Part Name Connector White cells are calculated

Mold Number A657 Fill in Yellow Cells

Green are Drop down Bars

Optimum Fill calculation

Machine Information
Machine Number 22
Intensification ratio 9.87 Units of Measure
Screw return position including decomp 150.0 Millimeters
Screw position at packing 3.0 Millimeters
Total Stroke 147.0 Millimeters

Machine set Fill time

velocity (sec) to Hydraulic
Sample (distance packing Pressure at Optimum
Number /sec) change-over Change-over Setting
1 5 0.69 1225 .
2 4.5 0.85 1150 .
3 3 1.05 1098 .
4 2.5 1.25 1040 .
5 1.5 1.89 1020 .
6 1 2.75 945 .
7 0.8 3.41 900 <--- Optimum)
8 0.6 4.52 930 .
9 0.4 6.8 1075 .
10 0.2 12.5 1385 .
11 0.2 12.5 1385 .
12 0.2 12.5 1385 .
13 0.1 13.7 1500 .
14 0.1 13.7 1500 .
15 0.1 13.7 1500 .

250000

200000
Relative Viscosity

150000

100000

50000

0
Shear (1/fill time)

Optimum fill time is where the sample points go essentially from vertical to horizantal.
 Inches
Millimeters

to horizantal.
 Part Name Connector White cells are calculated
Mold Number A657 Fill in Yellow Cells
Machine # 22

Gate freeze-off calculation

sample # Packing sample # Packing sample # Packing
time in shot wt. time in shot wt. time in shot wt.
seconds parts only seconds parts only seconds parts only
1 5 11.29 12 23
2 4.5 11.29 13 24
3 4 11.29 14 25
4 3.9 11.29 15 26
5 3.8 11.15 16 27
6 3.7 10.77 17 28
7 3.6 10.50 18 29
8 3.5 10.02 19 30
9 3.4 9.65 20 31
10 3.1 8.62 21 32
11 2.5 6.42 22

Gate Freeze off

12.00
11.00
10.00
Part Weight

9.00
8.00
7.00
6.00
1.8 2.3 2.8 3.3 3.8 4.3 4.8 5.3
Packing time

To rescale the chart with your data, click on the axis, Click on "Format Axis", Click on
"scale",
"scale",put
putin
inyour
yourminimum
minimumandandmaximum
maximumvalues.
values.
Gate Freeze of should be set just after the curve levels
 5.3

the curve levels

 Optimum Cool calculation
Part Name Connector White cells are calculated
Mold Number A657 Fill in Yellow Cells
Material PP
Machine Information
Machine Number 22
DO NOT USE BOTH FLOW CELLS Coolant Flow in GPM
OR Coolant Flow in LPM 3.8 Flow OK
Choose Recommend Ejection Temperature of Material from chart 190
Thickest section of part in Inches 0.125
Actual Gate Freeze off time (sec) calculated by experiment 4

Rule of Thumb cooling time(seconds)

21
Hold time = Total Cooling time - Gate Freeze off time

COOLING EXPERIMENT
Experimental Measured
Cooling time Surface Temp
set on of part
machine immediately on
(seconds) for ejection
Sample # experiment
1 26 165 Cooling time OK
2 25 170 Cooling time OK
3 24 175 Cooling time OK
4 23 180 Use more cooling time
5 22 185 Use more cooling time
6 21 190 Use more cooling time
7 20 195 Use more cooling time
8 19 200 Use more cooling time
9 18 205 Use more cooling time
10 17 210 Use more cooling time
11 16 220 Use more cooling time

