Xplorer UserGuide

SOLIDWORKS Plastics
Fill Results ................................................................................................................ 3
Fill Time: ....................................................................................................... 3

Velocity Vector at End of Fill:..................................................................... 8
Weld Lines:................................................................................................... 8
Air Traps: ...................................................................................................... 9
Pressure at End of Fill: ............................................................................. 10
Temperature at End of Fill: ...................................................................... 12
Central Temperature at End of Fill: ........................................................ 14
Average Temperature at End of Fill: ...................................................... 14
Bulk Temperature at End of Fill:.............................................................. 14
Flow Front Central Temperature: ............................................................ 15
Temperature Growth at End of Fill: ........................................................ 16
Shear Stress at End of Fill: ...................................................................... 18
Shear Rate at End of Fill: ......................................................................... 21
Volumetric Shrinkage at End of Fill: ....................................................... 23
Freezing Time at End of Fill: ................................................................... 24
Frozen Layer Fraction at End of Fill: ...................................................... 25
Venting Pressure: ...................................................................................... 26
Cooling Time: ............................................................................................. 26
Temperature at End of Cooling: .............................................................. 27
Sink Marks:................................................................................................. 28
Birefringence at End of Fill: ..................................................................... 29
Injection Location Filling Contribution: ................................................... 29
Ease of Fill:................................................................................................. 30
Frozen Area at End of Fill: ....................................................................... 31
Clamping Force: ........................................................................................ 32
Pack Results ........................................................................................................... 33
Pressure at End of Packing: .................................................................... 33

Temperature at the End of Packing: ....................................................... 34
Central Temperature at End of Packing: ............................................... 36
Average Temperature at End of Packing: ............................................. 37
Bulk Temperature at End of Packing: .................................................... 37
Shear Stress at End of Packing: ............................................................. 38
Shear Rate at the End of Packing: ......................................................... 41
Volumetric Shrinkage at the End of Packing: ....................................... 43
Temperature at Post-Filling End: ............................................................ 44
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Freezing Time at Post-Filling End: ......................................................... 44

Central Temperature at Post-Filling End: .............................................. 45
Average Temperature at Post-Filling End: ............................................ 46
Frozen Layer Fraction at Post-Filling End:............................................ 46
Residual Stress at Post-Filling End: ....................................................... 47
Frozen Area at Post-Filling End: ............................................................. 48
Cooling Results ....................................................................................................... 50
Warpage Results ..................................................................................................... 51
Fill Results
Fill Time:
The fill time plot displays the profile of the plastic melt as it flows through the mold part cavity during the
filling stage of the injection molding process. The blue regions indicate the start or beginning of the flow
front. The red regions indicate either of the following:
The flow front position at any given time interval during an animation of the filling stage
The end of fill when the flow has stopped, even if the software detects a short shot
Two views of the same part with a centrally located injection location.
The filling pattern radiates out from the center (blue) to the end of fill (red) located at each corner of the
part. Since fill time is a function of flow length (among other things), the corners that are the furthest away
from the injection location are the last to fill. The color scale located to the left of the part indicates the
time it takes for the flow front to reach a given region of the cavity.
SOLIDWORKS Plastics software automatically calculates a recommended fill time and volumetric flow
rate. The filling time can have a significant effect on most results generated from a simulation. For
example, a longer fill time may reduce injection pressures, shear rates, and shear stresses, while a
shorter fill time can increase injection pressures, shear rates, and shear stress. Note - changing the fill
time and running a new simulation overwrites existing results.
To change the fill time:

1) Under INPUT, Process Parameters, double-click Fill Settings.
2) Clear Auto.
3) For Filling Time, enter a value in seconds.
4) Click OK
5) Under RUN, double-click a fill option:
Flow
Flow + Pack (SOLIDWORKS Plastics Professional and Premium only)
6) Click Yes, when prompted to replace the fill results.
Injection locations:
The injection location is where the melted plastic enters a mold cavity. The last area of a cavity to fill is
called the end of fill, which is typically located furthest from the injection location or in the thinnest wall
sections. When a mold cavity cannot be filled by an injection location located on either end of the part
because the flow length is too long, you should move the injection location to a different location that
results in shorter flow paths.
Short shot resulting from an extreme flow length.
Moving the injection location to a central location will also minimize injection pressure requirements and
result in a more uniform filling pattern from the injection location to the end of fill. In this example, even
though the melt has to travel in two directions the flow length is cut in half, allowing the cavity to fill
completely. Note that a change in injection location might result in non-uniform filling of the cavity, where
the melt reaches one end of the cavity before the other.
Non-uniform filling of the cavity as pictured, the bottom of the part fills before the top.
You can review the fill time plot to ensure that the extremities of the cavity fill at the same time. Use the
results found from the initial change in injection location to find the optimum injection location. The
injection location located at the middle of the handles left edge fills the lower section before the head of
the drill casing. This uneven filling pattern will likely result in non-uniform packing and volumetric
shrinkage and could cause post-molding problems (such as warpage) in the part.
A uniform filling pattern both the top and bottom of the cavity fill at the same time.
Choosing an injection location further up along the left side of the drill casing results in uniform filling
patterns from the injection location to the end of fill.
To reposition an injection location:

1) Under INPUT, Boundary Conditions, double-click Injection Location.
2) To delete the existing injection location, click either:
Delete Injection Location
Delete All Injection Locations
Note: The previous injection location is highlighted in blue, indicating that you can
either move or delete it.
3) Click Yes, when prompted to delete an injection location.

