SolidWorks Plastics Adviser Flow Result ................................................................................................................. 3

Fill Time.........................................................................................................3 Pressure at End of Fill ................................................................................5 Pressure at Packing Switch Time .............................................................7 Temperature at End of Fill..........................................................................7 Central Temperature at End of Fill............................................................8 Average Temperature at End of Fill..........................................................8 Bulk Temperature at End of Fill .................................................................8 Flow Front Central Temperature ...............................................................9 Temperature Growth at End of Fill..........................................................10 Shear Stress at End of Fill .......................................................................10 Shear Rate at End of Fill ..........................................................................11 Skin Material Ratio at End of Fill.............................................................12 Volume Shrinkage at End of Fill..............................................................12 Freezing Time at End of Fill.....................................................................13 Frozen Layer Fraction at End of Fill .......................................................13 Cooling Time ..............................................................................................15 Temperature at End of Cool.....................................................................17 Sink Mark....................................................................................................17 Birefringence at End of Fill.......................................................................18 Gate Filling Contribution...........................................................................18 Ease of Fill..................................................................................................19 Frozen Area at End of Fill ........................................................................19 Clamping Force .........................................................................................19 Short shot ...................................................................................................20 Velocity Vector at End of Fill....................................................................21 Weld Lines ..................................................................................................22 Air Trap........................................................................................................24 Gate Location Index..................................................................................24 Material Reactive Conversion at End of Fill ..........................................24 Curing Time at End of Fill ........................................................................24

Pack result ................................................................................................................ 25 Pressure at End of Packing .....................................................................25 Temperature at End of Packing...............................................................25 Central Temperature at End of Packing.................................................25 Average Temperature at End of Packing...............................................25

Bulk Temperature at End of Packing......................................................26 Shear Stress at End of Packing ..............................................................26 Shear Rate at End of Packing .................................................................27 Skin Material Ratio at Post-Filling End ..................................................27 Volume Shrinkage at End of Packing.....................................................28 Temperature at Post-Filling End .............................................................28 Central Temperature at Post-Filling End ...............................................28 Average Temperature at Post-Filling End..............................................28 Freezing Time at Post-Filling End ..........................................................29 Frozen layer fraction at Post-Filling End ...............................................29 Residual Stress at Post-Filling End ........................................................29 Birefringence at End of Fill.......................................................................29 Frozen Area at Post-Filling End ..............................................................30 Material Reactive Conversion at Post-Filling End................................30 Curing Time at Post-Filling End ..............................................................30

Results Items Help

Flow Result Fill Time This presents the flow front position of fluid at regular intervals. The same flow front regions are the same

color. Blue regions mean the beginning of injection and red regions mean the end of injection.

The utilities of “set color range” and “dynamic show” can indicate the flow front pattern, welding line and

air trap position. From the flow front pattern, we can understand flow balance condition and whether the

over-packing is occurred for cavity or not.

There are three methods to present Fill Time.

1. User Defined Scale

Adjust min or max range bar to show fill time.

2. Animation

Click to Play/Pause/Stop the animation of result.

3. Iso-Surf Mode

Click Iso-Surf Mode and Play to display.

Iso-Surf Mode is only used in Solid style.

Note : Check weld line and air trap to show the forecasts.

Pressure at End of Fill Pressure is defined as normal force per unit area. In filling process, the injection force by means of screw

is used to push the fluid material into the cavity. The force is propagated via the fluid and result in a

pressure distribution in cavity. The pressure profile presents the decreasing from the inlet gates to

downstream position since the flow length is increasing in flow direction. It is noted that the pressure of

flow front position is as one atmosphere since the flow front contact with air. For a constant flow rate, the

inlet gate pressure is increasing with time since the contact area of fluid with cavity is growing.

The very high pressure is required for part with thin cavity since the flow resistance is enlarge and the

solidification may be occurred during filling process, therefore, if the injection pressure is not enough, the

short shot may be occurred.

