Copyright Autodesk, Inc. All rights reserved. (C)2009 2010 2011 2012 2013 2014 2015 2016 (C)2017 2018 2019 2020 2021 Portions of this software are covered by U.S. Patent Numbers 5,287,408 and 6,096,088. Coupled 3D Flow Solver. Version: Autodesk Moldflow Insight 2021.1 (Build 160) 64-bit build Analysis running on host: L0IEC155 Operating System: Windows 10 Processor type: GenuineIntel Intel64 Family 6 Model 85 Stepping 7 ~3791 MHz Number of Processors: 16 Total Physical Memory: 65239 MBytes Analysis commenced at Thu Feb 9 14:46:44 2023 Mesh and boundary conditions file name : case_4_230123_.sdy Results files core name : case_4_230123_ Residual stress calculation : ON Core shift calculation : ON -------------------------------------------------------------------------- Solver Parameters: ================= Solver setup: ------------ Solver = Coupled 3D Solution type = Stokes Simulate inertia effect = No Simulate gravity effect = No Simulate wall slip = No Gate diameter at cavity injection locations = Automatic Filling parameters: ------------------ Maximum % volume to fill per time step = 4.000 % Maximum iterations per time step = 50 Convergence tolerance (scaling factor) = 1.000 Flow front scheme = Level set Packing parameters: ------------------ Maximum time step = 2.000 s Maximum iterations per time step = 50 Convergence tolerance (scaling factor) = 1.000 Intermediate results: -------------------- Intermediate results type = Write at constant intervals Number of intermediate results in filling phase = 5 Number of intermediate results in packing phase = 5 Number of intermediate results in cooling phase = 3 -------------------------------------------------------------------------- Material Data: ============= Manufacturer LG MMA Co Ltd Trade name IH830C Family name PMMA Specific heat: Tabulated data: Temperature Specific Heat T (K) Cp (J/kg-K) ----------- ------------- 279.1500 1092.7000 293.1500 1148.0000 303.1500 1185.8000 313.1500 1220.1000 318.1500 1230.1000 328.1500 1258.3000 333.1500 1273.4000 343.1500 1332.5000 348.1500 1349.4000 353.1500 1377.9000 358.1500 1407.4000 363.1500 1434.4000 368.1500 1469.0000 373.1500 1523.0000 378.1500 1586.4000 383.1500 1665.0000 388.1500 1732.1000 393.1500 1777.2000 398.1500 1793.8000 403.1500 1810.6000 408.1500 1819.6000 413.1500 1845.2000 423.1500 1870.7000 433.1500 1898.2000 443.1500 1925.2000 453.1500 1940.1000 473.1500 1989.5000 493.1500 2034.9000 508.1500 2054.3000 Thermal conductivity: Tabulated data: Temperature Thermal Conductivity T (K) K (W/m-K) ----------- -------------------- 313.2500 0.2150 333.1500 0.2180 353.1500 0.2260 373.1500 0.2450 393.1500 0.2210 413.1500 0.2210 433.1500 0.2190 453.1500 0.2160 473.2500 0.2150 493.1500 0.2150 513.1500 0.2140 533.1500 0.2100 Transition temperature = 107.0000 C pvT Model: 2-domain modified Tait coefficients: b5 = 380.7100 K b6 = 2.2920E-07 K/Pa Liquid phase Solid phase ------------------------------- b1m = 0.0009 b1s = 0.0009 m^3/kg b2m = 6.0560E-07 b2s = 2.3300E-07 m^3/kg-K b3m = 1.8778E+08 b3s = 2.4240E+08 Pa b4m = 0.0052 b4s = 0.0039 1/K b7 = 0.0000 m^3/kg b8 = 0.0000 1/K b9 = 0.0000 1/Pa Viscosity model: Cross-WLF coefficients: n = 0.1953 TAUS = 2.2645E+05 Pa D1 = 2.7736E+13 Pa-s D2 = 377.1500 