Report

Shell/ Solid Based Surface Model

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of Plastic Injection Mold
 Content

1.Introduction 4.Special Note

2.Information 5.Figures
 Model  Material Parameter
 Material  Result
 Process Condition  FLOW
3.Summary  PACK
  COOL
FLOW Result
  WARP
PACK Result
  User-Defined
COOL Result
 WARP Result

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 1. Introduction
Title : TP2
Date : 24/04/2025
Department : genie mecanique
Institute : ENIM
Author : Boughdiri Mayssa

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 1. Introduction
This report presents a comprehensive analysis of the Shell/Solid Based Surface Model,
focusing on the simulation results of the injection molding process for a polypropylene (PP)
component. The study includes detailed evaluations of the FLOW, PACK, COOL, and WARP
stages, along with material properties and process conditions. Key parameters such as filling
time, clamping forces, temperature distributions, and shear stress are analyzed to assess the
manufacturability and quality of the final product. The report also highlights critical figures,
including polymer viscosity graphs and flow front animations, to provide a visual
understanding of the process dynamics.

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 2. Information
Information : Model
Name: Default
Type: Shell
Volume: 18.88 (cm3)
Mass: 17.29 (G)
Size:
X: 167.00 (mm)
Y: 78.00 (mm)
Z: 4.00 (mm)

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 2. Information
Information : Model

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 2. Information
Information : Material
Material Name = PP
Product Name = Generic material / Generic PP
Melt Temperature = 230.00 °C
Mold Temperature = 50.00 °C
Ejection Temperature = 95.00 °C
Transition Temperature = 135.00 °C
Specific Heat = 1 3.100000e+07
Thermal Conductivity = 1 1.500000e+04
Young Modulus = 2 1.350000e+10 1.350000e+10
Poisson's Ratio = 2 4.000000e-01 4.000000e-01
WLF Parameters = 1 4.821429e+09
WLF Parameters = -1
WLF Parameters = 1 SIMPOE
WLF Parameters = -1
Please enter a number. = -1

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 2. Information
Information : Process Condition
FLOW/PACK
Filling Time = 4.671 sec
Main Material Melt Temperature = 230 °C
Mold Wall Temperature = 50 °C
Injection Pressure Limit = 100 MPa
Flow Rate Limit = 400 cc/s
Fill/Pack Switch Point (% Filled Volume) = 100 %
Pressure Holding Time = 6.58 sec
Total Time in Pack Stage = 46.709 sec
Auto Filling Time (1: Yes, 0: No) = 1
Auto Packing Time (1: Yes, 0: No) = 1
Venting Analysis (1: Yes, 0: No) = 0
Cavity Initial Air Pressure = 0.101 MPa
Cavity Initial Air Temperature = 30 °C
Temperature Criteria for Short Shots (1: Yes, 0: No) = 1
Temperature Criteria for Short Shots = 135 °C
Clamp Force Limit = 100 Tonne
2nd Material Injection Pressure Limit = 100 MPa
2nd Material Injection Flow Rate Limit = 194 cc/s
2nd Material Fill/Pack Switch Point (% Filled Volume) = 100 %
2nd Material Pressure Holding Time = 10 sec
2nd Material TotalA Time in Pack
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CAE Package 20 Injection
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 2. Information
Information : Process Condition
COOL
Melt Temperature = 230 °C
Min. Coolant Temperature = 25 °C
Air Temperature = 30 °C
Mold Open Time = 5 sec
Average Coolant Flow Rate = 150 cc/s
Control type(1:Eject temp., 2:Cooling time) = 1
Eject Temperature (if control type is "1") = 90 °C
Cooling Time (if control type is "2") = 12 sec

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 2. Information
Information : Process Condition
WARP
Ambient Temperature = 30 °C

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 3. Summary
FLOW Result
X-dir. Clamping Force= 0.0600 Tonne
Y-dir. Clamping Force= 0.3000 Tonne
Z-dir. Clamping Force= 1.0800 Tonne
Required injection pressure= 15.1900 Mpa
Max. central temperature= 230.6100 °C
Max. average temperature= 215.0100 °C
Max. bulk temperature= 231.6400 °C
Max. shear stress= 0.1500 Mpa
Max. shear rate= 10805.8000 1/sec
Averaged perfect cooling time= 59.9000 sec
CPU Time= 19.92 sec
Cycle Time = 1237.36 sec
|- 1. Filling Time = 4.63 sec
|- 2. Cooling Time = 1227.72 sec
|- 3. Mold Open Time = 5.00 sec

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 3. Summary
PACK Result
No data.

