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1、 FOXCONN Proprietary and Confidential1CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONEV2DesignReview-BRACKET-POWER-BUTTON1.Toolingdesignreview(P2-P14)2.MoldflowAnalysis(P15-P31)3.SecondaryOperation(P32)4.Assemblyprocess(P33-P38)5.2DReview(P39)6.Measurementconcept(P40-P42)20130227UpdateP417.PMP(P43)EV2 molding
2、 part just same as EV1.5(Refer Page 2) FOXCONN Proprietary and Confidential2CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONProduct&ToolReviewReportqPartNumber:qPartRevision:TBDqReportVersion:qReportDate:20-Sep-2012qCustomer:ROCKqEngineer:LiuLiProducttype:SingleshotqProject:CRYSTAL_MOUNTAINqPartName:POWER-BIAS
3、-SINGLE-POSTEV2partjustsameasEV1.5GG1/30correcytnochange FOXCONN Proprietary and Confidential3CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONToolingbaseInformationMaterial/Supplier:PC+ABSCycoloyCX7240MoldbasematerialA,Bplates4CR13ShrinkageFromMaterialDatasheet46/1000Otherplates4CR13MoldShrinkageX,Y,Z5/1000Cav
4、itysteelORVARGateEdgeGateCoresteelCALMAXRunnerColdRunnerCoreinserts/PartRev.(3D/2D)X5/X5Cavityinserts/ToolingType2-PlatesMainsteelSlidersteel/Liftersteel/ FOXCONN Proprietary and Confidential4CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONDraftCheckandSurfaceTextureConfirmation1CoresideCavitysidePleaseconfirm
5、textureareaandspecificationsaccordingtothedraftfigureandtexturespecificationtable.MF:confirmed FOXCONN Proprietary and Confidential5CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONCoresideCavitysideDraftCheckandSurfaceTextureConfirmation2Pleaseconfirmtextureareaandspecificationsaccordingtothedraftfigureandtext
6、urespecificationtable.MF:confirmed FOXCONN Proprietary and Confidential6CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONDraftCheckandSurfaceTextureConfirmation3Onlyhave2draftanglemightscratchit,suggesttoincreaseto3cavitydraftangleandpolishonthepointedsurfaces.MF:Done FOXCONN Proprietary and Confidential7CRYSTA
7、L_MOUNTAIN_BRACKET_POWER_BUTTONDraftCheckandSurfaceTextureConfirmation4Mightformsticktocavity,pleasechangeto3coredraftangleMF:Done FOXCONN Proprietary and Confidential8CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONDraftCheckandSurfaceTextureConfirmation5Suggesttochangetocoredraftangleonthehighlightedsurfaces
8、avoidsticktocavity1.260ChangetocoredraftanglePresentdesignSuggesteddesignMF:Done FOXCONN Proprietary and Confidential9CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONGeneralQuestionsReviewPresentdesignSuggesteddesignSuggesttochancelthehighlightedradiusforPL0.2(0.5)Tinysittingsurfaceeasyflashsuggestmodifyto0.5m
9、mNote:CurrentDimension(suggestedvalue)PLMF:Done FOXCONN Proprietary and Confidential10CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONPLandSlider/LifterLayoutDiagramCavityCorePLPLisshownasredline.1.260MF:Done FOXCONN Proprietary and Confidential11CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONpower-bias-single-postpower
10、-bias-single-postAll surfaceSPI-C120120905MN:OK FOXCONN Proprietary and Confidential12CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONpower-bias-single-postEjectorEjectorpinslayoutareshownasabove,pleaseconfirmandshowusareaswithoutejectorpin!EjectorBladeGateCutinmoldrevisionsymbol:X3.11X3.1height:0.8mmwidth0.3m
11、mdepth0.05mm1.PLSconfirmtherevisionsymbolengraved2.PLSprovidethePARTNO.20120908MN:Confirmed,thisisok,butnoprotrusionabovethesurfaceProceedandwewillupdatethedrawings3.TheareaistoosmallsuggesttoengravetheCavityNo:1onthisarea. FOXCONN Proprietary and Confidential13CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONG
12、ateLocationPleaseconfirmwhetherthegatevestigeaffectpartappearanceorassembly.Analysis aimCAE adopt the following case to analyze, the results are shown below. The material used in simulation is supplied by customer: PC+ABS Cycoloy CX72402.5mmCold system, two plates, one cavities, one edge gate.Edge g
13、ate：1.0*0.5mmCut recess for gate vestige.0.2mm3.0mmadoptcutinmoldMF:Done.Thislocationisfine. FOXCONN Proprietary and Confidential14CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONPartthicknessdistributionPartthicknessdistributesisshownbelow.Moldshrinkage:5/1000Moldshrinkageindatasheet:4/10006/1000 FOXCONN Prop
14、rietary and Confidential15CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONProcessingConditionsNote:1MPa=10.2kgf/cm2ItemcaseCaseMaterialPC+ABSCycoloyCX7240Cavitynumbers1Filltime(s)0.26Injectionpressure(MPa)36.7Runnerpres.drop(MPa)25.7Partweight(1cavity)(g)0.06Runnerweight(Total)(g)0.55Totalinjectionvolume(cm3)0
