Mold flow analysis reports (such as Moldflow) are mainly used to evaluate cooling, filling, holding pressure and warpage during injection molding process, helping to optimize mold design and process parameters. Following are key analysis indicators and their interpretation methods:

(1) Coolant flow rate
Standard: Maximum flow rate of each circuit ≤ 5 times average flow rate
Impact: Flow rate is too low → Uneven cooling, extended cycle; Flow rate is too high → Increased pressure drop, cooling effect deviates from expectations
Optimization suggestion: Adjust cooling water channel diameter or pump flow rate to ensure turbulent flow (Reynolds number >10,000).
(2) Mold temperature variation range
Standard: Mold temperature fluctuation <30°F (≈16.7℃)
Impact: Uneven mold temperature → Increased residual stress in the part → Risk of warpage
Optimization suggestion: Check water channel layout to ensure uniform cooling
(3) Upper and lower mold temperature difference
Standard: Upper and lower mold temperature difference ≤20°F (≈11℃)
Impact: Excessive temperature difference → Uneven shrinkage → Warping
Optimization suggestion: Balance upper and lower mold cooling water channel design.
(4) Coolant temperature variation
Standard: Temperature variation <5°F (≈2.8℃)
Impact: Large temperature fluctuation → Low heat transfer efficiency → Uneven cooling
Optimization suggestion: Optimize flow channel design or adjust coolant flow rate.
(5) Coolant Reynolds number (Re)
Standard: Re >10,000 (ensure turbulent flow)
Impact: Re <10,000 → Laminar flow → Low heat exchange efficiency
Optimization suggestion: Increase flow rate or reduce water channel diameter to increase Re.

(1) Deformation in X/Y/Z directions
Standard: Deformation should be within allowable tolerance range
Impact: Excessive deformation → dimensional deviation, assembly problem
Key factors: Material shrinkage (primary cause); Uneven cooling (secondary cause); Molecular orientation (e.g. fiber reinforced materials)
Optimization suggestions: Adjust holding curve to reduce shrinkage differences; Optimize cooling system to reduce temperature differences

First, look at cooling analysis: ensure that mold temperature is uniform and Re number meets standard.
Check warpage analysis: confirm whether deformation is dominated by shrinkage (rather than uneven cooling).
Compare process parameters: For example, injection speed and holding pressure, to see if they are appropriate.
Optimization Suggestions: Adjust mold or process based on report's prompts.
Summary
Qualified Report: Uniform cooling (small temperature differential, high Re number), controlled warpage (shrinkage-driven).
Unqualified Report: Optimize cooling system design and adjust process parameters (such as holding pressure and mold temperature).
Systematic analysis of this data can effectively predict and correct injection molding issues, improving part quality.

 

Cooling Analysis - Coolant Flow Rate
Note: Supplier's equipment must be capable of meeting required coolant flow rate.
Maximum flow rate in each circuit should not exceed five times average flow rate.
Impact: If supplier's equipment fails to meet required flow rate requirements, part may not be adequately cooled.
If maximum flow rate in a circuit exceeds five times average flow rate, actual cooling effect will differ significantly from calculated analysis results, resulting in unexpected cooling effects.

 

Cooling Analysis - Mold Temperature Range
Note: Mold temperature range should be less than 30°F.
Mold temperature should remain close to setpoint.
Impact: Mold temperature ranges greater than 30°F can generate residual stresses in part, leading to part warpage.

 

Cooling Analysis - Upper and Lower Mold Temperature Difference
Note: Upper and lower mold temperatures should not differ by more than 20°F.
Impact: If upper and lower mold temperatures differ by more than 20°F, part warping may occur.

 

Cooling Analysis - Coolant Temperature
Note: Coolant temperature variations should be less than 5°F.
Impact: Excessive coolant temperature variations indicate problems with runner design or flow parameter settings, leading to heat transfer issues in part.

 

Cooling Analysis - Coolant Reynolds Number
Note: To ensure turbulent flow in cooling system, minimum Reynolds number should be greater than 10,000.
Impact: When Reynolds number is lower than 10,000, turbulent coolant flow cannot be guaranteed. If this fails to meet requirements for turbulent flow, system's heat transfer efficiency will decrease.

 

Warpage Analysis - X-Direction Deformation
Note: Primary factor affecting part shrinkage should be material shrinkage, not factors such as insufficient cooling and molecular orientation.
Impact: Excessive deformation may cause part to fail to meet dimensional requirements.

 

Warpage Analysis - Y-Direction Deformation
Note: Primary factor affecting part shrinkage should be material shrinkage, not factors such as insufficient cooling and molecular orientation.
Impact: Excessive deformation may cause part to fail to meet dimensional requirements.

 

Warpage Analysis - Z-Direction Deformation
Note: Primary factor affecting part shrinkage is material shrinkage, not factors such as insufficient cooling and molecular orientation.
Impact: Excessive deformation may cause part to fail to meet dimensional requirements.