Process Settings Wizard dialog-Fast fill Settings

This page of the Process Settings Wizard, which can be accessed by clicking (Home tab > Molding Process Setup panel > Process Settings), is used to specify the simulation-related process settings for the Fast Fill analysis.

To access this dialog, ensure that you have set the molding process to Thermoplastic Injection Molding, and the analysis sequence to Fast Fill, then click Analysis > Process Settings Wizard.

Note: The fill-only process normally contains three controls, as per the Fill+Pack process: filling control, velocity/pressure switch-over and pack/holding control. At the end of the velocity phase, the part is only partially filled according to the filling control and velocity/pressure switch-over settings. The remaining proportion is filled by the application of packing pressure, which is set using the pack/holding control. This is the reason packing pressure control is required for a fill-only analysis.

Note: Some of the items listed below may not be available on the current dialog. This is dependent on the mesh type, molding process and analysis sequence selected.

General settings

Mold surface temperature		The temperature of the mold at the plastic-metal interface, where the plastic touches the mold. In cases where this is an input box, enter the required mold temperature. Note: The temperature of the mold affects the cooling rate of the plastic. The mold temperature cannot be higher than the ejection temperature.
Melt temperature		The temperature of the molten plastic, or melt, as it starts to flow into the cavity. In cases where this is an input box, enter the required melt temperature. Note: If the model has a runner system, the melt temperature refers to the temperature of the melt as it enters the runner system. If the model does not have a runner system, the melt temperature is the temperature of the melt as it exits the gate(s). The melt temperature cannot be lower than the Transition temperature.
Maximum machine clamp force		Enter the maximum allowable clamping force to be used in the Gate Location analysis. This should be the maximum clamp force of your injection molding machine.
Machine pressure limit		Specifies the maximum allowable hydraulic pressure that can be used on the injection molding machine. You can set either a maximum machine injection pressure or a maximum hydraulic pressure with conversion ratio. [Maximum machine injection pressure] at Enter the maximum allowable injection pressure to be used in the Gate Location analysis. This should be the maximum injection pressure of your injection molding machine. [Maximum machine hydraulic pressure] at Enter the maximum allowable hydraulic pressure to be used in the Gate Location analysis. This should be the maximum hydraulic pressure of your injection molding machine.
Filling control		Specifies the method by which the filling phase of the analysis is controlled. You can control the filling phase automatically, by an injection time, by a flow rate, or by using a ram speed profile. Select the method to control polymer injection during the filling phase. Note: If you select Ram Speed Profile, you must select the profile variables, and enter the profile. [Relative/Absolute/Legacy ram speed profile] by Specifies the two variables by which the ram speed profile is controlled. Select the ram speed control method from the drop-down list. Click Edit profile and enter the ram speed profile. [Injection time] of Specify the time it takes for the part to fill completely. [Flow rate] at Specify the flow rate of the polymer as it is injected into the mold cavity.
Velocity/pressure switch-over		The criteria by which the molding machine will switch from velocity control to pressure control. Select the required switch-over method in the drop-down list, and then specify the switch-over point. Note: On a typical molding machine, the standard setting will be 99% of volume filled. If the switch-over is occurring early, look for a short shot or check material compressibility has been taken into account when setting the velocity/pressure switch-over point. [By % volume filled] at Specify the percentage of volume filled value at which the switch-over point from velocity control to pressure control should occur. [By injection pressure] at Specify the injection pressure value at which the switch-over point from velocity control to pressure control should occur. [By clamp force] at Specify the clamp force value at which the switch-over point from velocity control to pressure control should occur. Velocity/pressure switch-over by pressure control point Specify the switch-over point by selecting a pressure control point inside the cavity. Once the specified pressure is reached at the selected node, the program will change from velocity to pressure control, and the pressure profile will be applied. Enter the node number and pressure to specify the pressure control point. [By injection time] at Specify the injection time value at which the switch-over point from velocity control to pressure control should occur. Velocity/pressure switch-over will occur as soon as this amount of time in the filling phase has elapsed. [By ram position] at Specify the ram position value at which the switch-over point from velocity control to pressure control should occur. [By hydraulic pressure] at Specify the hydraulic pressure value at which the switch-over point from velocity control to pressure control should occur. By whichever comes first Specify the switch-over point from velocity control to pressure control, by setting more than one of the available switch-over criteria. Click Edit switch-over settings to set the switch-over criteria. Velocity/pressure switch-over will occur as soon as one of the specified criteria is fulfilled.
Pack/holding control		Important: For Injection-compression analysis, Pack/holding control controls the injection unit, not the compression unit. Specifies the method by which the pressure phase of the molding process is controlled. Select the required control method, click Edit profile, and then enter the pressure profile. %Filling pressure vs time Controls the packing phase of the molding cycle as a function of percentage filling pressure versus time. Packing pressure vs time Controls the packing phase of the molding cycle as a function of injection pressure versus time. Hydraulic pressure vs time Controls the packing phase of the molding cycle as a function of hydraulic pressure versus time. %Maximum machine pressure vs time Controls the packing phase of the molding cycle as a function of percentage maximum pressure versus time.