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What is the injection mold flow analysis of cosmetic cream jars? - Maypak

January 30, 2024

A Cosmetic Cream Jar is a container used to store and package cosmetic paste or cream products. These products may include face creams, skin balms, hand creams, etc. Cream jars are usually designed to be airtight containers to preserve the freshness and quality of the product. They can come in a variety of shapes and materials to suit different types of creams and market demands.

A Plastic Cream Jar or PP Cream Jar product has a diameter of 58mm and a height of 47.5mm. It uses a hot runner system to feed glue. There are four holes in one mold, and the gate is set at the center of the bottom surface.

The following will take this product as an example to introduce in detail the application method of Moldex3D mold flow analysis. The main purpose of the analysis is to improve production efficiency for the cooling system using special-shaped water channels.

Product drawings and mold design sketches:

( Above are H D pictures of the Cosmetic Cream Jar Case )

   1. Model Processing   

Create a new project with a file name of cream jar, import the drawing file containing the product, flow channel and cooling system in the model subclass, and define the properties of each component.

( Above are H D pictures of the Import Product Information )

   2. Divide the Network   

Select the appropriate grid side length for different components. The grid side length of the product is selected as 2mm, the hot runner is 1.5mm, and the cooling pipe is 2mm. The completed grid model is shown in Figure 3 below. After completion, the final grid Check it once to ensure it passes.

( Above are H D pictures of the Grid Model )

   3. Material Selection   

Select PP, TAIRIPRO, and K4635 in the material library, and set material parameters:

( Above are H D pictures of the Set Material Parameters )

   4. Molding Process Settings   

Use default molding conditions for initial analysis and parameter settings:

   5. Interpretation of Results   

Run a complete analysis and perform a 3D solid waterway analysis. After the analysis is complete, check the following results:

(1). Flow wave front time simulation analysis

Observe the smooth filling and balanced flow of the four-hole product through animation:

( Above are H D pictures of the Flow Wavefront Analysis )

(2). Simulation analysis of trapped air in rubber coating

According to the analysis, it can be seen that the position of the trapped air in the encapsulation is located at the top edge and bottom parting surface. It is necessary to pay attention to adding an exhaust mechanism on the mold:

( Above are H D pictures of the Analysis of the Location of Trapped Air in the Rubber Coating )

(3). Welding line simulation analysis

This product uses a single point of glue feeding at the bottom to avoid welding lines:

( Above are H D pictures of the Analysis of the Weld Line Inspection )

(4). Pressure simulation analysis

According to the preset filling speed, the pressure required to fill the four holes of this product is only 8.55MPa, which is lower:

( Above are H D pictures of the Analysis of the Filling Pressure Analysis )

(5). Simulation analysis of flow wavefront temperature

The flow front temperature distribution is uniform, and the temperature difference is less than 20°C:

( Above are H D pictures of the Plastic Pre-Fluctuation Temperature Analysis )

(6). Volume shrinkage analysis

Uniform volume shrinkage:

( Above are H D pictures of the Volume Shrinkage Analysis )

(7). Dent displacement analysis

If the dent displacement value is large, the risk of product appearance shrinkage is greater, and the pressure holding parameter settings need to be adjusted:

( Above are H D pictures of the Dent Displacement Analysis )

(8). Temperature analysis

At the end of cooling, the product temperature distribution is between 42.46°C and 155.686°C, as shown in Figure 13:

( Above are H D pictures of the Cooling end Temperature Analysis )

(9). Analysis of the time red to cool to ejectiquireon temperature

When the local area of the product is thicker, it will take a longer time to cool to the ejection temperature, as shown in Figure 14. This is the main reason that affects the molding cycle.

( Above are H D pictures of the Ejection Temperature Analysis )

(10). Analysis of maximum cooling time

The maximum cooling time of the product generally needs to reach 50s. This parameter affects the molding cycle:

( Above are H D pictures of the Maximum Cooling Time Estimate )

(11). Warpage-total displacement analysis

The warpage and shrinkage of the product are within a reasonable range, and the outer dimensions are stable:

( Above are H D pictures of the Warpage-Total Displacement Analysis )

(12). Warpage-roundness analysis

True roundness is 0.014mm:

( Above are H D pictures of the Warpage-Roundness Analysis)

Through the preliminary analysis of this case, the cosmetic cream jar is filled smoothly with glue in the center of the top center of a four-cavity hot runner mold. There are no injection molding defects such as welding lines, encapsulation, trapped air, etc. What needs to be improved is the appearance shrinkage and cooling time. Long wait problem.

   6. Solution Optimization   

In order to improve the problem of product shrinkage in the initial analysis, adjust the molding parameters:

Recheck the following results based on adjustments:

(1). Volume shrinkage analysis after parameter optimization

The product volume shrinkage is uniform and lower than the initial plan, which means the risk of shrinkage is reduced:

( Above are H D pictures of the Product Volume Shrinkage After Adjusting Molding Parameters )

(2).Dent displacement analysis after parameter optimization

The dent displacement value is reduced, and the risk of product appearance shrinkage is smaller:

( Above are H D pictures of the Analysis of Product dent Displacement After adjusting Molding Parameters )

(3). Analysis of the time required for cooling to ejection temperature after parameter optimization

The cooling time to the ejection temperature is shortened by 12 seconds compared with the initial plan:

( Above are H D pictures of the Time Required for Ejection Temperature After Adjusting Molding Parameters )

(4). Analysis of maximum cooling time after parameter optimization

At this time, the maximum cooling time of the product is only 40 seconds, which is 10 seconds less than the initial plan:

( Above are H D pictures of the Time Required for Ejection Temperature After Adjusting Molding Parameters )

Through this example, it shows that Moldex3D can predict potential risks in advance during the mold design stage and play the role of inspecting design quality. At the same time, it can further solve production molding problems, shorten the molding cycle, and reduce production costs.

*Maypak packaging is Cosmetic Cream Jar Manufacturer and has been focusing on Cosmetic Cream Jars for more than 17 years and was established in 2006,the company enjoys a good reputation at home and abroad. If you have any questions about lipstick tubes, please contact us.

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