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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)EV2moldingp
2、artjustsameasEV1.5(ReferPage2) FOXCONN Proprietary and Confidential2CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONProduct&ToolReviewReportqPartNumber:qPartRevision:TBDqReportVersion:qReportDate:20-Sep-2012qCustomer:ROCKqEngineer:LiuLiProducttype:SingleshotqProject:CRYSTAL_MOUNTAINqPartName:POWER-BIAS-SINGLE-
3、POSTEV2partjustsameasEV1.5GG1/30correcytnochange FOXCONN Proprietary and Confidential3CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONToolingbaseInformationMaterial/Supplier: PC+ABSCycoloyCX7240MoldbasematerialA,Bplates4CR13ShrinkageFromMaterialDatasheet46/1000Otherplates4CR13MoldShrinkageX,Y,Z5/1000Cavitystee
4、lORVARGateEdgeGateCoresteelCALMAXRunnerColdRunnerCoreinserts/PartRev.(3D/2D)X5/X5Cavityinserts/ToolingType2-PlatesMainsteelSlidersteel/Liftersteel/ FOXCONN Proprietary and Confidential4CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONDraftCheckandSurfaceTextureConfirmation1CoresideCavitysidePleaseconfirmtexture
5、areaandspecificationsaccordingtothedraftfigureandtexturespecificationtable.MF:confirmed FOXCONN Proprietary and Confidential5CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONCoresideCavitysideDraftCheckandSurfaceTextureConfirmation2Pleaseconfirmtextureareaandspecificationsaccordingtothedraftfigureandtexturespec
6、ificationtable.MF:confirmed FOXCONN Proprietary and Confidential6CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONDraftCheckandSurfaceTextureConfirmation3Onlyhave2draftanglemightscratchit,suggesttoincreaseto3cavitydraftangleandpolishonthepointedsurfaces.MF:Done FOXCONN Proprietary and Confidential7CRYSTAL_MOUNT
7、AIN_BRACKET_POWER_BUTTONDraftCheckandSurfaceTextureConfirmation4Mightformsticktocavity,pleasechangeto3coredraftangleMF:Done FOXCONN Proprietary and Confidential8CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONDraftCheckandSurfaceTextureConfirmation5Suggesttochangetocoredraftangleonthehighlightedsurfacesavoidst
8、icktocavity1.260ChangetocoredraftanglePresentdesignSuggesteddesignMF:Done FOXCONN Proprietary and Confidential9CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONGeneralQuestionsReviewPresentdesignSuggesteddesignSuggesttochancelthehighlightedradiusforPL0.2(0.5)Tinysittingsurfaceeasyflashsuggestmodifyto0.5mmNote:C
9、urrentDimension(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-bias-s
10、ingle-postAll surfaceSPI-C120120905MN:OK FOXCONN Proprietary and Confidential12CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONpower-bias-single-postEjectorEjectorpinslayoutareshownasabove,pleaseconfirmandshowusareaswithoutejectorpin!EjectorBladeGateCutinmoldrevisionsymbol:X3.11X3.1height:0.8mmwidth0.3mmdepth0
11、.05mm1.PLSconfirmtherevisionsymbolengraved2.PLSprovidethePARTNO.20120908MN:Confirmed,thisisok,butnoprotrusionabovethesurfaceProceedandwewillupdatethedrawings3.TheareaistoosmallsuggesttoengravetheCavityNo:1onthisarea. FOXCONN Proprietary and Confidential13CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONGateLoca
12、tionPleaseconfirmwhetherthegatevestigeaffectpartappearanceorassembly.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 gate：1.0
13、*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 Proprietary
14、 and Confidential15CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONProcessingConditionsNote:1MPa=10.2kgf/cm2Item caseCase MaterialPC+ABS Cycoloy CX7240Cavity numbers1Fill time(s)0.26Injection pressure(MPa)36.7Runner pres. drop (MPa)25.7Part weight(1 cavity) (g)0.06Runner weight (Total) (g)0.55Total injection v
15、olume(cm3)0.53Project area(Total) (cm2)1.21Predict clamp force (Ton)5V/P switch99Packing profile80Mpa*2sMelt temperature ()285Mold temperature ()75 FOXCONN Proprietary and Confidential16CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONFillingPatternFullscreencanseetheanimationThefillpatternisgood. FOXCONN Propr
