I NTRODUCTION TO NAUTILUS 8 M OLD Q UALIFICATION AND D ESIGN OF E XPERIMENTS S OFTWARE FOR I NJECTION M OLDING SUHAS KULKARNI FIMMTECH 1-760-525-9053

INTRODUCTION TO

NAUTILUS 8

MOLD QUALIFICATION AND

DESIGN OF EXPERIMENTS SOFTWAREFOR

INJECTION MOLDING

SUHAS KULKARNI FIMMTECH 1-760-525-9053

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

ONCE A PROCESS HAS BEEN ESTABLISHED ON ONE

MACHINE, THE SOFTWARE WILL CALCULATE THE PROCESSES

FOR ALL THE MACHINES IN THE SHOP. THE PROCESS CAN

NOW BE TRANSFERRED AND ‘STARTING FROM SCRATCH’

WILL NOT BE NECESSARY ON THE OTHER MACHINESSUHAS KULKARNI FIMMTECH 1-760-525-9053

BENEFITS OF USING THE TECHNIQUES:

• ESTABLISHED PROCESS IS ROBUST

• PROCESS WILL REQUIRE ‘NO OR LITTLE ATTENTION’

• WILL DETERMINE THE FASTEST CYCLE TIME POSSIBLE

• LESS SCRAP AT STARTUP

• ZERO SCRAP DURING PRODUCTION

• IMPROVED PART QUALITY AND PROCESS CAPABILITY

ABOVE FACTORS INCREASE THE BOTTOM LINE PROFITS!


THE SOFTWARE


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 TIMESUHAS KULKARNI FIMMTECH 1-760-525-9053

DESIGN OF EXPERIMENTS MODULE

• TORNADO CHARTS

• 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


QUALITY MODULE

• FULL DIMENSIONAL ANALYSIS

• STATISTICAL ANALYSIS

• POST MOLDING SHRINKAGE REPORT

• DOCUMENTATION OF QUALITY INSPECTION PLAN

CALCULATION WORKSHEETS COMMONLY USED IN MOLDING

USER PREVILAGES

CHOICE OF UNITS

NETWORK/CONCURRENT VERSIONS


SUMMARY OF ADDITIONS TO VERSION 8:


• PROCESS – MACHINE COMPATIBILITY

• ADD A PLASTIC PROCESS SHEET FOR A GIVEN MOLD

• GENERATE THE PLASTIC PROCESS SHEET FOR ANY GIVEN

MACHINE

• DETERMINE THE MACHINES IN THE SHOP THAT ARE COMPATIBLE

AND CAPABLE OF RUNNING THE MOLD BASED ON PLASTIC

VARIABLES

• UNITS MANAGEMENT –

• SELECT BETWEEN METRIC, ENGLISH OR A COMBINATION

• AUTO CONVERT ON DEMAND

• ONCE UNITS FOR A GIVEN MACHINE ARE SAVED ALL PROCESS

SHEETS ARE GENERATED IN THE MACHINE UNITS

SUMMARY OF ADDITIONS TO VERSION 8:


• USER ACCESS LEVELS

• DETERMINE WHO CAN AND CANNOT CHANGE DATABASES AND

DOCUMENTS

• CUSTOM READ/WRITE ACCESS

• ABILITY TO CREATE FAMILY MOLDS AND RUN THEM THROUGH

• 6-STEP STUDY, FOR EXAMPLE: DETERMINE CAVITY IMBALANCES

BETWEEN FAMILY PARTS

• DOE, SELECT THE PROCESSES FOR FAMILY MOLDS

• OPTIMIZE FOR ALL FAMILY PARTS

• MISCELLANEOUS:

• ALL STUDIES/DOCUMENTS FOR A GIVEN MOLD UNDER ONE TAB

• ADDITIONAL FIELDS ADDED TO ALL DATABASES

MAIN SCREEN:


NEW LOOK IN VER 8

DATABASES: MATERIAL – MOLD – MACHINE


MOLD MACHINE COMPATIBILITY REPORT:


CRITERIA BASED ON• REQUIRED TONNAGE• % SHOT SIZE USED• RESIDENCE TIME OF THE MATERIAL IN THE BARREL• PHYSICAL SIZE OF THE MOLD AND THE MACHINE SPECS

