DFM Pro

Design For Manufacturing
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DFM Report Of Upmold . c
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From Design To Manufacturing
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h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 1
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Customer VALEO
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Project Name V54X
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Part Number Right:L90060929 Left:L90060885
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Part Name HOUSING halogen
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Mold Number
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UP-140801
Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 2

Information
产品及模具基本信息 Base information for part and mold

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1 模腔数Cavity No. 1L*1R
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2 塑料Material PP TD40
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3 收缩率Shrinkage 1.009？
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4 产品外形Part Size 238 mmX 520 mmX 365 mm
5 产品重量Part Weight 875g per part
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6 模具零件钢材Cor. /Cav. 定模仁Cav steel: LKM738HH HRC33-36
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/Slide steel 动模仁Cor steel: 2738HH HRC33-36
滑块Slide steel: 2738HH HRC33-36
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镶件 Inserts steel:2343 HRC46~48
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7 模架钢材Mold base A板A Plate: 2312
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steel B板 B Plate: LKM738HH HRC33-36
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托板 Plate：2312
顶针底板Lower ejector plate : 2312
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其它Other: 1.1730
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8 注塑机Injection machine Please offer the machine datasheet of size 1000 Ton
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Catalogue
1.产品优化设计（The Part design optimization):
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2.产品缩痕分析（The analysis of sink marks）： Page5-13
3.产品拔模角分析（The analysis of draft）： Page14-17
4.产品刻字及外观要求 (engraving and Aspect ）：Page 18-22
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5.分型线（parting line）：Page 23-25
6.镶件线（insert line）：Page 26-30
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7.行位线与内抽线（ slide and retractor lines）： Page 31-40
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8.顶出线（ejector line）：Page 41-46
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9.浇口位置与尺寸 (gate location and size）：Page 47-48
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10.模具排位(mold layout)：Page 49-54
11. 机台确认（Injection machine): Page 54-55
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一：产品优化设计
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（The part design optimizing）
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http://upmold.com 5
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二：产品缩痕分析
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（The analysis of sink marks）
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http://upmold.com 6
2.1 The analysis of sink marks
1.The normal thickness of part is 1.9mm.
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2.But there are some big side of rib are1.6-3.8mm on part that will be sink mark on the
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visible side, UpMold proposed to make it with 1.5mm.
3.that will be potential risk of sink mark at red area as below picture showing, please
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improve that.
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Front View

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1.The normal thickness of part is 1.9mm.
.
2.But there are some big side of rib are1.6-3.8mm on part that will be sink mark on the
visible side, UpMold proposed to make it with 1.5mm.
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3.that will be potential risk of sink mark at red area as below picture showing, please
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improve that.
4.It will be sink mark of potential risk at the root of all bosses, please improve it.
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Back View

Origin（原始数据）
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Proposal（优化建议）
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1.Normal thickness is1.9mm 3.8mm
C
A
C
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A
B
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B
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Problem description SEC A-A Corrective Actions
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Upmold proposed to reduce the wall as above
It will be sink mark on part as the Section A-A showing. picture.

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1.Normal thickness is 1.9mm
.
2mm
D D
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3.5mm
2mm
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2mm
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2.9mm
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Problem description SEC D-D Corrective Actions
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Our Proposal as above pictures showing that
It will be sink mark at part as the SEC D-D showing
suggests to reduce wall thickness.

Origin（原始数据） Proposal（优化建议）
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1.Normal thickness is1.9mm
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E
pm 1.5mm
3.5mm
2mm
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E
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Problem description SEC E-E Corrective Actions
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Upmold proposed to reduce the thickness of rib
There will be sink mark on rib as above SEC E-E showing as above picture showing, please concern and
change the design
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1.9mm
3mm
1.5mm
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SEC F-F
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Problem description Corrective Actions
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Upmold proposed to change the thickness by
It will be sink mark on rib as above SEC F-F showing 1.5mm for sink mark issue。

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d .
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pm 2mm
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G
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G 3mm
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Our proposed to reduce the wall of boss by 2mm。
It will be sink mark at root of boss as SEC E-E showing.

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1.Normal thickness is1.9mm
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Please reduce the thickness by 1.5mm.
These ribs will be sink mark as pictures。

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三. 产品拔模角分析
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（The analysis of draft）
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3.1 The analysis of draft
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l d
o Please add a draft with
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1 degree on these green
surface fro demold.
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h tCustomer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 16
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Please add a draft angle
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with 1degree on these
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area for demold
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necessary.
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/ /u Please add a draft angle by
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0.5 degree to avoid scratch
problem.
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四：产品刻字及外观要求 l d
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(Engravingp
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and Aspect ）
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Marking Information（刻字信息）
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Please select following mark you want：（请选择你需要的标记）
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[ ] Date Code: Year & Month （日期章，年月合并型）
[ ] Date Code: Year（日期章年章）
[ ] Date Code: Month（日期章月章）
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[ ] Cavity No.（型腔号）
[ ] Part No.（零件编号）
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[ ] Rev. No.（版本号）
[ ] Material（材料标识）
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[ ] Recycle Symbol（回收标志）
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4.1 Engraving and Aspect
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pm
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tt The 2.4V will be
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removed,right?
Customer-Oriented & Quality-Adherence August 7, 2018 21

http://upmold.com 21
4.2 The difference on right and left hand
Please approve tow parts is mirroring design
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Housing-Hal-L Housing-Hal-R