The maximum pressure occurs at gate location and gets decreasing from the gate location to

downstream position, as shown in the following diagram.

You can also adjust percentage to show pressure of filling progress

Click Clipping Plane mode to display pressure distribution at end of fill.

This is only used in Solid style

You can also switch clipping planes and adjust the view.

Pressure at Packing Switch Time At packing switch point, the control type is from the flow rate control changed to pressure control. This

profile presents the pressure distribution in cavity at this moment.

Temperature at End of Fill Temperature is a physical property of matter that quantitatively expresses the common notions

of hot and cold. Generally, for thin thickness region, the cooling effect results in lower temperature in

such region. On the other hand, the high thickness region is with higher temperature.

Note :

Click Clipping Plane mode to display temperature distribution of clipping plane at end of fill.

This is only used in Solid style.

You can also switch clipping planes and adjust the view.

In Solid style, surface temperature is equal to mold wall temperature.

Central Temperature at End of Fill In FLOW-PACK, the central temperature distribution is defined as the melt temperature of central position

between to two surface faces for each region. Generally, the central position with a more far distance

from mold wall presents a high melt temperature. The temperature of central position may be drop

quickly for the part of very thin cavity, and the short shot may be occurred.

Average Temperature at End of Fill This distribution defined as the simple averaged melt temperature between to two wall faces for each

region. If such distribution is serious non-uniform, the part shrinkage and warpage may be occurred.

Bulk Temperature at End of Fill The temperature changes of flow front during the filling process are considered with some parameters

like time, location and thickness but without flow velocity, so bulk temperature is used. The bulk

temperature with a physical significance since such is a measurable temperature during fluid

flow. The definition of bulk temperature is a fluid velocity weighted average temperature across two

surface faces for each region. If the velocity field is zero, then the bulk temperature is same as average

temperature. Generally, a high bulk temperature is presented in the region with high convection since the

velocity weighed is pointed. And, such temperature will be reduced when the flow velocity is suddenly

degraded. The distribution of bulk temperature could provide the information whether the over-heating is

occurred during the process.

In Shell Style, the definition of bulk temperature is a fluid velocity weighted average temperature across

the part (or cavity) thickness. That is

T uTdz udzbulkb

b

b

b=

−

+

−

+

∫ ∫

Where u is the velocity, b is one half part (or cavity) thickness. +b and -b are the positive and negative

side of mold cavity, respectively.

In Solid Style, the definition of node bulk temperature is based on weighted average of volume velocity

around such node neighbor cells. That is

∫ ∫∫ ∫==

=N

i Vii

N

i Viibulk

ii

dVudVuTT11

)(

Where iu and iV is the cell i velocity and volume, respectively.

Note:

According to velocity parameter of filling process, the bulk temperature has more reference than

average temperature. The bulk temperature gap from high temperature regions to low

temperature regions could cause non-uniform shrinkages and warpages.

Flow Front Central Temperature This presents the flow front temperature of fluid at every time step. Since the fountain flow effect is

occurred at flow front region, the flow front central temperature could be approached as whole flow front

region temperature.

Note :

In Shell style

When the fountain flow reaches to each region, the temperature distribution on shell surface means the

flow front region temperature.

In Solid style

Flow Front Central Temperature is different from that in Shell style.

It actually means the temperature distribution at each region when the flow reaches

Click Clipping Plane mode to display temperature distribution

It is only used in Solid style

You can also switch clipping planes and adjust the view.

Temperature Growth at End of Fill In the actual process, the polymer melt undergoes shear heating during the filling stage. The temperature

during cavity might be higher than inlet melt temperature.

The temperature could rise as much as 30 °C, depending on the injection speed and the material

properties. Generally, we recommend that the temperature growth doesn’t above 30 °C since resin

degradation might be occurred at such condition.

Shear Stress at End of Fill Shear stress is defined as the shear force per unit area, and the direction of shear force is parallel with

the forced plane. This shear stress distribution presents the wall shear stress of whole part at end of fill.

