Result Types

Injection Results

Review material behavior through the injection stage. Result types for this stage include: Temperature, Head ID, Material ID, Density, Polyol [mg KOH], Pressure, Velocity, Mold Temperature, Isocyanate [wt%], and Viscosity.

Result Type	Description
Temperature	Review the temperature evolution of the material entering the part cavity. Check regions for excessive heating or cooling. Determine the appropriate fill speed for uniform temperature distribution.
Head ID	Review injection results for material coming from a particular nozzle.
Material ID	Review results for a particular material.
Density	Consider material density through the progression of the injection stage.
Polyol [mg KOH]	Review the levels of polyol that remain in the material. The initial level will be equal to the mixing ratio and will decrease during the polyurethane reaction.
Pressure	Review the impact of pressure on the material during the injection stage.
Velocity	Review the velocity of the polyurethane material to detect turbulences that can cause defects. Velocity is affected by pressure, mold cavity shape, the polyurethane reaction itself, and other factors. Note: To enable vectors, click the icon under the Show heading in the Analysis Explorer window, and enable Vector Plot.
Mold Temperature	Review the temperature variance in the mold throughout the injection stage.
Isocyanate [wt%]	Review the levels of isocyanate that remain in the polyurethane material. The initial value will be equal to the mixing ratio, and will decrease during the polyurethane reaction.
Isocyanurate	Review the level of isocyanurate that is forming in the polyurethane model. Polyisocyanurate requires a relatively high temperature and an index greater than 180. (Find the material's index in the Mixing Ratio tab in the Materials window.) Note: To get an isocyanurate result, you must: Ensure that Isocyanurate Reaction is enabled in the Materials window. Select Time for the ending condition, and enter enough time for the reaction to complete, in the Process Parameters window.
Viscosity	Review the dynamic viscosity of the polyurethane material. Viscosity will increase over the course of the process.
Residual Stress	Residual stress is pressure from gas generated during the foaming reaction without density change in the material. Residual stress values will be low during the injection stage. Temperature, foam density, and concentration of blowing agents affect Residual Stress. This result is only available when rigid polyurethane and a mold are in use.
Air Flow	View the behavior of air inside the mold during the injection process. As material enters the cavity, air inside the mold pushes out through vents, parting lines, and filling systems.
Shear Rate	Review the rate at which a progressive shearing deformation is applied to the material during the injection process. Because the velocity difference is large and the shear rate increases on the mold surface, you can use this result as an indicator of surface defects along with the shear stress result. A high shear rate generally indicates a lot of deformation.
Shear Stress	Shear stress is one of the forces that can cause deformation of the material by slippage along a plane. You can use this result along with the viscosity and shear rate results to predict surface defects. You can also use this result as an indicator for resistance to filling.

Foaming Results

Review material behavior through the foaming stage. Result types for this stage include: Temperature, Head ID, Material ID, Density, Polyol [mg KOH], Pressure, Velocity, Isocyanate [wt%], and Viscosity.

Result Type	Description
Temperature	Review the temperature evolution of the material during the foaming stage.
Head ID	Review the foaming results for material coming from a particular nozzle.
Material ID	Review results for a particular material.
Density	Consider material density through the progression of the foaming stage.
Polyol [mg KOH]	Review the levels of polyol that remain in the material. The initial level will be equal to the mixing ratio and will decrease during the polyurethane reaction.
Pressure	Review the impact of pressure on the material during the foaming stage.
Velocity	Review the velocity of the polyurethane material to detect turbulences that can cause defects. Velocity is affected by pressure, mold cavity shape, the polyurethane reaction itself, and other factors. Note: To enable vectors, click the icon under the Show heading in the Analysis Explorer window, and enable Vector Plot.
Isocyanate [wt%]	Review the levels of isocyanate that remain in the polyurethane material. The initial value will be equal to the mixing ration, and will decrease during the polyurethane reaction.
Isocyanurate	Review the level of isocyanurate that is produced in the polyurethane model.
Viscosity	Review the dynamic viscosity of the polyurethane material. Viscosity will increase over the course of the process.
Residual Stress	Residual stress is pressure from gas generated during the foaming reaction without density change in the material. Residual stress gradually decreases after reaching its maximum value. Temperature, foam density, and concentration of blowing agents affect Residual Stress. This result is only available when rigid polyurethane and a mold are in use.
Air Flow	View the behavior of air inside the mold during the foaming process. As material fills the cavity, air inside the mold pushes out through vents, parting lines, and filling systems.
Shear Rate	Review the rate at which a progressive shearing deformation is applied to the material during the foaming process. Because the velocity difference is large and the shear rate increases on the mold surface, you can use this result as an indicator of surface defects along with the shear stress result. A high shear rate generally indicates a lot of deformation.
Shear Stress	Shear stress is one of the forces that can cause deformation of the material by slippage along a plane. You can use this result along with the viscosity and shear rate results to predict surface defects.
Mold Temperature	Review the temperature variance in the mold throughout the foaming stage.