4.3 The difference on right and left hand
Please confirm these rib features is different on R&L part.
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Customer-Oriented & Quality-Adherence
Housing-Hal-R
August 7, 2018 http://upmold.com 23
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五：分型线
(Partingp
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Line Design）
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5.1: Parting Line design
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CAVITY
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PL
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CAVITY
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PL
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CORE
htCustomer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 25

5.2 Parting Line design
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Corrective Actions
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Problem description
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We proposed to add a radius at the root of lock as right picture for
part strengthened

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六：镶件线
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(Insert p m
Line Design）
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6.1 Split mark at cavity side that will be mark on part
Insert mark Insert mark
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Insert mark
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6.2 Insert mark at cavity side
Insert mark
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Insert mark
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6.3 Insert mark at core side
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Insert mark
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Insert mark
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6.4 Insert mark at core side
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Insert mark
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Insert mark

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七：行位线和内抽线
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(Slide and retractor Line）
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7.1 Slide 1 design concept for left part
Housing-Hal-L
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Insert mark
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Inset mark

7.2 Slide 1 design concept for right part
Housing-Hal-R
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Insert mark
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tt Insert mark

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Housing-Hal-L
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p : Slide mark
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Housing-Hal-L
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Insert mark
d .
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Insert mark

Housing-Hal-L
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Insert mark

Housing-Hal-L
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Insert mark
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Insert mark for ejector pin
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Housing-Hal-L
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It will be a draft angle
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with 0.5 degree for
demold.
We proposed to
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change the slide split
line as right picture.
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Insert mark
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Previous
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design proposal
concept for
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slide previous New parting line for slide

Housing-Hal-L
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7.9 Lifter design concept for left part
Housing-Hal-L
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Guide angle for lifter
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Ejector stroke
Lifter mark
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stroke
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八：顶出 l d
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(Ejector）
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8.1:Ejector layout on cavity side
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Movable inserts
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8.2 Ejector mark at cavity side
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8.2 Ejector mark at cavity side
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E
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8mm
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SEC E-E
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There will be thinnest, we
proposed to move the feature
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with 8 mm as right pictures Original Proposal
showing.

8.3 Ejector layout on core side
Ejector pin Ø12X19 Ejector pin Ø8X4
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Ø10X3 ejector pin Ø4X2 ejector pin
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with shoulder
Ø7.5X2 sleeves Ø8X2 sleeves
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Ø6X4 ejector pin

8.3 Ejector layout at core side
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We proposed to add
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some boss with 4 mm for
ejector pin.
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九: 浇口位置及尺寸 l d
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(Gate location and size）
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9.1 Injection gate design concept
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It will be used INCOE DFQ 18 hot runner system 2 drops with hydraulic valve gates
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Option 1 Option 2
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20mm
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10mm
F
4mm
nozzle。
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it will be poor cooling system around
That is good for cooling design, but it
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SEC F-F will be left a pads which is high 12mm
: / / ￠4mm
￠3mm
12mm
5°
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十: 模具排位
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（Mold m
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10.1 Mold design layout sketch
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Option 1
d . TOP
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TOP Insert for cavity A1
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B1 B1
: / / A1
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CAVITY CORE

It will be weakness at red mark showing, we suggest to choose option 2

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Option 1 side view
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There without insert for
Option 2
.
cavity
TOP
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TOP A1
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B1 B1
: / / A1
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CAVITY CORE

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Option 2
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A complete plate
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SEC A1-A1

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十一:机台确认
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（Injection machine):
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11 Molding Machine Information
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Please offer us machine datasheet, connectors for
.
water and electronics, clamping type etc.
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l d
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pm
/ / u
p : Thanks for attention
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Design For Manufacturing

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 2

产品及模具基本信息 Base information for part and mold

1.The normal thickness of part is 1.9mm.

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 7

h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 8

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 9

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 10

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 12

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 13

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 14

[ ] Date Code: Year（日期章年章）

[ ] Date Code: Month（日期章月章）

Customer-Oriented & Quality-Adherence August 7, 2018 21

Please approve tow parts is mirroring design

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 22

Please confirm these rib features is different on R&L part.

htCustomer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 25

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 26

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 28

h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 30

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 31

h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 33

h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 34

h tCustomer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 36

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 37

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 38

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 39

h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 40

h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 41

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 45

Ejector pin Ø12X19 Ejector pin Ø8X4

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 46

h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 51

It will be weakness at red mark showing, we suggest to choose option 2

h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 52

h Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 53

Customer-Oriented & Quality-Adherence August 7, 2018 http://upmold.com 54

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