4) In the Command Manager, click Mesh Model
to display the mesh.
5) Double-click a Node located in the mesh to select the new injection location.
6) To define the new injection location, click Add Injection Location
Note: The highlight color of the injection location will change from blue to light
purple.
7)
Click OK
Flow
You should examine the fill time plot and the pressure at end of fill plot to ensure uniform filling patterns
and pressure distributions. A uniform filling pattern is when both melt fronts reach their end of fill locations
at the same time and at the same pressure. The blue regions from the pressure at end of fill plot should
occur at the locations where the red regions from the fill time plot occur. Doing so will reduce post
molding problems with the final product.
Pressure at end of fill and fill time plots from the same simulation that display uniform filling patterns and
pressure distributions.
To display a section view of fill time:

1) Under RESULTS, double-click Fill Results.
2) Click Fill Time.
3) Click Clipping Plane Mode
The clipping plane mode of the fill time plot displays the internal flow front during the filling stage (Solid
Mesh only).
Animation of Fill Time:

You can display the melt flow front position during the filling stage by animating the fill time plot.
To animate the fill time:

2) Click Play
3) To pause the animation, click Pause
4) To stop the animation, click either:
Stop
clear Repeat
5) To view the filling profile as contour lines (Shell Mesh) or a wireframe cavity (Solid
Mesh), click Isosurface Mode
6) For a section view of the filling stage (Solid Mesh only), click Clipping Plane Mode
.
7) To slow down or speed up the animation, click Stop
desired rate, and click Play
, slide the Speed scale to the
To display the fill time manually:

2) Select + slide the Max or Min scale to move through the fill time.
3) After selecting the Max or Min scale, you can press the directional arrows on your
keyboard to adjust the fill time display.
Three manual display views of the fill time.

4) If an animation is currently playing, click Stop
before sliding the Max or Min
scale.
5) To view a contour line plot, click Isosurface Mode
and slide the Max or Min
scale (Solid Mesh only).
Three manual display views of the fill time using wireframe mode.
Velocity Vector at End of Fill:

The velocity vector at end of fill plot provides in indication of the molecular orientation that occurs as the
melted plastic flows through the mold part cavity.
To display velocity vector at end of fill:

2) Select Velocity Vector at End of Fill.
View of the velocity vector at end of fill plot.
Note: For fillers with high aspect ratios, mechanical properties in the direction of flow differ from those
transverse to the direction of flow. A material with a high aspect ratio filler will typically have improved
properties in the flow direction and lower mechanical properties transverse to the direction of flow.
Spherical fillers result in a more uniform distribution of mechanical properties in both the direction of flow
and transverse to the direction of flow.
Weld Lines:
Weld lines are formed when two or more plastic melt flow fronts come together and they can be caused
by mold shut-off surfaces, mold core features, multiple injection locations or wall thickness variations that
cause flow front promotion or hesitation. Weld lines are typically weaker than areas without weld lines
and they often result in cosmetic defects. They can also act as stress concentrators in the molded part.
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Weld lines generally form 180 opposite of the point where the melt front makes contact with the standing
core of a shut-off surface. Weld lines are unavoidable in parts with through-holes or multiple injection
locations. So while you might be able to move the injection location to change the weld line location, the
weld line cannot be eliminated.
To display weld lines:

2) Select Weld Lines.
View of the weld line plot.
Air Traps:
If the air in the mold cavity cannot be vented to the atmosphere during the filling stage, the trapped air
can prevent the plastic material from filling the volume where the air trap is located. This can result in
incomplete filling and packing in the air trap location or even a through-hole in the part due to the trapped
air. In a worst case scenario, the trapped air can get compressed, combust and cause burn marks on the
molded part and/or damage the mold core and cavity surfaces. Placing a parting line vent, ejector pin,
cavity insert, or a porous metal insert at these locations can help reduce or prevent air traps from
occurring, but it is best to avoid them completely.
To display Air Traps:

1)
Under RESULTS, double-click Fill Results.
2)
Select Air Traps.
View of Air Traps superimposed over a Fill Time plot.
Pressure at End of Fill:

During the filling stage, the forward injection velocity of the reciprocating screw is controlled, which
results in the pressure required to fill the cavity at that velocity. The injection pressure is propagated
through the molten plastic and results in a pressure drop distributed along the length of flow. The
pressure at the end of fill is a very good indication of how evenly the cavity has filled.
Uneven and even pressure at end of fill plots.
In the first example, an injection location was placed in the middle of an asymmetrical handle. The
pressure at end of fill plot shows an uneven distribution of pressure throughout the cavity. The second
example shows that repositioning the injection location slightly to the right results in an even pressure
distribution throughout the cavity. Even pressure at all end of fill locations will improve the effects of
packing pressures and cooling throughout the molded part. You should attempt to place the injection
location where the pressure at end of fill plot displays an even pressure distribution.
Note: Pressure drop is a function of flow length, part wall thickness, and melt viscosity. High pressures
are required to fill thin-walled injection molded parts, since the flow resistance through the smaller cross
sectional area is greater. When SOLIDWORKS Plastics detects a short shot, try the following:
1) Reposition the injection location: If the injection location is near the end of a part, the flow
length is essentially the entire length of the part. Place the injection location near the middle of
the part to reduce the flow length to about half the length of the part. With the injection location
located in the middle, even though the plastic flow must travel in two directions, flow lengths and
injection pressure requirements are reduced.
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To reposition an injection location:

2) To delete the existing injection location, click either:
Delete Injection Location
Delete All Injection Locations
Note: The previous injection location turns blue, indicating that you can
move it.
3) Click Yes, when prompted to delete an injection location.

4) In the Command Manager, click Mesh Model
5) Double-click a Node located in the mesh to select the new injection location.
6) To define the new injection location, click Add Injection Location
Note: The color of the injection location will change from blue to light purple.
7) Click OK
Flow
2) Change the fill time: A shorter fill time (or injecting faster) typically lowers the viscosity of the
melted plastic, allowing the material to flow further. Keep in mind that the shorter fill time may
increase the injection pressure required, shear rates and shear stress. The maximum injection
pressure will be limited by the machine, while plastic materials have maximum threshold values
for shear rate and stress.