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 3. Summary
COOL Result
No data.

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 3. Summary
WARP Result
No data.

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 4. Special Note

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 5. Figures
Figures ： Material Parameter
Polymer Viscosity Graph

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 5. Figures
Figures ： Material Parameter
Polymer Specific-Volume Graph

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 5. Figures
Figures ： Material Parameter
Polymer Specific-Heat Graph

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 5. Figures
Figures ： Material Parameter
Polymer Thermal-Conductivity Graph

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 5. Figures
Figures ： Material Parameter
Polymer Elastic-Modulus Graph

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 5. Figures
Figures ： Material Parameter
Polymer Poisson-Ratio Graph

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 5. Figures
Figures ： Material Parameter
Polymer Linear-Thermal-Expansion-Coefficient Graph

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 5. Figures
Figures ： Material Parameter
Polymer Relaxation-Modulus Graph

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 5. Figures
Figures ： Result
Max. Inlet Pressure

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 5. Figures
Figures ： Result
Melt Front Flow Rate

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 5. Figures
Figures ： Result
X-dir. Clamping Force

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 5. Figures
Figures ： Result
Y-dir. Clamping Force

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 5. Figures
Figures ： Result
Z-dir. Clamping Force

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 5. Figures
Figures ： FLOW
Filling Animation

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 5. Figures
Figures ： FLOW
Fill Time

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 5. Figures
Figures ： FLOW
Pressure at End of Fill

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 5. Figures
Figures ： FLOW
Central Temperature at End of Fill

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 5. Figures
Figures ： FLOW
Average Temperature at End of Fill

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 5. Figures
Figures ： FLOW
Bulk Temperature at End of Fill

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 5. Figures
Figures ： FLOW
Flow Front Central Temperature

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 5. Figures
Figures ： FLOW
Temperature Growth at End of Fill

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 5. Figures
Figures ： FLOW
Shear Stress at End of Fill

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 5. Figures
Figures ： FLOW
Shear Rate at End of Fill

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 5. Figures
Figures ： FLOW
Volumetric Shrinkage at End of Fill

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 5. Figures
Figures ： FLOW
Frozen Layer Fraction at End of Fill

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 5. Figures
Figures ： FLOW
Cooling Time

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 5. Figures
Figures ： FLOW
Temperature at End of Cooling

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 5. Figures
Figures ： FLOW
Sink Marks

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 5. Figures
Figures ： FLOW
Velocity Vector at End of Fill

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 5. Figures
Figures ： FLOW
Gate Filling Contribution

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 5. Figures
Figures ： FLOW
Ease of Fill

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 5. Figures
Figures ： FLOW
Weld Lines

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 5. Figures
Figures ： FLOW
Air Traps

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 5. Figures
Figures ： PACK
No Data

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 5. Figures
Figures ： COOL
No Data

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 5. Figures
Figures ： WARP
No Data

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 5. Figures
Figures ： User-Defined
No Data

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 CONCLUSION
• The simulation results demonstrate that the injection molding process for the PP
component is feasible under the specified conditions. The FLOW stage analysis
reveals optimal filling times and acceptable temperature distributions, while the
clamping forces remain within safe limits. However, the absence of data for the
PACK, COOL, and WARP stages suggests potential areas for further investigation.
Overall, the findings provide valuable insights for optimizing the manufacturing
process, ensuring product quality, and minimizing defects. Future work could include
refining the cooling strategy and validating the warp predictions to enhance the
model's accuracy.

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