Recommended Values for Ejected Part Temp

Material Lower Medium Upper Temp Material Lower Upper Temp

Temp Temp Temp Medium Temp
PS 68-95 95-113 113-140 PE rigid 104-122 122-140 140-167
SB 68-95 95-122 122-149 PP 113-131 131-149 149-176
SAN 95-122 122-158 158-185 PA 6 122-158 158-194 194-230
ABS 95-131 131-167 167-194 PA 6.6 167-194 194-248 248-302
PVC Rigid 113-149 149-176 176-212 PA 6.10 104-131 131-158 158-185
PVC Soft 77-95 95-113 113-131 PA 11 140-176 176-220 220-266
CA 95-122 122-149 149-176 PA 12 104-140 140-176 176-212
CAB 86-113 113-140 140-167 PA 131-158 158-185 185-212
CP 86-104 104-131 131-158 amorphous
PMMA 122-158 158-194 194-230 POM 140-176 176-212 212-266
PPE mod 149-176 176-203 203-230 PET 167-203 203-248 248-302
PC 140-185 185-230 230-266 PBT 140-167 167-194 194-248
PAR 248-284 284-320 320-366 PPS 248-293 293-338 338-374
 PSU 212-266 266-320 320-374 FEP 320-356 356-392 392-428
PES 266-294 294-330 330-374 ETFE 284-302 302-320 320-356
PEI 275-302 302-338 338-374 PAEK 248-293 293-320 320-356
PAI 392-428 428-446 446-464 LCP 140-212 212-284 284-356
PE soft 86-104 104-122 122-149 TPE-E 77-95 95-122 122-149
 Cavity Balance Calculation
Part Name Connector White cells are calculated
Mold Number A657 Fill in Yellow Cells
Machine # 22 Green are Drop down Bars
Unit of measure Grams
Part Weight Part Weight Part Weight Part Weight Part Weight Part Weight Part Weight Part Weight
Sample
Number Cavity #1 Cavity #2 Cavity #3 Cavity #4 Cavity #5 Cavity #6 Cavity #7 Cavity #8
1 11.005 10.850 12.020 11.006 11.020 11.100 11.015 11.089
2 14.194 13.540 12.114 11.010 11.945 10.950 11.002 11.205
3 10.890 10.889 12.420 11.026 11.420 10.877 11.001 11.774
4 11.205 10.899 12.130 10.650 10.638 10.855 11.004 11.030
5 10.744 10.855 11.950 10.778 11.770 11.036 11.090 11.015
6 10.595 11.035 11.970 10.500 11.360 11.043 11.089 11.026
7 11.410 11.550 12.226 11.410 11.425 11.045 11.205 11.010
8 11.266 11.010 11.190 11.300 11.335 10.877 11.780 11.015
9 11.150 11.150 11.910 11.150 11.110 10.855 11.002 11.059
10 11.440 11.825 12.000 11.263 11.502 11.038 11.001 11.410

%
Variation cavity balance chart by cavity
Average from
Cavity Wt mean
1 11.390 0.82% . Percent
1 fromNot
11.297 Overall Average
Balanc . 0
11.360 0.56% +/-1 5% 11.297
for FullNot
Shot
Balanc .15% on
+/- 0
2 .
50% shot is acceptaable
3 11.993 6.16% Not Balanced 1 11.297 Not Balanc . 1
4 11.009 -2.55% . 1 11.297 Not Balanc . 0
5 11.353 0.49% . 1 11.297 Not Balanc . 0
6 10.968 -2.92% . 1 11.297
8 Not Balanc . 0
7 11.141 -1.38% . 1 11.297 Not Balanc . 0
7
8 11.163 -1.18% . 1 11.297 Not Balanc . 0
mold balanced? NO 6
O/A Avg 11.297
5

1
%

%
0%

0%

00

00

00

00

00
.0

.0

0.

2.

4.

6.

8.
-4

-2
Ounces
Grams
Optimum Clamp Calculation

Part name: connector

Mold #: A657 White cells are calculated
Number of Cavities: 8 Fill in Yellow Cells
Machine ID 22 Green are Drop down Bars
Maximum Clamp Pressure 350
Unit of measure Tons

Use this
First try clamp Pressure Fine tune Clamp Setting clamp
settings Flash? Y/N Pressure Flash? Y/N Pressure
315 n 291 y
284 Y 298 n 298
255 305
230 312
207
186
7.0875 35
7.0875 31.5
7.0875 28.35
7.0875 25.515
7.0875 22.9635
20.66715
Tons

Newtons
 Universal Molding Setup Sheet White cells are calculated
Fill in Yellow Cells
Green are Drop down Bars
Customer: Acme Prepared / Approved by: JY / GH
Customer part #: 1234 Actual Cycle (secs): 19.7
Revision #: A Part Wt (grams) 32
Part name: connector Total shot weight (grams) 256
Mold #: A657 Material PP
Number of Cavities: 8 Supplier Plasticpro
Quoted Cycle (secs): 20.2 Mtl. Density see chart 0.9
Original New Volume of Hot runner (cc) 50
Qualifying Production
Machine Machine Original New
machine information
Machine # 22 35 barrel/screw diameter 50 60 Millimeters
Max tonnage 250 350 total stroke 300 200 Millimeters
Intensification ratio 9.87 11.28 Budgeted cycle (sec) 20.2
Shot capacity either (oz) Actual cycle (sec) 19.7
OR Shot capacity (grams) 531 730 Calculated cycle (sec) 19.6
pc/hour 1455 efficiency % 99.50%
Hrs/1000 pcs. 0.69

Fill in from Qualif. Run. These will not change in new machine Things that do change
OPTIONAL Original New Original New
Qualifying Production Qualifying Production
Settings Settings Settings Settings
Put appropriate units of PRESSURES PSI
MOLD measure in the cell next to
MEASUREMENTS (in/mm) the bold text Fill 1800 1575
Locator Ring Diameter 4 Pack 800 700
Sprue Ball Radius 0.5 Back pressure 150 131
Sprue Oriface 0.150 Inches DISTANCES (in-mm-%) Millimeters
Stack Height 24 Screw fully returned 150 1473
Daylight Opening req'd 16 Cushion 3 29
DISTANCES (in-mm-%) Millimeters Switch on Position set 10 98
Full Close 7.5 7.5 SPEEDS (in-mm/sec) Millimeters
Slow Open 2.5 2.5 fill or single profile 12 13
Fast Open 200 200 multiple profile (optional) No
Safety set point 190 190 profile setting #1
Full open 450 450 profile setting #2
Ejection Start 400 400 profile setting #3
Core Pull no no profile setting #4
Core Set no no profile setting #5
Core Lock no no profile setting #6
Fast Close 450 450 Machine Nozzle Oriface 0.100 0.090 Inches
Slow Close 2.5 2.5
TEMPERATURE F-C Deg F
Dryer Temp 120 120 Rules of Thumb:
oil 110 110 Original Shot Inventory - # of shots 3.42 Shot inventory is OK for residence time
front zone 375 375 Qualifying Residence time (min) heating 1.12 Residence time OK
middle zone 350 350 Settings Barrel Capcity v. Shot % 40% Barrel is correctly sized for shot
rear zone 350 350
nozzle 375 375
melt temp 375 375 Rules of Thumb:
mold coolant temp see chart below New Shot Inventory - # of shots 4.70 Shot inventory is OK for residence time
Clamp pressure PSI Production Residence time (min) heating 1.54 Residence time OK
Minimum clamp pressure 180 180 Settings Barrel Capcity v. Shot % 31% Barrel is correctly sized for shot
Mold movement Inches
slow open 2 2
Shot Inventory Allowance for molten
fast open 1 1 material in screw
ejection fast fast
fast close 1 1
slow close 0.3 0.3 Hot runner
Volume
TIME SETTINGS (sec) Seconds
fill 0.5 0.5
pack 2.5 2.5
cool 13 13
mold open 1.5 1.5
ejection 0.7 0.7
mold close 1.5 1.5
Total mold open time 3.7 3.7
Total mold closed time 16 16

Waterline circuits 1 gallon per minute (GPM) = 3.8 Liters per minute (LPM) || 1 LPM = .263 GPM
Stationary half Moving Half
Line # is looped to forming circuit LPM Deg F Line # is looped to forming circuit LPM
1 3 #1 1 2 #1
2 exit #2 4.5 90 2 3 #1
3 4 #1 3 4 #1
4 5 #1 4 exit #1 4
5 exit #1 4 90 5 6 #2
6 7 #3 6 7 #2
7 exit #3 5 90 7 exit #2 5
8 6 #3 8 exit #3 6
9 exit #4 6 90 9
10 exit #5 6 90 10
11 11
12 12
13 13
14 14
15 15

old machine New Machine

convert to gr 0 0
grams 531 730
shot cap gr 584 783
GP PS DENS 1.06
shot wt gr 256 256
 mtl den 0.9
dens ratio 0.849056604
Inventory 3.42015625 4.701909722
residenc min 1.122951302 1.543793692
% of volume 0.40188383 0.306220096
barrel diameter (mm) 50 60
total stroke (mm) 300 60
sq units barrel 1963.49375 200
 Inches PSI Deg F Yes FLOW RATE
Millimeters Tons Deg C No LPM
% Newtons GPM
JY / GH %
19.7
32
256
PP
Plasticpro
0.9
50

RESIN Density (gr/cc)

ABS 1.06
CA, CAP 1.26
CAB 1.2
GF PPS 1.65
HDPE 0.96
HIPS 1.05
IONOM 0.95
LCP 1.6
LDPE 0.92
MDPE 0.935
PA6 GF 1.38

intensificatio PA6, 6/6 1.14

0.875 PC 1.2
0.875 PEI 1.27
0.875 PET 1.33
PET© 1.36
1.041666667 PMMA 1.19
1.041666667 POM 1.42
1.041666667 PP 0.9
1.041666667 PP copol 0.9
PPO 0.9
1.041666667 PPO/PS 1.07
1.041666667 PS g.p. 1.06
1.041666667 PSU 1.24
1.041666667 PVC 1.29
1.041666667 PVC rigid 1.4
1.041666667 SAN 1.08
1.041666667 Styron478 dow 0.875

Rules of Thumb:
Shot inventory is OK for residence time
 Residence time OK
Barrel is correctly sized for shot

Rules of Thumb:
Shot inventory is OK for residence time
Residence time OK
Barrel is correctly sized for shot

Allowance for molten Non Molten

material in screw Material

PROCESS WINDOW
Inside the lines are acceptable tem-
perature/pressure combinations
500
Melt Temperature

450
PM = .263 GPM
400
f
Deg F
350

300
90
900 1000 1100 1200 1300 1400
Packing Pressure

90
90
 CP and CpK Calculation
Part name Connector Mold Number A657
Specified Dimension Mean 1.350
Specified Dim upper limit 1.355 Fill in Yellow Cells
Specified Dim lower limit 1.345 Green are Drop down Bars
Dimensions are in Inches
Dimension Dimension Dimension Dimension Dimension Dimension Dimension Dimension
Sample
Number Cavity #1 Cavity #2 Cavity #3 Cavity #4 Cavity #5 Cavity #6 Cavity #7 Cavity #8
1 1.351 1.347 1.350 1.352 1.345 1.353 1.353 1.346
2 1.352 1.348 1.352 1.352 1.347 1.352 1.352 1.345
3 1.352 1.348 1.351 1.352 1.346 1.352 1.354 1.347
4 1.351 1.347 1.352 1.351 1.346 1.352 1.353 1.345
5 1.352 1.348 1.352 1.351 1.346 1.353 1.351 1.346
6 1.353 1.347 1.351 1.351 1.345 1.352 1.353 1.346
7 1.352 1.348 1.351 1.352 1.346 1.352 1.353 1.347
8 1.351 1.348 1.352 1.351 1.345 1.353 1.352 1.347
9 1.352 1.348 1.350 1.351 1.346 1.353 1.352 1.345
10 1.352 1.346 1.352 1.351 1.345 1.352 1.352 1.346
11 1.352 1.349 1.350 1.350 1.347 1.354 1.353 1.346
12 1.353 1.348 1.352 1.352 1.346 1.352 1.352 1.346
13 1.351 1.347 1.351 1.350 1.345 1.352 1.353 1.346
14 1.353 1.346 1.349 1.350 1.347 1.353 1.352 1.347
15 1.352 1.347 1.352 1.350 1.345 1.353 1.353 1.346
16 1.353 1.346 1.349 1.350 1.347 1.352 1.354 1.346
17 1.352 1.347 1.350 1.351 1.345 1.354 1.353 1.345
18 1.352 1.347 1.351 1.352 1.345 1.353 1.353 1.345
19 1.352 1.347 1.349 1.350 1.345 1.352 1.353 1.347
20 1.351 1.347 1.350 1.351 1.345 1.354 1.354 1.347
21 1.352 1.348 1.350 1.352 1.346 1.353 1.352 1.345

