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User’s Manual Chapter 12, Introduction to Moldex3D-I2 Modules
Published: 2011-04-25_V03
Abstract
The application of CAE analysis in injection-molded plastic part is becoming popular in
the recent years, especially in part structure design and molding process optimization.
Users study the designs and experiments through numerous individual CAE tools. In
fact, these analyses and designs should be mutually dependent. The process-resulting
properties might be not favorable to the final products, such as fiber-induced anisotropic
mechanical property. Besides, the mesh requirement for different CAE analysis might be
different. In this chapter, an integrated approach from design phase to manufacturing
phase is proposed to seamlessly combine part structure analysis and injection molding
analysis through related-data linking and mesh property mapping. This developed
approach is proved from numerical experiments to be a cost-effective method for related
part/mold designers.
12........INTRODUCTION TO MOLDEX3D-I2 MODULES...................................................................................12-1
12.1 FUNCTION OVERVIEW................................................................................12-112.1.1 Thermal Residual Stress.......................................................................12-112.1.2 Anisotropic Material............................................................................12-212.1.3 Material Count Reduction....................................................................12-212.1.4 Map Function.......................................................................................12-312.1.5 High Order Element.............................................................................12-4
12.2 SHELL ANALYSIS OUTPUT.........................................................................12-512.2.1 Basic Procedures for Moldex3D/Shell-I2 Module...............................12-512.2.2 Interface to ABAQUS...........................................................................12-612.2.3 Interface to ANSYS...............................................................................12-712.2.4 Interface to MSC.Nastran....................................................................12-712.2.5 Interface to NE/Nastran.......................................................................12-712.2.6 Interface to LS-DYAN...........................................................................12-812.2.7 Interface to MSC.Marc.........................................................................12-812.2.8 Interface to NX Nastran.......................................................................12-9
12.3 SOLID ANALYSIS OUTPUT..........................................................................12-912.3.1 Basic Procedures for Moldex3D/Solid-I2 Module...............................12-912.3.2 Interface to ABAQUS.........................................................................12-1012.3.3 Interface to ANSYS.............................................................................12-1112.3.4 Interface to MSC.Nastran..................................................................12-1212.3.5 Interface to NE/Nastran.....................................................................12-1312.3.6 Interface to LS-DYNA.........................................................................12-1412.3.7 Interface to MSC.Marc.......................................................................12-1512.3.8 Interface to NX Nastran.....................................................................12-1612.3.9 Interface to Radioss............................................................................12-16
12.4 APPLICATION TIPS...................................................................................12-1712.5 MOLDEX3D TO DIGIMAT INTERFACES...................................................12-1812.6 MOLDEX3D-I2 FUNCTIONS TABLE.........................................................12-28
CONTENTS
Chapter 12
12. INTRODUCTION TO MOLDEX3D-I2 MODULES
12.1 Function Overview
The application of CAE analysis in injection-molded plastic part is becoming popular
in the recent years, especially in part structure design and molding process
optimization. Users usually study the designs and manufactures through numerous
individual CAE tools. An increasing number of industrial parts are made of plastic for
its low cost and superior material properties in the recent years. However, the
material characteristic of plastic part is extremely dependent on molding process.
The process-induced properties, such as fiber-induced anisotropic mechanical
properties, might not be favorable to the structural requirement of final products. The
traditional structure analysis is to perform CAE analysis based on the assumption of
one or several isotropic materials. But it neglects some molding effects. Sometimes
the results of analysis could be different from the real world.
Injection molding simulation is capable of simulating the filling, packing, and cooling
processes, as well as the part warpage after ejection. It has been widely applied in
industry and earns a fine reputation. Here we integrate injection molding and
structure analysis through an interfacing program to enhance structure analysis with
molding effects.
This chapter describes how to output relevant data of injection-molding analysis
through Moldex3D-I2 interface for other structure analysis software. Chapter12.1
describes function overview of Moldex3D-I2 interface, chapter 12.2 and 12.3
introduce how to output relevant data of injection molding analyses through
Moldex3D-I2 interface.