Generally, high shear stress will introduce the molecular orientation into a high tensile strength, and

reduce the surface finish of part, so the high shear stress should be avoided.

Where

τ = the shear stress

F = the force applied

A = the cross-sectional area of material with area parallel to the applied force vector

Note :

Shear stress should be less than the suggested max. shear stress of the material.

Slower flow rate can reduce shear stress

Increasing flow front temperature can also reduce shear stress

Shear Rate at End of Fill Shear rate is defined as the change of shear strain per unit time. For a special region with zero velocity

gradient presents the zero shear rate and the wall position also presents near zero shear rate since the

solidification is occurred in such area.

Suggested material Max. shear rate(1/sec) for various generic materials Material Grade 1/sec ABS 1.2x104 ASA 5.0x104 HDPE 6.5x104 LDPE 4.0x104 PA 6 (Nylon 6) 1.0x105 PA 66 (Nylon 66) 1.0x105 PA 12 (Nylon 12) 1.0x105 PC 4.0x104 PEI 4.0x104 PES 5.0x104 PET 4.0x104 PMMA 2.1x104 POM (ACETAL) 4.0x104

Suggested material Max. shear stress(Mpa) for various generic materials Material Grade Mpa ABS 0.28 ASA 0.30 HDPE 0.22 LDPE 0.11 PA 6 (Nylon 6) 0.31 PA 66 (Nylon 66) 0.31 PA 12 (Nylon 12) 0.31 PC 0.50 PEI 0.50 PES 0.50 PET 0.41 PMMA 0.41 POM (ACETAL) 0.45 PP 0.26 PPE (PPO) 0.47 PPS 0.50 PS 0.24 PVC 0.20 SAN 0.33

PP 2.4x104 PPE (PPO) 5.0x104 PPS 2.3x104 PS 4.0x104 PVC 3.2x104 SAN 3.8x104

Skin Material Ratio at End of Fill FLOW-PACK will estimate the ratio of skin material and core material for

the various region of part when the parameter of co-injection process is ready since

FLOW-PACK can simulate the co-injection process. For special planar

region, the skin material distribution is defined as the ratio of skin material and core

material across the thickness direction, which is between 0 and 1. Additionally, the

value 1 and 0 present the material across the thickness are pure skin and pure core

material, respectively.

For the co-injection process, the first material(skin material) is injected to fill the

mold cavity. When the occupied volume of cavity reaches a specified value, such as

60% ~ 70% of cavity volume, the injection is then switched to fill the second

material(core material). So, the second material would be located in the core area of

part. If the value of this switch is too small, the flow front of the second material may

be excess the flow front of the first material. In such case, FLOW-PACK

would exhibit a warring message and continue the process of filling.

Generally, the recycled material is used as the second material, which saves the

material and the surface finish is maintained.

Volume Shrinkage at End of Fill Polymer material is compressible since the specific volume of material is function of pressure and

temperature. The part temperature will reduce to room temperature after ejection, so the density

distribution of part will be changed. Additionally, since the total mass of part does not change, the

shrinkage of part volume would be occurred. The filling shrinkages present the volume shrinkage in filling

end is defined as

)1.()(1 atmofTempRoomendfillingS endfilling ρρ−=

where the ρ is the averaged density across the thickness direction of part.

SolidWorks Plastics accepts the compressible or incompressible density model for analysis. The results

would present the shrinkage distribution for the compressible model and zero for incompressible model.

Note :

Basically, the part area with high temperature presents a high shrinkage. The warpage tendency could

occur since the part shrinkage distribution is non-uniform, and high shrinkage could cause internal voids

or sink marks.

Volume Shrinkage at end of fill result uses colors distributions to indicate percentage of volume

shrinkage.

If percentage of volume shrinkage is minus, it means the region of cavity is expansion.

Freezing Time at End of Fill The local area material will be frozen when there temperature is below glassy transition temperature.

Freezing Time represents such the materials of each region need taken how much time to reach freeze

temperature and become solid.