2) Clear Auto.
3) For Filling Time, enter value for sec.
4) Click OK
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Flow
3) Increase part wall thickness: To reduce injection pressures, you can increase the wall
thickness of the solid model. Then you would have to create a new mesh and run the analysis
again. Increasing the part wall thickness will increase cooling times and require more plastic
material to mold the part.
To display a section view of pressure at end of fill:

2) Click Pressure at End of Fill.
The clipping plane mode of pressure at end of fill displays the internal pressure distribution throughout
the cavity at end of fill (Solid Mesh only).
Temperature at End of Fill:

At the end of fill, the plastic in contact with the cavity wall freezes into a very thin frozen layer that has
cooled down to the temperature of the mold. The thickness of this frozen layer is independent of the
thickness of the part wall. The thickness is dependent on the melt and mold temperature differential and
the material thermal conductivity.
The outside of the part cools, while the core volume remains molten, allowing the pressure of the pack
stage to prevent sink marks. Since the entire part surface temperature is equal to the mold temperature,
the part appears blue.
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View of temperature at end of fill.
To change the melt temperature:

2) For Melt Temperature, enter value for OC or OF.
Note: Materials in the SOLIDWORKS Plastics database have a maximum and a

minimum melt temperature value. This melt temperature range is the processing
window that the material supplier recommends for their material. A simulation
cannot be run outside of the melt temperature range.
3) Click OK
Flow
To display a section view of temperature at end of fill:

2) Click Temperature at End of Fill.
The clipping plane mode of temperature at end of fill displays the internal temperature differential
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throughout the part wall (Solid Mesh only).
Central Temperature at End of Fill:

The central temperature at end of fill plot indicates the melt temperature of the central position between
the two surfaces of a shell mesh. The plastic melt that is a further distance from the cavity wall will retain
heat for longer periods of time. The temperature of the molten core material may decrease quickly for a
thin walled part, and SOLIDWORKS Plastics will detect if a short shot has occurred.
View of central temperature at end of fill.
Average Temperature at End of Fill:

The average temperature at the end of fill plot indicates the average melt temperature between the two
surfaces of a shell mesh. If the temperature differential is non-uniform, sink marks and warpage may
occur.
View of average temperature at end of fill.
Bulk Temperature at End of Fill:

During the fill stage, changes in the melt temperature are calculated using parameters such as time,
distance from the cavity wall, and part wall thickness. The bulk temperature at end of fill plot displays how
much the melt has changed from the set melt temperature. The Bulk Temperature plot indicates stagnant
material, which has cooled significantly by the end of fill, in blue. The plastic material with a velocity just
before the end of fill, that retains heat, is displayed in red.
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View of bulk temperature at end of fill.
To display a section view of bulk temperature at end of fill:

2) Click Bulk Temperature at End of Fill.
The clipping plane mode of bulk temperature at end of fill displays the internal temperature differential
Flow Front Central Temperature:

The flow front central temperature plot represents the melt front temperature at the end of fill. As a result
of fountain flow, the flow front central temperature represents the temperature of the entire melt front.
Consequently, the melt does not change temperature until it makes contact with the mold wall.
The molten plastic flows through the center of the melt stream and then flows outward like a fountain.
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View of flow front central temperature.
To display a section view of flow front central temperature:

2) Click Flow Front Central Temperature.
The clipping plane mode of flow front central temperature displays the internal temperature differential
Temperature Growth at End of Fill:

In the injection molding process, the polymer melt undergoes shear heating during the fill stage. This
increase in temperature is due to elevated shear rates, which can raise the melt temperature in the cavity
to above the set melt temperature. The temperature increase can result from too short of a filling time, the
use of small injection locations, or material flow characteristics. Degradation of the material can occur
under extreme conditions.
View of temperature growth at end of fill.
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2) Clear Auto.
4) Click OK
Flow
To change an injection location dimension:

2) For Diameter, enter value for mm.
3) Click Add Injection Location
Note: The injection location dimension located in the Injection Location window
changes.
4) Click OK
Flow
To display a section view of temperature growth at end of fill:

2) Click Temperature Growth at End of Fill.
The clipping plane mode of temperature growth at end of fill displays the internal temperature differential
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Shear Stress at End of Fill:

Shear stress is a measure of shear force per unit area. The direction of the shear force is parallel to the
plane of the force (the cavity wall), and can be thought of as the force melt uses to push the cavity wall in
the direction of flow (not pushing outward normal to the wall).
= F/A
= Shear stress
F = Applied force
A = Cross-sectional area of the material that is parallel to the applied force vector
Diagram of applied shear stresses: This diagram displays a moving wall sliding past a stationary fluid. As
the wall moves, it drags the fluid forward with the motion. The moving wall applies more shear stress to
the fluid it is in contact with, and applies minimal shear stress on the fluid furthest away in contact with the
stationary wall. This example is backwards when compared to plastic flow through a cavity. The wall
does not move, the plastic melt moves along the cavity wall. Think of the stationary wall in the diagram as
the center of flow through a cavity. The material in the center of flow moves with the least resistance,
while the material along the cavity wall does not move due to the greater flow resistance. Now take a
cross-section of the melt, and imagine that extra force required to flow along the cavity wall is related to
the higher shear stresses. The material in the center of flow exhibits far less shear stress because there
less resistance to flow.
View of shear stress at end of fill.
To display a section view of shear stress at end of fill:

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2) Click Shear Stress at End of Fill.
The clipping plane mode of shear stress at end of fill displays the internal shear stress differential
Note:
1 ) Your reported shear stress values should be less than the suggested maximum value for the plastic
material used for a given simulation. The maximum shear stress is often found at the injection location of
the cavity. If the shear stress values at the injection location are over the recommended shear stress
value, you can increase the injection location diameter in an attempt to reduce the maximum shear
stress.
To check the recommended shear stress value:

1) Under INPUT, Material, double-click Polymer.
2) In the Polymer window, click the Polymer-Material Parameters tab.
Note: If the entire polymer-material parameter table is not visible, Click +

Drag the bottom right corner of the Polymer window to enlarge the viewing
area. The shear stress value is near the bottom of the table.
3) Observe the Max. Shear Stress value for your material.

4) Compare the Max. Shear Stress value to you simulated results
5) Close the Polymer window.

Note: The injection location dimension located in the Injection Location
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window changes.
4) Click OK
Flow
2 ) To reduce shear stresses, you should increase the fill time which decreases injection velocity.

2) Clear Auto.
3) For Filling time, enter value for sec.
4) Click OK
Flow
3 ) High shear stresses are commonly found at sharp corners of a molded part. You can redesign the part
with rounded corners, reducing the shear stresses found at these locations. Then you would have to
create a new mesh and run the analysis again.
4 ) You can also try increasing the melt temperature to reduce the shear stresses, but increasing the melt
temperature increases the cooling time.

