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Case Studies

Radiator Support – Cadpress SMC

This case presents an analysis of an automotive radiator support using Cadpress compression molding simulation software. The goal of the analysis was to avoid knit lines in those areas of structural importance.

The figure on the right shows the solid model of the part (courtesy of The Budd Company). As can be seen in the figures, this is a complex part where charge placement and molding conditions have a great effect on the mold filling of the part. The main goal of the mold filling study was to avoid knit lines in those areas of structural importance. The part is compression molded out of SMC.

Automotive Radiator

The initial charge layout (Figure 1) in the filling simulation generates a knit line in the area indicated with a circle (Figure 2). Here the knit line is located in an area of structural importance. In order to change the location of the knit line a new charge layout must be tested. With Cadpress is easy to test different cases in the computer to optimize mold filling and either avoid or relocate knit lines.

Figure 1

Figure 1 – Charge layout option 1

Figure 1-B

Figure 2 – Initial charge layout and mold filling

Figure 3 shows a better charge layout that eliminates the initial knit line. The optimized charge layout successfully leads to a much stronger part (Figure 4). The use of Cadpress proved invaluable to this project. Without Cadpress more tedious and expensive trial and error must be done in order to optimize the process.

Figure 2

Figure 3  – Charge layout option 2 (optimized)

Figure 2-B

Figure 4 – Optimized charge layout and mold filling

The Madison Group

The Madison Group is the recognized leader in plastics engineering. Over three decades, The Madison Group has focused on polymeric materials. We understand how these materials behave, how to properly design with them, how they are processed, and the numerous manufacturing steps required to produce a successful product.