15、.53Projectarea(Total)(cm2)1.21Predictclampforce(Ton)5V/Pswitch99Packingprofile80Mpa*2sMelttemperature()285Moldtemperature()75 FOXCONN Proprietary and Confidential16CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONFillingPatternFullscreencanseetheanimationThefillpatternisgood. FOXCONN Proprietary and Confidentia
16、l17CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONHesitationareaNovisiblehesitationareaonthepart FOXCONN Proprietary and Confidential18CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONInjectionPressureInjectionPressure/MPa36.7Runnerdrop/MPa25.7Theinjectionpressureissuitableformolding.Theactualinjectionpressurewillbeabout
17、1.21.5timesofanalysisvalue FOXCONN Proprietary and Confidential19CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONFlowFrontTemperatureFlowfronttemperature/284.9286.1Theflowfronttemperaturedistributesevenly FOXCONN Proprietary and Confidential20CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONWeldLineLocationsWeldlinesaresh
18、ownasredlines,thoseincircledarevisibleandmayaffecttheappearanceandstrengthofpart.1 11Conclusion FOXCONN Proprietary and Confidential21CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAirTrapsAirtrapsareshownaspinkballs,noteventingwheretheflowfrontmeetandtheendoffill. FOXCONN Proprietary and Confidential22CRYSTA
19、L_MOUNTAIN_BRACKET_POWER_BUTTONShearRateThegatesizeisokaftershearratecalculated. FOXCONN Proprietary and Confidential23CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONStressMarkNostressmarkonthepart. FOXCONN Proprietary and Confidential24CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTON%FrozenTimeSeries1.4s2.3s1.9sFromthe
20、frozencourse,thepackingeffectisgeneral.2.5s3.4s2.7sGatefrozen FOXCONN Proprietary and Confidential25CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONVolumetricShrinkageThevolumetricshrinkagevalueissmall,norisktooccursinkmark. FOXCONN Proprietary and Confidential26CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONSinkmarkare
21、aNosinkmarkareaonthepart. FOXCONN Proprietary and Confidential27CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONResultListCaseWhetherexisthesitationareaNOWhetherexistshortshotareaNOInjectionpressure/Mpa36.7Parttemperature/284.9286.1WeldlineswhetheraffectappearanceandstrengthYESAirtrapsneedtocutinserttoventNOWh
22、etherexistsinkmarkareaNOShearratewhetherexceedthematerialrecommendedlimitationNOWhetherexistgateblushNOWhetherexiststressmarkareaNO FOXCONN Proprietary and Confidential28CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONConclusion&SuggestionWeldlinesareshownasredlines,thoseincircledarevisibleandmayaffecttheappea
23、ranceandstrengthofpart.Pleaseconfirm!MF:Thisisfine. FOXCONN Proprietary and Confidential29CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONConclusionVersion:V1RiskEvaluationBeforeMoldingNumberCheckItemProblemRiskEst.FailureRatio1WeldLineLocationsWeldlineMiddle60 FOXCONN Proprietary and Confidential30CRYSTAL_MOU
24、NTAIN_BRACKET_POWER_BUTTONSecondaryoperationGatetype:EdgegateProcessingmethod:cutinmoldGatevestige:0.2mmmax(exceedthisplane0.2mmmax)qDegatingColdsystem,twoplates,onecavities,oneedgegateEdgegatesize:1.0*0.5mm FOXCONN Proprietary and Confidential31CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocessSt
25、ep1: Inspect bracket power and foam.bracket powerfoamPSA FOXCONN Proprietary and Confidential32CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocessFixture View:BottomplateLocationside FOXCONN Proprietary and Confidential33CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocess2.1.Located the bracket po
26、wer into the bottom plate.Bottomplate FOXCONN Proprietary and Confidential34CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocess FOXCONN Proprietary and Confidential35CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocess2.4: Package it according to the package of specification.2.3: Final Inspection.G
27、G2/5MatttoaddflagnotetoassydwgfoamtobeflushorbelowtheadhesivesurfaceHHM1 20130218Foam is higher than the adhesive surface ,please confirm it. FOXCONN Proprietary and Confidential36CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocessBecause the part is very samll, In order to make it easier for assembly.So we suggest change the assembly surface. PSAPSAGG2/5okforPoronFoamandbracketsmainsurfacetohavesomesmallgapcausedbydraftangleoftheadhesivesurfaceGG2/5notpossible FOXCONN Proprietary and Confidential37CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONThe End ,Thanks