Note: Materials in the SOLIDWORKS Plastics database have a maximum and

minimum melt temperature value. This melt temperature range is the
processing window that the material supplier recommends for their material. A
simulation cannot be run outside of the melt temperature range.
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3) Click OK
Flow
Shear Rate at End of Fill:

Shear rate measures the velocity of a fluid layer passing over another layer of fluid at a different velocity.
The frozen plastic material in contact with the cavity wall does not move relative to the wall, which results
in a shear rate of zero (0.0 1/sec). The molten plastic material just inside of the frozen layer moves over
the frozen material, which yields a positive shear rate (>0.0 1/sec). The shear rate continues to increase
until a maximum is reached just inside the wall. Then the shear rate begins to decrease toward the center
of flow, reaching a local minimum in the center. This minimum occurs because the polymer chains at the
center of the flow move at the same speed and do not move relative to each other, resulting in a zero (0.0
1/sec) shear rate.
Diagram of shear rate inside a cavity wall. This graph displays the value of relative movement of polymer
chains as they move past each other at different velocities. Polymer chains that slide past each other,
moving at different velocities, result in a positive shear rate. For example, the polymer chains that freeze
along the cavity wall do not move (outer minimums), but the molten polymer chains flowing past them
induce an extremely high shear rate (maximums). The two polymer chains at the center of flow move at
the same velocity which does not produce any shear (center minimum).
View of shear rate at end of fill.
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To display a section view of shear rate at end of fill:

2) Click Shear Rate at End of Fill.
The clipping plane mode of shear rate at end of fill displays the internal shear rate differential throughout
the part wall (Solid Mesh only).
Notes:
1 ) Shear rate should be less than the suggested maximum value for the plastic material.
To check the recommended shear rate value:


area. The shear rate value is near the bottom of the table.
3) Observe the Max. Shear Rate value for your material.

4) Compare the Max. Shear Rate value to you simulated results
2 ) To reduce shear rates, you can increase the fill time which decreases the injection velocity.

2) Clear Auto.
4) Click OK
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Flow
Volumetric Shrinkage at End of Fill:

The volumetric shrinkage at end of fill can indicate areas of potential concern. High rates of shrinkage will
occur in thick sections of a plastic part which do not undergo a sufficient packing stage during the
molding process. For example, if you do not include a sufficient packing stage, high amounts of
shrinkage will occur at the locations indicated in yellow and red by the volumetric shrinkage at end of fill
plot.
The first image displays the shrinkage that would occur if the packing stage was omitted from the
injection molding process. The second image displays how adding the packing stage can reduce the
volumetric shrinkage found in the part (SOLIDWORKS Plastics Professional and Premium only).
Note: Another form of shrinkage occurs in the form of voids. In a transparent molded part, sometimes
bubbles can be seen located inside the part wall. These bubbles are not air bubbles, they are vacuum
voids. A void occurs when the part surface is ridged enough to retain its shape and the molten core
material tears itself apart from the inside, creating a vacuum void. Voids also occur in opaque plastics
parts, but they cannot be seen from the outside. The molded part must be cut open to see if voids are
occurring. Typically, voids occur in thicker sections, and in areas of changing wall thicknesses (around
the connecting rim of a boss, or along the transition from a part wall to a rib).
To display a section view of volume shrinkage at end of fill:

2) Click Volume Shrinkage at End of Fill.
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The clipping plane mode of volume shrinkage at end of fill displays the internal volumetric shrinkage
throughout the part wall (Solid Mesh only). The first image displays the fill stage only, the second image
displays both fill + pack (Fill + Pack SOLIDWORKS Plastics Professional and Premium only). The
red regions found inside the part using the clipping plane mode of volume shrinkage at end of fill might
indicate the location of voids if an insufficient pack stage is used during production.
Freezing Time at End of Fill:

The scale used for the freezing time at end of fill indicates the time required for the molten plastic material
to cool down to its glass transition temperature. The time required to reduce a molten melt to its glass
transition temperature is not the time required to cool the part to its ejection temperature. The material
deflection temperature under flexural load is the material ejection temperature. A plastic material
deflection temperature under flexural load is roughly 2/3 the material glass transition (T g) or melt
temperature (Tm) in degrees Kelvin. The required time depends on the temperature differential between
the melt temperature and the mold temperature, and on the thermal conductivity of the melt and mold.
View of freezing time at end of fill.
To display a section view of freezing time at end of fill:

2) Click Freezing Time at End of Fill.
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The clipping plane mode of freezing time at end of fill displays the required internal freezing times
Frozen Layer Fraction at End of Fill:

When plastic melt makes contact with the mold wall, a thin layer of the melt instantly freezes along the
cavity wall. This layer of solidified plastic is called the frozen layer fraction. It is a friction because the
majority of the plastic located in the central core of the part wall remains molten. At the instant the cavity
is completely filled, the frozen layer closer to the injection location will be thicker than the frozen layer in
the area around the end of fill. This is true because the frozen layer closer to the injection location end
has been in contact with the cold mold wall for a longer time than the frozen layer around the end of fill.
Diagram of a developing frozen layer fraction.
The values given in the frozen layer fraction at end of fill plot are a percentage of the wall thickness. The
blue areas with a low value (0.0) are still molten along the cavity wall, and the red areas with a higher
value (>0.5) have a high percentage of frozen layer fraction. Areas that show a high percentage of frozen
layer fraction will not pack as well as section with a lower percentage of frozen layer fraction.
View of frozen layer fraction at end of fill.
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Frozen layer fraction has significant effects on flow resistance of the plastic melt. You can reduce the fill
time to reduce the frozen layer fraction. Reducing the fill time also increases shear rates and shear
stresses.

