Moldflow Plastics Insight InjectionCompression Molding Case Study ICM

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Moldflow Plastics Insight Injection-Compression Molding Case Study ICM Compact Disc

Moldflow Plastics Insight Injection-Compression Molding Case Study ICM Compact Disc

Case Study § Injection molding vs. injection compression molding § Various analysis outputs §

Case Study § Injection molding vs. injection compression molding § Various analysis outputs § Benefits of analysis DESIGN SOLUTIONS

ICM Compact Disc Part Geometry Material: CD Grade Polycarbonate Thickness (mm) DESIGN SOLUTIONS

ICM Compact Disc Part Geometry Material: CD Grade Polycarbonate Thickness (mm) DESIGN SOLUTIONS

Process Conditions Injection Molding Process Conditions Fill time (s) Switch-over time (%) Post-fill time

Process Conditions Injection Molding Process Conditions Fill time (s) Switch-over time (%) Post-fill time Pack/hold pressure (%) Melt temp. (F) Mold temp. (F) 0. 5 99 10 80 620 158 Additional Injection-Compression Process Conditions Press tonnage used (tons) 22 Press waiting time (s) 0. 52 Press open distance (mm) 0. 6 Press displacement vs. speed 0. 6 mm @ 1. 2 mm/s Press compression/packing time (s) 10 DESIGN SOLUTIONS

Analysis Results Unique to ICM § Same results as C-MOLD Filling & Post-filling §

Analysis Results Unique to ICM § Same results as C-MOLD Filling & Post-filling § Additional X-Y plot results § § Press displacement Press speed Press force Cavity volume DESIGN SOLUTIONS

Press Displacement DESIGN SOLUTIONS

Press Displacement DESIGN SOLUTIONS

Press Speed DESIGN SOLUTIONS

Press Speed DESIGN SOLUTIONS

Press Force DESIGN SOLUTIONS

Press Force DESIGN SOLUTIONS

Cavity Volume DESIGN SOLUTIONS

Cavity Volume DESIGN SOLUTIONS

Frozen-in Shear Stress Injection-Compression Molding Injection Molding vs. § ICM results in lower frozen-in

Frozen-in Shear Stress Injection-Compression Molding Injection Molding vs. § ICM results in lower frozen-in shear stress which produces better optical properties DESIGN SOLUTIONS

Part Displacement Injection Molding Injection-Compression Molding § ICM improves the dimensional stability of the

Part Displacement Injection Molding Injection-Compression Molding § ICM improves the dimensional stability of the part DESIGN SOLUTIONS

Analysis Results Comparison Injection Pressure (psi) Clamp Force (tons) Flatness (in) DESIGN SOLUTIONS IM

Analysis Results Comparison Injection Pressure (psi) Clamp Force (tons) Flatness (in) DESIGN SOLUTIONS IM ICM 5, 000 20 8 0. 0038 0. 0026

Benefits of ICM Analysis § § Determine molding feasibility Evaluate part & mold design

Benefits of ICM Analysis § § Determine molding feasibility Evaluate part & mold design Determine processing window Minimize part shrinkage & warpage DESIGN SOLUTIONS