Unit Conversion Section
D.C. Electrical Calculations
Fluids: Bubbler sizing , Equivalent Hydraulic Diameter - General Case, Equivalent Hydraulic Diameter - Annular Channel, Hydraulic Cylinder Calculations, Pneumatic Cylinder Calculations, Pressure Losses (Darcy's Equation), Pressure Loss or Flow Rate Through an Orifice, Pressure Losses in Valves and Fittings,
Reynolds Number Calculations
Galvanic Table
Gate Sizing, Hot Tip , Edge Gate, Sub-Gate
Helix and Cam Angle Calculations
Hot Runner Checklist
Properties of Metals Tensile strength, yield strength, elongation, impact strength, reduction of area, all at various hardnesses.
Molding Calculations: Chiller Sizing, Clamp Force Requirements, Cooling Time Estimator - Ballman and Shushman Method, Minimum Mold open Time - Time for highest part to clear bottom of mold, Mold Fill Time Calculator, Pounds or Kilograms of Plastic per Hour - Also in production calculations, Tie Bar Stretch .
Production Calculations: Quantity of Cavities Required, Quantity of Parts that be can molded, Time to Mold a Quantity of Parts, Pounds or Kilograms of Plastic per Hour - Also in molding calculations.
Runner Size Calculations
Machining Calculations: Effective Cutting Diameter, Feed Rate / Feed Per Tooth, IPM <> IPR, Surface Feet Per Minute, Surface Roughness, Three-Sided Cutter Calculator.
Strength of Materials: Beam Deflections - 9 different loading and support scenarios, Elastic Strain - How Much a Part Stretches or Compresses under Load, Hoop Stress - Stress and Strain in Circular Rings, Long Column Sudden Failure Calculations & the L/K Long Column Test, Moment of Inertia, Section Modulus, Area, Radius of Gyration, and Distance from Neutral Axis To Extreme Fiber in 10 Standard Geometric Shapes, Mold Plate Pocket distortion, Through Pocket and Blind Pocket.
Surface Finish Comparison Tables
Thermal Calculations: Expansion, Initial Size, Final Size, Coefficients of thermal expansion for 30 common mold making materials.
Thread Properties: Properties of Metric and Inch Threads, Course and Fine, Major Diameter, Tensile stress area in inches and millimeters, Minor diameter area, tap drill size, and torque calculator
Three Wire Measurement, Largest Wire - Threads per Inch or Pitch Know, Smallest Wire - Threads per Inch or Pitch Known, Best Wire - Threads per Inch or Pitch Known, Measurement over Wire - Threads per Inch or Pitch Known,
Pipe Threads: Tap drill sizes for N.P.T. and B.S.P.T threads, with and without pipe reamer,
Trigonometry: Chord, DD <> DMS, Right Angle Trigonometry, Roll Dimensions, Acute and Obtuse angles, Sine Plate Dimensions, degrees, minutes, seconds, or decimal degrees, any sine plate length, Tooling Ball Dimensions.
Unscrewing Mold Calculations - in threads per inch or by pitch, Stroke per revolution, Number of turns required, Minimum stroke, Cam Rise, Total Rise for stroke.
Vent Calculations: Table of typical vent depths, by material and a Vent Width Calculator.
Extensive Help files with a great deal of data and reference information.
Monday, December 6, 2010
Plastics Today Article about DZynSource
The article that I mentioned in a previous post has been released today, December 6, 2010. Their web site appears to be down for maintenance at the moment, but I am sure it will be up soon.
http://www.facebook.com/l.php?u=http%3A%2F%2Fwww.plasticstoday.com%2Fimm%2Farticles%2Ftessy-plastics-dzynsource-mold-engineering-software&h=5efda
http://www.facebook.com/l.php?u=http%3A%2F%2Fwww.plasticstoday.com%2Fimm%2Farticles%2Ftessy-plastics-dzynsource-mold-engineering-software&h=5efda
Saturday, November 20, 2010
ProWrite Communications Doing Article about DZynSource Mold Engineering Software
I got some really nice news today. Clare Goldsberry, Owner at ProWrite Communications, Sr. Editor at Modern Plastics Worldwide, and Senior Editor at Canon Communications, is going to write an article about DZynSource Mold Engineering Software. I am honored and quite excited!
