Process Settings Wizard dialog-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 filling phase simulation related process settings for the selected analysis sequence.

Note: The Fill analysis process settings normally contains three controls, as per the Fill+Pack analysis sequence process settings: filling control, velocity/pressure switchover 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 switchover settings. The remaining portion 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 analysis.

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

Dialog entry	Explanation
Mold surface temperature	The temperature of the mold at the plastic-metal interface, where the plastic touches the mold. The temperature of the mold affects the cooling rate of the plastic. Note: 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. 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). Note: The melt temperature cannot be lower than the Transition temperature.
Delay timer (Multiple Barrel thermoplastics injection molding only)	Delay the start of the injection for the master barrel. By default No delay is set. By ram position Enter the distance in mm, and the node ID for the reference barrel location. By time Enter the delay time in seconds, and the node ID for the reference barrel location.
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. Note: 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 (Additional options are available for the microcellular molding process)	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 %weight reduction] at (Microcellular injection molding only) If you would like the part to be 10% lighter than a conventional part, enter 10 here. The part will fill until the weight is 10% lighter than a conventional injection molded part, then switch to pressure control to allow bubble growth. [By part weight (excluding runners)] at (Microcellular injection molding only) Enter the weight of material that you would like injected, before switching from velocity to pressure control. [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. [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	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. Important: For Injection-compression analysis, Pack/holding control controls the injection unit, not the compression unit. %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.
Cooling time	Specify a cooling time, or have it calculated automatically during the Fill+Pack analysis. During a Fill+Pack analysis, cooling time can either be specified or calculated automatically. If the required cooling time is known, enter it here. [Specified] of Specify the time, after the packing phase, when the part is sufficiently frozen to be ejected from the mold. Automatic Sets the cooling time automatically. Click Edit ejection criteria to specify the part ejection criteria for a Cool analysis with automatic calculation of the required cooling time.
Advanced options	Advanced options include defining process settings, solver parameters, mold/molding material, molding machine capabilities.
Fiber orientation analysis if fiber material	Enables a Fiber orientation analysis if the material includes fiber.
Birefringence analysis if material data includes optical properties	Produces stress-optical birefringence results if the material has optical properties. Birefringence calculations add extra time to the analysis. Leave this option off if you do not need birefringence results. Note: You must also enable principal stress output results in the Warp process settings.