Introduction to Nautilus 8 Mold Qualification and Design of Experiments Software

INTRODUCTION
TO
NAUTILUS 8
MOLD QUALIFICATION
AND
DESIGN OF EXPERIMENTS SOFTWARE
FOR
INJECTION MOLDING
SUHAS KULKARNI FIMMTECH 1-760-525-9053

The Nautilus Software is a program that helps in the
evaluation, analysis, development and documentation of
the injection molding process.
The software also has a complete design of experiments

module that is customized for injection molding
Once a process has been established on one machine, the

software will calculate the processes for all the
machines in the shop. The process can now be
transferred and ‘starting from scratch’ will not be
necessary on the other machines

Benefits of using the techniques:
• Established process is robust
• Process will require ‘no or little attention’
• Will determine the fastest cycle time possible
• Less scrap at startup
• Zero scrap during production
• Improved part quality and process capability
Above factors increase the bottom line profits!

THE SOFTWARE

Following are some of the features of the software:
 Material, mold and machine databases
 Mold – Machine compatibility report
 Scientific molding worksheets (6-step study)
• Viscosity study
• Pressure drop study
• Cavity balance study
• Process window study
• Gate seal study
• Cooling time
Design of experiments module
• Tornado charts
• Process sensitivity charts
• Cosmetic process window
• Dynamic process window
• Visual prediction equation
 Mold trial and qualification progress report
Mold setup and operation documentation

 Quality module
• full dimensional analysis
• statistical analysis
• post molding shrinkage report
• Documentation of quality inspection plan
 Calculation worksheets commonly used in molding
 User privileges
 Choice of units
 Network/concurrent versions

Other features:
• Process – machine compatibility

• Add a plastic process sheet for a given mold
• Generate the plastic process sheet for any given machine
• Determine the machines in the shop that are compatible and
capable of running the mold based on plastic variables
• Units management –
• Select between metric, English or a combination
• Auto convert on demand
• Once units for a given machine are saved all process sheets
are generated in the machine units

Other features:
• User access levels
• Determine who can and cannot change databases and documents
• Custom read/write access
• Ability to create family molds and run them through

• 6-step study, for example: determine cavity imbalances
between family parts
• Doe, select the processes for family molds
• Optimize for all family parts
• Miscellaneous:
• All studies/documents for a given mold under one tab
• Additional fields added to all databases

MAIN SCREEN:

DATABASES: MATERIAL – MOLD – MACHINE

MOLD MACHINE COMPATIBILITY REPORT:
Criteria based on
• Required tonnage
• % Shot size used
• Residence time of the material in the barrel
• Physical size of the mold and the machine specs

PROCESS – MACHINE COMPATIBILITY
• Add a plastic process sheet for a given mold

• GENERATE THE PLASTIC PROCESS SHEET FOR ANY GIVEN MACHINE IN THE DATABASE
• DETERMINE IF THE MACHINES ARE CAPABLE OF RUNNING THE MOLD BASED ON PLASTIC VARIABLES
ESTABLISHED
CALCULATED PROCESS SHEETS FOR OTHER MACHINES
PROCESS
NOT ACCEPTABLE ACCEPTABLE

• ONCE THE TARGET MACHINE IS SELECTED, SELECT THE PROCESS SHEET FROM THE DROP DOWN
LIST AND CLICK ON ‘GENERATE PROCESS SHEET’ TO PRINT THE PROCESS SHEET FOR THE
MACHINE

MOLD QUALIFICATION PART 1: 6-STEP STUDY
(AKA: SCIENTIFIC MOLDING)

WORKSHEET NO. 1: IN MOLD RHEOLOGY

WORKSHEET NO. 2: CAVITY BALANCE STUDY FAMILY MOLDS
OPTION NEW IN
VER 8

WORKSHEET NO. 3: PRESSURE DROP STUDY

WORKSHEET NO. 4: COSMETIC PROCESS WINDOW

WORKSHEET NO. 5: GATE SEAL STUDY – COLD RUNNER

WORKSHEET NO. 5: GATE SEAL STUDY – HOT RUNNER

WORKSHEET NO. 6: COOLING STUDY

WORKSHEET FOR HOT RUNNER AND VALVE GATED MOLDS

MOLD QUALIFICATION PART 2:
DESIGN OF EXPERIMENTS

Key features:
• No prior math or statistics experience required
• With 4 easy steps you will be able to design a doe
and run the experiments.
• The data will visually show you what you can and
cannot mold as far as the dimensions of the part
are concerned.
• No guesswork: data driven decisions for all changes
in mold steel and/or nominal - specifications
• Adjust the steel with confidence and leave the
process alone!