Clare saw a press release that I issued this week about Tessy Plastics buying my software. She remembered my name from when we were both writing for Injection Molding Magazine. She was a senior editor, at the time, and I was writing book reviews for the IMM Book Club. Thank you Clare.
I'll post a link to the article, when it goes live.
Clare saw a press release that I issued this week about Tessy Plastics buying my software. She remembered my name from when we were both writing for Injection Molding Magazine. She was a senior editor, at the time, and I was writing book reviews for the IMM Book Club. Thank you Clare.
I'll post a link to the article, when it goes live.
Friday, October 29, 2010
Side Action Flash, Part 1, Mold Engineering Software
Have you ever seen a mold with the side action flashing across the split face? Have you checked the design and the steel over and over only to find that the dimensions appear to be correct? The flash problem may be due to an under-designed mold plate. This is particularly true with “A”-side action molds for large parts, and even more so when the side action is contained in a mold plate with a “through-pocket”, like the one shown below.
In this case, each part has 1.25 square inches of surface area for the cavity pressure to generate force on. This force must be overcome by the strength of the plate. Let’s assume that the cavity pressure is 10,000 p.s.i., which is not an unreasonable assumption. This is a 4-cavity mold, so the force trying to separate the slide faces is 50,000 pounds.
You can see from the calculation here that the center of the plate, left as designed, would blow apart approximately .0012 inches, which would probably flash when molding a polypropylene part. In this case, as you can see in the drawing, the plate weakness was overcome by installing an interlock between the slide pocket plate and the stripper plate. This interlock gave the plate enough additional strength to mold flash-free parts. Of course, if the designer had the DZynSource Mold Engineering Software, this problem could have been avoided by doing “what if” scenarios with plate sizes and thicknesses to come to a more robust design that would not flash without extra mold components.
In this case, each part has 1.25 square inches of surface area for the cavity pressure to generate force on. This force must be overcome by the strength of the plate. Let’s assume that the cavity pressure is 10,000 p.s.i., which is not an unreasonable assumption. This is a 4-cavity mold, so the force trying to separate the slide faces is 50,000 pounds.
You have two types of plate distortion to calculate here: one is the stretching of the 2 legs that form the upper and lower boundaries (the ends) of the pocket. You can get a better visualization of that in the DZynSource Mold Engineering Software screenshot shown below. The other distortion is the “bow” of the sides of the pocket, again see the DZynSource screenshot.
You can see from the calculation here that the center of the plate, left as designed, would blow apart approximately .0012 inches, which would probably flash when molding a polypropylene part. In this case, as you can see in the drawing, the plate weakness was overcome by installing an interlock between the slide pocket plate and the stripper plate. This interlock gave the plate enough additional strength to mold flash-free parts. Of course, if the designer had the DZynSource Mold Engineering Software, this problem could have been avoided by doing “what if” scenarios with plate sizes and thicknesses to come to a more robust design that would not flash without extra mold components.
Monday, October 18, 2010
How Much Will That Round Tapered Part Stretch or Crush?
When an object of round tapered cross section is subjected to tension or compression within the elastic limit of the material, the deformation can be approximated with the equation:
¶ = FL/(p E R1 R2)
Where
¶ = = the deformation
F = the load or force
L = the length of the object in the direction that the force is acting
p = Pi (3.14159265358979)
E = the Modulus of Elasticity of the material
R1 = the radius at the small end of the cone
R2 = the radius at the large end of the cone
This equation works for tapered cylinders that don't get too small at the small end. The answers become meaningless (they approach infinity) as the radius approaches zero.
You have to use several menus to get to this form. From the Main menu, choose “Strength of Materials”; from there choose “Elastic Strain”. Once the Elastic Strain sub-menu is open, you have three choices; choose “Tapered Cross-Section, Single Material”.
