJECTION MOLDING

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The Nautilus Software 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

Once a process has been established on one machine, the

software will calculate the processes for all the

machines in the shop. The process can now be

transferred and ‘starting from scratch’ will not be

necessary on the other machines

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Benefits of using the techniques:

• Established process is robust

• Process will require ‘no or little attention’

• Will determine the fastest cycle time possible

• Less scrap at startup

• Zero scrap during production

• Improved part quality and process capability

Above factors increase the bottom line profits!

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THE SOFTWARE

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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

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➢Design of experiments module

• Tornado charts

• Process sensitivity charts

• Cosmetic process window

• Dynamic process window

• Visual prediction equation

➢ Mold trial and qualification progress report

➢Mold setup and operation documentation

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➢ Quality module

• full dimensional analysis

• statistical analysis

• post molding shrinkage report

• Documentation of quality inspection plan

➢ Calculation worksheets commonly used in molding

➢ User privileges

➢ Choice of units

➢ Network/concurrent versions

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Other features:

• Process – machine compatibility

• Add a plastic process sheet for a given mold

• Generate the plastic process sheet for any given machine

• Determine the machines in the shop that are compatible and

capable of running the mold based on plastic variables

• Units management –

• Select between metric, English or a combination

• Auto convert on demand

• Once units for a given machine are saved all process sheets

are generated in the machine units

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• User access levels

• Determine who can and cannot change databases and documents

• Custom read/write access

• Ability to create family molds and run them through

• 6-step study, for example: determine cavity imbalances

between family parts

• Doe, select the processes for family molds

• Optimize for all family parts

• Miscellaneous:

• All studies/documents for a given mold under one tab

• Additional fields added to all databases

Other features:

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MAIN SCREEN:

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DATABASES: MATERIAL – MOLD – MACHINE

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MOLD MACHINE COMPATIBILITY REPORT:

Criteria based on• Required tonnage• % Shot size used• Residence time of the material in the barrel• Physical size of the mold and the machine specs

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PROCESS – MACHINE COMPATIBILITY

• Add a plastic process sheet for a given mold

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PROCESS – MACHINE COMPATIBILITY

• GENERATE THE PLASTIC PROCESS SHEET FOR ANY GIVEN MACHINE IN THE DATABASE

• DETERMINE IF THE MACHINES ARE CAPABLE OF RUNNING THE MOLD BASED ON PLASTIC VARIABLES

ESTABLISHED PROCESS

CALCULATED PROCESS SHEETS FOR OTHER MACHINES

NOT ACCEPTABLE ACCEPTABLE

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PROCESS – MACHINE COMPATIBILITY

• ONCE THE TARGET MACHINE IS SELECTED, SELECT THE PROCESS SHEET FROM THE DROP DOWN

LIST AND CLICK ON ‘GENERATE PROCESS SHEET’ TO PRINT THE PROCESS SHEET FOR THE

MACHINE

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MOLD QUALIFICATION PART 1: 6-STEP STUDY

(AKA: SCIENTIFIC MOLDING)

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WORKSHEET NO. 1: IN MOLD RHEOLOGY

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WORKSHEET NO. 2: CAVITY BALANCE STUDY FAMILY MOLDS OPTION NEW IN

VER 8

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WORKSHEET NO. 3: PRESSURE DROP STUDY

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WORKSHEET NO. 4: COSMETIC PROCESS WINDOW

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WORKSHEET NO. 5: GATE SEAL STUDY – COLD RUNNER

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WORKSHEET NO. 5: GATE SEAL STUDY – HOT RUNNER

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WORKSHEET NO. 6: COOLING STUDY

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WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS

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MOLD QUALIFICATION PART 2:

DESIGN OF EXPERIMENTS

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Key features:

• No prior math or statistics experience required

• With 4 easy steps you will be able to design a doe

and run the experiments.

• The data will visually show you what you can and

cannot mold as far as the dimensions of the part

are concerned.

• No guesswork: data driven decisions for all changes

in mold steel and/or nominal - specifications

• Adjust the steel with confidence and leave the

process alone!

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INPUTS WORKSHEETS FOR DOE:

STEP 1: SELECT THE FACTORS FROM A DROPDOWN LIST

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STEP 2: ENTER THE UNITS, HIGH AND LOWS FOR THE STUDIES

THE HIGHS AND LOWS ARE DETERMENIED FROM THE COSMETIC PROCESS WINDOW.

