Project "cooling socket"

Volume: 8 molds
Lead time: 4 weeks

Job definition:
Detailed shrinkage and warpage calculation for 4 cooling sockets located in the engine compartment.
Camber of the mould data, according to the warpage calculation to obtain warpage free parts and avoid the high costs associated with mould corrections

Difficulty:
In the worst case scenario, the complexity of the moulds would have led to a necessary new building of all the moulds for a negative sampling process. ) In earlier projects, the client was already forced to invest a lot of money in mould corrections resulting from high warpage).

Course of action:
Our client provided product data and material specifications. After the shrinkage and warpage analysis, we used the resulting data to change the original data with the cambered geometry. This was extremely complex as the geometry of the part contains a lot of areas that are completely surrounding a core and, therefore, have to be treated with different shrinkage and warpage than calculated. Also the sockets had a free form surface that had to be adjusted with the covers, which would be welded to the sockets in a later process. The calculated warpage was up to 4mm!

Results:
We were already able to produce useable parts during the first sample process. A cost intensive mould correction could be fully avoided.