Frozen Layer Fraction at End of Fill

The local area material will be frozen when there temperature is below glassy transition temperature.

This value represents the thickness fraction of the frozen layer. It ranges from zero to one. A higher value

indicates a thicker frozen layer (or thinner flow layer) and higher flow resistance. As the thickness of the

frozen layer increases, the thickness of the flow layer is also reduced. It is noted that excessive high

pressure is required to fill parts in which hesitation occurs early in the filling stage.

Note :

Frozen layer fraction has very significant effects on the flow resistance. Reducing filling time can reduce

frozen layer fraction.

Frozen Layer Fraction at end of fill is only used in shell style

Cooling Time In SolidWorks Plastics, the cooling time is based on that each location temperature is below than ejection

temperature and it's until 90 % volume of part temperature less than ejection temperature.

Cooling time is the time after the packing end that materials reach freeze temperature and become solid. This usually represents 80%~90% of total

cycle time. Cooling time stage is between the filling end stage and post-filling end stage, showed in point D to point F of Fig. 1

Two major factors affecting the cooling time are mold temperature and melt temperature. Increasing melt and mold temperature will increase the cooling time. These conditions will increase the cycle time. So Lower mold temperature makes shorter cycle time and brings benefits in improved economic performance.

To get an economy and acceptable cooling time, part thickness should be as uniform as possible. Required cooling time increases rapidly with part thickness.

In theory, cooling time is proportional to the square of the thickest part thickness or the power of 1.6 for the largest runner diameter. In other words, doubling the thickness quadruples the cooling time. Temperature at End of Cool When the mold wall temperature is based on the specified value, then such temperature distribution is

defined as the 90% part temperature < material ejection temperature. If such distribution is serious

non-uniform, the part shrinkage and warpage may be occurred. From this temperature at every position

of part, it could be provided as reference for cooling channel design.

Sink Mark Sink marks are depressions on the surface of injection molded plastic parts caused during the plastic

cooling process. Thicker sections of plastic will cool at a slower rate than others, and will yield a higher

percentage of shrinkage in that local area. After the material on the outside has cooled and solidified, the

core material starts to cool. Its shrinkage pulls the surface of the main wall inward, causing a sink mark.

The following design rules could be avoid sink mark occurred.

1. Part thickness should be uniform, if possible

2. The thickness of rib or bosses should be 50% ~ 80% of the attached wall thickness.

3. Avoid using gates that are too small since which can prevent full packing of the cavity.

4. Fill thicker sections first to allow them to be packed before the thinner sections freeze off.

This sink mark is based on linear shrinkage of material, it's from PVT data.

Birefringence at End of Fill

Multi-mode compressible Leonov model (nonlinear viscoelastic model) is used to predict flow induced residual stress. Birefringence includes flow induced birefringence and thermal induced birefringence. Due to flow induced residual stress and

thermal residual stress, respectively, flow birefringence and thermal birefringence. The stress optical law is used to predict birefringence, in particular, two different stress-optical coefficient is used

to predict the flow-induced birefringence and thermal birefringence, respectively. The birefringence components Δnxy, Δnyz and Δnxz are measured in the XY plane, YZ plane and XZ plane, respectively, in the direction of the light.

Gate Filling Contribution At end of filling, the material is fully filled cavity. For multi gates injection, the color index could indicate

each location material is from what gate. And such results could help to understand the whether the input

material is balance or not.

Note :

For example

In following diagram, the colors distributions indicate filled regions.

Green region is filled by gate 1 and blue region is filled by gate 2.

Ease of Fill This can help user to understand that the part can be successfully filled or not. The “green” color region

indicates such area could be filled under normal injection pressure. The “yellow” color region indicates

such area drop excesses 70% of maximum injection pressure. The “red” color region indicates such area

drop excesses 85% of maximum injection pressure, and it need note about the injection pressure is

enough or not, the user could be increase maximum injection pressure to ensure the part can be

successfully filled.

