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DFM案例分析


产品1:这个产品还 有一件镜像体,这 里不重复分析。

Part 1: RH and LH is mirrored so only one of it is shown in this report.

注意,本文件底色绿色部分 的翻译文本为比较合适的表 述效果。

Improve: 改善 Optimize:优化 Tuning:调整 ,if any: 如果有的话 In case

镶针深入0.10MM封胶,避免出披锋 。 To avoid occur flash ,suggest to let insert go deep into seal off surface 0.01mm Suggest to create a 0.1mm concave at core (cavity) steel for the pin insert seal off in order to optimize/improve the flash direction, if any.

0.1M M

前后模镶针碰穿,避免出现段差,前模镶 针比后模镶针做大0.1MM. Due to core insert pin shutting off,suggest to make the size of cavity insert pin biger 0.1mm than core insert pin size to avoid occur lever There is shutoff between core pins, mark we suggest to make cavity side core pin 0.1mm bigger.

Positive:正面的 Negative: 负面的 Draft: 出模角 MMC: Maximum Material Condition

如图,红色部分出前模, 产品减胶0.05MM
Indicated red surface for cavity,suggest to remove material 0.05mm The surfaces in red is formed by the cavity which need to create positive draft by removing material, max. 0.05mm

PL surface be parallel to the bottom surface of rib

分型面与骨位底 面平行

Parting line will be in parallel to the bottom surface this rib.

Update: 升级 Modify: 更改 Latest=updated: 最新

Indicated red surface without draft angle,suggest to apply 2 degree at the cavity side,max. material added is 0.06mm,more details refer to modified part 3D

所指红色面直身,建议 往前模加胶拨模2度,最 大加胶0.06MM 详见修改后的产品3D There is no draft in the red surfaces, s apply 2 degree in cavity direction by a material, max. material added is 0.06m refer to part 3D data updated/modified

所指红色面倒扣,建 议往前模拨模0.3 度,最大加胶0.19MM 详见修改后的产品3D

所指红色面倒扣,建 议往前模加胶拨模2度, 最大减胶0.13MM 详见修改后的产品3D Indicated red surface is undercut, suggest to apply 2 degree at the cavity side by removing material,max. material removal is 0.19mm,more details refer to modified part 3D

Indicated red surface is undercut, suggest to apply 0.3 degree at the cavity side by adding material,max. material added is 0.19mm,more details refer to modified part 3D Undercut in red surface as indicated….

Level up For your approval.

Thin steel condition in slide at red surfaces, suggest to increase material to level up the surface to parting line, max. material added is 0.09mm, please refer to the updated data for your approval.

为避免行位薄钢建议 所指红色面加胶到行 位分型面,最大加胶 0.09MM 详见修改后的产品3D 所指红色面倒扣,建 议往行位减胶拨模2度, 最大减胶0.05MM 详见修改后的产品3D

Suggest to add material into parallel with PL to avoid slide too thin, max. material added is 0.09mm,more details refer to modified part 3D

Indicated red surface is undercut, suggest to apply 2 degree at the cavity side by removing material,max. material removal is 0.05mm,more details refer to modified part 3D

为避免行位薄钢建议 所指红色面加胶到行 位分型面,最大加胶 0.05MM 详见修改后的产品3D Suggest to add material into parallel with PL to avoid slide too thin, max. material added is 0.05mm,more details refer to modified part 3D

The insert is too small,whick is no space to make water-line,so we propose to apply the material is made of BeCu.

This insert is too small to apply water line, we suggest to apply BeCu for better cooling.

后模镶件太小,运 水无法到达胶位上 面

第 2色 2nd shot

修改前 Before

After 修改后

It is only 0.5mm steel to sealing-off that is too thin,propose to increase another 1.5mm minimum ( the red surface) as indicated, Then the steel thickness becomes 2mm for sealing.

0.5 2
如图示第二色红色面处出行位(如下 图)封胶面出现薄钢(0.5mm)影响 第二色行位封胶钢料强度,建议此处 红色面处减胶由0.5mm变更至2mm ,OK?

There is 0.5mm steel for seal-off which is too thin, propose to increase 1.5mm min.as indicated in red, so that the steel thickness becomes 2mm for seal off.

0.5 2

Slide movement direction Travelling Removal: 去除量 Galling: 磨伤
为避免第二色行位成型复位插烧坏产品及增 加行位强度,建议如图所指红色面延行位出 模方向做3°减胶0.3拔模,OK?

To avoid red surface being scratched during the slide travelling, suggest to apply 3 degree draft at slide movement direction by removing material, max. removal is 0.3mm, which is also better for slide seal off to avoid galling.

To avoid getting part surface scrached when the slide returns back during the 2nd shot and increase the slide shrengh,suggest to apply 3 degree by removing material 0.3mm in red surface slide direction.

Indicated green surface without angle draft in slide direction
如图绿色面为出行位方向直升面

如右图示按粉色面延伸下去,延伸面会与红色面 有0.04间距,为便于行位分型加工,建议红色面 替平粉色面,OK? JL7B-19K617-A-PIA-6B Slider Knob Substrate w Overmold Rev 0产品问题点一样

Indicated pink surface ,extend surface will occur 0.04mm distance between with red surface,suggest to changed the red surface be parallel to pink surface,the same as JL7B-19K617-A-PIA-6B Slider Knob Substrate w Overmold Rev 0 The pink surface is 0.04mm off the plan for red surface, suggest to level up the pink surface in order to simplify the machining.