K D3 = 0.0000 K/Pa A1 = 32.7060 A2T = 51.6000 K Juncture loss equation : DPe = c1 * TAUW^c2 where c1 = 3.0500E-09 Pa^(1-c2) c2 = 2.6600 Mechanical properties data: E1 = 3491.4299 MPa E2 = 3511.8001 MPa v12 = 0.3660 v23 = 0.3970 G12 = 1209.2000 MPa Transversely isotropic coefficient of thermal expansion (CTE) data: Alpha1 = 0.0000709 1/C Alpha2 = 0.0000722 1/C No mesh for the cores was found. Core shift analysis switched OFF -------------------------------------------------------------------------- Model Details: ============= Mesh Type = 3D Tetrahedra Tetrahedral refinement layers (specified minimum) = 6 Laminates across radius of beam elements = 12 Total number of part nodes = 84679 Number of tetrahedron nodes = 83905 Number of beam nodes = 760 Number of beam-tetrahedron connection nodes = 14 Total number of injection location nodes = 1 The injection location node numbers are: 894652 Total number of elements = 437297 Number of part elements = 437297 Number of tetrahedral elements = 436524 Number of sprue/runner/gate elements = 773 Number of hot sprue/runner/gate elements = 773 Total volume = 2751.2603 cm^3 Volume of tetrahedral elements = 186.0622 cm^3 Volume of sprue/runner/gate elements = 2565.1981 cm^3 Volume of hot sprue/runner/gate elements = 2565.1981 cm^3 Volume filled initially = 2565.1981 cm^3 Volume to be filled = 186.0622 cm^3 Part volume to be filled = 186.0622 cm^3 Sprue/runner/gate volume to be filled = 0.0000 cm^3 Parting plane normal (dx) = 0.0000 (dy) = 0.0000 (dz) = 1.0000 Total projected area = 594.2815 cm^2 -------------------------------------------------------------------------- Process Settings: ================ Machine parameters: ------------------ Maximum injection pressure = 1.8000E+02 MPa Maximum machine clamp force = 7.0002E+03 tonne Apply the clamp force limit = No Maximum machine injection rate = 5.0000E+03 cm^3/s Machine hydraulic response time = 1.0000E-02 s Temperature control: ------------------- Melt temperature = 240.00 C Mold temperature = 75.00 C Mold-melt heat transfer coefficients Global values. (Superseded by any values set on individual elements.) Filling = 5000.0000 W/m^2-C Packing = 2500.0000 W/m^2-C Detached = 1250.0000 W/m^2-C Atmospheric temperature = 25.00 C Filling Control: --------------- Filling control type = Injection time Fill time = 4.50 s Stroke volume determination = Automatic Valve gate setting control: -------------------------- Valve gate group name : Valve gate controller defaults Valve gate control by = Flow front Trigger location for valve gate = Specified Trigger location specified at node number = 894575 Trigger delay time for valve gate = 0.0000 s Opening Closing ------- ------- By flow front 30.000 s Velocity/pressure switch-over control: ------------------------------------- Velocity/pressure switch-over control type = By % volume filled Percentage volume of the part = 98.00 % Pack/holding control: -------------------- Pack/holding control type = Packing pressure vs time Pressure profile: duration pressure ---------------------------- 0.00 s 45.0000 MPa 5.00 s 45.0000 MPa 0.00 s 20.0000 MPa 3.00 s 20.0000 MPa 0.00 s 0.0000 MPa Cooling time: ------------ Cooling time determination = Specified Cooling time = 20.0000 s -------------------------------------------------------------------------- Matrix Solver Settings: ====================== AMG matrix solver selection = Automatic Matrix solver used = AMG Number of threads for parallelization = Maximum Number of threads used in the analysis = 8 -------------------------------------------------------------------------- Filling Phase: Status: V = Velocity control ============= V/P = Velocity/pressure switch-over P = Pressure control |----------------------------------------------------------------------| | Time | Fill Vol| Inj Press | Clamp F | Flow Rate| Frozen | Status| | (s) | (%) | (MPa) | (tonne) | (cm^3/s) | Vol (%)| | |----------------------------------------------------------------------| | 0.002 | 0.004 | 4.025e-01 | 0.00e+00 | 0.000 | 0.00 | V | | 0.115 | 0.004 | 5.526e+00 | 0.00e+00 | 31.462 | 0.00 | V | | 0.209 | 1.073 | 7.564e+00 | 8.33e-03 | 34.179 | 0.00 | V | | 0.260 | 1.734 | 8.453e+00 | 2.99e-02 | 37.362 | 0.01 | V | | 0.492 | 2.791 | 1.184e+01 | 1.77e-01 | 38.276 | 1.78 | V | | 0.783 | 4.189 | 1.584e+01 | 6.40e-01 | 38.880 | 3.60 | V | | 0.940 | 5.297 | 1.799e+01 | 1.13e+00 | 39.084 | 3.96 | V | | 1.105 | 6.476 | 2.028e+01 | 1.83e+00 | 39.175 | 4.36 | V | | 1.363 | 7.702 | 2.392e+01 | 3.13e+00 | 39.286 | 5.42 | V | | 1.494 | 8.639 | 2.582e+01 | 4.07e+00 | 39.373 | 5.78 | V | | 1.661 | 9.841 | 2.831e+01 | 5.51e+00 | 39.408 | 6.15 | V | | 1.858 | 10.784 | 3.135e+01 | 7.21e+00 | 39.471 | 6.87 | V | | 2.132 | 12.108 | 3.573e+01 | 1.00e+01 | 39.561 | 7.96 | V | | 2.259 | 13.027 | 3.785e+01 | 1.17e+01 | 39.627 | 8.25 | V | | 2.489 | 14.141 | 4.181e+01 | 1.48e+01 | 39.689 | 9.09 | V | | 2.686 | 15.100 | 4.535e+01 | 1.79e+01 | 39.769 | 9.81 | V | | 2.910 | 16.199 | 4.955e+01 | 2.17e+01 | 39.848 | 10.56 | V | | 3.119 | 17.220 | 5.362e+01 | 2.56e+01 | 39.932 | 11.27 | V | | 3.394 | 18.237 | 5.924e+01 | 3.11e+01 | 40.035 | 12.30 | V | | 3.695 | 19.354 | 6.572e+01 | 3.78e+01 | 40.163 | 13.47 | V | | 3.975 | 20.399 | 7.207e+01 | 4.46e+01 | 40.299 | 14.48 | V | | 4.484 | 21.938 | 8.451e+01 | 5.83e+01 | 40.487 | 16.49 | V | | 5.149 | 24.076 | 1.027e+02 | 7.98e+01 | 40.782 | 18.98 | V | Open valve gate group: Valve gate controller defaults ** WARNING 302105 ** Flow solution failed to converge within the allowed iterations. | 5.175 | 24.204 | 1.035e+02 | 8.15e+01 | 40.989 | 18.99 | V | ** WARNING 302105 ** Flow solution failed to converge within the allowed iterations. | 5.176 | 24.270 | 1.028e+02 | 8.17e+01 | 41.034 | 18.92 | V | ** WARNING 302105 ** Flow solution failed to converge within the allowed iterations. | 5.177 | 24.375 | 1.018e+02 | 8.21e+01 | 43.744 | 18.85 | V | ** WARNING 302105 ** Flow solution failed to converge within the allowed iterations. | 5.178 | 24.581 | 1.004e+02 | 8.26e+01 | 49.294 | 18.72 | V | ** WARNING 302105 ** Flow solution failed to converge within the allowed iterations. | 5.179 | 24.844 | 9.902e+01 | 8.31e+01 | 54.020 | 18.55 | V | ** WARNING 302105 ** Flow solution failed to converge within the allowed iterations. | 5.180 | 25.242 | 9.769e+01 | 8.38e+01 | 56.328 | 18.27 | V | ** WARNING 302105 ** Flow solution failed to converge within the allowed iterations. | 5.181 | 25.602 | 9.650e+01 | 8.47e+01 | 56.300 | 17.96 | V |