Frozen Area at End of Fill The local area material will be frozen when there temperature is below glassy transition temperature.

This value represents the regions of the frozen layer. It ranges from zero to one. The “green” color region

(value=1) indicates such the materials reach freeze temperature and become solid. The “red” color

region (value=0) indicates such the materials do not reach freeze temperature.

Clamping Force Clamping force refers to the force applied to a mold by the clamping unit of an injection molding machine.

In order to keep the mold closed, this force must oppose the separating force, caused by the injection of

molten plastic into the mold. The required clamping force can be calculated from the cavity pressure

inside the mold and the shot projected area, on which this pressure is acting. If X-Y plane is the parting

plane, then Z-direction clamping force is the required clamping force. The calculated clamping force can

be used to select a proper machine that will prevent part defects, such as excessive flash.

Short shot For flow rate control, if the injection pressure exceeds the machine maximum injection pressure or after

the packing switch point. Then the control type is from the flow rate control changed to pressure control,

and the flow rate maybe drops rapidly. Short shot error will be occurred when the ratio of the current flow

rate and initial flow rate is less than 0.001 or unreasonable flow rate is detected. The following design

rules could use to avoid short shot occurred.

1. Use the proper processing temperature recommended by the resin suppliers.

2. Always fill the thick areas before filling thin areas.

3. Increase the number and/or size of gates.

4. Increase the injection pressure.

Velocity Vector at End of Fill Velocity Vector at end of fill shows the direction and speed of nodes

Adjust number and length to display vector

Weld Lines

A (visible) line that flow front flow together in opposite directions during mold filling process. On a finished

part that may cause weakening or breaking of the component.

The following design rules could reduce weld lines effect on the part.

1. Adjust the gate position and dimension or part thickness to shift the welding lines in low stress or low

visibility areas.

2. Let welding line form at higher temperature and under a high packing pressure.

Note :

Select fill time and check weld lines

Adjust to observe weld lines

Check Weld Lines and play Fill Time animation:

The display of weld line is based on the mesh quality

Air Trap When the air is caught inside the mold cavity, it becomes trapped by converging polymer flow fronts

during filling process. Air-trap locations are usually in areas that fill last. Lack of vents or undersized vents

in these areas are a common cause of air traps and the resulting defects. Another common cause is that

the tendency of polymer melt fill preferentially in thicker sections(race-tracking). The following design

rules could reduce air trap effect on the part.

1. Avoid a large thickness ratio in part, to minimize the race tracking effect of melt.

2. Place the vent in the areas of mold that fill last.

Gate Location Index When the flow is unbalanced, portions of the flow front reach the end of the cavity while other portions

are still moving. Melt-front area changes abruptly whenever such an unbalanced situation occurs.

Balanced flow has a minimum variation of melt-front area in the cavity. For a given complex part

geometry, the gate location index can provide user a reference initial condition to reduce minimizing

melt-front area deviation in the cavity.

Material Reactive Conversion at End of Fill Since the variation of the pressure and temperature during the reactive injection molding process, the

chemical reaction is occurred for the process. The degree of heat released could be used to designate

the degree of conversion. Additionally, the range of such conversion value is between 0 and 1. Generally,

the conversion is rising when the time is increasing, and the small conversion distribution is desirable for

mold filling process.

Curing Time at End of Fill Curing time stage is between the filling end stage and post-filling end stage, the simulation will be

executed until the materials reach 80 percentage of reactive eject conversion, and the materials will

become solid.

Pack result Pressure at End of Packing Pressure is defined as normal force per unit area. In filling process, the injection force by means of screw

is used to push the fluid material into the cavity. The force is propagated via the fluid and result in a

pressure distribution in cavity. The pressure profile presents the decreasing from the inlet gates to

downstream position since the flow length is increasing in flow direction. It is noted that the pressure of

flow front position is as one atmosphere since the flow front contact with air. For a constant flow rate, the

inlet gate pressure is increasing with time since the contact area of fluid with cavity is growing.

