DZYNSOURCE

Desktop Engineering Tools for Mold Designers, Engineers, Moldmakers,

Processors, etc.

Mold Engineering Software

DZynSource Software Increases Your Bottom Line

Build better molds the first time Optimize mold cooling Plan for thermal expansion and contraction Specify chillers, cylinders, valves, and

pumps Size mold plates appropriately Specify correct components and fasteners Troubleshoot molds and molding processes Over-design is expensive Under-design can be disastrous

DZynSource Main Screen

Direct Current Electrical Calculations

These calculations are commonly used when working with heaters and hot runner systems.

Calculate the wattage of a spare heater by entering the measured resistance in ohms, and using the known voltage in the bottom calculation.

Fluids Sub-MenuMolds are heat exchangers, and the medium is usually water. You can calculate your pressure losses, Reynolds Number and flow rates to ensure turbulent flow for water, laminar flow for hydraulics.

Hydraulic and pneumatic cylinder calculations, for force flow rate S.C.F.M. are done in seconds. This makes it easier to size cylinders, valves and pumps.

Bubbler Size CalculationsDon’t spend your time doing repetitive calculations. We do these all of the time, so why not automate routine tasks?

The feeder line size calculator works for water manifolds too. Enter the size line that you need to feed, and enter the number of waterlines, and instantly get the required size for the main feeding waterline.

Equivalent Hydraulic Diameter

The equivalent diameter of an irregular shaped passage is not the same as a diameter of equal area. It is much smaller due to the increased periphery.

The equivalent diameter of an annular channel is much smaller than most people think it is. Drilled holes in cores are traditionally undersized in the moldmaking community.

Hydraulic Cylinder Calculations

You can calculate the forward force, the return force, and number of gallons per minute of hydraulic fluid needed, all while talking to your customer on the phone.

Pneumatic Cylinder Calculations

Calculate the correct piston bore size for your application.

Calculate the forward force

Calculate the return force

Calculate the SCFM of air required for operation.

Get the answers as fast as you can type.

Pressure Losses

You can calculate the pressure losses in your mold, or hoses.

You can also calculate the fact that there is very little pressure lost through small fittings, in many cases.

Reynolds NumberMake sure that your cooling is maximized by achieving a flow rate that indicates a Reynolds Number over 4000.Make sure that your hydraulic lines don’t exceed a Reynolds Number of 2000.

See how anti-freeze hampers your mold cooling by increasing the coolant viscosity!

You can sometimes increase cooling, in marginal situations, by warming the water temperature.

When the Reynolds Number is near 4000, and you can’t increase the flow rate, increasing the water temperature can sometimes change the flow from transitional to turbulent due to the decreased viscosity.

Hot Runner Checklist

Here’s a list of questions that you can use as a checklist when checking hot runner drawings. The list is based on experience .

The checklist is in a limited word processor, so you can add your own items to the list.

Machining Calculations

DZynSource Mold Engineering Software is not just for designers. There is a section for people involved in machining as well.

Calculate Surface Roughness

When cutting with a ball end mill, there will always be ridges and valleys left from the radius on the bottom of the cutter. The height of these ridges increases with the amount that you “step over” your cutter.

Calculate the expected roughness before you cut.

Feed RateCalculate the amount of chip load per tooth, or the feed rate for machining. Enter your known data to get your required information.

Calculate Effective Cutter Diameter

When cutting with a ball end mild, or a flat bottom end mill with a corner radius, the effective cutter diameter is determined by the diameter of the cutter at the point on the cutter radius where the full depth of cut intersects that radius.

Multiple Machining Calculations

Conversion Between Inches Per Minute & Inches Per Revolution

Moldmaking Material Properties

You can open up to 4 material properties windows to compare the properties of 36 different mold making metals.

Mold or Plate Weight Estimator

Quickly estimate the weight of either steel or aluminum rectangular plates and blocks.

Molding Calculations Sub-Menu

DZynSource Mold Engineering Software is not just for designers and toolmakers. The cooling and molding calculations make this software a valuable tool for molders, molding managers, and production planners too.

Chiller Sizing and Processing Information

Quickly calculates:

the pounds of material to be processed per hour

The BTU’s per hour to be removed

The gallons per minute of water required to remove the heat

And the chiller capacity, in tons.

Table of Typical Required Clamp Force For Various Materials

Molded Part Cooling Time Estimator

Colorant Let Down Ratio

Calculates the required colorant in terms of let-down ratio, or percentage. Choose pounds or kilograms.

