ultracool3d-corporate-r11
DESCRIPTION
http://ultracool3d.com/wp-content/uploads/2011/10/UltraCool3D-Corporate-R11.pdfTRANSCRIPT
Jayesh Modi
Managing Director, Ultra Cool 3D
+61 410 095 160
REDUCING CYCLE TIMES
AND IMPROVING PART QUALITY
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
• Most plant engineers have spent endless hours in trying to control Warpage.
• Many hours were spent on meeting tolerances of part.
• Even after all efforts, residual stress in parts made part unacceptable in field service,
can you afford brand damage?
Warpage, Long Cycle Times, Tolerances
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Cas
e 1
Simplified cooling causing heat build-up
50% cycle time reduction target
• Very high temperature gradient
• 40 sec cycle time
• High warpage
Development Possibilities – Automotive Siren
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Cas
e 2
Simplified cooling causing heat build-up
40% cycle time reduction target
• Very high temperature gradient
• 50 sec cycle time
• High warpage
Development Possibilities – Automotive ECU
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Limitation of cooling in
tool shows up instantly
on a simple IR image.
Far more effective than
single point pyrometers
used.
Cas
e 3
Development Possibilities - Mirror
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Excessive temperature variation, long
cycle time, warpage.
Cas
e 4
Development Possibilities – Air Intake Manifold
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Husky Analysis, 12.6 sec. Cycle time
Rigid Packaging Benchmarking Study C
ase
5
(Source: Husky Seminar Notes)
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Blocked cooling channel, product quality issues.
Rigid Packaging Tool Diagnostic C
ase
6
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Ultra Cool 3D’s rigorous design methodology with proprietary algorithm
aims to deliver a remarkable thermal response.
UltraCool3D will help you:
- Control Warpage
- Control Weld lines
- Control gas blow out in MuCell
- Reduce Cycle time
- Unlock “Hidden Capacity” Cost
Quality
Realise Those Profits
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
• Substantially reduce cycle times
• Improve part quality
• Reduce molded-in stresses and warpage
• Control process drift
• Shorten new tool commissioning time
• Sustainability
• Reduced energy & material consumption
• Get ready to minimize your carbon tax
Solution UltraCool3D
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Finished poppet
3D cooling on poppet head.
Very small temperature differential over entire part, leading to
great warpage control and shortest possible cycle time.
Project- Lid
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
3D Conformal Cooling
Conventional cooling
30% Cycle time reduction target.
Project- Bezel
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Project- “Rib Cage” 3D Cooling
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
2o C temperature differential over entire part !
Flatness achieved 40 Micron !!
Project- Ultra Precision Moulding
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
In addition to part thickness….
Distance- cooling channel maximum distance to mold wall.
Distance- cooling channel minimum distance to mold wall.
Distance- cooling channel pitch distance.
What Affects My Cycle Times?
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
54 % extra cycle time
Profit lost ! 23
o C differential
Warpage !
Why Does It Matter?
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Process drift (100+ shots to stabilise)
Poor Quality !
23o C differential-
Warpage
Reversal from
-7 o C to + 23
o C Un-
stable tool
-7 o C
+ 23o C
Why Does It Matter?
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
o Based on algorithm developed at MIT.
o Design for six different criteria- uniform cooling of part, part eject temperatures,
part mid plane temperature, mold deflection, coolant temp., pressure drop.
o This ensures- shortest cycle times with uniform cooling of parts ensuring best
possible crystallisation, minimal residual stress and warpage.
o We can help- gap analysis, tooling specification, design review, tooling
manufacture.
Proprietary Software
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Proprietary Software At Your Service
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
• Our technology is developed in Australia and analysis carried out
• at CSIRO and Dept. of Defense facilities by use of advanced scanning electron
microscopes.
Quality Built-In
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
At UltraCool3D we are dedicated to bringing innovative technological solutions to plastics
moulding industry in a manner that will set new standards of quality and service. We, in our
humble way, will help reduce carbon footprint that our industry leaves behind. This will lead
to more profit for our customers and have lasting impact on our planet.
Jayesh Modi Managing Director Ultra Cool 3D
Mission Statement
Confidential, Patent Pending © Ultra Cool 3D 2011 www.ultracool3d.com
Confidentiality Note: Intellectual property protection is sought for various stages of our products, they are protected under various patents in various stages of application.
No part of this presentation or technologies described herein may be copied, reproduced without express written permission of its proprietors.
Good Cooling is Not Optional…