The very high pressure is required for part with thin cavity since the flow resistance is enlarge and the

solidification may be occurred during filling process, therefore, if the injection pressure is not enough, the

short shot may be occurred.

Temperature at End of Packing Temperature is a physical property of matter that quantitatively expresses the common notions

of hot and cold. Generally, for thin thickness region, the cooling effect results in lower temperature in

such region. On the other hand, the high thickness region is with higher temperature.

Central Temperature at End of Packing In FLOW-PACK, the central temperature distribution is defined as the melt temperature of central position

between to two surface faces for each region. Generally, the central position with a more far distance

from mold wall presents a high melt temperature. The temperature of central position may be drop

quickly for the part of very thin cavity, and the short shot may be occurred.

Average Temperature at End of Packing This distribution defined as the simple averaged melt temperature between to two wall faces for each

region. If such distribution is serious non-uniform, the part shrinkage and warpage may be occurred.

Bulk Temperature at End of Packing The temperature changes of flow front during the filling process are considered with some parameters

like time, location and thickness but without flow velocity, so bulk temperature is used. The bulk

temperature with a physical significance since such is a measurable temperature during fluid flow. The

definition of bulk temperature is a fluid velocity weighted average temperature across two surface faces

for each region. If the velocity field is zero, then the bulk temperature is same as average temperature.

Generally, a high bulk temperature is presented in the region with high convection since the velocity

weighed is pointed. And, such temperature will be reduced when the flow velocity is suddenly degraded.

The distribution of bulk temperature could provide the information whether the over-heating is occurred

during the process.

In Shell Style, the definition of bulk temperature is a fluid velocity weighted average temperature across

the part (or cavity) thickness. That is

T uTdz udzbulkb

b

b

b=

−

+

−

+

∫ ∫

Where u is the velocity, b is one half part (or cavity) thickness. +b and -b are the positive and negative

side of mold cavity, respectively.

In Solid Style, the definition of node bulk temperature is based on weighted average of volume velocity

around such node neighbor cells. That is

∫ ∫∫ ∫==

=N

i Vii

N

i Viibulk

ii

dVudVuTT11

)(

Where iu and iV

are the cell i velocity and volume, respectively.

Shear Stress at End of Packing Shear stress is defined as the shear force per unit area, and the direction of shear force is parallel with

the forced plane. This shear stress distribution presents the wall shear stress of whole part at end of fill.

Generally, high shear stress will introduce the molecular orientation into a high tensile strength, and

reduce the surface finish of part, so the high shear stress should be avoided.

Where

τ = the shear stress

F = the force applied

A = the cross-sectional area of material with area parallel to the applied force vector

Shear Rate at End of Packing Shear rate is defined as the change of shear strain per unit time. For a special region with zero velocity

gradient presents the zero shear rate and the wall position also presents near zero shear rate since the

solidification is occurred in such area.

Skin Material Ratio at Post-Filling End FLOW-PACK will estimate the ratio of skin material and core material for

the various region of part when the parameter of co-injection process is ready since

FLOW-PACK can simulate the co-injection process. For special planar

region, the skin material distribution is defined as the ratio of skin material and core

material across the thickness direction, which is between 0 and 1. Additionally, the

value 1 and 0 present the material across the thickness are pure skin and pure core

material, respectively.

For the co-injection process, the first material(skin material) is injected to fill the

mold cavity. When the occupied volume of cavity reaches a specified value, such as

60% ~ 70% of cavity volume, the injection is then switched to fill the second

material(core material). So, the second material would be located in the core area of

part. If the value of this switch is too small, the flow front of the second material may

be excess the flow front of the first material. In such case, FLOW-PACK

would exhibit a warring message and continue the process of filling.

Generally, the recycled material is used as the second material, which saves the

material and the surface finish is maintained.