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STEP 3: ENTER THE NOMINALS AND TOLERANCES

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STEP 3: SOFTWARE GENERATES THE EXPERIMENTAL MATRIX

MOLD THE PARTS, ENTER DATA AND CLICK ON THE ANALYSIS BUTTON TO VIEW THE RESULTS

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SUHAS KULKARNI FIMMTECH 1-760-525-9053

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 DOE PROCESS RUN

DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED CAVITIES AND DIMENSIONS

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DIMENSIONAL 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

DIMENSIONAL PROCESS WINDOW

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DIMENSIONAL PROCESS WINDOW

MOLD PARTS BETWEEN THE PROCESS WINDOWS TO MAINTAIN THE PARTS WITHIN THE DIMENSIONS. DIMENSIONAL PROCESS WINDOW

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DIMENSIONAL PROCESS WINDOW

WITH A DIMENSIONAL PROCESS WINDOW AS SHOWN IT WILL BE IMPOSSIBLE TO MOLD PARTS CONSISTENTLY TO THE REQUIRED DIMENSIONS.

IT WILL BE IMPOSSIBLE TO OBTAIN GOOD CpKs

TIME TO MAKE A DATA DRIVEN DECISION!

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SUHAS KULKARNI FIMMTECH 1-760-525-9053

VISUAL PREDICTION EQUATION

USL

LSL

USL

LSL

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

Cavity No →

Cavity No →

THE DIMENSION CAN GO OUT OF SPEC

SUHAS KULKARNI FIMMTECH 1-760-525-9053

VISUAL PREDICTION EQUATION

USL

LSL

USL

LSL

STABLE DIMENSION –WILL ALWAYS BE IN SPEC

LSL

THE DIMENSION CAN GO OUT OF SPEC

Cavity No →

Cavity No →

SUHAS KULKARNI FIMMTECH 1-760-525-9053

VISUAL PREDICTION EQUATION

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 →

SUHAS KULKARNI FIMMTECH 1-760-525-9053

VISUAL PREDICTION EQUATION

USL

LSL

USL

SIMULATED PROCESS:CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES(SEE NEXT SLIDE)

Cavity No →

Cavity No →

VISUAL PREDICTION EQUATION

SIMULATED PROCESS:CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES

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NUMERICAL PREDICTION EQUATION

USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY

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ACHIEVING DIMENSIONS: MAKING STEEL AND/OR NOMINAL – TOLERANCE CHANGES

GOOD Cp BUT A BAD CpK??? YOUR CHOICES ARE• MODIFY THE STEEL DIMENSION AND/OR• MODIFY THE NOMINAL – SPEC LIMITS

ROBUST PROCESS

MODIFY MOLD AND/OR NOMINAL-SPEC LIMITS BY THIS NUMBER TO HIT THE MOMINAL VALUE

NEW IN VER 8

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CAPABILITY NOT A REQUIREMENT? WANT TO BE ONLY IN SPEC??

ROBUST PROCESS

MODIFY MOLD AND/OR NOMINAL-SPEC LIMITS BY THIS NUMBER TO HIT BE INSIDE THE USL OR LSL

0

NEW IN VER 8

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CONFIDENCE RATINGS

USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY

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PRINTING: SELECTION SCREEN

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PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS

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MOLD SPECIFIC TROUBLE SHOOTING GUIDE NEW IN VER 8

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QUALITY MODULE:

FULL DIMENSIONAL ANALYSIS:

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QUALITY MODULE:

STATISTICAL ANALYSIS :

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MACHINE QUALIFICATION:

INJECTION SPEED LINEARITY :

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MACHINE QUALIFICATION:

SHOT TO SHOT REPEATABILITY TEST :

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MACHINE QUALIFICATION:

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:

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SHOT SIZE ESTIMATION WORKSHEET:

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HOPPER SIZE CALCULATION WORKSHEET:

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REGRIND CALCULATIONS (CLOSED LOOP SYSTEMS)

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MISCELLANEOUS FEATURES

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UNITS MANAGEMENT

• UNITS MANAGEMENT –

• SELECT BETWEEN METRIC, ENGLISH OR A COMBINATION

• AUTO CONVERT ON DEMAND

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USER ACCESS LEVELS

• USER ACCESS LEVELS

• DETERMINE WHO CAN AND CANNOT CHANGE DATABASES AND DOCUMENTS

• CUSTOM READ/WRITE ACCESS

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FAMILY MOLDS

• ABILITY TO CREATE FAMILY MOLDS AND RUN THEM THROUGH

• 6-STEP STUDY, FOR EXAMPLE: DETERMINE CAVITY IMBALANCES BETWEEN FAMILY PARTS

• DOE, SELECT THE PROCESSES FOR FAMILY MOLDS

• OPTIMIZE FOR ALL FAMILY PARTS

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FAMILY MOLDS

• ABILITY TO CREATE FAMILY MOLDS IN THE DATABASE

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FAMILY MOLDS

• ABILITY TO QULAIFY FAMILY MOLDS IN 6-STEP AND DOE MODULE

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CONTACT INFO:

Barış Bozkurt @ baris.bozkurt@bwetr.com

Cem Barış Özgüven @cembaris.ozguven@bwetr.com

+90 216 515 68 80

www.brightworksengineering.com

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