2) Clear Auto.
4) Click OK
Flow
Venting Pressure:
As the part is being filled the air inside the cavity will try to escape. If it cannot escape, burning or
dieseling will create a black, gray, or brown discoloration on the surface of the part. This is a result of
gasses and volatiles becoming trapped inside the mold. This causes the gasses to get compressed and
heated during 1st stage injection (filling). These gasses can be released through vents to avoid these
discolorations.
Cooling Time:
The cooling stage is dedicated to reducing the material temperature to the deflection temperature under
flexural load, the ejection temperature. Typically, cooling time is 70% of the total cycle time.
Diagram of stage-times for the injection molding cycle.
Two factors that affect cooling time are melt temperature and mold temperature. Increasing either
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temperature typically results in increased cooling time. Plastics require long cooling times because they
are good insulators with low thermal conductivities. Cooling time is proportional to the square of the part
wall thickness, doubling the thickness quadruples the cooling time. To reduce cooling times, you should
make the part wall thickness uniform and as thin as safely possible.
View of cooling time.
To display a section view of cooling time at end of fill:

2) Click Cooling Time at End of Fill.
The clipping plane mode of cooling time displays the required internal cooling times throughout the
part wall (Solid Mesh only).
Temperature at End of Cooling:

The temperature at end of cooling plot is based on when 90% of the part volume is below the material
deflection temperature under flexural load, the ejection temperature. If there is a large temperature
distribution in thick regions of the part, several problems may occur: sink marks, internal voids, or
warpage. To reduce these problems, you should design the part with a uniform wall thickness.
Non-uniform wall thicknesses are sometimes unavoidable, but solutions are available.
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View of temperature at end of cooling.
To display a section view of temperature at end of cooling:

2) Click Temperature at End of Cooling.
The clipping plane mode of temperature at end of cooling displays the internal temperature differential
Sink Marks:
Sink marks are depressions on the surface of an injection molded plastic part. The fundamental cause of
sink marks is that not enough polymer molecules have been packed into a part to compensate for the
shrinkage that occurs. Thicker sections of a part cool at slower rates than thinner sections, resulting in
significant shrinkage in the thicker sections. After the outer layer of plastic material has cooled and
solidified, the molten core material must transfer heat through the solidified plastic surface to the cavity
wall. Plastic materials are insulators and do not transfer heat efficiently, which slows down the cooling
rate of the thicker core volumes. The more time a plastic material has to cool, the more the material will
shrink. The high degree of shrinkage in the core volume pulls the surface of the part inward, causing a
depression on the part surface.
You can use these design rules to minimize sink marks:

1) When safely possible, design with uniform part wall thickness.
2) Place injection locations at thicker sections of the part, so the thicker sections can be
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packed at higher pressures.

3) Avoid using injection locations that are too small, which can prevent sufficient
packing of the part cavity.
4) The thickness of ribs and bosses should be approximately 60 to 80 percent of the
nominal wall thickness.
View of sink marks.
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 nxy, nyz and nxz are measured in the XY plane, YZ
plane and XZ plane, respectively, in the direction of the light.
Injection Location Filling Contribution:

When you only use one injection location, the cavity is filled by that one injection location. When you use
multiple injection locations, the cavity is partially filled with material entering from each of the injection
locations.
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View of injection location filling contribution. The phone housing was filled by two injection locations - one
injection location is located by the mouth piece and the second by the speaker. The green region was
filled by the first injection location, and the blue region was filled by the second injection location.
Note: As a result of using multiple injection locations, there will be a significant weld line located where
the flow fronts merge together. The weld line is at the interface of the green and blue regions.
To display weld lines:

2) Select Weld Lines.
View of weld lines from the use of two injection locations.
Ease of Fill:
You can use the ease of fill plot to determine whether the cavity fills successfully. The green regions
indicate areas that can be filled under normal injection pressures. The yellow regions indicate areas
where the injection pressure exceeds 70 percent of the machines maximum injection pressure. The red
regions indicate areas where the injection pressure exceeds 85 percent of the machine maximum
injection pressure.
30
View of ease of fill.
If you run a simulation on a part cavity only (with no runners), and the ease of fill plot has yellow or red
areas, you should try increasing wall thickness, moving the injection location, adding additional injection
locations, changing the material or adjusting the processing parameters to try to decrease the pressure
require to fill.
Frozen Area at End of Fill:

The frozen area at end of fill plot indicates the regions of the part that have reached the material glass
transition temperature. The green regions (value 1) indicate that the material has reached the material
glass transition temperature. The red regions (value 0) indicate that the material is still above its glass
transition temperature. The frozen area at end of fill indicates the thickness of the frozen layer that builds
up during fountain flow.
To display a section view of frozen area at end of fill:

2) Click Frozen Area at End of Fill.
31
The clipping plane mode of frozen area at end of fill displays the internal temperature differential
throughout the part wall (Solid Mesh only). This plot also displays the frozen layer fraction at end of fill.
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.
32
Pack Results
Pressure at End of Packing:
The pressure exerted on the cavity during the packing stage is controlled by the reciprocating screw. This
results in relatively slow forward velocity of the screw to pack the cavity at that pressure. The packing
pressure is propagated through the molten plastic and results in a pressure drop distributed along the
length of flow. Pressure drop is a function of flow length, part wall thickness, and material viscosity. High
pressures are required to pack a part with thin walls, since the flow resistance is greater through a thinner
cross sectional area. If the packing pressure is not high enough, the part might show surface defects
such as sink marks, flow hesitations, and possibly internal voids.
View of pressure at end of packing.

.
To change the pack time:

1) Under INPUT, Process Parameters, double-click Pack Settings.
2) Clear Auto.
3) For Pressure Holding Time, enter value for sec.
4) Click OK
5) Under RUN, double-click a run option:
Pack
Flow + Pack
6) Click Yes, when prompted to replace results.
To change the pack profile settings:

2) Click Profile
3) Under the Time(s) tab:

a.
If the last value does not equal the value for Pressure Holding Time(sec),
click Apply.
b.
Click Yes, in following prompt window to auto adjust.
33
4) Change any value under Time(s) or Injection pressure(%).

