In this section, you perform a part fill simulation, which predicts the flow of plastic melt inside the mold during the filling process.
To do it, the flow front is calculated as it grows through the part incrementally from the injection location. The simulation runs until the velocity pressure switch-over point has been reached. There are two types of fill simulation: a Part Fill analysis evaluates individual parts, and a Mold Fill analysis evaluates the entire mold design, including the feed system. Before running a Part Fill analysis, the material and the part process settings must be defined, and at least one gate location must exist.
The top of the Summary dialog box indicates that the part can be filled easily but part quality may be unacceptable. This information indicates to review the Quality prediction plot, determine the magnitude of the quality problems, and check whether the locations of these problems are critical to part performance. Additional fill analyses can be displayed to determine whether changes in variables, such as the process settings, gate location, and material, improve the results.
The Fill time result shows the position of the flow front at regular intervals as the cavity fills. The color contour represents the parts of the mold that are being filled simultaneously. At the start of the injection, the flow front is represented in dark blue. The last places to fill are represented in red. An absence of color indicates sections that did not fill, that is, the part has a short shot.
The spacing between the contour lines, or width of the color bands, is an indication of the flow velocity. Because the time duration between each line or band is the same, the further apart the lines or bands are, the faster the flow front is moving. A part with a good fill time result has a balanced flow pattern. The following also applies:
In this tutorial, the central location of the gate provides a nearly balanced fill pattern. The flow front reaches the top of the part slightly before the bottom. The flow velocity is high near the gate, and relatively high on the bottom of the part (below the keypad). These regions have high velocities because the flow front is not large compared to the rest of the part. Areas of high velocity tend to have higher shear stress.
The quality prediction result estimates the expected quality of the appearance of the part, and its mechanical properties. The quality predictions that are displayed are based on the following sliding scale:
Most of the display for this model is green, indicating high quality. The model is yellow in some areas, indicating there may be some quality issues that need further investigation. None of the areas that indicate quality issues are large.