INPUTS WORKSHEETS FOR DOE:
STEP 1: SELECT THE FACTORS FROM A DROPDOWN LIST
SUHAS KULKARNI FIMMTECH 1-760-

525-9053
STEP 2: ENTER THE UNITS, HIGH AND LOWS FOR THE STUDIES
THE HIGHS AND LOWS ARE DETERMENIED FROM THE

COSMETIC PROCESS WINDOW.

525-9053
STEP 3: ENTER THE NOMINALS AND TOLERANCES

525-9053
STEP 3: SOFTWARE GENERATES THE EXPERIMENTAL MATRIX
MOLD THE PARTS, ENTER DATA AND CLICK ON THE ANALYSIS BUTTON TO
VIEW THE RESULTS

525-9053
TORNADO CHARTS
GIVES YOU INFO ON THE FACTOR THAT MOST IMPACTS THE PART QUALITY
(POSITIVE FACTORS ABOVE THE LINE, AND NEGATIVE BELOW THE LINE)

PROCESS SENSITIVITY GRAPH
GIVES YOU A QUICK SNAP SHOT OF HOW THE DIMENSION WAS AFFECTED BY THE
DOE PROCESS RUN

DETERMINING THE OPTIMUM PROCESS BASED ON SELECTED
CAVITIES AND DIMENSIONS

DIMENSIONAL PROCESS WINDOW
GREEN CONTOURS – PARTS IN DIMENSION RED – PARTS OUT OS SPEC
YOU CAN DRAW A BOX AS SHOWN TO DETERMINE ALARM AND TOLERANCE SETTINGS

MOLD PARTS BETWEEN THE PROCESS WINDOWS TO MAINTAIN THE PARTS WITHIN THE
DIMENSIONS. DIMENSIONAL PROCESS WINDOW

WITH A DIMENSIONAL PROCESS WINDOW AS SHOWN IT WILL BE IMPOSSIBLE

TO MOLD PARTS CONSISTENTLY TO THE REQUIRED DIMENSIONS.
IT WILL BE IMPOSSIBLE TO OBTAIN GOOD CpKs
TIME TO MAKE A DATA DRIVEN DECISION!

VISUAL PREDICTION EQUATION
THE DIMENSION CAN

GO OUT OF SPEC
USL
LSL
Cavity No → EXTENT TO WHICH
THE DIMENSION CAN BE
USL INFLUENCED BETWEEN
THE EXTREMES OF THE
DOE PARAMETERS
LSL
Cavity No →
THE DIMENSION CAN

GO OUT OF SPEC
USL
LSL
Cavity No → STABLE DIMENSION –
USL WILL ALWAYS BE IN SPEC
LSL
Cavity No →
VISUAL PREDICTION EQUATION PROCESS GOLD SPOT - BEST
PROCESS TO BRING ALL
DIMENSIONS CLOSEST TO
NOMINAL
USL
LSL
Cavity No → STABLE DIMENSION –
USL WILL ALWAYS BE IN SPEC
LSL
Cavity No →
SIMULATED PROCESS:
CHANGE THE PROCESS AND
SEE WHAT IT DOES TO
THE PART DIMENSIONS.
THE BLACK X WILL MOVE
WITH PROCESS CHANGES
(SEE NEXT SLIDE)
USL
LSL
Cavity No →
USL
Cavity No →
SIMULATED PROCESS:
CHANGE THE PROCESS AND SEE WHAT IT DOES TO THE PART
DIMENSIONS. THE BLACK X WILL MOVE WITH PROCESS CHANGES

NUMERICAL PREDICTION EQUATION
USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON
THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY

ACHIEVING DIMENSIONS: NEW IN
VER 8
MAKING STEEL AND/OR NOMINAL – TOLERANCE CHANGES
GOOD Cp BUT A BAD CpK??? YOUR CHOICES ARE
• MODIFY THE STEEL DIMENSION AND/OR
• MODIFY THE NOMINAL – SPEC LIMITS
ROBUST PROCESS
MODIFY MOLD AND/OR