Minimum Time for a Part to Drop

This allows you to calculate the pause time for the molding machine to wait for the molded part to fall from the highest cavity to the bottom of

the mold.

Calculate the Amount of Material to be Processed Per

HourWhen you don’t need the heat content, water requirements, or chiller capacity, you can just calculate the amount of material to be processed per hour.

Plastic Shrinkage Calculator

Calculate steel sizes, knowing plastic size and shrink rate, or calculate plastic size, knowing steel size and shrink rate.

Includes a table of typical shrink rates for some common plastic materials.

Calculate Tie Bar Stretch

Production Calculations

Calculate the Amount of Material to be Processed Per Hour is found here, as well as in the molding calculations section.

Molding Capacity

Calculate your production capacity quickly and easily!

Convert Hours Into Days or Weeks

Sometimes you know your production run in hours, and want to convert it to a larger unit of time. Done and done.

Calculate How Many Cavities are Required in Your Mold to Meet Your Production Needs.

Calculate How Many Parts Your Mold Can Produce in a Given Amount of Time

How long will it take to mold that many parts?

Runner Sizing

Calculate runner sizes based on part wall thickness.

Calculate the size of a feeder runner based on the size and number of branch runners it will be feeding.

Strength of Materials Section

The strength of materials section is sort of the heart of the DZynSource Mold Engineering Software, and the reason that I originally started writing this code.

There are many options from this selection set, and many more choices within each section.

Bending and Deflection

You can calculate the bending, or deflection, of plates, cores, or many other mold components.

For slightly tapered parts, use the average diameter of the part.

Cantilever With Load at Opposite End

Cantilever, Load at Any Point

Three Different Support Scenarios3 Loading Scenarios for Each Support Type

Answer Box

When you click on the “Moment of Inertia” button, you are presented with 10 standard shapes to choose from. This is the geometric shape of the piece that you are analyzing, at 90 degrees to the “L” direction.

Using The Features

The Moment of Inertia and Section Modulus are automatically sent to the proper text boxes.

Deflection of Circular Discs2 different loading scenarios,2 different support scenarios.

Good for calculating the distortion from gating on a core, or the collapse of a cap or closure, among other things.

Answers

The answers for this section appear in a separate dialog box.

Fixed Both Ends, Central Load

Fixed Both Ends, Load at Any Point

Euler’s Long Column TestI have seen ejector pins buckle due to injection pressure when gating was positioned directly over the pin. This long column test will tell you if the proportions of your pin put it at risk of buckling. Of course, it is not restricted to just ejector pins.

Parts that meet the requirements to be classified as “Long Columns” are likely to fail by sudden and catastrophic buckling. The L/K test will tell you

if the geometry of your part meets the definition of “Long Column”.

Critical Load for Long Column Buckling

Here again, the modulus of elasticity can be chosen from a list, or entered manually. The moment of inertia is transferred from the worksheet shown earlier.

This feature will tell you what the critical load is to avoid long column buckling for your pin or post.

This example shows that the critical load for a 12” long, .125 diameter ejector pin, is about 25 pounds.

Calculate the expansion of a Round Cavity, Blind or Through Hole

This calculation becomes more critical for face mounted cavities. Since there is no plate to contain cavity expansion, you must ensure that the wall thickness of the cavity is thick enough so that the expansion will be less than the expected shrinkage of the wall stock of your molded part.

Elastics StrainStretching and Compression

Within The Elastic Limit of a Material

Stretch or CompressionUniform Cross-section

One MaterialWhen you press the “Enter Modulus of Elasticity” command button, you are presented with a table of materials to choose from. The appropriate number will be transferred to the text box, when you click on your material. You can always enter your own data, if your material isn’t listed.The modulus of elasticity for steels is within 10% of

30,000,000 p.s.i. regardless of the steel or its hardness.

Stretch or CompressionTapered Cross-section

One Material

Tapered Strain Answer

Stretch or CompressionUniform Cross-section

Two Materials

Two Material Strain Answers

Hoop Stress & Expansion

Leader Pin Bend with 1, 2, or 3 Moving PlatesEnter your Known Weight, or use the Plate Weight

Estimator

Moment of Inertia and other Properties of Geometric Shapes

Moment of inertia, section modulus, radius of gyration, and area are all used in the calculations of strength of materials.

Just enter your known dimension for one of the ten standard shapes to get the values you need.

Most values are sent to the appropriate text boxes automatically.

Mold Plate Distortion

Have you ever seen a mold with “A” side action fail to keep the slides fully closed during injection? You don’t have to experience this again if you size the plate correctly the first time.