PROCESS – MACHINE COMPATIBILITY


• ADD A PLASTIC PROCESS SHEET FOR A GIVEN MOLD

NEW IN VER 8



• GENERATE THE PLASTIC PROCESS SHEET FOR ANY GIVEN MACHINE IN THE DATABASE

• DETERMINE IF THE MACHINES ARE CAPABLE OF RUNNING THE MOLD BASED ON PLASTIC

VARIABLESESTABLISHED PROCESS CALCULATED PROCESS SHEETS FOR OTHER

MACHINES

NOT ACCEPTABLE ACCEPTABLE

NEW IN VER 8



• ONCE THE TARGET MACHINE IS SELECTED, SELECT THE PROCESS SHEET FROM THE DROP

DOWN LIST AND CLICK ON ‘GENERATE PROCESS SHEET’ TO PRINT THE PROCESS SHEET

FOR THE MACHINE

NEW IN VER 8

MOLD QUALIFICATION PART 1: 6-STEP STUDY

(AKA: SCIENTIFIC MOLDING)


WORKSHEET NO. 1: IN MOLD RHEOLOGY


WORKSHEET NO. 2: CAVITY BALANCE STUDY


FAMILY MOLDS OPTION NEW IN

VER 8

WORKSHEET NO. 3: PRESSURE DROP STUDY


WORKSHEET NO. 4: COSMETIC PROCESS WINDOW


WORKSHEET NO. 5: GATE SEAL STUDY – COLD RUNNER


WORKSHEET NO. 5: GATE SEAL STUDY – HOT RUNNER


WORKSHEET NO. 6: COOLING STUDY



WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS

MOLD QUALIFICATION PART 2:

DESIGN OF EXPERIMENTS


KEY FEATURES:

• NO PRIOR MATH OR STATISTICS EXPERIENCE REQUIRED

• WITH 4 EASY STEPS YOU WILL BE ABLE TO DESIGN A

DOE AND RUN THE EXPERIMENTS.

• THE DATA WILL VISUALLY SHOW YOU WHAT YOU CAN

AND CANNOT MOLD AS FAR AS THE DIMENSIONS OF THE

PART ARE CONCERNED.

• NO GUESSWORK: DATA DRIVEN DECISIONS FOR ALL

CHANGES IN MOLD STEEL AND/OR NOMINAL -

SPECIFICATIONS

• ADJUST THE STEEL WITH CONFICDENCE AND LEAVE THE

PROCESS ALONE!SUHAS KULKARNI FIMMTECH 1-760-525-9053


INPUTS WORKSHEETS FOR DOE:

STEP 1: SELECT THE FACTORS FROM A DROPDOWN LIST


STEP 2: ENTER THE UNITS, HIGH AND LOWS FOR THE STUDIES

THE HIGHS AND LOWS ARE DETERMENIED FROM THE COSMETIC PROCESS WINDOW.


STEP 3: ENTER THE NOMINALS AND TOLERANCES


STEP 3: SOFTWARE GENERATES THE EXPERIMENTAL MATRIX

MOLD THE PARTS, ENTER DATA AND CLICK ON THE ANALYSIS BUTTON TO VIEW THE RESULTS


TORNADO CHARTS

GIVES YOU INFO ON THE FACTOR THAT MOST IMPACTS THE PART QUALITY(POSITIVE FACTORS ABOVE THE LINE, AND NEGATIVE BELOW THE LINE)


PROCESS SENSITIVITY GRAPH

GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE DOE PROCESS RUN


DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED CAVITIES AND DIMENSIONS


DIMENSIONAL 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




MOLD PARTS BETWEEN THE PROCESS WINDOWS TO MAINTAIN THE PARTS WITHIN THE DIMENSIONS. DIMENSIONAL PROCESS

WINDOW



WITH A DIMENSIONAL PROCESS WINDOW AS SHOWN IT WILL BE IMPOSSIBLE TO MOLD PARTS CONSISTENTLY TO THE REQUIRED DIMENSIONS.

IT WILL BE IMPOSSIBLE TO OBTAIN GOOD CpKs

TIME TO MAKE A DATA DRIVEN DECISION!