Volume Shrinkage at End of Packing Polymer material is compressible since the specific volume of material is function of pressure and

temperature. For a planar region, the density is variation across the thickness direction of part since the

temperature of each layer is different. The part temperature will reduce to room temperature after ejection,

so the density distribution of part will be changed. Additionally, since the total mass of part does not

change, the shrinkage of part volume would be occurred. The filling and post-filling shrinkages present

the volume shrinkage in filling and post-filling stage, respectively. Defined as

where the ρ is the averaged density across the thickness direction of part. Basically, the part area with high averaged temperature presents a high shrinkage. And, the warpage tendency would be occurred

since the shrinkage distribution is non-uniform for the part.

FLOW-PACK accepts the compressible or incompressible density model for analysis. The results would

present the shrinkage distribution for the compressible model and zero for incompressible model.

Temperature at Post-Filling End Temperature is a physical property of matter that quantitatively expresses the common notions

of hot and cold. Generally, for thin thickness region, the cooling effect results in lower temperature in

such region. On the other hand, the high thickness region is with higher temperature.

Central Temperature at Post-Filling End In FLOW-PACK, the central temperature distribution is defined as the melt temperature of central position

between to two surface faces for each region. Generally, the central position with a more far distance

from mold wall presents a high melt temperature. The temperature of central position may be drop

quickly for the part of very thin cavity, and the short shot may be occurred.

Average Temperature at Post-Filling End This distribution defined as the simple averaged melt temperature between to two wall faces for each

region. If such distribution is serious non-uniform, the part shrinkage and warpage may be occurred.

Freezing Time at Post-Filling End The local area material will be frozen when there temperature is below glassy transition temperature.

Freezing Time represents such the materials of each region need taken how much time to reach freeze

temperature and become solid.

Frozen layer fraction at Post-Filling End The local area material will be frozen when there temperature is below glassy transition temperature.

This value represents the thickness fraction of the frozen layer. It ranges from zero to one. A higher value

indicates a thicker frozen layer (or thinner flow layer) and higher flow resistance. As the thickness of the

frozen layer increases, the thickness of the flow layer is also reduced. It is noted that excessive high

pressure is required to fill parts in which hesitation occurs early in the filling stage.

Residual Stress at Post-Filling End The interaction of mechanical and thermal effects is occurred in the polymer material during the injection

molding process. The residual stress is induced during the process that the material is from the melt state

transformed to the glassy state. The residual stress is deduced from the fact that the non-equilibrium

cooling and pressure variation is occurred in viscoelastic polymer material during molding process. The

part of high residual stress region may be fracture; therefore, the high residual stress distribution is not

desirable.

Birefringence at End of Fill Multi-mode compressible Leonov model (nonlinear viscoelastic model) is used to predict flow induced

residual stress. Birefringence includes flow induced birefringence and thermal induced birefringence.

Due to flow induced residual stress and thermal residual stress, respectively, flow birefringence and

thermal birefringence. The stress optical law is used to predict birefringence, in particular, two different

stress-optical coefficient is used to predict the flow-induced birefringence and thermal birefringence,

respectively. The birefringence components Δnxy, Δnyz and Δnxz are measured in the XY plane, YZ

plane and XZ plane, respectively, in the direction of the light.

Frozen Area at Post-Filling End The local area material will be frozen when there temperature is below glassy transition temperature.

This value represents the regions of the frozen layer. It ranges from zero to one. The “green” color region

(value=1) indicates such the materials reach freeze temperature and become solid. The “red” color

region (value=0) indicates such the materials do not reach freeze temperature.

Material Reactive Conversion at Post-Filling End Since the variation of the pressure and temperature during the reactive injection molding process, the

chemical reaction is occurred for the process. The degree of heat released could be used to designate

the degree of conversion. Additionally, the range of such conversion value is between 0 and 1. Generally,

the conversion is rising when the time is increasing, and the small conversion distribution is desirable for

mold filling process.

Curing Time at Post-Filling End Curing time stage is between the filling end stage and post-filling end stage, the simulation will be

executed until the materials reach 80 percentage of reactive eject conversion, and the materials will

become solid.

Yoon(1995) experiment End of Packing prediction