It is not always necessary to create a complete model. Simplifications that save modeling and analysis time can often be made. The fundamental principle is that the model must be equivalent to the flow in the real part. Flow is dictated by the following elements, listed according to their significance.
The aim should therefore be to create a model with the same thickness, flow length and volume as the real part. When good practices are observed, a simple model will generally provide similar results to a more complex model of the same part.
A fan gate is a wide edge gate with variable thickness which permits rapid and balanced filling of large parts through a large gate cross-section.
There are three distinct processing phases in injection molding.
Cycle time is the total time required to complete all the stages of the injection molding cycle.
Molten plastic will preferentially flow through thicker sections of a mold, but subtle changes to the part geometry can help to balance the flow.
Some mold surfaces must be tapered so that the plastic part can be ejected from the mold when it has cooled sufficiently.
The machine intensification ratio, or the material/hydraulic pressure ratio is the direct relationship between the injection pressure and the hydraulic pressure. This is the ratio of the resin pressure in front of the screw, compared to the oil pressure in the piston of the injection molding machine.