16、ietary and Confidential17CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONHesitationareaNovisiblehesitationareaonthepart FOXCONN Proprietary and Confidential18CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONInjectionPressureInjection Pressure/MPa36.7Runner drop/MPa25.7Theinjectionpressureissuitableformolding.Theactualinje
17、ctionpressurewillbeabout1.21.5timesofanalysisvalue FOXCONN Proprietary and Confidential19CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONFlowFrontTemperatureFlow front temperature/ 284.9 286.1Theflowfronttemperaturedistributesevenly FOXCONN Proprietary and Confidential20CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONWel
18、dLineLocationsWeldlinesareshownasredlines,thoseincircledarevisibleandmayaffecttheappearanceandstrengthofpart.1 11Conclusion FOXCONN Proprietary and Confidential21CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAirTrapsAirtrapsareshownaspinkballs,noteventingwheretheflowfrontmeetandtheendoffill. FOXCONN Propriet
19、ary and Confidential22CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONShearRateThegatesizeisokaftershearratecalculated. FOXCONN Proprietary and Confidential23CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONStressMarkNostressmarkonthepart. FOXCONN Proprietary and Confidential24CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTON%FrozenT
20、imeSeries1.4s2.3s1.9sFromthefrozencourse,thepackingeffectisgeneral.2.5s3.4s2.7sGatefrozen FOXCONN Proprietary and Confidential25CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONVolumetricShrinkageThevolumetricshrinkagevalueissmall,norisktooccursinkmark. FOXCONN Proprietary and Confidential26CRYSTAL_MOUNTAIN_BRA
21、CKET_POWER_BUTTONSinkmarkareaNosinkmarkareaonthepart. FOXCONN Proprietary and Confidential27CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONResultListCaseWhether exist hesitation areaNOWhether exist short shot areaNOInjection pressure/Mpa36.7Part temperature/284.9 286.1Weld lines whether affect appearance and
22、strengthYESAir traps need to cut insert to ventNOWhether exist sink mark areaNOShear rate whether exceed the material recommended limitation NOWhether exist gate blushNOWhether exist stress mark areaNO FOXCONN Proprietary and Confidential28CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONConclusion&SuggestionWe
23、ldlinesareshownasredlines,thoseincircledarevisibleandmayaffecttheappearanceandstrengthofpart.Pleaseconfirm!MF:Thisisfine. FOXCONN Proprietary and Confidential29CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONConclusionVersion: V1 Risk Evaluation Before MoldingNumberCheck ItemProblemRisk Est. Failure Ratio1Weld
24、 Line LocationsWeld lineMiddle60 FOXCONN Proprietary and Confidential30CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONSecondaryoperationGatetype:EdgegateProcessingmethod:cutinmoldGatevestige:0.2mmmax(exceedthisplane0.2mmmax)qDegatingColdsystem,twoplates,onecavities,oneedgegateEdgegatesize:1.0*0.5mm FOXCONN Pr
25、oprietary and Confidential31CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocessStep1: Inspect bracket power and foam.bracket powerfoamPSA FOXCONN Proprietary and Confidential32CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocessFixture View:BottomplateLocationside FOXCONN Proprietary and Confidenti
26、al33CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocess2.1.Located the bracket power into the bottom plate.Bottomplate FOXCONN Proprietary and Confidential34CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyprocess FOXCONN Proprietary and Confidential35CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONAssemblyproces
27、s2.4: Package it according to the package of specification.2.3: Final Inspection.GG2/5MatttoaddflagnotetoassydwgfoamtobeflushorbelowtheadhesivesurfaceHHM1 20130218Foam is higher than the adhesive surface ,please confirm it. FOXCONN Proprietary and Confidential36CRYSTAL_MOUNTAIN_BRACKET_POWER_BUTTONA
28、ssemblyprocessBecause 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
