Influence of Mesh Density On Injection Molding Simulation Results

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Zeitschrift Kunststofftechnik
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Journal of Plastics Technology

archivierte, rezensierte Internetzeitschrift des Wissenschaftlichen Arbeitskreises Kunststofftechnik (WAK)
archival, reviewed online Journal of the Scientific Alliance of Polymer Technology
www.kunststofftech.com; www.plasticseng.com
eingereicht/handed in: 07.12.2006

angenommen/accepted: 26.02.2007
Prof. Maria Vicoria Candal, Rosa Amalia Morales, Kathleen Gorrin,

Universidad Simón Bolívar, Departamento de Mecánica, Grupo de Polímeros,
Venezuela
Influence of Mesh Density on Injection Molding

Simulation Results
The principal objective of this work was to study the influence of the number of elements has on a fi-
nite element mesh’s (FEM) simulation results. The simula-tion results analyzed were weight, and
linear shrinkage along the length and width of a injected plastic specimen. Also, simulation results
were compared with results obtained from solids modeling software (CAD) and from a simulator
software (CAE). The convergence simulation results showed similar trends with the experimental
ones. The modeling mesh gives a faster convergence than the simulator one.
Einfluss der Netzdichte auf die Ergebnisse von

www.kunststofftech.com
Spritzgießsimulationen
Das Hauptziel dieser Arbeit besteht in dem Studium des Einflusses der Num-mer von Elementen ei-
nes Finite-Elementen-Netzes (FEM) auf die Ergebnisse der Simulation. Die Ergebnisse der Simulati-
on, die analysiert wurden, waren das Gewicht und die lineare Kontraktion in der Länge und Breite
Richtungen eines Kunststoffteiles, das durch Spritzgiessen hergestellt wurde. Die Ergebnisse, die mit
einem CAD-Netz erhalten wurden, wurden mit einem CAE-Netz verglichen. Die Simulationserbegnis-
se, die konvergiert wurden, haben ähnliche Tendenzen gezeigt wie die experimetellen Ergebnisse.
Die mit dem Modellierungsprogramm erhaltene Netze konvergieren schneller als die mit dem Simula-
© 2007 Carl Hanser Verlag, München
tionsprogramm erhaltene Netze.
Autor/author
Prof. Maria Vicoria Candal, Rosa Amalia Morales, E-Mail-Adresse: mcandal@usb.ve

Kathleen Gorrin,
Universidad Simón Bolívar,
Departamento de Mecánica, Grupo de Polímeros,
Apartado 89000,
Caracas 1080-A, Venezuela
© Carl Hanser Verlag Zeitschrift Kunststofftechnik/Journal of Plastics Technology 3 (2007) 1

M.V. Candal et. al. Influence of Mesh Density on Injection
Molding Simulation Results
Influence of Mesh Density on Injection Molding

Simulation Results
Maria Vicoria Candal, Rosa Amalia Morales, Kathleen Gorrin,
Universidad Simón Bolívar, Departamento de Mecánica, Grupo de Polímeros,
Venezuela
The principal objetive of this work was to study the influence of the number of
elements has on a finite element mesh’s (FEM) simulation results. The simula-
tion results analyzed were weight, and linear shrinkage along the length and
width of a injected plastic specimen. Also, simulation results were compared
with results obtained from solids modeling software (CAD) and from a simulator
software (CAE). The convergence simulation results showed similar trends with
the experimental ones. The modeling mesh gives a faster convergence than the
simulator one.
Das primäre Ziel dieser Arbeit war es, den Einfluss der Anzahl von Elementen
in einem Finite-Elemente-Netz (FEM) auf die Ergebnisse einer Simulation zu
untersuchen. Die analysierten Ergebnisse waren das Gewicht und die Längen-
und Breitenkontraktion eines Spritzgießbauteils. Die Ergebnisse bei Ver-
wendung eines CAD-Netzes wurden mit denen eines CAE-Netzes verglichen.
Die Konvergenz der Simulationsergebnisse zeigte vergleichbare Trends wie die
experimentellen. Die Netze aus dem Modellierungsprogramm konvergierten
schneller als die aus dem Simulationsprogramm erzeugten Netze.
Zeitschrift Kunststofftechnik 3 (2007) 3 1

