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INTRODUCTION
TO
NAUTILUS 2012
MOLD QUALIFICATION
AND
DESIGN OF EXPERIMENTS SOFTWARE
FOR
INJECTION MOLDING
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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
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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 – 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
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�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
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MAIN SCREEN:
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DATABASES: MATERIAL – MOLD – MACHINE
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MOLD MACHINE COMPATIBILITY REPORT:
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WORKSHEET NO. 1: IN MOLD RHEOLOGY
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WORKSHEET NO. 2: CAVITY BALANCE STUDY
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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
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WORKSHEET NO. 6: COOLING STUDY
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INPUTS WORKSHEETS FOR DOE:
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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)
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PROCESS SENSITIVITY GRAPH
GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE
PROCESS
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COMPOSITE PROCESS SENSITIVITY GRAPH
GIVES YOU A QUICK SNAP SHOT OF HOW ALL THE DIMENSION WAS AFFECTED BY THE
PROCESS (ALL ON ONE SCREEN)
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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
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PREDICTION EQUATION
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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
THE DIMENSION CAN
GO OUT OF SPEC
Cavity No →
Cavity No →
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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 →
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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 →
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SUHAS KULKARNI FIMMTECH 1-760-525-9053
VISUAL PREDICTION EQUATION
USL
LSL
USL
SIMULATED PROCESS
Cavity No →
Cavity No →
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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
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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: