RENAULT J77 Modus Wing

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RENAULT J77 Modus Wing
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RENAULT J77 Modus Wing
Material GEP Noryl GTX VP7146 Mould -
Ampcoloy 940 - P20 Melt temperature 305
C Inlet water temperature 105 C Total water
flow rate 7 m3/h Injection time 3.8
" Packing time 6 " Cooling time 13 " Open
mould time 32 " During this presentation,
keep in mind that this tool was already optimized
for optimal production with a P20 steel.
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RENAULT J77 Modus Wing
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RENAULT J77 Modus Wing
P 20 Steel
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Point of viewMold temperatureorCooling
Quality and Efficiency
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Average mold wall temperatureduring filling
P 20 Steel
Ampco allows an average temperature more or less
than 7C. Therefore productivity increase thank
to a more important heat extraction Ampco 116.7
to 123.5C (6.8C) P20 122.9 to 143.4C (20.5C)
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Average mold wall temperatureduring filling
(scaled result)
P 20 Steel
Ampco allows homogenous temperature on whole mold
wall temperature. Ampco allows the reduction of
local differential stresses.
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Mold wall temperature (during cycle)
P 20 Steel
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Temperature difference MP / FP(scaled result)
P 20 Steel
Ampco allows the reduction of the mold wall
difference between fixed part and mobile part.
(from 18.5 to 4.8C) Therefore, Ampco allows the
reduction of the warpage of the part in the case
of unfilled material.
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Statistical distribution of the temperature
Mobile side
Mobile side
P 20 Steel
Ampco allows the reduction of the hot spot number
and the smoothing of the wall temperature. Even
in the case of a mobile side with a mobile parts
hard to cool. In addition, the average wall
temperature is less.
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Statistical distribution of the temperature
Fixed side
Fixed side
P 20 Steel
Ampco allows the reduction of the hot spot number
and the smoothing of the wall temperature. Even
in the case of a mobile side with a mobile parts
hard to cool. In addition, the average wall
temperature is less.
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Point of viewProductivity improvement
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Mold wall stabilization
P 20 Steel

• Ampco allows the reduction of the mold wall
  stabilization time
• the time to start production is reduced
• the time to switch between 2 productions is
  reduced
• the quantity of not-in conformity parts
  produced is reduced

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Theoretical cycle time
P 20 Steel
Full steel mould 15.03" Full Ampco mould
13.83" Ampco allow the reduction of the global
cycle time of 1.2", which represents a
productivity gain of 8 for an optimized mold
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Mold wall temperature / cooling time
P 20 Steel
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Point of viewQuality improvement
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Displacement
P 20 Steel
Ampco allows to reduce deformation problems due
to the mold regulation. In this case, the maximal
deformation decreases from 64 mm to 54 mm. This
represents a 15.6 reduction.
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Summary (for a P20 optimized mould)

• Thermal quality
• Hot spot reduction of 7C
• Smoothing of wall temperature
• Ampco range 116.7 to 123.5C (6.8C) during
  filling
• P20 range 122.9 to 143.4C (20.5C) during
  filling
• MP / FP difference reduction (from 18.5 for P20
  to 4.8C for Ampco)
• Quantifiable profits
• Production launching reduction
• Cycle time reduction of 8
• Part quality improvement
• Deformation reduction of 15

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ECONOMICAL ANALYSIS - Cycle Time Profits

• For 500 000 parts
• Injection molding machine 2200 T, Cost per hour
  220/H
• With unequal warpage result

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ECONOMICAL ANALYSIS - Cycle Time Profits

• For 500 000 parts
• Injection molding machine 2200 T, Cost per hour
  220/H
• With equal warpage result

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ECONOMICAL ANALYSIS - Stabilization of mold

• For 500 000 parts
• Restart each 2000 parts, 250 restarts
• With unequal warpage result

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ECONOMICAL ANALYSIS - Stabilization of mold

• For 500 000 parts
• Restart each 2000 parts, 250 restarts
• With equal warpage result

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ECONOMICAL ANALYSIS

• Profits on cycle time for 500 000 parts
• Profits on 250 restarts
• Raw material
• Profits total

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Consulting proposition

• Simulation on prospect cases
• Quantification of Ampco contribution vs. Steel
  mould
• Specific regulation optimization for Ampco
• number of channel
• distance between channel and cavity
• distance between channels
• 3D simulation of Ampco contribution