Curing Results

Review material behavior through the curing stage. Result types for this stage include: Temperature, Head ID, Material ID, Density, Polyol [mg KOH], Pressure, Isocyanate [wt%], and Viscosity.

Result Type	Description
Temperature	Review the temperature evolution of the material during the curing stage. Check regions for excessive heating or cooling.
Head ID	Review curing results for the material coming from a particular nozzle.
Material ID	Review the curing results for a particular material.
Density	Consider material density during the curing stage.
Polyol [mgKOH]	Review the levels of polyol that remain in the material. The initial level will be equal to the mixing ratio and will decrease during the polyurethane reaction.
Pressure	Review the impact of pressure on the material during the curing stage.
Isocyanate [wt%]	Review the levels of isocyanate that remain in the polyurethane material. The initial value will be equal to the mixing ration, and will decrease during the polyurethane reaction.
Isocyanurate	Review the level of isocyanurate that is produced in the polyurethane model.
Viscosity	Review the dynamic viscosity of the polyurethane material.
Residual Stress	Residual stress is pressure from gas generated during the foaming reaction without density change in the material. Residual stress gradually decreases after reaching its maximum value. Temperature, foam density, and concentration of blowing agents affect Residual Stress. This result is only available when rigid polyurethane and a mold are in use.
Air Flow	View the behavior of air inside the mold during the curing process. As material changes shape inside the cavity, air can enter the mold through vents, parting lines, and filling systems.
Shear Rate	Review the rate at which a progressive shearing deformation is applied to the material during the curing process. Because the velocity difference is large and the shear rate increases on the mold surface, you can use this result as an indicator of surface defects along with the shear stress result.
Shear Stress	Shear stress is one of the forces that can cause deformation of the material by slippage along a plane. You can use this result along with the viscosity and shear rate results to predict surface defects.
Mold Temperature	Review the temperature variance in the mold throughout the curing stage.

Defects Results

Review a range of defects that can occur at the end of the foaming process. Result types for this stage include: Air Pressure, Filling Time, Surface Defect Modulus, Shrinkage Defect Modulus, Weld Lines, and Weld Lines Movement.

Option	Description
Air Pressure	Display the accumulated air pressure effects on the part at the end of the simulation. Look for porosity and void defects.
Filling Time	Review the time the material takes to reach different areas of the mold. Consider adjustments to the nozzle paths and tooling.
Surface Defect Modulus	Review the surface of the foam part for coarseness, toughness and melting that could be due to high mold temperatures, poor sealing, undried demolding spray, or contaminants. Consider controlling the mold temperature or modifying the sealing process. These surface defects can occur when a highly viscous foam flows through the mold. The Surface Defect Modulus is dimensionless, and the result is displayed only on the surface between the part and mold. The following example, where (a) is 20℃, (b) is 40℃, and (c) is 60℃, shows a defect area that increases as the mold temperature increases.
Shrinkage Defect Modulus	To produce results that predict the Shrinkage Defect Modulus, you must select Time as an ending condition when defining the Process Parameters for your analysis. A shrinkage defect can occur if the polyurethane foam is too soft during the molding process or after demolding. Shrinkage can occur due to over-packing, slow gelling, and low index. Note that the shrinkage defect model is appropriate for flexible, polyurethane foam only, not rigid polyurethane foam. The following examples show model results where (a) the mold is 40℃, (b) the mold is 20℃, (c) the temperature is shown through the cross-section of the part, and (d) the mold is 20℃ and the shrinkage modulus is shown. No shrinkage occurs when the mold temperature is 40℃ (a). However, when the mold temperature dips to 20℃, shrinkage occurs as shown in (b). Looking at the cross-section (c), shrinkage occurs mainly on the outer surface of the part because the surface temperature is lower than the core temperature.
Weld Lines	Weld lines occur when two separate fluid streams recombine as a result of multiple nozzles or the shape of the part. Material does not bond perfectly along weld lines, which can cause cosmetic imperfections and structural weakness. The Weld Lines result shows the initial position of weld lines in the part.
Weld Lines Movement	Weld lines can shift position as the foam expands. The Weld Lines Movement result shows the final position of weld lines in the part.