When entering the required information, it is imperative that the units used are consistent. For instance, if pounds per square inch are used for the modulus of elasticity, quantities must be entered in units of pounds and inches.
First choose whether you want to use p.s.i. or N/mm²; next choose how many places beyond the decimal point you like the answer carried.
Enter the Force, the length, the large radius, the small radius, and the Modulus of Elasticity in the text boxes next to the questions asked. When entering modulus of elasticity values like 30,000,000 pounds per square inch, as would usually be used for steel, you may enter as 30e6 as a shortcut.
Press Calculate. The strain and stress values are shown on a separate Answers form. Answers are valid if the stress is from a static load and is within the elastic limit of the material in question.
Use the Clear button to clear all of the text boxes; however this is not necessary in order to do another calculation. You may simply type over the previous entries.
You may send the page to your default printer by pressing Print.
Press Menu to return to the main menu selection area.
¶ = FL/(p E R1 R2)
Where
¶ = = the deformation
F = the load or force
L = the length of the object in the direction that the force is acting
p = Pi (3.14159265358979)
E = the Modulus of Elasticity of the material
R1 = the radius at the small end of the cone
R2 = the radius at the large end of the cone
This equation works for tapered cylinders that don't get too small at the small end. The answers become meaningless (they approach infinity) as the radius approaches zero.
You have to use several menus to get to this form. From the Main menu, choose “Strength of Materials”; from there choose “Elastic Strain”. Once the Elastic Strain sub-menu is open, you have three choices; choose “Tapered Cross-Section, Single Material”.
When entering the required information, it is imperative that the units used are consistent. For instance, if pounds per square inch are used for the modulus of elasticity, quantities must be entered in units of pounds and inches.
First choose whether you want to use p.s.i. or N/mm²; next choose how many places beyond the decimal point you like the answer carried.
Enter the Force, the length, the large radius, the small radius, and the Modulus of Elasticity in the text boxes next to the questions asked. When entering modulus of elasticity values like 30,000,000 pounds per square inch, as would usually be used for steel, you may enter as 30e6 as a shortcut.
Press Calculate. The strain and stress values are shown on a separate Answers form. Answers are valid if the stress is from a static load and is within the elastic limit of the material in question.
Use the Clear button to clear all of the text boxes; however this is not necessary in order to do another calculation. You may simply type over the previous entries.
You may send the page to your default printer by pressing Print.
Press Menu to return to the main menu selection area.
How Many Surface Feet per Minute is That?
It is sometimes desirable to calculate the quantity of surface feet per minute attained, when the diameter of the rotating cutter (i.e. milling) or the work piece (i.e. turning) is known, and the RPM's are established. The equation used in this calculation is:
SFM = (Pi * Diameter * RPM) / 12
where, SFM = Surface Feet per Minute, RPM = revolutions per minute
You can find the Surface Feet Per Minute calculator under the "Machining Calculations" sub-menu.
Enter the diameter and revolutions per minute in the appropriate text boxes. Press Calculate. The answer appears in the Answer frame.
Use the Clear button to clear all fields, however this is not necessary in order to do another calculation. You may simply type over the previous entries.
You may send the page to your default printer by pressing Print.
Press Menu to return to the main menu selection area.
SFM = (Pi * Diameter * RPM) / 12
where, SFM = Surface Feet per Minute, RPM = revolutions per minute
Enter the diameter and revolutions per minute in the appropriate text boxes. Press Calculate. The answer appears in the Answer frame.
Use the Clear button to clear all fields, however this is not necessary in order to do another calculation. You may simply type over the previous entries.
You may send the page to your default printer by pressing Print.
Press Menu to return to the main menu selection area.
