----------------------------------------
	Fill
----------------------------------------
Copyright Autodesk, Inc. All rights reserved.
(C)2009 2010 2011 
Portions of this software are covered by U.S. Patent Numbers 5,287,408 and 6,096,088.

 
Flow Analysis
 

Version: ami2012-barium_main_ml_sp1  (Build 11221-002)
         64-bit build

Analysis commenced at        Thu Dec 18 11:35:55 2025

Analysis running on host: X6X8-20150713ZY
        Operating System: Windows 7 Service Pack 1
          Processor type: GenuineIntel Intel64 Family 6 Model 61 Stepping 4 ~2394 MHz
    Number of Processors: 4
   Total Physical Memory: 8102 MBytes


  No mesh for the cores was found. 
  Core shift analysis switched OFF 
 
--------------------------------------------------------------------------


Fill Analysis

Residual Stress Analysis
 
--------------------------------------------------------------------------

Date : DEC18-25    
Time : 11:35:59    
 
Allocating memory for analysis...
... finished allocating memory

Analysis has detected a mesh change since initial mesh 
generation ... recalculating mesh match and thickness information 
Processing Dual Domain mesh...
Computing match using the maximal-sphere algorithm
... finished processing Dual Domain mesh
Reading input data...
  File name : hc_2025_023(ls241101_49_x1_top_case)_2025_1124_study~1    
  Reading solver parameters...
  Reading material data...
  Reading process settings...
  Reading finite element mesh...
 
** WARNING 98780 ** No cooling channel is specified.
  Reading cooling data...

NOTE: In the analysis sequence for this study, a Cool analysis has not 
      been run before Flow.  Flow will use the constant mold temperature
      setting in the Process Settings Wizard.
      Running a Cool analysis before Flow provides more detailed information 
      about mold temperatures and heat fluxes.
Finished reading input data
Checking input data...
 
** WARNING 98742 ** Triangle element  117043 has a large aspect ratio (    58.9305), 
                    which may affect the analysis.  Try running the Auto 
                    Repair and Fix Aspect Ratio commands from the Mesh Tools 
                    to fix the problem. 
 
** WARNING 98742 ** Triangle element  117048 has a large aspect ratio (    64.4931), 
                    which may affect the analysis.  Try running the Auto 
                    Repair and Fix Aspect Ratio commands from the Mesh Tools 
                    to fix the problem. 
 
** WARNING 98742 ** Triangle element  117074 has a large aspect ratio (    56.7372), 
                    which may affect the analysis.  Try running the Auto 
                    Repair and Fix Aspect Ratio commands from the Mesh Tools 
                    to fix the problem. 
 
** WARNING 98742 ** Triangle element  127020 has a large aspect ratio (    51.2665), 
                    which may affect the analysis.  Try running the Auto 
                    Repair and Fix Aspect Ratio commands from the Mesh Tools 
                    to fix the problem. 
... 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    =           0
   Intermediate output options for packing phase
     No. of results at constant intervals             =          20
     No. of profiled results at constant intervals    =           0
   Flow rate convergence tolerance                    =      0.5000 %
   Melt temperature convergence tolerance             =      0.0200 C
   Mold-melt heat transfer coefficient
                       Filling                        =   5000.0000 W/m^2-C
                       Packing                        =   2500.0000 W/m^2-C
                       Detached, cavity side          =   1250.0000 W/m^2-C
                       Detached, core side            =   1250.0000 W/m^2-C
   Maximum no. of flow rate iterations                =         125 
   Maximum no. of melt temperature iterations         =         200
   Nodal growth mechanism                             = Multiple
   Pressure trace sample frequency                    =          10 Hz
     Total number of pressure trace nodes             =           1
        Node       1                                 =       91495
   Pressure work option                               =           1
 
--------------------------------------------------------------------------
 
Material data : 

   Polymer   : Polylac PA-764B : Chi Mei Corporation
   ---------
   pvT Model:    2-domain modified Tait
                 coefficients: b5 =    367.8500 K
                               b6 =  1.0400E-07 K/Pa
                               Liquid phase        Solid phase
                               -------------------------------
                               b1m =      0.0009  b1s =      0.0009 m^3/kg
                               b2m =  5.6200E-07  b2s =  2.5500E-07 m^3/kg-K
                               b3m =  7.6294E+07  b3s =  8.3852E+07 Pa
                               b4m =      0.0032  b4s =      0.0029 1/K
                                                  b7  =      0.0000 m^3/kg
                                                  b8  =      0.0000 1/K
                                                  b9  =      0.0000 1/Pa

   Specific heat (Cp)                                 =   1657.9000 J/kg-C

   Thermal conductivity                               =      0.2200 W/m-C

   Viscosity model:                Cross-WLF
                                   coefficients: n    =      0.2807
                                                 TAUS =  5.1300E+04 Pa
                                                 D1   =  6.2400E+10 Pa-s
                                                 D2   =    373.1500 K
                                                 D3   =      0.0000 K/Pa
                                                 A1   =     22.8580
                                                 A2T  =     51.6000 K

   Transition temperature                             =     94.0000 C

   Mechanical properties data:                    E1  =   2240.0000 MPa
                                                  E2  =   2240.0000 MPa
                                                  v12 =      0.3920
                                                  v23 =      0.3920
                                                  G12 =    804.6000 MPa

   Transversely isotropic coefficent of 
     thermal expansion (CTE) data:            Alpha1  =  8.0000E-05 1/C
                                              Alpha2  =  8.0000E-05 1/C
  
   Residual stress model without CRIMS
 
--------------------------------------------------------------------------
 
Process settings : 
 
   Machine parameters :    
   ------------------
   Maximum machine clamp force                        = 7.0002E+03 tonne
   Maximum injection pressure                         = 1.8000E+02 MPa
   Maximum machine injection rate                     = 5.0000E+03 cm^3/s
   Machine hydraulic response time                    = 1.0000E-02 s
 
   Process parameters :    
   ------------------
   Fill time                                          =      3.9000 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
     ---------------------------------
            0.0000           100.0000
          100.0000           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                                   =    190.0000 C
   Ideal cavity-side mold temperature                 =     45.0000 C
   Ideal core-side mold temperature                   =     45.0000 C

   Hot runner  control:
        ELEM ID   Outer heater temperature   Inner heater temperature
        -------   ------------------------   ------------------------
       183784            190.0000 C
       183785            190.0000 C
       183786            190.0000 C
       183787            190.0000 C
       183788            190.0000 C
       183789            190.0000 C
       183790            190.0000 C
       183791            190.0000 C
       183792            190.0000 C
       183793            190.0000 C
 
   NOTE: Mold wall temperature data from Cool analysis not available
 
--------------------------------------------------------------------------
 
Model details :
    
   Mesh Type                                          = Dual Domain

   Mesh match percentage                              =  90.4 %

   Reciprocal mesh match percentage                   =  86.8 %
   Total number of nodes                              =       28686
   Total number of injection location nodes           =           1
      The injection location node labels are:
                                                              91495
   Total number of elements                           =       57426
     Number of part elements                          =       57416
     Number of sprue/runner/gate elements             =          10
     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          =      2.9531
   Maximum aspect ratio of triangle elements          =     64.4931
   Element number with maximum aspect ratio           =      117048
   Minimum aspect ratio of triangle elements          =      1.1578
   Element number with minimum aspect ratio           =      146068
   Total volume                                       =   2434.3841 cm^3
     Volume filled initially                          =     13.7270 cm^3
     Volume to be filled                              =   2420.6571 cm^3
       Part volume to be filled                       =   2420.6571 cm^3
       Sprue/runner/gate volume to be filled          =      0.0000 cm^3
   Total projected area                               =   2262.0422 cm^2
 
--------------------------------------------------------------------------


Fill 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) |       |
|-------------------------------------------------------------|
|   0.20 |  0.67 |       36.44 |       0.67 |  255.32 |   V   |
|   0.39 |  4.73 |       46.10 |       5.38 |  576.81 |   V   |
|   0.59 |  9.27 |       50.63 |      18.45 |  577.81 |   V   |
|   0.78 | 13.85 |       54.87 |      39.05 |  587.67 |   V   |
|   0.98 | 18.45 |       58.58 |      65.90 |  593.44 |   V   |
|   1.17 | 23.08 |       62.10 |      99.05 |  595.69 |   V   |
|   1.37 | 27.74 |       65.63 |     136.57 |  598.41 |   V   |
|   1.56 | 32.38 |       69.09 |     177.54 |  601.10 |   V   |
|   1.76 | 37.04 |       72.49 |     222.66 |  602.93 |   V   |
|   1.95 | 41.57 |       76.19 |     276.56 |  604.75 |   V   |
|   2.15 | 46.28 |       79.54 |     326.46 |  608.42 |   V   |
|   2.34 | 50.88 |       82.51 |     373.78 |  610.60 |   V   |
|   2.54 | 55.45 |       85.31 |     420.72 |  612.20 |   V   |
|   2.73 | 60.15 |       88.11 |     468.53 |  613.75 |   V   |
|   2.93 | 64.84 |       90.96 |     519.76 |  614.75 |   V   |
|   3.13 | 69.55 |       93.83 |     573.09 |  615.94 |   V   |
|   3.32 | 74.02 |       96.96 |     634.72 |  616.66 |   V   |
|   3.51 | 78.48 |      100.31 |     703.89 |  618.45 |   V   |
|   3.71 | 83.06 |      103.48 |     767.68 |  619.01 |   V   |
|   3.90 | 87.42 |      110.11 |     902.45 |  620.66 |   V   |
|   4.10 | 91.16 |      121.36 |    1151.27 |  620.65 |   V   |
|   4.29 | 94.88 |      132.18 |    1431.25 |  620.67 |   V   |
|   4.30 | 95.03 |      132.40 |    1438.66 |  619.37 |  V/P  |
|   4.31 | 95.24 |      105.92 |    1409.36 |  208.50 |   P   |
|   4.49 | 97.06 |      105.92 |    1262.73 |  174.86 |   P   |
|   4.68 | 98.13 |      105.92 |    1255.87 |  119.92 |   P   |
|   4.88 | 98.82 |      105.92 |    1256.48 |   86.22 |   P   |
|   5.07 | 99.28 |      105.92 |    1264.77 |   66.19 |   P   |
|   5.27 | 99.60 |      105.92 |    1274.76 |   50.99 |   P   |
|   5.46 | 99.83 |      105.92 |    1283.98 |   39.96 |   P   |
|   5.66 | 99.98 |      105.92 |    1295.48 |   31.75 |   P   |
|   5.67 |100.00 |      105.92 |    1296.52 |   31.75 |Filled |
|-------------------------------------------------------------|


