This report was prepared by Kyle Michael Kulwicki, the part that you will be seeing in this report is a battery cover. The part comes from a remote of a surround sound system, it holds two triple A batteries. The battery cover has two under cuts in it that are on the opposite that side of the gate that can be formed by one core blade, the mold to make this part is a two cavity AB mold. The mold base was purchased from DME and all of the lifter components were purchased from Progressive Components. The battery covers injection time is .39 seconds and the full cycle time is estimated to be around 15.5 seconds. The volume of the part is 4.24 CU.CM and you would need 1.42+ tons to clamp the mold down. Also the part is made out of polycarbonate (PC), the begging runner is a 3/16 full round runner that leads into another runner that is a 1/8 full round runner and ends at a edge gate that is .06 X.06 X.03 deep. The over all quality prediction for this part is rated as high by mold advisor so as long as we follow what we figured out in the software package we should get quality parts.

In this model we are able to see straight threw the part, which will give us a better understanding of some of the more complex geometry.

In this mold we see what the part will look like once the runner and gate is taken off.

In this simulation you are able to see were the plastic goes after it gets past the gate almost like as if you are filling a water bottle. The plastic starts at the injection point and slowly moves out from a half circle to a flat line, the guide bars on the bottom act as flow leaders to help the plastic flow at a constant rate and have a uniform ending point.

The fill time analysis will show you how fast the plastic is moving, sort of like what the plastic filling analysis will do, but there is one major difference and that is now we can see how long it takes to get to a certain point in the cavity. Aslo in this analysis you can see the end fill point, that is were the venting will go. The vent depth for this part is .003.

The confidence of fill is not 100% important but it is still important, it show were there might be problems filling the cavity, on this we can see one point that has a little area that has yellow indicating that that area might be a little harder to fill then the rest of a part.

The quality of fill is high on this part, it shows that there will not be any problem areas with flow or premature freeze off problems. So in short the part will a high quality part and that there probably wont be to many scrap parts due to problems with the mahy factors that mold flow factors in.

The weld lines analysis is fairly accurate, on this part we can see that there are not too many weld lines and for the use of this part the weld lines are not relevant.

The air trap analysis show quiet a few air traps, the air traps can be vented on or by the parting line. There are a few on the top but those are not a major concern because the top of this part is going to be cosmetic, it will be painted once it has cooled eliminating the look of a burn mark.

The cooling quality of this part is good except for the lettering, but mold flow dose not factor in your cooling of the part. So in other words make sure that you have your coolent zone touching that area.

The sink mark estimate is not to high, the largest one is .027 deep witch is not that deep and if you look at the part more then 90% are less then .009 deep so over all it sink marks are not that bad. Also you have to remember that there are still some cosmetics that need to be done to the part and that will take care of some of the smaller ones.

The sink mark shaded dose not really do anything, you see more of that in the sink mark estimate. The largest sink mark one .027 deep witch is not that deep and if you look at the part more then 90% are less then .009 deep so over all it sink marks are not that bad. Also you have to remember that there are still some cosmetics that need to be done to the part and that will take care of some of the smaller ones.

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