Process Settings Wizard - 1st Injection Settings dialog

This page of the Process Settings Wizard is used to specify the following for a Co-injection Molding or Thermoplastics Bi-injection Molding process analysis:

• Process settings specific to the first injection unit, which controls Material A, and
• Certain process settings shared by the first and second injection units.

Prerequisites

Analysis technology: Midplane mesh

Molding Process: Co-injection molding or Thermoplastics Bi-injection

Analysis sequence: Includes Fill or Fill+Pack

Dialog location

Click (Home tab > Molding Process Setup panel > Process Settings).

All solver parameters have a default value that is suitable for most analyses.

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

Dialog element	Explanation
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.
Filling control	Specifies the method by which the filling phase of the analysis is controlled. Select the method to control polymer injection during the filling phase. Relative/Absolute/Legacy ram speed profile Specifies the two variables by which the ram speed profile is controlled. Select the ram speed control method from the drop-down list. Note: If you select Ram Speed Profile, you must select the profile variables, and enter the profile. Injection time Specify the time it takes for the part to fill completely. Flow rate Specify the constant 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/ram position/injection pressure/hydraulic pressure/clamp force/injection time Specify the parameter value at which the switch-over from velocity control to pressure control should occur. By pressure control point Select a pressure control point inside the cavity. Once the specified pressure is reached at the node that represents the pressure control point, 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 whichever comes first Click Edit switch-over settings to select which criteria to monitor. 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. For example, Packing pressure vs time controls the packing phase of the molding cycle as a function of injection pressure verses time. Select the required control method, click Edit profile, and then enter the pressure profile.
Cooling time	Specifies the cooling phase of the molding process. Specified Enter the cooling time required. Automatic Click Edit target ejection criteria and enter the ejection criteria required. Default values are based on the material recommended mold surface and ejection temperatures, along with a specified Part frozen percentage at ejection temperature
Switch to the other controller by (Co-injection only)	Define the maximum % filled by the first material before switching to the second controller.
Advanced options	Displays the advanced options for the analysis. Parameters such as process controller settings can be specified from this dialog.
Fiber orientation analysis if fiber material	Enables a Fiber orientation analysis if the material includes fiber.
Fiber Solver Parameters	When the Fiber orientation analysis is enabled, click this button to display the Fiber Solver Parameters dialog.