thin wall cosmetic application & deflection reduction : a flexflow … · 2018-07-20 · thin...
TRANSCRIPT
![Page 1: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/1.jpg)
Thin wall cosmetic application & Deflection
reduction : a FLEXflow story
HRSflow
Pavan Nicola
![Page 2: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/2.jpg)
2
Company Structure
![Page 3: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/3.jpg)
3
Around 14.000 Systems delivered in 2017
42.000 Drops produced in 2017
More than 2000 Customers
More than 1100 End users
More than 140 Designers in 10 countries
HRSflow: a Worldwide partner
![Page 4: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/4.jpg)
4
15 Plastic engineers in the world
5 Teams on different jet lags
More than 1800 Simulation projects in 2017
Certification of Outstanding Partner
Expert Certification
HRSflow: a Worldwide partner
![Page 5: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/5.jpg)
5
HRSflow Advanced Development
![Page 6: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/6.jpg)
6
Italy - San Polo di Piave50km north of Venice
China – Hangzhou175km south west of Shanghai
6
Our worldwide production plants
USA- Michigan – Grand Rapids250km west of Detroit
![Page 7: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/7.jpg)
Project description
Case Introduction
![Page 8: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/8.jpg)
8
FLEXflow Laptop cover application
Introduction – status quo
- Electronic applications are very demanding in order to achieve high structural
performances and very low weight.
- More and more the wall thickness is reduced
- Aesthetical surface (mix of matt and glossy surface)
- Function integration
![Page 9: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/9.jpg)
9
Currently industry standards for A-Cover is to use 2 steps process:
- 1 Part in PC CF 20 (or thermoset CF reinforced)
- 1 part in PC GF 50
This implies
- 6 to 10 tips for the hot runner (per shot)
- 1,8÷2 mm thickness
- Stiffness is provided by the CF
- Antenna area is done with GF
- 2 steps process – non continuous
- Expensive – cycle time – Complexity
FLEXflow Laptop cover application
![Page 10: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/10.jpg)
10
Project details
- A Cover 14”
- Thickness range between 1.5 to 1.7 mm
- Dimensions : 232 *335*7,3 mm
- Material: PC 50% GF
- Hot Runner system: 5 FLEXflow drops
- Special Features: Surface Effect produced in one shot
as combination of high gloss and low gloss surface
- Special Features: FLEXflow One for high flatness
- Special Features: Combine in one shot radio
transparency and stiffness
- Partnered with: FLEX, KraussMaffei, Roctool, Sabic
FLEXflow Laptop cover application
![Page 11: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/11.jpg)
11
Tool details
- Hot Runner system cascade by HRS (5 drops – Ma serie)
- Conical valve gate with end ring through the cavity
- Electric motors for valve gate control – FLEXflow One technology
FLEXflow Laptop cover application
![Page 12: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/12.jpg)
FLEXflow Introduction
How it works
![Page 13: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/13.jpg)
13
13
FLEXflow: how it works
![Page 14: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/14.jpg)
14
7/20/2018 14
0,0
200,0
400,0
600,0
800,0
1000,0
1200,0
1400,0
1600,0
1800,0
2000,0
0 5 10 15 20
Sp
ecific
pre
ssu
re[b
ar]
Valve pin opening position [mm]
400 cm^3/s
300 cm^3/s
200 cm^3/s
FLEXflow: how it works
![Page 15: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/15.jpg)
15
Opening and closing settings - Max 8 steps can be setted
Sequence parameters based on time or screw position or pressure value in the cavity
Possiblity to handle up to 2 different injection units on the same IMM.
FLEXflow: how it works
![Page 16: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/16.jpg)
16
aesthetical quality improvement
clamping force reduction
warpage Control - reduction
Less maintenance & spare parts
wider process window parameters
Clean Operation:No WaterNo oilNo cooling
16
FLEXflow: how it works
![Page 17: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/17.jpg)
Moldex 3D Simulation
Input and Results
![Page 18: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/18.jpg)
18
Modelling
Mesh type BLM 10
Mesh size runner ~745600
Mesh size part ~1670800
Volume runner 317.1 cm³
Volume part 137.1 cm³
Moldex 3D Laptop cover simulation
![Page 19: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/19.jpg)
19
Material Information
Generic name PC
SupplierSABIC Innovative Plastics
Trade name THERMOCOMP D551
Fiber percent 50% Glass Fiber Filled
Melt temperature range 285 - 310 (°C)
Mold temperature range 80 - 95 (°C)
Freeze temperature 96 (°C)
Moldex 3D Laptop cover simulation
![Page 20: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/20.jpg)
20
Moldex 3D Laptop cover simulation Fill and cooling
![Page 21: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/21.jpg)
21
Moldex 3D Laptop cover simulation
animation
![Page 22: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/22.jpg)
22
Moldex 3D Laptop cover simulation
temperature
![Page 23: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/23.jpg)
23
Moldex 3D Laptop cover simulation
![Page 24: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/24.jpg)
24
Moldex 3D Laptop cover simulation
Pressure and SN
![Page 25: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/25.jpg)
25
Moldex 3D Laptop cover simulation
Deflection
![Page 26: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/26.jpg)
Question time
Acknowledgement and Conclusion
![Page 27: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/27.jpg)
27
This application project shows:
- performance of FLEXflow to be simulated accurately with Moldex 3D
- FLEXflow technology can be applied also on high filled material (PC 50%GF) in a
thin wall component (1,7 mm)
- Sequential molding and FLEXflow optimization gives a strong contribute for
warpage control
- Cycle time and cost reduction can be reached on current production with a more
comprehensive approach involving main contributors on part and process design
Conclusion
![Page 28: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/28.jpg)
28
Partnership
FLEXflow Laptop cover application
![Page 29: Thin wall cosmetic application & Deflection reduction : a FLEXflow … · 2018-07-20 · thin wall component (1,7 mm) - Sequential molding and FLEXflow optimization gives a strong](https://reader034.vdocuments.us/reader034/viewer/2022050413/5f8a19b6caa47234c110a293/html5/thumbnails/29.jpg)
Thank You