Chrome components in a single shot

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HASCO Hasenclever GmbH + Co KG

BORIDE Engineered Abrasives

Oerlikon HRSflow

The volume of injected melt for each individual nozzle is accurately controlled during filling and packing by changing needle strokes up to reach desired local pressure. So we have a local control of flow rates and applied pressure and the possibility to easily balance family tools and control warpage without part or runner modifications.”

Simulation analysis with Moldex 3D

A mold-filling analysis with both the simulation programs Moldex 3D and Autodesk Moldflow calculated the optimum parameters for each of the ten nozzles of the Flexflow system. During the injection process, every valve assumes a position that has been freely programmed by the user. The needles can be programmed using up to 8 different control points for both opening and closing, by defining velocity and position for each step. Up to two cycles of opening and closing can be programmed for each needle. The simulation analysis and practical application show very high conformity with the actual progress of the flow front in the individual cavities.

"Flexflow balances out the different shot weights in an optimum manner and fills the different part volumes of all the cavities within the same time and thus avoids issues of flash, reduce warpage and allow precise control of weld lines," says Nicola Pavan, summing up. With the Flexflow technology, it is possible, with a short fine tuning stage, to produce parts without any surface defects even with limitation typical of family tools. This also drastically reduces the reject rate for the injection molder. The molded parts show reduced frozen-in stresses, are not overpacked, with controlled warpage and are ideally suited for the chrome-plating process.

Gallery

Flexflow controls the melt flow precisely

With Flexflow, the individual valve pins of the currently up to 16 hot runner nozzles can be precisely opened and closed sequentially, independently of one another. Depending on the opening or closing step, up to eight valve positions can be predefined with a motor accuracy of ± 10µm. Through this extremely precise positioning and speed control of the valve pins, a very homogeneous pressure distribution in the mold cavity and thus in the entire molding is attained. As result of the much larger process window, necessary clamping force and even weight of the part can be reduced without any loss of quality. In automotive construction, the Flexflow technology has advantages in particular on injection molding of large-area exterior and interior parts such as bumpers, spoilers, instrument panel supports (IPS), door liners, roof liners, components for the vehicle's lighting and glazing systems, headlamp lenses and panoramic roofs.

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