Both through pocket and blind pocket options.

Surface Finish Comparisons

SPI/SPE Finish Comparison

Surface Roughness Comparison

Thermal Considerations

Chiller Tonnage, Material Per Hour, Water Requirements, and BTU’s to Be Removed

Linear Thermal Expansion Coefficients and Calculations

You can choose to calculate the expansion and the final size.

You can also calculate what to make the initial size in order for a part to grow to the correct size after a change in temperature.

Thread Properties

Three Wire Thread Measurement

You can calculate the size for measuring threads with the “three wire measurement” technique.

You can calculate the largest, smallest, and best wire size to use based on the threads per inch, or the thread pitch.

Pipe Threads

You can select N.P.T. threads, or B.S.P.T threads. Once you click on the thread size, you are presented with the tap drill size for that thread. You will get 2 answers, one for the drill size if using a pipe reamer too, or a larger size if no pipe reamer will be used.

Properties of Screws and Threads

Trigonometry

Chord and Segment Calculations

Using the image at the right to decide, choose the 3 options to calculate the value that you need to know. You can calculate the chord, the radius, or the height of the segment, if you know the other two values.

Degrees, Minute, Seconds <> Decimal Degrees

Most calculators include a decimal degree to degree, minute, second, calculator.We included one here so that you have another source for when your calculator batteries lose their charge.

Right Angle Trig

Choose any two values that you know, from the list, and press Calculate to get the other 3 values.

The 90º corner is constant.

You can enter your angle in decimals degrees or degrees, minutes, seconds.

Roll Dimensions

Using a roll, dowel pin, or gage pin to measure angles is very common in mold and tool making. There are two choices available to represent the orientation of the angle. Just enter the angle, the height to the theoretical sharp corner, and the pin or roll diameter, press calculate, and the height over the roll is calculated for you. No more using charts and cheat sheets.

Roll Dimensions

Sine Plate Gage Block Calculator

Tooling Ball CalculatorThe tooling ball is often used for measuring the size of cone shaped holes.

You can calculate how much the ball sits above or below datum surface S. An answer with a minus value indicates that the ball is below the surface. The tangent diameter is given so you can tell if the angle surface is large enough for the ball to rest tangent to the angle.

Unscrewing Mold Worksheet

Venting Considerations

Table of Typical Vent Depths

A Vent Width Calculator

Of course, it’s still up to you to put the vents in the right spot. But this calculator tells you the minimum vent width you need to prevent burning” of the plastic material.

It’s usually better to have more vents, as long as the structural integrity of the core and cavity are not compromised.

EconomicsAt $149, this software is extremely inexpensive.

At a $75 per hour shop rate, this software will pay for itself in 4 weeks, assuming 30 minutes per week of savings.

There will be times where each use will save you hours of time.

Some calculations are complicated, and can take an hour or more, if not done regularly.

Instead of looking through notes and books for the appropriate formula or equation, all of your engineering calculations are automated in one convenient location.

Have you ever seen an “A” side action mold flash due to an under-designed plate?

Imagine the money saved if you avoid just one engineering mistake!

A Few of Our Commendations

"Finally, a one-source location for the plastics mold design engineer to find just about everything from material properties to conversion tables to cooling requirement calculations, the list just goes on. If you're involved in the design of plastic injection molds, you need DZynSource on your Desktop. I highly

recommend it."--Dieter Meyer, Custom Micro-Cadd Systems

“Every mold making company should own a copy.  Great idea, great implementation.”  Jim Philippe / Tooling Engineer   CORNING LIFE

SCIENCES

“

Very impressive and a must for anyone in the business from bench to processing”

                Robert Pozzo, Sr. Design Engineer at Applied Medical; CSWP I just purchased DZynSource tonight for use during estimation, design and analysis. I have my own Excel workbook with many of the formulas I use for calculating similar functions but I appreciate the way you have compiled them into an accessible package with a friendly menu system. I am sure this will be a handy resource for years to come.

 Derek Beattie, PolySurf Design Services

More CommendationsA while ago we switched from 32 bit to 64 bit computers.When we did this our beam analysis software would no longer run.So the main reason for buying your package was for the beam deflection calculations.We are finding more uses for it as we go along. This leader pin calculation has me intrigued because we never could get a good number for this.So thanks! Marty Ricciotti,  Chief EngineerRedoe Mold LTD

“ I am impressed with your software; talk about practical and useful!  Anyone in the business can sure appreciate what you have done.”

Brett Niggel, Designer, Studio One Eleven