Moldex3D-I2 is the interface between Moldex3D and other CAE software. It
translates Moldex3D data to ABAQUS/ANSYS/MSC.Nastran/NASTRAN/LS-
DYNA/MSC.Marc/NX Nastran/Radioss data. These data include original/warpage
mesh and material properties. Original mesh describes the geometry before molding
process. Warpage mesh describes the geometry of molded part. The material
properties include material stiffness, thermal expansion coefficient, density etc. The
pure polymer is assumed as isotropic material. However, the material will be
anisotropic for fiber-filled polymer. These anisotropic material properties are related
to molding-induced fiber orientation. Moldex3D-I2 will translate these aniostropic
properties into other CAE software automatically. The following chapter will describe
more details.
12.1.1 Thermal Residual Stress
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An injection-molding part is shaped from a high temperature melt to a solid state.
Variation of temperature and pressure will induce volumetric shrinkage and produce
internal forces. Thus, the internal forces cause warpage of a plastic part. In this
situation, this internal stress is also named residual stress. There are a lot of factors
that will affect plastics’ residual stress, such as material selection, part design, mold
design and processing. Through Moldex3D-I2 interface, Moldex3D can output
residual stress from injection molding analyses. Yet this function is not available in
Moldex3D/Shell-I2 module.
12.1.2 Cooling Temperature Distribution
冷卻不均會使成品收縮不平均,引起翹曲。User can use End-of-
cooling temperature to analysis tempering process and the
effective solutions to solve the warping problem can be
found. Yet this function is not available in Moldex3D/Shell-I2
module.
12.1.3 T he Strength in Weld-Line Region
Weld-lines or knit-lines are formed during the mold filling process when the split melt
flow fronts meet at the same downstream location. Weld-lines look like cracks on the
appearance of plastic parts. The local mechanical strength in the weld-line area could
be significantly weaker. It could be one of the most significant problems for structural
applications due to the potential failure in the weld-line areas. Through Moldex3D-I2
interface, Moldex3D can transfer part geometry and weld-lines strength into stress
solver.User can define meeting angle and material parameter reduction
coefficients。Yet this function is not available in Moldex3D/Shell-I2 module.
12.1.4 D ensity Distribution
密度的分布,會影響模態分析的共振頻率;而塑膠的密度會隨著溫度及受壓縮程度的
變化而改變。溫度高時密度小 ,受壓縮程度大時密度大。User can use the density
distribution to do Modal analysis.Yet this function is not available in Moldex3D/Shell-
I2 module.
12.1.5 Anisotropic Material
If materials are fiber-contained, they will result in anisotropic mechanical properties
for fiber orientation. Moldex3D-I2 can also calculate and output the full stress-
strain relationship matrix relates terms ordered x, y, z, xy, yz, xz via. 21
2 User’s Manual
Symmetric
Chapter 12
constants as shown below:
同時,Moldex3D-I2 也支援輸出前一射含有非等向性質的 Part Insert 之材料,使用者
只要開啟計算參數精靈進行條件設定,Moldex3D-I2 在輸出時便會一起輸出前一射的
Part Insert 材料性質。
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Fig 12-1 設定前一射的Part Insert run ID
12.1.6 Material Count Reduction
Because of fiber orientation and its strength, every element of a model has a different
material property. For most of professional CAE software, material settings in
structure analyses are quite limited. Consequently, Moldex3D-I2 reduces fiber-
contained materials in the outputs by sorting the materials with similar fiber
orientation and strength as a classification. A schematic diagram of fiber orientation
is shown in Fig.12-1, where θ and ψ are angles of fiber in the spherical coordinate.
Due to the lack of GUI interface, users have to update those parameters manually
from cmi files, which can be found in the folder where your project is located. Assume
that your project is located in D disc; this cmi file is under D:\R9.0 Manual\
MDXProject20080108\Analysis\Run01, where MDXProject20080108 is the folder of
your project, Run01 is the run where you export the results through Moldex3D-I2.
The function Moldex3D toolbar helps user find cmi files more easily.
