---------------------------------------- Flow ---------------------------------------- Copyright Moldflow Corporation and Moldflow Pty. Ltd. All Rights Reserved. (C)2000 2001 2002 2003 This product may be covered by US patent 6,096,088 , Australian Patent No. 721978 , and foreign patents and pending applications Flow Analysis Version: mpi410 (Build 03203) Analysis commenced at Fri Dec 17 13:22:33 2004 -------------------------------------------------------------------------- Filling Analysis Packing Analysis Fiber Orientation Analysis Residual Stress Analysis -------------------------------------------------------------------------- Date : DEC17-04 Time : 13:22:35 Allocating memory for analysis... ... finished allocating memory Processing fusion mesh... ... finished processing fusion mesh Reading input data... File name : icetray~1 Reading solver parameters... Reading material data... Reading process settings... Reading finite element mesh... ** WARNING ** No cooling channel is specified Reading cooling data... NOTE: The analysis sequence does not start with a cooling analysis. The current flow analysis will assume constant mold temperatures. ** WARNING ** The flow analysis is continuing without using the .C2P file Reading restart data... Note: No restart data was found. Finished reading input data Checking input data... ... finished checking input data Optimizing memory usage... ... finished optimizing memory usage Initializing variables... ... finished initializing variables 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 Pressure trace sample frequency = 10 Hz Total number of pressure trace nodes = 1 Node 1 = 10977 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 % Reciprocal 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 Parting plane normal (dx) = 0.0000 (dy) = 0.0000 (dz) = 1.0000 Average aspect ratio of triangle elements = 1.8652 Maximum aspect ratio of triangle elements = 44.9206 Element number with maximum aspect ratio = 4230 Minimum aspect ratio of triangle elements = 1.1624 Element number with minimum aspect ratio = 16922 Total volume = 143.9380 cm^3 Volume filled initially = 0.0000 cm^3 Volume to be filled = 143.9380 cm^3 Part 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 Analysis Packing Analysis Fiber Orientation Analysis Residual Stress Analysis analysis is beginning .... Filling phase: Status: V = Velocity control P = Pressure control V/P= Velocity/pressure switch-over |-------------------------------------------------------------| | Time | Volume| Pressure | Clamp force|Flow rate|Status | | (s) | (%) | (MPa) | (tonne) |(cm^3/s) | | |-------------------------------------------------------------| | 0.13 | 4.34 | 7.64 | 0.11 | 55.18 | V | | 0.26 | 9.23 | 9.75 | 0.29 | 55.53 | V | | 0.39 | 14.04 | 11.57 | 0.63 | 55.64 | V | | 0.52 | 18.86 | 13.32 | 1.18 | 55.79 | V | | 0.65 | 23.67 | 15.02 | 1.92 | 55.77 | V | | 0.78 | 28.40 | 17.53 | 3.40 | 55.71 | V | | 0.91 | 33.27 | 19.93 | 5.02 | 55.86 | V | | 1.04 | 38.03 | 21.78 | 6.48 | 56.00 | V | | 1.17 | 42.82 | 23.82 | 8.51 | 55.75 | V | | 1.30 | 47.56 | 26.47 | 11.42 | 55.93 | V | | 1.43 | 52.21 | 28.37 | 13.56 | 56.12 | V | | 1.56 | 57.04 | 30.21 | 15.83 | 56.16 | V | | 1.69 | 61.82 | 32.16 | 18.58 | 56.11 | V | | 1.82 | 66.44 | 34.82 | 22.67 | 56.26 | V | | 1.95 | 71.29 | 36.68 | 25.63 | 56.39 | V | | 2.08 | 75.93 | 38.34 | 28.49 | 56.41 | V | | 2.21 | 80.67 | 40.28 | 32.05 | 56.36 | V | | 2.34 | 85.42 | 43.32 | 37.90 | 56.46 | V | | 2.47 | 90.06 | 45.93 | 42.93 | 56.54 | V | | 2.60 | 94.68 | 48.91 | 49.18 | 56.59 | V | | 2.70 | 98.26 | 53.37 | 59.54 | 56.20 | V/P | | 2.71 | 98.57 | 42.70 | 55.16 | 23.53 | P | | 2.73 | 98.97 | 42.70 | 50.90 | 30.50 | P | | 2.82 | 99.98 | 42.70 | 67.04 | 14.29 | P | | 2.83 |100.00 | 42.70 | 67.34 | 14.03 |Filled | |-------------------------------------------------------------| Execution time in Filling Phase = 7616.17 s Packing phase: |-------------------------------------------------------------| | Time |Packing| Pressure | Clamp force| Status | | (s) | (%) | (MPa) | (tonne) | | |-------------------------------------------------------------| | 2.83 | 0.00 | 42.70 | 67.39 | P | | 3.03 | 0.69 | 42.70 | 84.23 | P | | 4.48 | 5.55 | 42.70 | 68.48 | P | | 5.98 | 10.57 | 42.70 | 34.13 | P | | 7.48 | 15.60 | 42.70 | 13.17 | P | | 8.98 | 20.62 | 42.70 | 8.31 | P | | 10.48 | 25.64 | 42.70 | 4.80 | P | | 11.98 | 30.66 | 42.70 | 2.54 | P | | 12.72 | 33.10 | 0.00 | 1.65 | P | | 12.72 | | | |Pressure released| |-------------------------------------------------------------| | 13.61 | 36.10 | 0.00 | 0.97 | P | | 15.11 | 41.12 | 0.00 | 0.45 | P | | 16.61 | 46.14 | 0.00 | 0.20 | P | | 18.11 | 51.16 | 0.00 | 0.09 | P | | 19.61 | 56.19 | 0.00 | 0.04 | P | | 21.11 | 61.21 | 0.00 | 0.01 | P | | 22.61 | 66.23 | 0.00 | 0.00 | P | | 24.11 | 71.25 | 0.00 | 0.00 | P | | 25.61 | 76.27 | 0.00 | 0.00 | P | | 27.11 | 81.29 | 0.00 | 0.00 | P | | 28.61 | 86.31 | 0.00 | 0.00 | P | | 30.11 | 91.33 | 0.00 | 0.00 | P | | 31.61 | 96.35 | 0.00 | 0.00 | P | | 32.86 |100.00 | 0.00 | 0.00 | P | -------------------------------------------------------------------------- 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 % Preparing interface data... Preparing PPC file for cooling analysis... Preparing LSP file for warpage analysis... Finished preparing the interface data -------------------------------------------------------------------------- Filling Analysis Packing Analysis Fiber Orientation Analysis Residual Stress Analysis has completed successfully. Processing fusion mesh... ... finished processing fusion mesh Weld line/air trap analysis completed Preparing output data... Finished preparing output data SYNERGY Weld-line and air trap has completed successfully. 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. (C)1999 2000 2001 2002 2003 This product may be covered by US patent 6,096,088 , Australian Patent No. 721978 , and foreign patents and pending applications Warpage Analysis Version: mpi410 (Build 03203) Analysis commenced at Fri Dec 17 16:02:55 2004 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 % Reading solver parameters... Reading mechanical property and residual stress data... Analysis model: residual stress without crims. Establishing MPC constraint relationship... Defining anchor plane... Number of separate cavities = 1 Writing input file for structural analysis program... Launching structural analysis program... Reading structural analysis input file... Size in global stiff. matrix = 26239200 Required disk space (MByte) = 226 Total block number of [K] = 7 ...finished reading structural analysis input file. Beginning load incrementation loop... Setting structure information... Assembling stiffness matrix... Solving finite element static equilibrium equations... ----------------------------------------------------------------------- Kstep Kstra Nref Nite Node Ipos Negpv Detk Rfac Displacement ----------------------------------------------------------------------- 1 1 1 0 2760 3 0 1.0e+00 1.000e+00 1.666e+00 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 ----------------------------------------------- Sum G 2.1741e-08 -1.1713e-08 -3.3746e-09 Structural analysis completed: CPU time = 700.59 secs. Writing result file... 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 Warpage analysis has completed successfully. --------------------------------------------------------------------------