Filling phase results summary :

   Maximum injection pressure          (at      4.2970 s) =    132.4005 MPa
 
End of filling phase results summary :

   Time at the end of filling                         =      5.6655 s
   Total weight (part + runners)                      =   2697.3531 g
   Maximum Clamp force - during filling               =   1438.6629 tonne
   Recommended ram speed profile (rel):
       %Shot volume         %Flow rate
     ---------------------------------
            0.0000            12.7461
           10.0000            51.2260
           20.0000            71.2146
           30.0000            82.9175
           40.0000            86.5087
           50.0000            99.6758
           60.0000           100.0000
           70.0000            91.9636
           80.0000            85.9390
           90.0000            33.8124
          100.0000            13.4043
   Melt front is entirely in the cavity at % fill     =      0.0000 %
 
Filling phase results summary for the part :
 
   Bulk temperature - maximum          (at   4.297 s) =    215.2772 C
   Bulk temperature - 95th percentile  (at   4.297 s) =    207.8592 C
   Bulk temperature - 5th percentile   (at   5.659 s) =    184.3878 C
   Bulk temperature - minimum          (at   5.659 s) =     59.8930 C

   Wall shear stress - maximum         (at   5.665 s) =      1.7734 MPa
   Wall shear stress - 95th percentile (at   0.392 s) =      1.2426 MPa

   Shear rate - maximum                (at   3.705 s) =  1.0257E+05 1/s
   Shear rate - 95th percentile        (at   0.392 s) =  9.5967E+04 1/s
 
End of filling phase results summary for the part :
 
   Total part weight (excluding runners)              =   2697.3531 g

   Bulk temperature - maximum                         =    206.5576 C
   Bulk temperature - 95th percentile                 =    200.3505 C
   Bulk temperature - 5th percentile                  =    184.3981 C
   Bulk temperature - minimum                         =     59.8930 C
   Bulk temperature - average                         =    193.8770 C
   Bulk temperature - root-mean-square deviation      =      5.8845 C

   Wall shear stress - maximum                        =      1.7734 MPa
   Wall shear stress - 95th percentile                =      0.2384 MPa
   Wall shear stress - average                        =      0.1488 MPa
   Wall shear stress - root-mean-square deviation     =      0.0648 MPa

   Frozen layer fraction - maximum                    =      1.0000
   Frozen layer fraction - 95th percentile            =      0.1697
   Frozen layer fraction - 5th percentile             =      0.0752
   Frozen layer fraction - minimum                    =      0.0000
   Frozen layer fraction - average                    =      0.1225
   Frozen layer fraction - root-mean-square deviation =      0.0307

   Shear rate - maximum                               =   8148.0361 1/s
   Shear rate - 95th percentile                       =     35.2225 1/s
   Shear rate - average                               =     12.2081 1/s
   Shear rate - root-mean-square deviation            =     35.3594 1/s
 
Preparing interface data...
  Preparing PPC file for Cool analysis...
Finished preparing the interface data
 
--------------------------------------------------------------------------


Fill Analysis

Residual Stress Analysis
has completed successfully.               
 

Analysis has detected a mesh change since initial mesh 
generation ... recalculating mesh match and thickness information 
Processing Dual Domain mesh...
Computing match using the maximal-sphere algorithm
... finished processing Dual Domain mesh
   
Beginning weld line/air trap analysis...
 
Preparing output data...
Finished preparing output data
Weld line/air trap analysis completed
 
Execution time
   Analysis commenced at        Thu Dec 18 11:35:55 2025
   Analysis completed at        Thu Dec 18 12:20:13 2025
   CPU time used                     2489.54 s
