1、EV2 Design Review- BRACKET-POWER-BUTTON,Tooling design review (P2-P14) Mold flow Analysis (P15-P31) Secondary Operation (P32) Assembly process(P33-P38) 2D Review (P39) Measurement concept (P40-P42) 20130227 Update P41 PMP(P43),EV2 molding part just same as EV1.5(Refer Page 2),Product & Tool Review R

2、eport,Part Number:,Part Revision: TBD,Report Version:,Report Date: 20-Sep-2012,Customer :ROCK,Engineer: Liu Li,Product type: Single shot,Project: CRYSTAL_MOUNTAIN,Part Name: POWER-BIAS-SINGLE-POST,EV2 part just same as EV1.5,GG 1/30 correcyt no change,Tooling base Information,Draft Check and Surface

3、 Texture Confirmation 1,Please confirm texture area and specifications according to the draft figure and texture specification table.,MF: confirmed,Draft Check and Surface Texture Confirmation 2,Please confirm texture area and specifications according to the draft figure and texture specification ta

4、ble.,MF: confirmed,Draft Check and Surface Texture Confirmation 3,Only have 2 draft angle might scratch it , suggest to increase to 3 cavity draft angle and polish on the pointed surfaces.,MF: Done,Draft Check and Surface Texture Confirmation 4,Might form stick to cavity , please change to 3 core dr

5、aft angle,MF: Done,Draft Check and Surface Texture Confirmation 5,Suggest to change to core draft angle on the highlighted surfaces avoid stick to cavity,1.2,60,Change to core draft angle,Present design,Suggested design,MF: Done,General Questions Review,Present design,Suggested design,Suggest to cha

6、ncel the highlighted radius for PL,0.2(0.5),Tiny sitting surface easy flash suggest modify to 0.5mm,Note: Current Dimension ( suggested value),PL,MF: Done,PL and Slider/Lifter Layout Diagram,PL is shown as red line.,1.2,60,MF: Done,power-bias-single-post,All surfaceSPI-C1,20120905 MN: OK,power-bias-

7、single-post,Ejector,Ejector pins layout are shown as above, please confirm and show us areas without ejector pin!,Ejector Blade,Gate,Cut in mold,revision symbol: X3.1,1,X3.1,height:0.8mm width0.3mm depth0.05mm,1.PLS confirm the revision symbol engraved,2.PLS provide the PART NO.,20120908 MN: Confirm

8、ed, this is ok, but no protrusion above the surface Proceed and we will update the drawings,3.The area is too small suggest to engrave the Cavity No:1 on this area.,Gate Location,Please confirm whether the gate vestige affect part appearance or assembly.,Analysis aimCAE adopt the following case to a

9、nalyze, the results are shown below. The material used in simulation is supplied by customer: PC+ABS Cycoloy CX7240,2.5mm,Cold system, two plates, one cavities, one edge gate.,Edge gate：1.0*0.5mm,Cut recess for gate vestige.,adopt cut in mold,MF: Done. This location is fine.,Part thickness distribut

10、ion,Part thickness distributes is shown below.,Mold shrinkage: 5/1000,Mold shrinkage in datasheet: 4/1000 6/1000,Processing Conditions,Note: 1MPa=10.2 kgf/cm2,Filling Pattern,Full screen can see the animation,The fill pattern is good.,Hesitation area,No visible hesitation area on the part,Injection

11、Pressure,The injection pressure is suitable for molding.,The actual injection pressure will be about 1.21.5 times of analysis value,Flow Front Temperature,The flow front temperature distributes evenly,Weld Line Locations,Weld lines are shown as red lines, those in circled are visible and may affect

12、the appearance and strength of part.,1,1,Conclusion,Air Traps,Air traps are shown as pink balls, note venting where the flow front meet and the end of fill.,Shear Rate,The gate size is ok after shear rate calculated.,Stress Mark,No stress mark on the part.,%Frozen Time Series,1.4s,2.3s,1.9s,From the

13、 frozen course, the packing effect is general.,2.5s,3.4s,2.7s,Gate frozen,Volumetric Shrinkage,The volumetric shrinkage value is small, no risk to occur sink mark.,Sink mark area,No sink mark area on the part.,Result List,Conclusion & Suggestion,Weld lines are shown as red lines, those in circled ar

14、e visible and may affect the appearance and strength of part. Please confirm!,MF: This is fine.,Conclusion,Secondary operation,Gate type: Edge gate,Processing method:cut in mold,Gate vestige:0.2mmmax (exceed this plane 0.2mm max),Degating,Cold system, two plates, one cavities, one edge gate,Edge gat

15、e size: 1.0*0.5mm,Assembly process,Step1: Inspect bracket power and foam.,bracket power,foam,PSA,Assembly process,Fixture View:,Bottom plate,Location side,Assembly process,2.1.Located the bracket power into the bottom plate.,Bottom plate,Assembly process,Assembly process,2.4: Package it according to the package of specification.,2.3: Final Inspection.,GG 2/5Matt to add flag note to assy dwgfoam to be flush or below the adhesive surface,HHM1 20130218Foam is higher than the adhesive surface ,please confirm it.,Assembly process,Because the part is very sam