1 INTRODUCTION
Nowadays, the search of greater productivity and improvement in the product

quality, by the manufacturers, of plastic components has lead to the rapid de-
velopment of computer aided engineering (CAE) and computer aided design
(CAD) systems. There exist plenty of software available in the market that give
numerous advantages to the design and manufacturing areas, as well as to the
engineering area by means of the computerized simulation of different proc-
esses.
Development of CAD tools for polymers has been carried out since the early
80´s, and since those days it has been considered the main source of predictive
engineering. The tools, part of this category, are known as flow analysis. They
allow specialist Engineers to create a prototype of one piece or mold for specific
processes.
During the last ten years, the use of polymers in manufacturing and the demand
of the quality improvement of the molded pieces has increased rapidly, giving
as a result, a greater interest in the mathematical modeling of the mold injection
process. The first software packages allowed the users to determine the basic
processing conditions (temperature injection, mold temperature and injection
time), and to balance the flow in the cavities and mold cooling system. For that,
the package required a flat model of the selected piece to reduce the fluid prob-
lem from 3-D to 2-D. However, during the years the use of CAD software has
considerably developed. Among recent advances is the introduction of the Fini-
te Element Method, FEM, which is considered as an important improvement of
the molding injection simulation. The benefits in the development of the simula-
tion software of the injection process are not only found in the filling mold pha-
se, but also in the cooling phase and in the shrinkage and warpage analysis.
Moreover, alternative methods such as injection assisted by gas, coinjection
and thermostabile materials injection, among others are introduced.

Now it is more common to use CAD and CAE for modeling a variety of proces-
ses. In the plastic industry these resources are mostly used in the simulation of
the injection process. Generally, those tools carried out a numerical analysis
through FEM, allowing for engineers to obtain reliable results. Chan et al [1]
analyzed the cooling system of a complex panel car using the Fast Finite Ele-
ments Method (FFEM) to determine the mold temperatures distribution, in this
way the warpage analysis can be performed. Chan et al concluded that the coo-
ling system was well optimized, and they also proved that the suggested me-
thod gives an excellent performance calculation without convergence problems

even in the most complicated cases.
Specifically, CAE tools use a numerical analysis of the designed model in order
to predict the real behavior of the piece. One of the numerical techniques more
widely used in the science and engineering field is the Finite Element Method
(FEM). Basically, this technique requires the idealization of a real physical prob-
lem into a mathematical model, transforming the structure into various ele-