The control parameters within this file is described as follows:
IsDoMaterialReduction: 0 or 1 (ON: 1, OFF: 0)
Parameter (Segment of θangle): 1~35 (Integer, Min=1, Max=35, Default=3)
Segment number of θangle. The θ angle is 0~900. This parameter is limited from
1~35, and must be an integer. The default parameter is 3.
Parameter (Segment ofψangle): 1~35 (Integer, Min=1, Max=35, Default=3)
Segment number of ψangle. The ψ angle is 0~900. This parameter is limited from
1~35, and must be an integer. The default parameter is 3.
Parameter (Segment of Orientation strength): 1~10(Integral, Min=1, Max=10,
Default=5)
This parameter is limited from 1~35, and must be an integer. The default parameter
is 5.
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Fig 12-2 Sketch of fiber orientation
Users can get reasonable reduced material counts by the control parameters, but yet
only Moldex3D/Solid-I2 supports this function. Of course, users also have to
determine the rationality of this simplification by their engineering experience.
12.1.7 Map Function
The accuracy of finite element analysis or finite volume analysis is extremely
dependent on the mesh. Except for element qualities, the mesh structure is another
critical factor. The requirement of mesh structure for injection-molding analyses is
different from that for structure analyses due to different domains. Structure analyses
focus on the area of stress concentration while injection-molding analyses emphasize
the higher element resolution across the thickness direction. Injection molding
analyses typically need more elements and more diverse mesh densities than
structure analyses. Therefore, even though the meshes with molded properties in
injection-molding analyses are correctly taken into structure analyses, the accuracy
could not meet criterions.
In order to solve this awkward situation, a function to map element properties
between Moldex3D mesh and user-specified mesh is developed. This approach is to
look for matched elements between two meshes and assign proper element
properties into the specified mesh. Afterward users only need to import this mesh on
the platform of structure CAE and proceed advanced analyses.
Currently, Moldex3D/Shell-I2 supports three kinds of file formats for user-specified
mesh.
Moldex3D shell mesh file (*.msh)
ABAQUS mesh file (*.inp)
NASTRAN mesh file (*.bdf;*.dat;*.nas)
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For solid element, Moldex3D/Solid-I2 supports various file formats for user-specified
mesh.
Moldex3D solid mesh file (*.mfe)
ABAQUS mesh file (*.inp)
ANSYS mesh file (*.ans)
NASTRAN mesh file (*.bdf;*.dat;*.nas)
Marc mesh file created by Mentat (*.dat)
LS-DYNA mesh file(*.dyn)
In Interfacing Function Option, to map element properties to other mesh files, firstly
select Mapped in Output mesh as: list, and then selecting a mesh file which the
original data will be mapped to in Mesh file box. After selecting the items you would
like to map along with the original mesh in Function options list, click Export, and
all the element data will be mapped to the chosen mesh file.
12.1.8 High Order Element
Sometimes user would like to use high order element (Quadratic element) for more
accurate simulation. Therefore, Moldex3D-I2 further supports the auto-translation of
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normal element to high order element. In order to meet such demands, Moldex3D-I2
provides a function to output high order element. Users can select linear/output as
higher order element in Element type list. It should be noted that ANSYS stress
solver takes element of Solid-185 as linear and Solid-186 as higher order element.
While “Output as high order element” is selected, Moldex3D-I2 will translate the
element type automatically.
Fig 12-3 Interfacing Function Dialog
12.2 Shell Analysis Output
12.2.1 Basic Procedures for Moldex3D/Shell-I2 Module
The basic procedures of Moldex3D/Shell-I2 Module analysis are described as
follows.
Step 1: Create a new project
Step 2: Import a new mesh
Step 3: Select/import a new material
Step 4: Generate a new process condition
Step 5: Set the Computation parameter
Step 6: Check the requirement Run data
Step 7: Perform Flow/Pack/Cool/Warp analyses first
Step 8: Perform Interfacing function to output these interface files
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Step 9: Load these interface files on other CAE platform and perform advanced
analyses
As pointed in item 8, users have to assign the requirement in Interfacing Function
Option dialog as shown in Fig. 12-3.
