Fill analysis

The Fill analysis predicts the thermoplastic polymer flow inside the mold in the filling phase. This analysis is often run as the first part of a Fill+Pack analysis sequence.

A Fill analysis calculates the flow front that grows through the part incrementally from the injection location, and continues until the velocity/pressure switch-over point has been reached. A Runner Balance analysis can be used with a Fill analysis to ensure equal pressure is delivered at each cavity.

A Fill analysis accepts a minimum of 8 and a maximum of 20 laminates across the part thickness to calculate results. The default number of laminates across the thickness is 12. You can change this value by editing the solver parameters.

If symmetrical thermal boundary conditions exist (Cool analysis results are not available), the analysis is based on a half-gap calculation and the actual number of laminates used in the calculation is half of the specified number, reflected symmetrically across the part. Running a Cool analysis prior to running a Fill analysis provides asymmetrical cooling information, and the full specified number of laminates is used to calculate results.

Before running a Fill analysis, pay close attention to the edge length of the mesh around high curvature areas on your model, and make sure the mesh in these areas is not too coarse. It is recommended that you mesh with a smaller edge length so the mesh approximates the corners correctly.

Supported analysis technologies

Select the most suitable analysis technology by using the following information:

Midplane analysis technology, Fill analysis:

This predicts material behavior during the filling phase by analyzing a model which has a Midplane mesh. The mesh consists of 3-node, triangular elements. In general, the more elements there are in the mesh the more detailed the results. However, with more nodes the analysis time is also increased. This analysis is most accurate for thin-walled parts.

Dual Domain analysis technology, Fill analysis:

This works by simulating the flow of the melt on both the top and bottom surfaces of the mold cavity (surface shell). This analysis is most accurate for thin-walled parts.

The model has a surface shell mesh, consisting of 3-node, triangular elements. Consistency between the results on the opposite sides is maintained by using "connectors"-elements with zero flow and heat resistance. The connectors are inserted automatically at locations determined according to the geometrical features of the model.

3D analysis technology, Fill analysis:

This is a high-end flow simulation tool that helps you understand how plastic flows in thick-walled parts, or parts containing thick sections.

3D analysis technology allows the Fill analysis to directly analyze a volume mesh (4-node, tetrahedral mesh) of a solid model, removing the need for time consuming Midplane mesh preparation of a 3D part model.