ments, all of which are connected by a nodes [2]. Then, the model is resolved
with a great algebraic equation system.
FEM is a numerical procedure to resolve complex engineering problems. Impor-
tant considerations should be taken into account to provide accurate analysis of
the results and the numerical solution convergence [3], and to understand the
convergence process that leads the numerical method closer to the exact solu-
tion. The convergence in FEM can be obtained by two different ways: refine-
ment of the mesh (greater number of elements) known as convergence-h, whe-
re the “h” term stands for the size of the element side that is reduced giving rise
to a finer discretization, and increase in the polynomial degree of equations
known as convergence-p [4].
Wang [5] focused his attention on studying the limitations of the CAE software
for the simulation of an injection molding process. This investigator modeled a
part with different meshes, to show that the results of air-trap depend on the
elements employed. Also, Villarroel et al [6] studied the effect of the number of
elements in the simulation of injection molded pieces. They found that when the
number of elements increased, the time for obtaining simulation results also
increased, but with a better convergence in the values obtained. Morales et al
[7] studied some results of the CAE software for the simulation of an injection
molding process where a convergence was obtained by means of increasing
the number of elements. Such areas of interest are: wall shear stress, cycle
and filling times.
Furthermore, Jawoski and Yuan [8] discussed the advantages and disadvanta-
ges of four different mesh types (1D, 2.5D, modified 2.5D, and 3D) in simulation
of the injection process through theoretical and experimental data. They compa-
red the reality of the simulation, the injection of a rack, with each type of mesh
to demonstrate how the acceptance of the different types of mesh can affect the
accuracy of the filling analysis results. Jawoski and Yan found that the simulati-
on results with 2.5-D meshes and 2.5-D modified meshes, particularly for this
piece, are not precise in the tooth section, while simulations for filling pattern
with elements 1-D and 3-D are precise.
This work has the purpose of studying the influence of the modification of the
characteristics of a finite element mesh (elements number, distribution, and si-
ze) and of the CAD/CAE tools for its generation, on the results of weight and
linear shrinkage along the length and width of the piece, obtained by the simula-
tion of the injection molding process. This analysis was done for two different
materials, one amorphous and one semi-crystalline.
2 METHODOLOGY
A homopolymer PP J600 from Propilven (MFI = 7.0 g/10 min at 230 ºC) and a
HIPS 4320 from Estirenos del Zulia (MFI = 8.5 g/10 min at 200 ºC) were used.
Both materials are injection molding grades.
Such materials are Venezuelan national production, and they cannot be found
in the data base of the simulator software. In order to overcome this limitation, a
rheological characterization was executed, since the analysis requires accuracy
on the data of materials properties, so the best predictions can be generated
[9].
Melt capillary flow properties for both materials were measured using a capillary
rheometer, Rheograph Model 2000, at several crosshead speeds. Tests were
done at 190ºC, 210ºC, and 230ºC for the PP and 170ºC, 190ºC, and 210ºC for
the HIPS with a length/diameter ratio (L/D) of 30/1, 20/1, 10/1, and 5/1. After-
wards, a plastometer was used in order to measure the Melt Flow Indexes of
both materials, ASTM D3835 and D1238 procedures were followed.
Bagley and Rabinowitsch corrections were done. The Cross, exponential of
hydraulic loss and William-Landel-Ferry, WLF, models were also employed to
calculate the specific constants for both materials in order to include them in the
simulator software. Then, simulation of the injection molding process of a nor-
malized tensile test specimen type I was done. This was performed with 3-D
solids modeler software. Figure 1 shows the mold employed. For simulation,
processing conditions found to be optimal for the experimental injection process
of the specimens were used. Moreover, results convergence of wall shear
stress, cycle and filling times, were verified. Simulation time was recorded for all
simulations, with the meshes of the modeling software as well as with the simu-
lation software.
Figure 1: Representation of a mold for injection of normalized tensile test

specimen type I
Specimen mesh was done with nine different models, varying the elements
number, using both programs with a midplane meshing (2 ½ mesh), and trian-
gular elements. The filling, cooling, and solidification of the mold were simula-
ted, and the convergence of the results of weight and lineal shrinkage along the
length and width of the piece as a function of the element number of the mesh
was studied.
The number of elements studied is presented in Table 1.

Table 1: Elements Number using fort he study
Specimens were injection molded experimentally in search of the optimum pro-

cessing conditions. An injection molding machine with a clamping force of 100
ton was used. Such specimens were weighed in a digital balance with an accu-
racy of 0.01 g. Also, length and width of each specimen were measured by
means of a digital Vernier with an accuracy of 0.01 mm, 1 h and 24 h after
being injection molded, as suggested by ASTM D955 procedure.
3 RESULTS AND DISCUSSION
Simulation software of an injection molding process include analysis of the filling

stage, where accuracy on the data of materials properties is very important, sin-
ce the reproduction of best predictions by the simulation depends on this fact
[9]. Thus, a rheological characterization of the materials employed was execu-
ted since they are not reported in the software data base.
Semi-crystalline polymers as well as amorphous polymers have complex ther-
mo-rheological behaviors, which influence significantly the injection molding
process. Thermoplastic materials exhibit non-Newtonian properties in the flow
behavior, their melt viscosity decreases when shear rate or temperature increa-
ses. Besides, injection molded pieces are generally thin-walled, so high injecti-
on rates are needed in order to fill the mold, with the subsequent generation of
high shear stresses, and dynamical changes in polymer properties while it flows
[10].
There exist various models employed by these software in order to describe the
resin behavior under different processing variables. The Cross and WLF models
permit the simulation of the filling and post-filling stages of the injection molded
piece, since they incorporate the dependency of the viscosity with shear rate
and with temperature. Another model employed is the exponential of hydraulic
loss for the filling stage, which calculates the loss occurred when the melt pas-
ses along a very small but long diameter, from the end of the channel to the
entrance of the cavity [9]. From these models, different rheological constants
required by the software so simulation could take place, were calculated.
Afterwards, injection molding of normalized tensile specimens type I was done,
thus obtaining the optimum processing conditions for each material under study.
Injection molding temperature for PP was 210 ºC while for HIPS it was 190 ºC.
Injection and packing/holding pressures were similar (800 psi). Cooling time
used for PP specimens was 18 s and 33 s for HIPS specimens. Weight and li-
neal shrinkage along the length and width of each specimen were measured 1 h
and 24 h after being injection molded.
Simulation of the injection molding process followed, for both materials under
the processing conditions mentioned above. Firstly, values of the specimen
weight were compared. Figures 2 (left) and (right) show the convergence of the
last four runs for this result.
Figure 2: Weight convergence for (a) PP and (b) HIPS

left: Polypropylene
right: High Impact Polystyrene
When comparing theoretical results reported by the software with the experi-
mental data, it can be noticed that they do not vary significantly for the speci-
men weight, as seen in Table 2. The difference between both values is slightly
higher for HIPS (3.44% between simulation and experimental values, and
3.476% between modeler and experimental values). While for the semicrystalli-
ne polymer the difference is unnoticeable (0.0641% and 0.0595% in the mes-
hes created by the simulator and modeler respectively).
Weight (g)
Material Experimental Simulator Software Modeler Software
Polypropylene 21.840 ± 0.026 21.854 21.853
High Impact
27.150 ± 0.010 26.216 26.206
Polystyrene
Table 2: Weight of the normalized tensile test specimen
Also, it can be observed that theoretical values obtained from the meshes of the
modeller resemble more to the machine results, since this mesh better copies

the details of the specimen due to its capability for modifying size and position
of the triangles employed. The user can locate more element density where a
more exhaustive study is required. However, with the CAE meshes only the
number of elements can be chosen and the software distributes them equally
along the specimen.
Other result evaluated, related to the quality of the molded piece and its dimen-
sional stability, was the shrinkage percentage. The linear shrinkage along the
length of the specimen after demolding and 24 h afterwards was measured. An
increasing tendency on contraction was observed when element number inc-
reased, Figure 3 left and right. Convergence was found on the last four meshes,
resulting values of 0.01482 mm for PP and 0.0038 for HIPS.
Figure 3: Linear shrinkage along lenght convergence

left: Polypropylene
When comparing the shrinkage values of PP and HIPS (Table 3), it was found
that the smaller percentage corresponds to the amorphous material HIPS. This
finding agrees with the values reported in the literature for this material (0.004 -
0.007 mm/mm) [10]. In this type of material, the chain mobility is not enough for
forming crystals, thus contraction is not favored.
Linear shrinkage along the length

(mm/mm)
Material 1h 24 h
Polypropylene 0,014191 0,015822
High Impact Polystyrene 0,002433 0,004500
Table 3: Linear shrinkage along lenght fort he normalized tensile test

specimen
In addition, the tendency on shrinkage along the width of the specimen is pre-
sented, obtaining the same behavior explained previously, Figure 4 left and
right.