Fig 12-4 Interfacing Function Dialog
12.2.2 Interface to ABAQUS
ABAQUS was founded in 1978 by David Hibbitt, Bengt Karlsson, and Paul Sorensen.
The ABAQUS suite of software for finite element modeling and solution is able to
solve many kinds of challenging simulations. ABAQUS provides a powerful and
unified system for engineering analysis and digital prototyping in support of design
and manufacturing. (More information please refer to http://www.hks.com)
There are various file types that can be exported from Moldex3D/Shell-I2 ABAQUS,
which are further described below:
Original/Warpage mesh files with material properties of molded parts:
* _ABAQUS_Part_Ori.inp/ *_ABAQUS_Part_Wap.inp.
User-specified mesh with material properties of molded parts:
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*_ABAQUS_ Part_MAPMESH.inp.
After importing these files in ABAQUS, users can further conduct other analyses.
12.2.3 Interface to ANSYS
ANSYS is committed to developing simulation solutions — from mechanical to
computational fluid dynamics (CFD) — that illustrate realistic and accurate modeling
and simulation of components, subsystems, and systems. Replacing hardware
prototyping and testing, ANSYS solutions drive product designs from concept to
reality, providing an engineering simulation system for a fast, efficient and cost-
conscious information-based development process. (More information please refer to
http://www.ansys.com)
There are various file types that can be exported from Moldex3D/Shell-I2 ANSYS,
which are further described below:
Original/Warpage mesh files with material properties of molded parts:
*_ANSYS_Part_Ori.ans/ *_ANSYS_Part_Wap.ans.
User-specified mesh with material properties of molded parts:
*_ANSYS_ Part_MAPMESH.ans.
After importing these files in ANSYS, users can further conduct other analyses.
12.2.4 Interface to MSC.Nastran
MSC.Software provides simulation technology and services to manufacturers and
research facilities in many fields. The MSC.Nastran product family is modular,
enabling you to analyze products ranging from simple components to complex
structures and systems. (More information please refer to
http://www.mscsoftware.com)
There are various file types that can be exported from Moldex3D/Shell- I2
MSCNASTRAN, which are further described below:
Original/Warpage mesh with material properties of molded parts:
*_MSCNASTRAN_Part_Ori.bdf/* MSCNASTRAN_Part_Wap.bdf.
User-specified mesh with material properties of molded parts:
*_MSCNASTRAN_ Part_MAPMESH.bdf.
After importing these files in MSCNASTRAN, users can further conduct other
analyses.
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Chapter 12
12.2.5 Interface to NE/Nastran
Noran Engineering, Inc. is established in 1991, created with the idea of bringing a
true Nastran analysis tool from the mainframe to the desktop. NE/Nastran is a
comprehensive finite element analysis (FEA) tool based on NASA's popular
NASTRAN finite element analysis software. NE/Nastran offers structural analysis
software solutions including: linear static, buckling, pre-stress, modal dynamics,
nonlinear, steady state, and transient heat transfer. (More information please refer to
http://www.nenastran.com)
There are various file types that can be exported from Moldex3D/Shell-I2
NENASTRAN, which are further described below:
Original/ Warpage mesh with material properties of molded parts:
* _NENASTRAN_Part_Ori.nas/* _NENASTRAN_Part_Wap.nas.
User-specified mesh with material properties of molded parts:
*_NENASTRAN_ Part_MAPMESH.bdf.
After importing these files in NE/NASTRAN, users can further conduct other
analyses.
12.2.6 Interface to LS-DYAN
LS-DYNA, which is developed by the Livermore Software Technology Corporation
(LSTC), is being used by Automobile, Aerospace, Military, Manufacturing, and
Bioengineering companies. LS-DYNA has the capabilities from simple linear static
mechanical analysis up to advanced thermal and flow solving methods.(For more
information, please link to http://www2.lstc.com/)
There are various file types that can be exported from Moldex3D/Shell-I2 LS-DYNA,
which are further described below:
Original/ Warpage mesh with material properties of molded parts:
*_LSDYNA_Part_Ori.dyn/*_LSDYNA_Part_Wap.dyn
User-specified mesh with material properties of molded parts:
*_LYDYNA_Part_MAPMESH.dyn.
