Shadow cap conformal cooling study
17
www.shadowpolymer.com 01/07/2013 1 Project: STX-50-001-2012 Engineering with a Purpose
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Transcript of Shadow cap conformal cooling study
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1Project: STX-50-001-2012
Engineering with a Purpose
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2Project: STX-50-001-2012
01/07/2013
Prepared for:
Doug HeplerPolyshot Corporation
West Henrietta, New York
Polyshot Brazed Core Mold Flow Analysis Project
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3Project: STX-50-001-2012
01/07/2013Project Statement
The purpose of this mold flow study was to evaluate the manufacturing performance change in a single cavity simple Cap mold with conformal cooling utilizing Polyshot’s brazed core technology and one utilizing a standard baffle design.
Both scenario’s inputs were identical with the exception of the mold insert and cooling configuration.
Baffle Conformal
Cap
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4Project: STX-50-001-2012
01/07/2013Finite Element Mesh – Tetra / Prismatic Mixed
622,301 Part elements1,074,897 Cooling elements2,949,503 Mold elements
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5Project: STX-50-001-2012
01/07/2013Material Properties (PP – Sabic 575P)
Units = English
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6Project: STX-50-001-2012
01/07/2013Processing Conditions
Units = English
80% of EOF Pressure
70% of machine capacity of 20 ksi
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7Project: STX-50-001-2012
01/07/2013Filling Pattern @ EOP
Animated Animation will play when shown as a slide show.
Baffle Conformal
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8Project: STX-50-001-2012
01/07/2013Part Temperature at End of Packing Phase
Baffle Conformal
36% lower
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9Project: STX-50-001-2012
01/07/2013Part Temperature at End of Cooling Phase
Baffle Conformal
38% lowerDenotes a faster
cycle
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10Project: STX-50-001-2012
01/07/2013Mold Temperature at End of Cooling Phase (Cross Section View)
Baffle Conformal
Showing much cooler mold inserts when
results are scaled to identical values
Temperature difference resulted in a 39%
reduction in cycle time.
Req’d Cooling Time
3.1 sec
Req’d Cooling Time
1.9 sec
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11Project: STX-50-001-2012
01/07/2013Mold Temperature at End of Cooling Phase – Detail View
Baffle Conformal
Showing much cooler mold inserts when
results are scaled to identical values
Temperature difference resulted in a 39%
reduction in cycle time.
Req’d Cooling Time
3.1 sec
Req’d Cooling Time
1.9 sec
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12Project: STX-50-001-2012
01/07/2013Coolant Temperature at End of Cooling Phase
Baffle Conformal
99% lower temperature rise in coolant during the
cooling phase. Greater cooling
efficiency.
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13Project: STX-50-001-2012
01/07/2013Coolant Pressure at End of Cooling Phase
Baffle Conformal
98% higher coolant pressure
during the cooling phase. Greater
cooling efficiency.
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14Project: STX-50-001-2012
01/07/2013Total Displacement (Warpage) after Ejection at Room Temp
Baffle Conformal
5X Magnification 25% lowertotal warpage
(all effects included)
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15Project: STX-50-001-2012
01/07/2013Total Displacement (Warpage) after Ejection at Room Temp
Baffle Conformal
10X Magnification 25% lowertotal warpage
(all effects included)
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16Project: STX-50-001-2012
01/07/2013Total Displacement (Warpage) after Ejection at Room Temp
Baffle Conformal
5X Magnification 25% lowertotal warpage
(all effects included)
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17Project: STX-50-001-2012
01/07/2013Contact Information
Robert A. HickmanPresident
Shadow Polymer Industries, Inc.Houston, Texas
(281) 789-7520 office
(330) 224-5640 cell
For more information, visit us online at:
www.shadowpolymer.com
