Computer-implemented simulation method for injection-molding process

A method for operating an inj ection-molding apparatus, wherein the injection-molding apparatus comprises:

• a mold defining a mold cavity;
• and
• an injection machine including a barrel and a screw being movable in the barrel, the barrel being configured to connect to the mold cavity and including a screw movement zone in which the screw moves to inject a molding material into the mold cavity,
• the method comprising:
• specifying, via computer-assisted engineering simulation software, a simulating domain comprising the mold cavity, the barrel, and the screw;
• creating, via computer-assisted engineering simulation software, at least one mesh by dividing the mold cavity and the screw movement zone into mesh components;
• determining, via computer-assisted engineering simulation software, boundary conditions of the mesh by taking into consideration at least one motion of the screw in the barrel to process the molding material in the barrel;
• simulating, via computer-assisted engineering simulation software, a first injection-molding process to force the molding material out of the barrel and into the mold cavity by moving the screw using the boundary conditions, wherein the simulation generates a plurality of molding conditions indicating phenomena of the molding material transferred from the barrel and into the mold cavity from a calculation using factors in a part of the mesh components associated with the screw movement zone, the factors including a volume of the molding material and a volume of the screw in the part of the mesh components, thereby accurately predicting a melt front of the molding material in the mold cavity;
• and
• adjusting operations of the injection-molding apparatus for performing an actual molding by using the generated plurality of molding conditions.