5) Click Apply.
6) You can change other operations if desired:
Click Time(s) tab, and change to Time(%)
Select Machine pressure control(Absolute control)

i. change any value under Time(s) or Injection pressure(Mpa).
ii. Click Apply.
iii. Click the Injection pressure(MPa) tab, and select Injection
pressure(%).
Click Apply, when finished
Click OK, in the Flow/Pack Profile dialog box
7) Click OK
Pack
Flow + Pack
To display a section view of pressure at end of packing:

1) Under RESULTS, double-click Pack Results.
2) Click Pressure at End of Packing.
The clipping plane mode of pressure at end of packing displays the pressure distribution throughout the
cavity at the end of the pack stage (Solid Mesh only).
Temperature at the End of Packing:

At the end of the packing stage, the part surface has cooled to the temperature of the mold and the part
appears blue. The core volume of the part might still be molten, near the material glass transition (Tg) or
the melt temperature (Tm). The areas that display elevated internal temperatures at the end of pack, can
34
create sink marks or internal voids. Pack pressures between 50 and 80 percent of the maximum injection
pressure are generally required to minimize post mold part defects.
View of temperature at end of packing.
To change the pack time:

2) Clear Auto.
3) For Pressure Holding Time, enter value for sec.
4) Click OK
Pack
Flow + Pack
To change the pack profile settings:

2) Click Profile
3) Under Time(s) tab:

a.
If the last value does not equal the value for Pressure Holding Time(sec),
click Apply.
b.
Click Yes, in following prompt window to auto adjust.
4) Change any value under Time(s) tab or Injection pressure(%) tab.

5) Click Apply.
6) You can change other operations if desired:
Click Time(s) tab, and change to Time(%)
Select Machine pressure control(Absolute control)

i. change any value under Time(s) or Injection pressure(Mpa).
ii. Click Apply.
iii. Click Injection pressure(MPa) tab, and select Injection
35
pressure(%), if desired.
Click Apply, when finished
Click OK, in the Flow/Pack Profile dialog box
7) Click OK
Pack
Flow + Pack
To change the pure cooling time:

2) Clear Auto.
3) For Pure Cooling Time, enter value for sec.
4) Click OK
Pack
Flow + Pack
To display a section view of temperature at end of packing:

2) Click Temperature at End of Packing.
The clipping plane mode of temperature at end of packing displays the internal temperature differential
Central Temperature at End of Packing:

The central temperature at end of packing plot indicates the melt temperature of the central position
between the two surfaces of a shell mesh. The plastic melt that is a further distance from the cavity wall
36
will retain heat for longer periods of time. The temperature of the molten core material may decrease
quickly for a thin walled part, and SOLIDWORKS Plastics will detect if a short shot has occurred.
View of central temperature at end of packing.
Average Temperature at End of Packing:

The average temperature at the end of packing plot indicates the average melt temperature between the
two surfaces of a shell mesh. If the temperature differential is non-uniform, sink marks and warpage may
occur.
View of average temperature at end of packing.
Bulk Temperature at End of Packing:

The bulk temperature plot indicates where material has cooled down to the mold temperature (blue), and
where material is still molten (red or yellows). The changes in melt temperature during the packing stage
are calculated from parameters such as time, mold temperature, and part wall thickness.
View of bulk temperature at end of packing.
To display a section view of bulk temperature at end of packing:

37

2) Click Bulk Temperature at End of Packing.
The clipping plane mode of bulk temperature at end of packing displays the internal temperature
differential throughout the part wall (Solid Mesh only).
Shear Stress at End of Packing:

Shear stress is a measure of shear force per unit area. The direction of the shear force is parallel to the
plane of the force (the cavity wall), and can be thought of as the force melt uses to push the cavity wall in
the direction of flow (not pushing outward normal to the wall).
= F/A
= Shear stress
F = Applied force
A = Cross-sectional area of the material that is parallel to the applied force vector
Diagram of applied shear stresses: This diagram displays a moving wall sliding past a stationary fluid. As
the wall moves, it drags the fluid forward with the motion. The moving wall applies more shear stress to
the fluid it is in contact with, and applies minimal shear stress on the fluid furthest away in contact with the
stationary wall. This example is backwards when compared to plastic flow through a cavity. The wall
does not move, the plastic melt moves along the cavity wall. Think of the stationary wall in the diagram as
the center of flow through a cavity. The material in the center of flow moves with the least resistance,
while the material along the cavity wall does not move due to the greater flow resistance. Now take a
cross-section of the melt, and imagine that extra force required to flow along the cavity wall is related to
38
the higher shear stresses. The material in the center of flow exhibits far less shear stress because there
less resistance to flow.
View of shear stress at end of packing.
To display a section view of shear stress at end of packing:

2) Click Shear Stress at End of Packing.
The clipping plane mode of shear stress at end of packing displays the internal shear stress differential
Note:
1 ) Your reported shear stress values should be less than the suggested maximum value for the plastic
material used in simulation. The maximum shear stress is sometimes found at the injection location of the
cavity. If the shear stress values at the injection location are the recommended shear stress value,
attempt to increase the injection location diameter to the next fraction of an inch or half millimeter.
To check the recommended shear stress values:


39
area. The shear stress value is near the bottom of the table.
3) Observe the Max. Shear Stress value for your material.

4) Compare the Max. Shear Stress value to you simulated results

Note: The injection location dimension located in the Injection Location

window changes.
4) Click OK
Flow
2 ) To reduce shear stresses, you should increase the fill time which decreases injection velocity.

2) Clear Auto.
3) For Filling time, enter value for sec.
4) Click OK
Flow
3 ) High shear stresses are commonly found at sharp corners of a molded part. You can redesign the part
with rounded corners, reducing the shear stresses found at these locations. Then you would have to
create a new mesh and run the analysis again.
40
4 ) You can also try increasing the melt temperature to reduce the shear stresses, but increasing the melt
temperature increases the cooling time.

Note: Materials in the SOLIDWORKS Plastics database have a maximum and

minimum melt temperature value. This melt temperature range is the
processing window that the material supplier recommends for their material. A
simulation cannot be run outside of the melt temperature range.
3) Click OK
Flow
Shear Rate at the End of Packing:

Shear rate measures the velocity of a fluid layer passing over another layer of fluid at a different velocity.
At the end of the pack stage, the material is no longer moving, so there is no strain exerted on the
material. The shear rate at end of packing plot should indicate a blue surface, and a blue core when
using the clipping plane mode of shear rate at end of packing. For more information on shear rate during
the fill stage, review shear rate at end of fill in the results adviser.
Diagram of shear rate inside a cavity wall. This graph displays the value of relative movement of polymer
chains as they move past each other at different velocities. Polymer chains that slide past each other,
moving at different velocities, result in a positive shear rate. For example, the polymer chains that freeze
along the cavity wall do not move (outer minimums), but the molten polymer chains flowing past them
induce an extremely high shear rate (maximums). The two polymer chains at the center of flow move at
41
the same velocity which does not produce any shear (center minimum).
View of shear rate at end of packing.
To display a section view of shear rate at end of packing:

2) Click Shear Rate at End of Packing.
The clipping plane mode of shear rate at end of packing displays the internal shear rate differential
Notes:
1)
Shear rate should be less than the suggested maximum value for the plastic material.
To check the recommended shear rate value:


area. The shear rate value is near the bottom of the table.
3) Observe the Max. Shear Rate value for your material.
42
4) Compare the Max. Shear Rate value to you simulated results

2)
To reduce shear rates, you can increase the fill time which decreases the injection velocity.

2) Clear Auto.
4) Click OK
Flow
6) Click Yes when prompted to replace the fill results.
Volumetric Shrinkage at the End of Packing:

Plastic materials are compressible because their specific volumes are a function of temperature and
pressure. High rates of shrinkage will occur in areas of the plastic part that do not undergo a sufficient
pack stage. You will have problems if the volume shrinkage at end of packing plot indicates significant red
areas. The red areas indicate sink marks, and might result in voids or warpage.
View of volume shrinkage at end of packing.
To display a section view of volume shrinkage at end of packing:

2) Click Volume Shrinkage at End of Packing.
43
The clipping plane mode of volume shrinkage at end of packing displays the internal volumetric
shrinkage throughout the part wall (Solid Mesh only). The red regions found inside the part using the
clipping plane mode of volume shrinkage at end of packing might indicate the location of voids.
Temperature at Post-Filling End:

The temperature at post-filling end plot is based on when 90% of the part volume is below the material
deflection temperature under flexural load, the ejection temperature. If there is a large temperature
distribution in thick regions of the part, several problems may occur: sink marks, internal voids, or
warpage. To reduce these problems, you should design the part with a uniform wall thickness.
Non-uniform wall thicknesses are sometimes unavoidable, but solutions are available.
To display a section view of temperature at post-filling end:

2) Click Temperature at Post-Filling End.
The clipping plane mode of temperature at post-filling end displays the internal temperature differential
Freezing Time at Post-Filling End:

The scale used for the freezing time at post-filling end indicates the time required for the molten plastic
44
material to cool down to its glass transition temperature. The time required to reduce a molten melt to its
glass transition temperature is not the time required to cool the part to its ejection temperature. The
material deflection temperature under flexural load is the material ejection temperature. A plastic material
deflection temperature under flexural load is roughly 2/3 the material glass transition (T g) or melt
temperature (Tm) in degrees Kelvin. The required time depends on the temperature differential between
the melt temperature and the mold temperature, and on the thermal conductivity of the melt and mold.
View of freezing time at post-filling end.
To display a section view of freezing time at post-filling end:

2) Click Freezing Time at Post-Filling End.
The clipping plane mode of freezing time at post-filling end displays the required internal freezing times
Central Temperature at Post-Filling End:

The central temperature at post-filling end plot indicates the melt temperature of the central position
between the two surfaces of a shell mesh. The plastic melt that is a further distance from the cavity wall
will retain heat for longer periods of time. The temperature of the molten core material may decrease
quickly for a thin walled part, and SOLIDWORKS Plastics will detect if a short shot has occurred.
45
View of central temperature at post-filling end.
Average Temperature at Post-Filling End:

The average temperature at post-filling end plot indicates the average melt temperature between the two
surfaces of a shell mesh. If the temperature differential is non-uniform, sink marks and warpage may
occur.
View of average temperature at post filling end.
Frozen Layer Fraction at Post-Filling End:

When plastic melt makes contact with the mold wall, a thin layer of the melt instantly freezes along the
cavity wall. This layer of solidified plastic is called the frozen layer fraction. It is a fraction because the
majority of the plastic located in the central core of the part wall remains molten. At the instant the cavity
is completely filled, the frozen layer closer to the injection location end will be thicker than the frozen layer
in the area around the end of fill. This is true because the frozen layer closer to the injection location end
has been in contact with the cold mold wall for a longer time than the frozen layer around the end of fill.
Diagram of a developing frozen layer fraction.
46
The values given for frozen layer fraction at post-filling end indicate the percentage of part wall that has
solidified. The majority of the part should be displayed in red, and small sections at the end of fill might be
at 80 percent solidified.
View of frozen layer fraction at end of fill.
Residual Stress at Post-Filling End:

During the injection molding process, the polymer is exposed to thermal and physical stresses. Residual
stresses are forces locked within the polymer as it cools from the molten state through the glass
transition temperature. The residual stresses are a result of the non-uniform cooling and pressure
variations that occur in the viscoelastic polymer material during molding. A part with high levels of
residual stresses might fracture, or it might undergo other physical changes after molding.
View of residual stresses at post-filling end.
To display a section view of residual stresses at post-filling end:

2) Click Residual Stresses at Post-Filling End.
47
The clipping plane mode of residual stresses at post-filling end display the residual stresses throughout
the part wall (Solid Mesh only).
Frozen Area at Post-Filling End:

The plot of the frozen area at post-filling end indicates the portions of the material that have reached the
material glass transition temperature (green, value=1). The red regions (value=0) indicate that the
material is above its glass transition temperature.
View of frozen area post-filling end.
To display a section view of frozen area at post-filling end:

