Bulk conversion result

The Bulk conversion result shows the average material conversion (cure) across the part thickness, calculated over the entire molding process (filling + curing phases).

This result is generated from a Midplane and Dual Domain Reactive Molding analysis.

Using this result

Premature conversion is a typical molding problem and occurs when the material solidifies (cures) in the mold cavity before the curing phase is complete. If the material pre-cures, you will see an acceleration of the melt, followed by strong hesitation, that is, viscosity suddenly decreases because the material is too hot and then abruptly increases as material pre-cures.

If pre-cure occurs, increase the specified curing time until conversion throughout the entire part reaches the recommended Ejection conversion value for the material.

As a rule of thumb, thermosets should reach 80% conversion at the end of the process; however, for less expensive products, and depending on the material, 50% conversion, or less, may suffice.

Note: Animate the Bulk conversion result to check for late-curing areas.

Things to look for

Pre-cure

Increase cure time or decrease melt and/or mold temperature and re-run. Longer cure times impart more heat resistance and a longer life to the product.

Flow rate

If the flow rate is too high, the material will shear heat and conversion will have progressed too much when material enters the mold. This will cause the material to cure completely too early.

Note: For example, when reading this plot, "Bulk conversion at Time = 54 (s) is 0.42 means that the material has reached 42 % conversion (cure) at the end of curing.

Note: Adjustments such as those above can only be made using a licensed Autodesk Simulation Moldflow Adviser or Autodesk Simulation Moldflow Insight product.