NOMINAL-SPEC
LIMITS BY THIS
NUMBER TO HIT THE
MOMINAL VALUE

NEW IN
VER 8
CAPABILITY NOT A REQUIREMENT?
WANT TO BE ONLY IN SPEC??
ROBUST PROCESS
MODIFY MOLD AND/OR

NOMINAL-SPEC
LIMITS BY THIS
NUMBER TO HIT BE
INSIDE THE USL OR
LSL
0

CONFIDENCE RATINGS
USE THE ARROWS TO CHANGE THE PROCESS AND SEE THE EFFECT ON
THE DIMENSIONS. DIMENSIONS ARE DISPLAYED NUMERICALLY

PRINTING: SELECTION SCREEN

PRINTING: EXPORTED REPORT AND ‘SAVE AS’ OPTIONS

MOLD SPECIFIC TROUBLE SHOOTING GUIDE NEW IN
VER 8

QUALITY MODULE:
FULL DIMENSIONAL ANALYSIS:

QUALITY MODULE:
STATISTICAL ANALYSIS :

MACHINE QUALIFICATION:
INJECTION SPEED LINEARITY :

SHOT TO SHOT REPEATABILITY TEST :

LOAD SENSITIVITY TEST :

FREQUENTLY USED MOLDING CALCULATIONS:

WATER FLOW CALCULATION:

PROCESS TRANSFER BETWEEN MACHINES WORKSHEET:

SHOT SIZE ESTIMATION WORKSHEET:

HOPPER SIZE CALCULATION WORKSHEET:

REGRIND CALCULATIONS (CLOSED LOOP SYSTEMS)

MISCELLANEOUS FEATURES

UNITS MANAGEMENT
• UNITS MANAGEMENT –
• SELECT BETWEEN METRIC, ENGLISH OR A COMBINATION
• AUTO CONVERT ON DEMAND

USER ACCESS LEVELS
• USER ACCESS LEVELS
• DETERMINE WHO CAN AND CANNOT CHANGE DATABASES AND DOCUMENTS
• CUSTOM READ/WRITE ACCESS

FAMILY MOLDS
• ABILITY TO CREATE FAMILY MOLDS AND RUN THEM THROUGH
• 6-STEP STUDY, FOR EXAMPLE: DETERMINE CAVITY IMBALANCES BETWEEN FAMILY PARTS
• DOE, SELECT THE PROCESSES FOR FAMILY MOLDS
• OPTIMIZE FOR ALL FAMILY PARTS

FAMILY MOLDS
• ABILITY TO CREATE FAMILY MOLDS IN THE DATABASE

FAMILY MOLDS
• ABILITY TO QULAIFY FAMILY MOLDS IN 6-STEP AND DOE MODULE

CONTACT INFO:
SUHAS KULKARNI
suhas@fimmtech.com
1-760-525-9053
WWW.FIMMTECH.COM
WWW .I NJECTION M OLDING O NLINE . COM

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INTRODUCTION

SUHAS KULKARNI FIMMTECH 1-760-525-9053

The software also has a complete design of experiments

Once a process has been established on one machine, the

SUHAS KULKARNI FIMMTECH 1-760-525-9053

• Established process is robust

• Process will require ‘no or little attention’

• Will determine the fastest cycle time possible

• Less scrap at startup

• Zero scrap during production

• Improved part quality and process capability

Above factors increase the bottom line profits!

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

 Material, mold and machine databases

 Mold – Machine compatibility report

 Scientific molding worksheets (6-step study)

• Pressure drop study

• Cavity balance study

• Process window study

• Gate seal study

• Process sensitivity charts

• Cosmetic process window

• Dynamic process window

• Visual prediction equation

 Mold trial and qualification progress report

Mold setup and operation documentation

SUHAS KULKARNI FIMMTECH 1-760-525-9053

• full dimensional analysis

• post molding shrinkage report

• Documentation of quality inspection plan

 Calculation worksheets commonly used in molding

SUHAS KULKARNI FIMMTECH 1-760-525-9053

• Process – machine compatibility

SUHAS KULKARNI FIMMTECH 1-760-525-9053

• Ability to create family molds and run them through

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

NOT ACCEPTABLE ACCEPTABLE

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-

THE HIGHS AND LOWS ARE DETERMENIED FROM THE

SUHAS KULKARNI FIMMTECH 1-760-

SUHAS KULKARNI FIMMTECH 1-760-

SUHAS KULKARNI FIMMTECH 1-760-

SUHAS KULKARNI FIMMTECH 1-760-525-9053

SUHAS KULKARNI FIMMTECH 1-760-525-9053