Material Utilization for Plastic Molding
IM Material Utilization
Material costs and utilization are determined with the help of the following formulas:
Part Rough Mass = Part Finish Mass / Utilization
Rough mass is the quotient of the following:
Finish mass (see formula below)
Utilization (see formula below)
Utilization = ( 1 – Material Waste Factor ) * Mold Efficiency
Utilization depends on the following:
Material waste factor (see formula below)
Mold efficiency (machine property, typically 0.95)
Part Finish Mass = Part Volume * Material Density
Finish mass is the product of the following:
Part volume (obtained from GCD extraction)
Material density (listed in the Material Selection dialog)
Material Waste Factor = Runner Factor – Regrind Allowance
Material waste percentage is the difference between the following:
Runner factor (see below)
Regrind allowance (default of 0.25 specified in plant variables or user-specified value—see User Inputs for Plastic Molding)
Runner factor is a function of the following:
Runner volume (see Runner System Model)
Number of cavities (see Number and Layout of Mold Cavities)
Part volume (obtained from GCD extraction)
SFM Material Utilization
Material costs and utilization are determined with the help of the following formulas:
Foam Cost Per Part Mass = (Gas Cost Per Mass * Percent Gas) + (CFA Cost Per Mass * Percent CFA)
The cost of physical gas and chemical foaming agent as a function of the total mass of the part depends on the following:
Gas Cost Per Mass (see User Inputs for Plastic Molding)
Percent Gas (see User Inputs for Plastic Molding)
CFA Cost Per Mass (see User Inputs for Plastic Molding)
Percent CFA (see User Inputs for Plastic Molding)
Default Gas and CFA costs and percentages are determined by the foaming agents lookup table’s lowest cost entry for the current foaming agent (see User Inputs for Plastic Molding) and material type. If no match is available, the process will fail. If the process feasibility rules are turned off and no match is available, the cost and usage percentage are set to zero.
Part Rough Mass = Part Finish Mass / Utilization
Rough mass is the quotient of the following:
Finish mass (see formula below)
Utilization (see formula below)
Part Finish Mass = Part Volume * Material Density * Percent Filled
With SFM, injection partially fills a part’s mold with material. Only after the foam expands is the mold’s entire volume occupied. So finish mass is the product of the following:
Part volume (obtained from GCD extraction)
Material density (listed in the Material Selection dialog)
Percent filled (default of 0.75 specified in plant variables or user-specified value—see User Inputs for Plastic Molding)
Utilization = ( 1 – Material Waste Factor ) * Mold Efficiency
Utilization depends on the following:
Material waste factor (see formula below)
Mold efficiency (machine property, typically 0.95)
Material Waste Factor = Runner Factor – Regrind Allowance
Material waste percentage is the difference between the following:
Runner factor (see below)
Regrind allowance (default of 0.25 specified in plant variables or user-specified value—see User Inputs for Plastic Molding)
Runner factor is a function of the following:
Runner volume (see below)
Number of cavities (see Number and Layout of Mold Cavities)
Part volume (obtained from GCD extraction)
RIM Material Utilization
Material costs and utilization are determined with the help of the following formulas:
Part Rough Mass = Part Finish Mass / Utilization
Rough mass is the quotient of the following:
Finish mass (see formula below)
Utilization (see formula below)
Part Finish Mass = Part Volume * Material Density
Finish mass is the product of the following:
Part volume (obtained from GCD extraction)
Material density (listed in the Material Selection dialog)
Utilization = ( 1 – Material Waste Factor ) * Mold Efficiency
Utilization depends on the following:
Material waste factor (see below)
Mold efficiency (machine property, typically 0.95)
Material waste factor is a function of the following:
Runner volume (see Runner System Model)
Number of cavities (see Number and Layout of Mold Cavities)
Part volume (obtained from GCD extraction)