nautilus 2012 m q d e s -...

INTRODUCTION

TO

NAUTILUS 2012

MOLD QUALIFICATION

AND

DESIGN OF EXPERIMENTS SOFTWARE

FOR

INJECTION MOLDING

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

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

�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:

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

INPUTS WORKSHEETS FOR DOE:

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)

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

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

THE DIMENSION CAN

GO OUT OF SPEC

Cavity No →

Cavity No →

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

Cavity No →

Cavity No →

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: