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Thank you for stopping by
from Plastics News Daily

Tight Tolerances Concerns?
Call or Contact us Today!

AND scroll down to see how we solved a
tight tolerance warpage problem with windage.

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ATME - Take Away

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Step 1 - Correlation Existing Warpage

  1. Old material deck predicted right trend, wrong magnitude
  2. New material deck predicted trend and magnitude correctly
  3. Determined cause of warpage to be fiber orientation
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Old Material Deck
Max deviation = 0.014”
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New Material Deck
Max deviation = 0.008”

Step 2 – Minimize Warpage

  1. Change Gate Location for more favorable fiber alignment
  2. Warpage reduced slightly, but not within tolerance
  3. Sink marks eliminated
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Max. Deflections
Downward - 0.0070”
Inward – 0.0099”
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Fiber Orientation More Uniform Across Part

Step 3 – Use Windage to Fix Warpage

  1. Determine Windage Factor
  2. Decide on Shrinkage Number
  3. Morph the Part (avoid die lock)
  4. Confirm in Moldflow
  5. One week to complete analysis, material testing, and delivery of morphed windage file.
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Purple = Nominal
Blue = Windage

Step 4 - Final Molded Samples - Dimensions

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  • Perpendicularity of L-shape
    • Actual = (0.005, 0.004, 0.005)
    • Well within 0.010” tolerance
  • Perpendicularity of boss (0.0025”)
    • Actual = (0.0011, 0.0013, 0.0012)
    • Well within 0.0025” tolerance
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Thank you for stopping by from Plastics News Daily

Tight Tolerances Concerns?Call or Contact us Today!

AND scroll down to see how we solved a tight tolerance warpage problem with windage.

ATME – Take Away

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fill: #f1f1f1
}
#id-4011 .carousel-slider-nav-icon:hover {
fill: #00d1b2
}
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#id-4011 .owl-next,
#id-4011 .carousel-slider-nav-icon {
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width: 48px
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left: -48px
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background-color: #f1f1f1;
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height: 10px;
}
#id-4011 .owl-dots .owl-dot.active span,
#id-4011 .owl-dots .owl-dot:hover span {
background-color: #00d1b2
}

Step 1 – Correlation Existing Warpage

Old material deck predicted right trend, wrong magnitude
New material deck predicted trend and magnitude correctly
Determined cause of warpage to be fiber orientation

Old Material Deck

Max deviation = 0.014”

New Material Deck

Max deviation = 0.008”

Step 2 – Minimize Warpage

Change Gate Location for more favorable fiber alignment
Warpage reduced slightly, but not within tolerance
Sink marks eliminated

Max. Deflections

Downward – 0.0070”

Inward – 0.0099”

Fiber Orientation More Uniform Across Part

Step 3 – Use Windage to Fix Warpage

Determine Windage Factor
Decide on Shrinkage Number
Morph the Part (avoid die lock)
Confirm in Moldflow
One week to complete analysis, material testing, and delivery of morphed windage file.

Purple = NominalBlue = Windage

Step 4 – Final Molded Samples – Dimensions

Perpendicularity of L-shape

Actual = (0.005, 0.004, 0.005)
Well within 0.010” tolerance

Perpendicularity of boss (0.0025”)

Actual = (0.0011, 0.0013, 0.0012)
Well within 0.0025” toleranceImageImageImageImageImageImageImageImageImageImageImage