Computer-implemented simulation method for injection-molding process

A method for operating an injection-molding apparatus, the method comprising:

• specifying, via computer-assisted engineering simulation software, a simulating domain comprising a mold cavity, a barrel of an injection machine, and a screw in the barrel, wherein the barrel is configured to connect to the mold cavity;
• creating, via computer-assisted engineering simulation software, at least one mesh by dividing the mold cavity and a screw movement zone in the barrel into a set of elements;
• 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 a 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 the use of the screw using the boundary conditions, wherein the simulation uses densities and viscosities of the elements in the screw movement zone for generating a plurality of molding conditions indicating phenomena of the molding material discharged from the barrel to accurately predict a melt front of the molding material in the mold cavity;
• and
• adjusting operations of the injection-molding apparatus for performing an actual molding in response to the molding conditions.