After importing these files in LS-DYNA, users can further conduct other analyses.
12.2.7 Interface to MSC.Marc
MSC.Software provides simulation technology and services to manufacturers and
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Chapter 12
research facilities in many fields. The MSC.Marc product family is a nonlinear FEA
program that enables you to assess the structural integrity and performance of parts
undergoing large permanent deformations as a result of thermal or structural load.
(More information please refer to http://www.mscsoftware.com)
There are various file type that can be exported from Moldex3D/Shell-I2
MSCMARC, which are further described below:
Original/Warpage mesh with material properties of molded parts:
* _MARC_Part_Wap.dat
User-specified mesh with material properties of molded part:
*_MARC_ Part_MAPMESH.bdf.
After importing these files in MSCMARC, users can further conduct other analyses.
12.2.8 Interface to NX Nastran
NX Nastran is a premium computer-aided engineering (CAE) tool that major
manufacturers worldwide rely on to produce safe, reliable and optimized designs
within increasingly shorter design cycle times. (More information please refer to
http://www.designviz.com)
There are various file types that can be exported from Moldex3D/Shell- I2
NXNASTRAN, which are further described below:
Original/Warpage mesh with material properties of molded parts:
*_NXNASTRAN_Part_Ori.dat/* NXNASTRAN_Part_Wap.dat.
User-specified mesh with material properties of molded parts:
*_NXNASTRAN_ Part_MAPMESH.dat.
After importing these files in NXNASTRAN, users can further conduct other analyses.
12.3 Solid Analysis Output
12.3.1 Basic Procedures for Moldex3D/Solid-I2 Module
The basic procedures of Moldex3D/Solid-I2 Module analysis are described as
follows.
Step 1: Create a new project
Step 2: Import a new mesh
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Step 3: Select/import a new material
Step 4: Generate a new process condition
Step 5: Set the Computation parameter
Step 6: Check the requirement Run data
Step 7: Perform Flow/Pack/Cool/Warp analyses first
Step 8: Perform Interfacing function to output these interface files
Step 9: Load these interface files on other CAE platform and perform advanced
analyses
As pointed in item 8, users have to assign the requirement in Interfacing Function
Option dialog as shown in Fig. 12-4.
Fig 12-5 Interfacing Function Dialog
12.3.2 Interface to ABAQUS
ABAQUS was founded in 1978 by David Hibbitt, Bengt Karlsson, and Paul Sorensen.
The ABAQUS suite of software for finite element modeling and solution is able to
solve many kinds of challenging simulations. ABAQUS provides a powerful and
12 User’s Manual
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unified system for engineering analysis and digital prototyping in support of design
and manufacturing. (More information please refer to http://www.hks.com)
There are various file types that can be exported from Moldex3D/Solid-I2 ABAQUS, which
are further described below:
(1) Original/Warpage mesh files with material properties of molded parts:
ABAQUS_ Part_Ori_*.inp/ ABAQUS_ Part_Wap_*.inp.
(2) Original/Warpage residual stress files:
Thermal Residual Stress:
ABAQUS_ Part_Ori_*_ThermalStress.sts/ ABAQUS_ Part_Wap_*_ThermalStress.sts.
Flow Residual Stress:
ABAQUS_ Part_Ori_*_FlowStress.sts/ ABAQUS_ Part_Wap_*_FlowStress.sts.
(3) User-specified mesh with material properties of molded parts:
ABAQUS_ Part_MAPMESH_*.inp/ ABAQUS_ Part_MAPMESH_*.sts.
(4) Pressure outputs of multi-component models at various times:
ABAQUS_ PartInsert_Pressure_Ori_*_00x(step time).inp/
ABAQUS _ PartInsert_Pressure_Ori_*_EOF.inp/
ABAQUS_ PartInsert_Pressure_Ori_*_EOP.inp,
Where x presents the number of time steps, which ranges from 1 to the total amount of time
steps.