Figure 4: Linear shrinkage along width convergence fort he (a) PP and (b)
HIPS
left: Polypropylene
Concerning the simulation time, possible differences between the simulation

with a mesh obtained from modeler software and a mesh obtained from simula-
tor software, were studied. There were no clear differences in the run time (Fi-
gure 5), probably due to the fact that the element size in both meshes was very
similar. Figure 6 illustrates the more dense meshing of specimens created with
each software. It can be seen that elements of similar size exist in the majority
of the part. Moreover, the number of elements compared for both types of mes-
hes was also similar (Table 1).
Figure 5: Run Time vs Elements Number

left: Polypropylene
Figure 6: Density Mesh maked with

up: Simulator Software
down: Modeler Software
The results obtained for the correlation of simulation time with increasing ele-
ment number agree with Villarroel's et al conclusion that run time increases with
increasing number of mesh elements [6].

Other results from the simulation of the injection molding process were also ve-
rified. Similar results compared to those presented by Morales et al were found
[7]. By means of increasing the number of elements, the values of cycle time,
filling time and wall shear stress increased until a convergence was obtained.
This is evident for the amorphous and the semi-crystalline materials, and for
meshes made with the modeler and the simulator software. The type of speci-
men does not influence these results.
4 CONCLUSIONS
The semi-crystalline material presented convergence in the results faster than

its amorphous peer.
When increasing the number of elements for the simulation, the results of
weight and linear shrinkage along the length and width of the specimen are mo-
dified, increasing until convergence is reached, so an optimum mesh could be
chosen, combining results similar to reality and reducing simulation time.
The mesh of the modeler software exhibits a faster convergence than the simu-
lator software, and its results are closer to experimental data.
The results from the simulation software using a mesh from the modeler pro-
gram as well as a mesh from the simulation program about weight and shrinka-
ge along the length and width of the specimen achieve a high accuracy compa-
red to experimental data.
5 REFERENCES
[1] Chang, R., Three-Dimensional Computer-Aided Mold

Yang, W., Cooling Design For Injection Molding
Liu, L., SPE´s ANTEC Proceedings, 2003, 656
Yanh, V.,
Hsu, D.
[2] Cook, R. Finite Elements Modeling for Stress Analysis

John Wiley & Sons Inc., USA, 1995
[3] Bathe, K. Finite Element Procedures
Prentice Hall, USA, 1996
[4] Reddy, J. An Introduction to the Finite Element Method
McGraw Hill, USA, 1993

[5] Wang, T. Numerical Simulation and Process Window

design of Injection/Compression Molding
SPE´s ANTEC Proceedings, 1999, 658
[6] Villarroel, S., Effect of the Mesh Number Elements in the
Morales, R., Simulation Results of Normalized Test
Sanchez, A. Specimens Injection Molded
SPE´s ANTEC Proceedings, 2002, w/p
[7] Morales, R., Effect of the finite element meshing for
Candal, M., designing plastic pieces
González, O. Polymer Plastics Technology and
Engineering 44 (8-9), 1573 (2005)
[8] Jaworski, M., Theoretical And Experimental Comparison
Yuan, Z. Of The Four Major Types Of Mesh Currently
Used In CAE Injection Molding Simulation
Software SPE´s ANTEC Proceedings, 2003,
w/p
[9] C-MOLD C-MOLD Reference Manual
Advanced CAE Technology Inc., USA, 1998
[10] Mark, H., Encyclopedia of Polymer Science and Engi-
Bikales, N., neering”
Overberger, C., John Wiley & Sons, Vol. 16, USA, 1990
Menges G. (eds)
Keywords:
injection molding, mesh, computer aided design, engineer aided design,
software
Kontakt:
Autoren: Prof. Maria Victoria Candal,
Rosa Amalia Morales,
Kathleen Gorrin
Herausgeber: Prof. em. Dr.-Ing. Dr. h.c. Gottfried W. Ehrenstein,
Prof. Dr. Tim Osswald
Erscheinungsdatum: Mai/Juni 2007

Herausgeber/Editor:
Europa/Europe Amerika/The Americas
Prof. Dr.-Ing. Dr. h.c. G. W. Ehrenstein, verantwortlich Prof. Dr. Tim A. Osswald, responsible
Lehrstuhl für Kunststofftechnik Polymer Engineering Center, Director
Universität Erlangen-Nürnberg University of Wisconsin-Madison
Am Weichselgarten 9 1513 University Avenue
91058 Erlangen Madison, WI 53706

Deutschland USA
Phone: +49/(0)9131/85 - 29703 Phone: +1/608 263 9538
Fax.: +49/(0)9131/85 - 29709 Fax.: +1/608 265 2316
E-Mail-Adresse: ehrenstein@lkt.uni-erlangen.de E-Mail-Adresse: osswald@engr.wisc.edu
Verlag/Publisher:
Carl-Hanser-Verlag
Jürgen Harth
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Tel.: 089/99 830 - 300

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E-mail: harth@hanser.de
Beirat/Editorial Board:
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Professors of the Scientific Alliance of Polymer Technology

Influence of Mesh Density On Injection Molding Simulation Results

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Wissenschaftlicher

Journal of Plastics Technology

eingereicht/handed in: 07.12.2006

Prof. Maria Vicoria Candal, Rosa Amalia Morales, Kathleen Gorrin,

Influence of Mesh Density on Injection Molding

Einfluss der Netzdichte auf die Ergebnisse von

tionsprogramm erhaltene Netze.

Prof. Maria Vicoria Candal, Rosa Amalia Morales, E-Mail-Adresse: mcandal@usb.ve

© Carl Hanser Verlag Zeitschrift Kunststofftechnik/Journal of Plastics Technology 3 (2007) 1

Influence of Mesh Density on Injection Molding

Zeitschrift Kunststofftechnik 3 (2007) 3 1

Nowadays, the search of greater productivity and improvement in the product

and thermostabile materials injection, among others are introduced.

thod gives an excellent performance calculation without convergence problems

Zeitschrift Kunststofftechnik 3 (2007) 3 2

Figure 1: Representation of a mold for injection of normalized tensile test

Zeitschrift Kunststofftechnik 3 (2007) 3 4

Table 1: Elements Number using fort he study

Specimens were injection molded experimentally in search of the optimum pro-

3 RESULTS AND DISCUSSION

Simulation software of an injection molding process include analysis of the filling

Figure 2: Weight convergence for (a) PP and (b) HIPS

Table 2: Weight of the normalized tensile test specimen

Zeitschrift Kunststofftechnik 3 (2007) 3 6

Figure 3: Linear shrinkage along lenght convergence

Linear shrinkage along the length

Table 3: Linear shrinkage along lenght fort he normalized tensile test

Zeitschrift Kunststofftechnik 3 (2007) 3 7

Concerning the simulation time, possible differences between the simulation

Figure 5: Run Time vs Elements Number

Figure 6: Density Mesh maked with

Zeitschrift Kunststofftechnik 3 (2007) 3 8

The semi-crystalline material presented convergence in the results faster than

[1] Chang, R., Three-Dimensional Computer-Aided Mold

[2] Cook, R. Finite Elements Modeling for Stress Analysis

Zeitschrift Kunststofftechnik 3 (2007) 3 9

[5] Wang, T. Numerical Simulation and Process Window

Zeitschrift Kunststofftechnik 3 (2007) 3 10

91058 Erlangen Madison, WI 53706

Tel.: 089/99 830 - 300

Zeitschrift Kunststofftechnik 3 (2007) 3 11

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