---------------------------------------- Flow ---------------------------------------- Copyright Moldflow Corporation and Moldflow Pty. Ltd. All Rights Reserved. Flow Analysis Version: mpi410 (Build 03203) Date : DEC17-04 Time : 13:22:35 File name : icetray~1 ** WARNING ** No cooling channel is specified ** WARNING ** The flow analysis is continuing without using the .C2P file Summary of analysis inputs : -------------------------------------------------------------------------- Solver parameters : No. of laminae across thickness = 12 Intermediate output options for filling phase No. of results at constant intervals = 20 No. of profiled results at constant intervals = 20 Intermediate output options for packing phase No. of results at constant intervals = 20 No. of profiled results at constant intervals = 20 Melt temperature convergence tolerance = 0.2000 C Mold-melt heat transfer coefficient = 2.5000E+04 W/m^2-C Maximum no. of melt temperature iterations = 100 Fiber interaction coefficient (Ci) = 0.0018 Thickness moment interactive coefficient (Dz) = 0.2538 Orientation boundary condition option = Aligned at skin / transverse at core[DEFAULT] Micro-mechanics model option = Tandon-Weng[DEFAULT] Thermal expansion coefficient model option = Schapery Closure approximation model option = Orthotropic 3[DEFAULT] -------------------------------------------------------------------------- Material data : Polymer : Durethan BKV 30 H : Bayer USA --------- PVT Model: 2-domain modified Tait coefficients: b5 = 497.1500 K b6 = 2.5000E-08 K/Pa Liquid phase Solid phase ------------------------------- b1 = 0.0008 b1 = 0.0008 m^3/kg b2 = 5.1440E-07 b2 = 1.9530E-07 m^3/kg-K b3 = 1.9423E+08 b3 = 2.1134E+08 Pa b4 = 0.0048 b4 = 0.0033 1/K b7 = 3.9970E-05 m^3/kg b8 = 0.0457 1/K b9 = 5.0030E-09 1/Pa Specific heat (Cp) = 2150.0000 J/kg-C Thermal conductivity = 0.2230 W/m-C Viscosity model: Cross-WLF coefficients: n = 0.4695 TAUS = 4.3200E+04 Pa D1 = 1.6000E+12 Pa-s D2 = 323.1500 K D3 = 0.0000 K/Pa A1 = 25.7120 A2T = 51.6000 K Transition temperature = 170.0000 C Transversely isotropic elastic tensor coefficients: E1 = 7200.0000 MPa E2 = 4700.0003 MPa v12 = 0.3740 v23 = 0.4000 G = 2000.0000 MPa Transversely iso thermal expansion coefficients: a1 = 4.0500E-05 1/C a2 = 8.5700E-05 1/C Fiber properties Constant fiber density (RHO) = 2.5400 g/cm^3 Fiber elastic tensor coefficients: E = 7.2000E+04 MPa v = 0.2200 Fiber thermal expansion coef. (af) = 5.0000E-06 1/C Fiber weight fraction (PHI) = 0.3000 Fiber aspect ratio (L/D) = 25.0000 Polymer matrix property (decomposed from composite and fiber properties) Polymer matrix elastic tensor coefficients: E = 2306.3199 MPa v = 0.3406 Polymer matrix thermal expansion coeffcient coefficients: a = 9.7240E-05 1/C Residual stress model without CRIMS -------------------------------------------------------------------------- Process settings : Machine parameters : ------------------ Maximum machine clamp force = 7.0002E+03 tonne Maximum injection pressure = 1.0000E+02 MPa Maximum machine injection rate = 5.0000E+03 cm^3/s Machine hydraulic response time = 1.0000E-02 s Process parameters : ------------------ Fill time = 2.6000 s Injection time has been determined by automatic calculation. Stroke volume determination = Automatic Cooling time = 20.0000 s Velocity/pressure switch-over by = Automatic Packing/holding time = 10.0000 s Ram speed profile (rel): % shot volume % ram speed --------------------------------- 100.0000 100.0000 0.0000 100.0000 Pack/hold pressure profile (rel): duration % filling pressure --------------------------------- 0.0000 s 80.0000 10.0000 s 80.0000 20.0000 s 0.0000 Ambient temperature = 25.0000 C Melt temperature = 230.0000 C Ideal cavity-side mold temperature = 40.0000 C Ideal core-side mold temperature = 40.0000 C NOTE: Mold wall temperature data from cooling analysis not available -------------------------------------------------------------------------- Model details : Mesh Type = Fusion Match ratio = 92 % Total number of nodes = 10978 Total number of injection location nodes = 1 The injection location node labels are: 10977 Total number of elements = 21952 Number of part elements = 21952 Number of sprue/runner/gate elements = 0 Number of channel elements = 0 Number of connector elements = 0 Average aspect ratio of triangle elements = 1.8652 Maximum aspect ratio of triangle elements = 44.9206 Minimum aspect ratio of triangle elements = 1.1624 Total volume = 143.9380 cm^3 Volume filled initially = 0.0000 cm^3 Volume to be filled = 143.9380 cm^3 Sprue/runner/gate volume to be filled = 0.0000 cm^3 Total projected area = 232.4120 cm^2 Filling phase results summary : Maximum injection pressure (at 2.702 s) = 53.3707 MPa End of filling phase results summary : Time at the end of filling = 2.8253 s Total weight = 186.6000 g Maximum Clamp force - during filling = 67.3391 tonne Recommended ram speed profile (rel): % stroke % speed --------------------------------- 0.0000 34.3749 10.0000 84.4833 20.0000 100.0000 30.0000 90.4385 40.0000 91.9987 50.0000 89.2658 60.0000 90.8980 70.0000 90.6168 80.0000 86.2131 90.0000 71.3390 100.0000 24.6339 Melt front is entirely in the cavity at % fill = 0.0000 % Filling phase results summary for the part : Bulk temperature - maximum (at 2.702 s) = 235.6870 C Bulk temperature - 95th percentile (at 2.702 s) = 231.2650 C Bulk temperature - 5th percentile (at 2.824 s) = 190.5600 C Bulk temperature - minimum (at 2.824 s) = 177.2840 C Wall shear stress - maximum (at 2.600 s) = 2.1771 MPa Wall shear stress - 95th percentile (at 0.132 s) = 2.1645 MPa Shear rate - maximum (at 2.600 s) = 3.8494E+04 1/s Shear rate - 95th percentile (at 0.132 s) = 3.7556E+04 1/s End of filling phase results summary for the part : Total part weight = 186.6000 g Bulk temperature - maximum = 234.3150 C Bulk temperature - 95th percentile = 230.3210 C Bulk temperature - 5th percentile = 190.5600 C Bulk temperature - minimum = 177.2990 C Bulk temperature - average = 214.3000 C Bulk temperature - RMS deviation = 13.0368 C Wall shear stress - maximum = 1.1828 MPa Wall shear stress - 95th percentile = 0.1803 MPa Wall shear stress - average = 0.0690 MPa Wall shear stress - RMS deviation = 0.0591 MPa Frozen layer fraction - maximum = 0.7802 Frozen layer fraction - 95th percentile = 0.6260 Frozen layer fraction - 5th percentile = 0.1660 Frozen layer fraction - minimum = 0.0388 Frozen layer fraction - average = 0.3978 Frozen layer fraction - RMS deviation = 0.1475 Shear rate - maximum = 9450.7998 1/s Shear rate - 95th percentile = 123.1180 1/s Shear rate - average = 29.8275 1/s Shear rate - RMS deviation = 113.9730 1/s Packing phase results summary : Peak pressure - minimum (at 3.030 s) = 31.4410 MPa Clamp force - maximum (at 3.030 s) = 84.2303 tonne Total weight - maximum (at 24.112 s) = 193.0020 g End of packing phase results summary : Time at the end of packing = 32.8618 s Total weight = 193.0020 g Packing phase results summary for the part : Bulk temperature - maximum (at 2.825 s) = 234.3140 C Bulk temperature - 95th percentile (at 2.825 s) = 230.3190 C Bulk temperature - 5th percentile (at 32.862 s) = 40.7920 C Bulk temperature - minimum (at 32.862 s) = 40.3180 C Wall shear stress - maximum (at 7.485 s) = 3.2061 MPa Wall shear stress - 95th percentile (at 2.825 s) = 0.1782 MPa Volumetric shrinkage - maximum (at 2.825 s) = 9.2297 % Volumetric shrinkage - 95th %ile (at 2.825 s) = 7.4497 % Volumetric shrinkage - 5th %ile (at 22.612 s) = 1.0929 % Volumetric shrinkage - minimum (at 18.112 s) = 0.5999 % Total part weight - maximum (at 24.112 s) = 193.0020 g End of packing phase results summary for the part : Total part weight = 193.0020 g Bulk temperature - maximum = 67.0350 C Bulk temperature - 95th percentile = 52.2880 C Bulk temperature - 5th percentile = 40.7920 C Bulk temperature - minimum = 40.3180 C Bulk temperature - average = 43.1780 C Bulk temperature - RMS deviation = 3.5999 C Frozen layer fraction - maximum = 1.0000 Frozen layer fraction - 95th percentile = 1.0000 Frozen layer fraction - 5th percentile = 1.0000 Frozen layer fraction - minimum = 1.0000 Frozen layer fraction - average = 1.0000 Frozen layer fraction - RMS deviation = 0.0000 Volumetric shrinkage - maximum = 3.9801 % Volumetric shrinkage - 95th percentile = 2.4696 % Volumetric shrinkage - 5th percentile = 1.0929 % Volumetric shrinkage - minimum = 0.5999 % Volumetric shrinkage - average = 1.8026 % Volumetric shrinkage - RMS deviation = 0.4081 % Sink index - maximum = 0.0000 % Sink index - 95th percentile = 0.0000 % Sink index - minimum = 0.0000 % Sink index - RMS deviation = 0.0000 % Execution time Analysis commenced at Fri Dec 17 13:22:33 2004 Analysis completed at Fri Dec 17 16:02:38 2004 CPU time used 9604.72 s ---------------------------------------- Warp ---------------------------------------- Copyright Moldflow Corporation and Moldflow Pty. Ltd. All Rights Reserved. Warpage Analysis Version: mpi410 (Build 03203) Model file name: icetray.udm Fusion mesh statistics: Percentage of edge element (number) 4.18 % Percentage of edge element (area) 2.89 % Percentage of matched elements 83.04 % Percentage of reciprocal_matched elements 92.75 % Analysis model: residual stress without crims. Number of separate cavities = 1 Size in global stiff. matrix = 26239200 Required disk space (MByte) = 226 Total block number of [K] = 7 Minimum/maximum displacements at last step (unit: mm): Node Min. Node Max. ----------------------------------------------------- Trans-X 10810 -2.8237e-01 10687 1.3622e+00 Trans-Y 3130 -1.1014e-01 7357 1.4726e+00 Trans-Z 10776 -2.8694e-01 3089 1.7206e+00 Support reactions at last step (unit: N) (G = Global, L = Local) Node G/L Trans-X Trans-Y Trans-Z ----------------------------------------------- 10685 L 0.0000e+00 -1.0531e-06 -3.1113e-06 10754 L -2.1741e-08 1.0518e-06 -5.1988e-06 10784 L 0.0000e+00 0.0000e+00 8.2980e-06 Best-fit transformation will be used to display warpage deflections if no anchor plane is defined. Execution time Analysis commenced at Fri Dec 17 16:02:55 2004 Analysis completed at Fri Dec 17 16:17:51 2004 CPU time used 899.67 s