Thursday, October 7, 2010
Compression in a Multi-Material Component With Uniform Cross Section
When an object is constructed with two different materials, and both have uniform cross-section, and both are subjected to the same tension or compression within the elastic limit of the material, the forces, stresses, and deformation can be predicted with the following equations:
F1 = F * (A1 * E1) / ((A1 * E1) + (A2 * E2))
F2 = F * (A2 * E2) / ((A1 * E1) + (A2 * E2))
¶ = (F1 * L) / (A1 * E1) = (F2 * L) / (A2 / E2)
Stress1 = F1 / A1
Stress2 = F2 / A2
Where
¶ = = the deformation
F = the total load or force acting on the objects
F1 = the load or force carried by object 1
F2 = the load or force carried by object 2
L = the length of the objects in the direction that the force is acting
E1 = the Modulus of Elasticity of the material for object 1
E2 = the Modulus of Elasticity of the material for object 2
A1 = The cross-sectional area of object 1, perpendicular to the force
A2 = The cross-sectional area of object 2, perpendicular to the force
It is assumed that the object is constructed in such a way that there is no slippage between objects 1 & 2.
When entering the required information into the DZynSource Mold Engineering Software, it is imperative that the units used are consistent. For instance, if pounds per square inch are used for the modulus of elasticity, quantities must be entered in units of pounds and inches. See the previous article to see you access this calculation from within DZinSource.
First choose whether you want to use p.s.i. or N/mm², then choose how many places beyond the decimal point you like the answer carried.
Enter the Force, the length, the outer objects area, the inner objects area, and the Modulus of Elasticity for each object in the text boxes next to the questions asked. When entering modulus of elasticity values, 30,000,000, as would usually be used for steel, may be entered as 30e6 as a shortcut. The area of 10 basic shapes can be calculated by choosing Strength of Materials, Moment of Inertia from the main menu, choosing the desired shape, and entering the required information.
Press Calculate. A separate answer page appears with the values for Force 1, Force 2, the deflection, and stress induced in each component are shown. Answers are valid if the stress from a static load is within the elastic limit of the material in question.
Use the Clear button to clear all entry fields, however this is not necessary in order to do another calculation. You may simply type over the previous entries.
Press OK on the answer page to close that page.
You may send the either page to your default printer by pressing Print.
Press Menu to return to the main menu selection area.
F1 = F * (A1 * E1) / ((A1 * E1) + (A2 * E2))
F2 = F * (A2 * E2) / ((A1 * E1) + (A2 * E2))
¶ = (F1 * L) / (A1 * E1) = (F2 * L) / (A2 / E2)
Stress1 = F1 / A1
Stress2 = F2 / A2
Where
¶ = = the deformation
F = the total load or force acting on the objects
F1 = the load or force carried by object 1
F2 = the load or force carried by object 2
L = the length of the objects in the direction that the force is acting
E1 = the Modulus of Elasticity of the material for object 1
E2 = the Modulus of Elasticity of the material for object 2
A1 = The cross-sectional area of object 1, perpendicular to the force
A2 = The cross-sectional area of object 2, perpendicular to the force
It is assumed that the object is constructed in such a way that there is no slippage between objects 1 & 2.
When entering the required information into the DZynSource Mold Engineering Software, it is imperative that the units used are consistent. For instance, if pounds per square inch are used for the modulus of elasticity, quantities must be entered in units of pounds and inches. See the previous article to see you access this calculation from within DZinSource.
First choose whether you want to use p.s.i. or N/mm², then choose how many places beyond the decimal point you like the answer carried.
Enter the Force, the length, the outer objects area, the inner objects area, and the Modulus of Elasticity for each object in the text boxes next to the questions asked. When entering modulus of elasticity values, 30,000,000, as would usually be used for steel, may be entered as 30e6 as a shortcut. The area of 10 basic shapes can be calculated by choosing Strength of Materials, Moment of Inertia from the main menu, choosing the desired shape, and entering the required information.
Press Calculate. A separate answer page appears with the values for Force 1, Force 2, the deflection, and stress induced in each component are shown. Answers are valid if the stress from a static load is within the elastic limit of the material in question.
Use the Clear button to clear all entry fields, however this is not necessary in order to do another calculation. You may simply type over the previous entries.
Press OK on the answer page to close that page.
You may send the either page to your default printer by pressing Print.
Press Menu to return to the main menu selection area.
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