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Fill time

The fill time plot displays the profile of the plastic melt as it flows through the mold part
cavity during the filling stage of the injection molding process. The blue regions indicate
the start or beginning of the flow front. The red regions indicate either of the following:

The flow front position at any given time interval during an animation of the filling stage

The end of fill when the flow has stopped, even if the software detects a short shot

Note
This part can be successfully filled with an injection
pressure of 20.6 MPa (2993.50 psi).
The injection pressure required to fill is less than 66% of
the maximum injection pressure limit specified for this
analysis, which means you are well under your specified
limit.

Pressure at End of Fill:


During the filling stage, the forward injection velocity of
the reciprocating screw is controlled, which results in the
pressure required to fill the cavity at that velocity. The
injection pressure is propagated through the molten
plastic and results in a pressure drop distributed along
the length of flow. The pressure at the end of fill is a very
good indication of how evenly the cavity has filled.
Temperature at End of Fill

At the end of fill, the plastic in contact with the cavity


wall freezes into a very thin frozen layer that has cooled
down to the temperature of the mold. The thickness of
this frozen layer is independent of the thickness of the
part wall. The thickness is dependent on the melt and
mold temperature differential and the material thermal
conductivity.

Bulk Temperature at End of Fill:


During the fill stage, changes in the melt temperature are
calculated using parameters such as time, distance from
the cavity wall, and part wall thickness. The bulk
temperature at end of fill plot displays how much the melt
has changed from the set melt temperature. The Bulk
Temperature plot indicates stagnant material, which has
cooled significantly by the end of fill, in blue. The plastic
material with a velocity just before the end of fill, that
retains heat, is displayed in red.
Shear Stress at End of Fill:
Shear stress is a measure of shear force per unit area. The direction of the shear force
is parallel to the plane of the force (the cavity wall), and can be thought of as the force
melt uses to push the cavity wall in the direction of flow (not pushing outward normal to
the wall).

= F/A
= Shear stress

F = Applied force

A = Cross-sectional area of the material that is parallel to the applied force vector

Volumetric Shrinkage at End of Fill:


The volumetric shrinkage at end of fill can indicate areas of potential concern.
High rates of shrinkage will occur in thick sections of a plastic part which do not
undergo a sufficient packing stage during the molding process. For example, if you
do not include a sufficient packing stage, high amounts of shrinkage will occur at
the locations indicated in yellow and red by the volumetric shrinkage at end of fill
plot.
Cooling Time:
Two factors that affect cooling time are melt temperature
and mold temperature. Increasing either temperature
typically results in increased cooling time. Plastics require
long cooling times because they are good insulators with
low thermal conductivities. Cooling time is proportional to
the square of the part wall thickness, doubling the
thickness quadruples the cooling time. To reduce cooling
times, you should make the part wall thickness uniform
and as thin as safely possible

Temperature at End of Cooling: vip


The temperature at end of cooling plot is based on when 90% of the part
volume is below the material deflection temperature under flexural load, the
ejection temperature. If there is a large temperature distribution in thick
regions of the part, several problems may occur: sink marks, internal voids,
or warpage. To reduce these problems, you should design the part with a
uniform wall thickness.

Sink Marks:
Sink marks are depressions on the surface of an injection molded plastic part. The fundamental cause of sink marks
is that not enough polymer molecules have been packed into a part to compensate for the shrinkage that occurs.

You can use these design rules to minimize sink marks:

1) When safely possible, design with uniform part wall thickness.

2) Place injection locations at thicker sections of the part, so the thicker sections can be packed at higher
pressures.

3) Avoid using injection locations that are too small, which can prevent sufficient packing of the part
cavity.

4) The thickness of ribs and bosses should be approximately 60 to 80 percent of the nominal wall
thickness.
Ease of Fill:
You can use the ease of fill plot to determine whether the cavity fills successfully. The green regions indicate areas
that can be filled under normal injection pressures. The yellow regions indicate areas where the injection pressure
exceeds 70 percent of the machines maximum injection pressure. The red regions indicate areas where the injection
pressure exceeds 85 percent of the machine maximum injection pressure.

Frozen Area at End of Fill:


The frozen area at end of fill plot indicates the regions of the part that have reached the material glass transition
temperature. The green regions (value 1) indicate that the material has reached the material glass transition
temperature. The red regions (value 0) indicate that the material is still above its glass transition temperature. The
frozen area at end of fill indicates the thickness of the frozen layer that builds up during fountain flow.