设计师要求:不同问题点用不同颜色,放大图片 必须与全景图片相同颜色、相同角度。

Indicated red surface is undercut(the same as other side),suggset to apply 3 degree by removing material 0.08mm in red surface extend direction,the same as JL7B-19K617-A-PIA-6B Slider Knob Substrate w Overmold Rev 0
如图示红色面出前模倒扣(另一侧一样),建议红 色面延前模出模方向做3°减胶0.08mm拔模,OK? JL7B-19K617-A-PIA-6B Slider Knob Substrate w Overmold Rev 0产品问题点一样

Uniform: 试,,, 一致 Simplify: 简化

如图示产品大面处间距只有0.014mm, 为便于加工,产品此面能否修该成一致,OK? JL7B-19K617-A-PIA-6B Slider Knob Substrate w Overmold Rev 0 产品问题点一样

The same as JL7B-19K617A-PIA-6B Slider Knob Substrate w Overmold Rev 0

Distance between the indicated surfaces is 0.014mm, suggest to uniform the surface in order to simplify the machine.

0.014

Indicated large surface distance is 0.014mm. suggest to modify the surface be consistent to machine convenient.

Landing: 碰(穿)

13
Remove plastic from red surface to create a landing surface for better seal-off. Make flat for better seal off. 2nd shot part. 平位封胶 软胶件

Suggest to remove 0.5mm material to make a flat surface to make a good seal off condition for 2nd OK shot. 如图红色面所示减胶0.5,有一 平位出来封胶,(十个处)。

修改后 修改前
Before. Existing After Proposal

After 修改后

因为此处硬胶悬空 ,啤软胶时会将硬 胶击穿,
Suggest to rotate the highlighted features by 18 degrees. 所以缺口位置向两边移18度 To optimize the mold structure, Suggest to rotate the highlighted features by 18 degrees. Modified part CAD data will be provided for approval later. The hard plastic is not supported by steel and hence it may be broken by 2nd shot material flow (melt), suggest to …

修改前
Before. 此红色面为第二色封胶面,建议减胶加大斜度 到30度有利于封胶,减胶0.61)

修改后
After

Suggest to increase the chamfer to 30 degree by removing material to make a good seal off condition for 2nd shot.

Core-out: 掏空 Locally: 局部 Potential: 可能

16

A

To improve the sink mark issue, suggest to reduce the thickness at the root…

Before 修改前

B-B B A B
To avoid sink mark issue, suggest to reduce the thickness at bottom from 2mm to 1.6mm. Also need apply 1 degree draft for this rib features.

2.0MM(3X)

建议骨位大头由2.0减到1.6MM并移除根部 R角,中间骨位出后模为直身建议减胶做出 模角单边1度出后模

B-B A-A
修改前

3.7MM

A-A

修改后 After

修改后 After 1.6MM

1.6MM
1.6MM

胶位较厚可能有缩水,建议做减胶如 图红色面所示.

3.7

Before

Too thick to create sink mark issue, suggest core off material to improve.

Potential sink mark concern due to the thick section, suggest to core out locally for improvement.

Second shot

此处不能放进胶点,热咀与 胶位干涉,此段软胶建议取 消。

Hot drop to direct to the part

第二色产品尖点进胶,进 胶位置做0.3深凹点 We propose to add 0.3 Recess for gate vestige Ok Propose to create a simple (0.3mm depth) to hide the gate vestige.

It's not reasonalbe as indicated not feasible to apply hot by the circle,beacuse hot tipIt’s and tip here because there is plastic location will be impacted by each other,so suggest to confliction between the hot drop and the hard plastic. We cancel flexible material. suggest to eliminate/remove the runner feature here.

Proposal

Currently

产品红色面要减胶改前模出,因圆 球要强脱出模,前模开后再顶出,

We propose to move the red surfaces to cavity side. Please confirm.
Suggest to reverse the draft in the red surfaces by removing material, so that it can be formed by the cavity steel, because we need space for strip-off at the ball shape feature after mold is opened.

Proposal

建议产品红色面单边加胶加大 0.2mm,注塑第二色时碰孔不错位 In order to shut-off well in 2nd shot,we proopose to add 0.2mm resin per side on these ribs in 1st shot. Suggest to increase the material in each side of the indicators (0.2mm per side), which can make the indicators more robust during 2nd shot.

Propoal

It is not good for 2nd shot seal off at the radius, suggest to eliminate the radius by leveling up the other surface as shown in left hand side picture, in total 4 places.

此处有圆角过度,二射不好封胶,建议 做平上平面,前模后模共四处 There is a C angle and the second injection is not easily to seal plastic,and suggest to cancel the step by increasing the height to parallel the hige surface at cavity and core in total 4 point.

修改后 modified

第二色单咀尖点式进胶,增加一段胶位辅助 进胶,尺寸如下图所示。 Second shot:HRS drop(tip) into part ,and add a length of plastic to contribute melt filling as indicated in the picture.
Suggest to create a runner on top of the 1st shot for gating.

6.0MM 1.0MM 1.5MM

6mm

Gate size
60 deg.

45 deg.

热流道转4点潜进胶,具体位置待模流分析确定

4 drops HRS, sub-gate, Gate location will finalize after mold flow study. 4 hot drops to cold runner
sub-gate. Gate location to be finalized by Moldflow study.

注:走胶平衡要等模流分析后再 调整。 Melt filing balance will finalize after mold flow study. 1.5mm

0.8mm

Φ5mm

Φ6m m 热咀

Φ5mm

Shoot balance to be adjusted/optimized as per moldflow study.


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