Analysis allows for perfect parts from day oneAnalysis allows for perfect parts from day one

Still not sold on the fact that moldfilling analysis works? Check out the following field report before you choose your final answer. Tom Peeler, Design Center manager at PolyOne Distribution, shares one of his recent projects with IMM to illustrate how tricky design problems can be solved via the virtual prototyping of moldfilling analysis.

Case Specifics
The subject of the field report was filling analysis of a wheel center cap for the GMC Tracker (Figure 1). The part is molded by Hunjan Molded Products (Waterloo) Ltd. (Waterloo, ON) for CAMI Automotive Inc. (Ingersoll, ON). The objective of the analysis was to determine if filling problems would occur in the cap using the side gate location. Designers were concerned about trapped air or a severe weldline opposite the gate. Additional objectives of the analysis were to minimize part stress to help achieve acceptable plating, to check gate orifice diameter and gate tab thickness, eliminate downtime, and to produce a part with no runout (see sidebar, below). The material to be used was Dow Magnum 3490 ABS. Molding conditions for part production include a melt temperature of 465F, a mold temperature of 150F, and a first-stage injection time of 1.5 seconds.