VISUAL PREDICTION EQUATION

USL

LSL

USL

LSL

EXTENT TO WHICH THE DIMENSION CAN BE INFLUENCED BETWEEN THE EXTREMES OF THE DOE PARAMETERS

Cavity No →

Cavity No →

THE DIMENSION CAN GO OUT OF SPEC



USL

LSL

USL

LSL

STABLE DIMENSION – WILL ALWAYS BE IN SPEC

LSL

THE DIMENSION CAN GO OUT OF SPEC

Cavity No →

Cavity No →



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 →



USL

LSL

USL

SIMULATED PROCESS:CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES(SEE NEXT SLIDE)

Cavity No →

Cavity No →



SIMULATED PROCESS:CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES


NUMERICAL PREDICTION EQUATION

USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY


ACHIEVING DIMENSIONS: MAKING STEEL AND/OR NOMINAL – TOLERANCE CHANGESGOOD Cp BUT A BAD CpK??? YOUR CHOICES ARE

• MODIFY THE STEEL DIMENSION AND/OR• MODIFY THE NOMINAL – SPEC LIMITS

ROBUST PROCESS

MODIFY MOLD AND/OR NOMINAL-SPEC LIMITS BY THIS NUMBER TO HIT THE MOMINAL VALUE

NEW IN VER 8


CAPABILITY NOT A REQUIREMENT? WANT TO BE ONLY IN SPEC??

ROBUST PROCESS

MODIFY MOLD AND/OR NOMINAL-SPEC LIMITS BY THIS NUMBER TO HIT BE INSIDE THE USL OR LSL

0

NEW IN VER 8


CONFIDENCE RATINGS

USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY


PRINTING: SELECTION SCREEN


PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS


MOLD SPECIFIC TROUBLE SHOOTING GUIDE NEW IN VER 8

QUALITY MODULE: FULL DIMENSIONAL ANALYSIS:


QUALITY MODULE: STATISTICAL ANALYSIS :


MACHINE QUALIFICATION: INJECTION SPEED LINEARITY :


MACHINE QUALIFICATION: SHOT TO SHOT REPEATABILITY TEST :


MACHINE QUALIFICATION: LOAD SENSITIVITY TEST :


FREQUENTLY USED MOLDING CALCULATIONS:


WATER FLOW CALCULATION:


PROCESS TRANSFER BETWEEN MACHINES WORKSHEET:


SHOT SIZE ESTIMATION WORKSHEET:


HOPPER SIZE CALCULATION WORKSHEET:


REGRIND CALCULATIONS (CLOSED LOOP SYSTEMS)


MISCELLANEOUS FEATURES


UNITS MANAGEMENT


• UNITS MANAGEMENT –

• SELECT BETWEEN METRIC, ENGLISH OR A COMBINATION

• AUTO CONVERT ON DEMAND

NEW IN VER 8

USER ACCESS LEVELS


• USER ACCESS LEVELS

• DETERMINE WHO CAN AND CANNOT CHANGE DATABASES AND DOCUMENTS

• CUSTOM READ/WRITE ACCESS

NEW IN VER 8

FAMILY MOLDS


• ABILITY TO CREATE FAMILY MOLDS AND RUN THEM THROUGH

• 6-STEP STUDY, FOR EXAMPLE: DETERMINE CAVITY IMBALANCES BETWEEN FAMILY

PARTS

• DOE, SELECT THE PROCESSES FOR FAMILY MOLDS

• OPTIMIZE FOR ALL FAMILY PARTS

NEW IN VER 8

FAMILY MOLDS


• ABILITY TO CREATE FAMILY MOLDS IN THE DATABASE

NEW IN VER 8

FAMILY MOLDS


• ABILITY TO QULAIFY FAMILY MOLDS IN 6-STEP AND DOE

MODULE

NEW IN VER 8


CONTACT INFO:

SUHAS KULKARNI

[email protected]

1-760-525-9053

WWW.FIMMTECH.COM

WWW.INJECTIONMOLDINGONLINE.COM

Documents

I NTRODUCTION TO NAUTILUS 8 M OLD Q UALIFICATION AND D ESIGN OF E XPERIMENTS S OFTWARE FOR I NJECTION M OLDING SUHAS KULKARNI FIMMTECH 1-760-525-9053