mean 1.3520 1.3473 1.3508 1.3510 1.3457 1.3527 1.3527 1.3460

1 sigma 0.0007 0.0008 0.0011 0.0008 0.0008 0.0007 0.0008 0.0008
mean+3sig 1.3540 1.3497 1.3540 1.3535 1.3481 1.3549 1.3551 1.3483
mean-3sig 1.3499 1.3449 1.3475 1.3486 1.3434 1.3505 1.3504 1.3437
spec mean 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35
one or more no no no no no no no no
out of spec
calc beyond No No No No No No Yes No
upper limit?
Calc beyond No Yes No No Yes No No Yes
lower limit?
upper spec 1.355 1.355 1.355 1.355 1.355 1.355 1.355 1.355
lower spec 1.345 1.345 1.345 1.345 1.345 1.345 1.345 1.345

Cp= 2.49 2.09 1.53 2.07 2.13 2.28 2.13 2.15

GOOD =>1.33 GOOD =>1.33 GOOD =>1.33 GOOD =>1.33 GOOD =>1.33 GOOD =>1.33 GOOD =>1.33 GOOD =>1.33
CpK= 2.53 Fix cavity 2.48 2.89 Fix cavity 2.06 FIX cavity Fix cavity
GOOD =>1.33 GOOD =>1.33 GOOD =>1.33 GOOD =>1.33

OVERALL STATISTICS using maximum values

spec mean 1.35 Comments: parts to print but not with capability
upper spec 1.36
lower spec 1.35
max sigma 0.001
calc max UL 1.355 greater than upper limit
calcMax LL 1.343 below lower limit
 Inches
Millimeters

GOOD =>1.33
 Process Window Calculation

Part name: connector White cells are calculated

Mold #: A657 Fill in Yellow Cells
Number of Cavities: 8 Green are Drop down Bars
Machine ID 22
Material Type/name PP Talc filled
Min Melt Point Temp 350 F <-Units of Temperature
Max Melt Point Temp 475 F
Unit of measure PSI <--click on this cell for pulldown

Packing Packing
pressure At Acceptable pressure At Acceptable
Min Melt Part Quality? Max Melt Part Quality?
Sample # Point YN Point YN
1 700 n 700 n
2 750 n 750 n
3 800 n 800 n
4 850 n 850 y
5 900 n 900 y
6 950 n 950 y
7 1000 n 1000 y
8 1050 y 1050 y
9 1100 y 1100 y
10 1150 y 1150 y
11 1200 y 1200 y
12 1250 y 1250 y
13 1300 y 1300 y
14 1350 n 1350 y
15 1400 n 1400 y
16 1450 n 1450 y
17 1500 n 1500 n
18 1550 n 1550 n
19 1600 n 1600 n
20 1650 n 1650 n

Pressures
Low 1050 850
High 1300 1450
Range 250 600
1/4 of Range 62.5 150
Proc Low 1112.5 1000
Proc High 1237.5 1300
min max
Temperatures
Low 350
High 475
 Range 125
1/4 of Range 31.25
Proc Low 381.25
Proc High 443.75

PROCESS WINDOW
Inside the lines are acceptable tem-
perature/pressure combinations
500
NOTE This graph will autom
show up on the setup shee
Melt Temperature

450

400

350

300
900 1000 1100 1200 1300 1400
Packing Pressure
 PSI F
Newtons C

White cells are calculated

Fill in Yellow Cells
Green are Drop down Bars

<-Units of Temperature

Min Melt lisMax Melt List

850
900
950
1000
1050 1050
1100 1100
1150 1150
1200 1200
1250 1250
1300 1300
1350
1400
1450

P @Min T P @Min T
Min 1050 850
max 1300 1450
Range 250 600
0.25 62.5 150
proc min 1112.5 1000
proc max 1237.5 1300

Temp calc
min 350
max 475
25% of Ra 118.75
 Proc Low 468.75
Proc High 356.25

Chart Plot Data

1000 468.75
1112.5 356.25
1237.5 356.25
1300 468.75
1000 468.75
NOTE This graph will automatically
show up on the setup sheet