2) Click Frozen Area at Post-Filling End.
The clipping plane mode of frozen area at post-filling end displays the internal temperature differential
throughout the part wall (Solid Mesh only). Internal regions that are still indicated in red might be areas
that pull vacuum voids.
48
49
Cooling Results
In general, there are 2 primary considerations to take into account when running cooling analyses:
1. Maintaining a uniform cooling time across the surface area of the plastic part geometry.
2. Maintaining a uniform temperature distribution across the core and cavity mold surfaces.
Regarding plastic part geometry, uniform cooling times across the surface area of the part lead to more
uniform molded-in stress distributions, as well as more uniform volumetric shrinkage distributions.
All of
these factors combine to result in a molded part that is less likely to warp (or deform) out of shape due to
non-uniform cooling, shear stress or shrinkage.
Regarding the injection mold itself, it is generally desirable to achieve uniform temperature distributions
across the surfaces of the mold cores and cavities. Because if we assume the part being molded has a
uniform wall thickness, uniform temperatures across the mold surfaces will promote uniform cooling
times across the surface area of the part, which leads to a part that is less likely to warp (as described
above).
50
Warpage Results
Molded part warpage is a complex phenomenon that can occur due to a number of causes, including, but
not limited to:
Non-uniform shrinkage this can be caused by non-uniform mold temperatures, differential

cooling rates between thin and thick sections of a part, shrinkage variations between the
direction of melt flow and transverse to the direction of melt flow and in general, non-uniform
pressure, temperature and shear stress distributions across the surface area or throughout the
volume of a molded part.
Differential molded-in stress polymer molecules can be thought of as coiled springs. As

melted plastic flows during the injection molding process, the polymer molecules get stretched
out and aligned (or oriented) in the direction of flow.
As the molded part cools down, some of
the molecules return to a relaxed state but others remain stretched out and get frozen into place
as the part cools, putting them in a state of stress, referred to as molded-in stress.
Molded-in
stress is normal for injection molded parts and may not necessarily result in any particular
problems. However, when the molded-in stress varies significantly from one area of a part
compared to another, molded part warpage is often the consequence of the varying stress
levels.
Non-uniform cooling rates non-uniform cooling can occur due to varying wall thickness
throughout a plastic part, that is, thinner wall sections take less time to cool compared to thicker
wall sections.
However, even for properly designed parts with a uniform wall thickness,
non-uniform cooling can occur if there are temperature variations across the injection mold core
and cavity surfaces.
Non-uniform cooling generally leads to non-uniform shrinkage and
molded-in stress distributions, which both contribute to part warpage.
Molecular and fiber orientation in general, molded part shrinkage is greatest transverse to
the direction of polymer melt flow and transverse to the direction of fiber orientation in fiber-filled
materials.
As a result, the direction of melt flow and fiber orientation can have a significant
effect on the shrinkage distributions within a molded part, possibly causing the molded part to
warp.
Variable packing the packing phase of the injection molding process is the phase during
which pressure is maintained on the sprue, runners, gates and cavities until the gates have
frozen off and no more pressure can be transmitted to the mold cavities.
However, if the filling
distributions throughout a molded part are not uniform to begin with, some areas of a part could
start packing while other areas of the part are still being filled. When this occurs, the pressure
distributions within the mold cavity can get significantly skewed, resulting in one area of the part
filling and packing at relatively high pressure and another area of the part filling and packing at
relatively low pressures. When this occurs, the molded part is much more likely to warp
because the non-uniform packing results in non-uniform shrinkage and stress distributions
51
which both contribute to part warpage.
Based on all of these potential causes of molded part warpage, it is best to choose gate locations that
result in uniform filling, pressure and temperature distributions throughout the mold cavities.
And while
it may be desirable to minimize volumetric shrinkage and shear stress values, its even better to try to
achieve uniform distributions for volumetric shrinkage, shear stress, pressure and temperature, because
when those distributions are uniform, the result is a part that is much less likely to warp out of shape.
52

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SOLIDWORKS Plastics

Fill Results ................................................................................................................ 3

Fill Time: ....................................................................................................... 3

Pressure at End of Packing: .................................................................... 33

Freezing Time at Post-Filling End: ......................................................... 44

To change the fill time:

5) Under RUN, double-click a fill option:

Flow + Pack (SOLIDWORKS Plastics Professional and Premium only)

6) Click Yes, when prompted to replace the fill results.

Short shot resulting from an extreme flow length.

To reposition an injection location:

Delete Injection Location

Delete All Injection Locations

3) Click Yes, when prompted to delete an injection location.

to display the mesh.

8) Under RUN, double-click a fill option:

Flow + Pack (SOLIDWORKS Plastics Professional and Premium only)

9) Click Yes, when prompted to replace the fill results.

To display a section view of fill time:

Animation of Fill Time:

To animate the fill time:

3) To pause the animation, click Pause

4) To stop the animation, click either:

7) To slow down or speed up the animation, click Stop

desired rate, and click Play

, slide the Speed scale to the

To display the fill time manually:

Three manual display views of the fill time.

before sliding the Max or Min

and slide the Max or Min

scale (Solid Mesh only).

Velocity Vector at End of Fill:

To display velocity vector at end of fill:

View of the velocity vector at end of fill plot.

To display weld lines:

View of the weld line plot.

To display Air Traps:

Under RESULTS, double-click Fill Results.

Select Air Traps.

View of Air Traps superimposed over a Fill Time plot.

Pressure at End of Fill:

Uneven and even pressure at end of fill plots.

To reposition an injection location:

Delete Injection Location

Delete All Injection Locations

3) Click Yes, when prompted to delete an injection location.

8) Under RUN, double-click a fill option:

Flow + Pack (SOLIDWORKS Plastics Professional and Premium only)

9) Click Yes, when prompted to replace the fill results.

To change the fill time:

5) Under RUN, double-click a fill option:

Flow + Pack (SOLIDWORKS Plastics Professional and Premium only)

6) Click Yes, when prompted to replace the fill results.

To display a section view of pressure at end of fill:

Temperature at End of Fill:

View of temperature at end of fill.

To change the melt temperature:

Note: Materials in the SOLIDWORKS Plastics database have a maximum and a

4) Under RUN, double-click a fill option:

Flow + Pack (SOLIDWORKS Plastics Professional and Premium only)

5) Click Yes, when prompted to replace the fill results.

To display a section view of temperature at end of fill:

throughout the part wall (Solid Mesh only).