(5) Pressure outputs of moldbase at various times:
ABAQUS_ Moldbase_Pressure_*_00x(step time).inp/
ABAQUS_ Moldbase_Pressure_*_EOF.inp/
ABAQUS_ Moldbase_Pressure_*_EOP.inp,
ABAQUS_Moldbase_AllPressure_*.inp
Where x presents the number of time steps, which ranges from 1 to the total amount
of time steps.
After importing these files in ABAQUS, users can further conduct other analyses.
12.3.3 Interface to ANSYS
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ANSYS is committed to developing simulation solutions — from mechanical to
computational fluid dynamics (CFD) — that illustrate realistic and accurate modeling
and simulation of components, subsystems, and systems. Replacing hardware
prototyping and testing, ANSYS solutions drive product designs from concept to
reality, providing an engineering simulation system for a fast, efficient and cost-
conscious information-based development process. (More information please refer to
http://www.ansys.com)
There are various file types that can be exported from Moldex3D/Solid-I2 ANSYS,
which are further described below:
(1) Original/Warpage mesh files with material properties of molded parts:
ANSYS_ Part_Ori_*.ans/ ANSYS_ Part_Wap_*.ans.
(2) Original/Warpage residual stress files:
Thermal Residual Stress:
ANSYS_ Part_Ori_*_ThermalStress.ist/ ANSYS_ Part_Wap_*_ThermalStress.ist.
Flow Residual Stress:
ANSYS_ Part_Ori_*_FlowStress.ist/ ANSYS_ Part_Wap_*_FlowStress.ist.
(3) User-specified mesh with material properties of molded parts:
ANSYS_ Part_MAPMESH_*.ans/ ANSYS_ Part_MAPMESH_*.ist.
(4) Pressure outputs of multi-component models at various times:
ANSYS_ PartInsert_Pressure_Ori_*_00x.cdb/
ANSYS _ PartInsert_Pressure_Ori_*_EOF.cdb/
ANSYS_ PartInsert_Pressure_Ori_*_EOP.cdb
Where x right presents the number of time steps, which ranges from 1 to the total amount of time steps.
(5) Pressure outputs of moldbase at various times:
ANSYS_ Moldbase_Pressure_*_00x.cdb/
ANSYS_ Moldbase_Pressure _*_EOF.cdb/
ANSYS_ Moldbase_Pressure _*_EOP.cdb/
Where x right presents the number of time steps, which ranges from 1 to the total
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amount of time steps.
(6) Iinitial Strain Output:
ANSYS_Part_InitialStrain_Ori_*.cdb
After importing these files in ANSYS, users can further conduct other analyses.
12.3.4 Interface to MSC.Nastran
MSC.Software provides simulation technology and services to manufacturers and
research facilities in many fields. The MSC.Nastran product family is modular,
enabling you to analyze products ranging from simple components to complex
structures and systems. (More information please refer to
http://www.mscsoftware.com)
There are various file type that can be exported from Moldex3D/Solid-I2 MSCNASTRAN,
which are further described below:
(1) Original/Warpage mesh with material properties of molded parts:
MSCNASTRAN_Part_Ori_*.bdf/
MSCNASTRAN_Part_Wap_*.bdf.
(2) User-specified mesh with material properties of molded part:
MSCNASTRAN_ Part_MAPMESH_*.bdf.
(3) Pressure outputs of multi-component models at various times:
MSCNASTRAN_PartInsert_Pressure_Ori_*_00x.bdf
MSCNASTRAN_PartInsert_Pressure_Ori_*_EOF.bdf
MSCNASTRAN_PartInsert_Pressure_Ori_*_EOP.bdf
Where x right presents the number of time steps, which ranges from 1 to the total amount of
time steps.
(4) Pressure outputs of moldbase at various times:
MSCNASTRAN_Moldbase_Pressure_*_00x.bdf
MSCNASTRAN_Moldbase_Pressure_*_EOF.bdf
MSCNASTRAN_Moldbase_Pressure_*_EOP.bdf
Where x right presents the number of time steps, which ranges from 1 to the total amount of
time steps.
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After importing these files in MSCNASTRAN, users can further conduct other analyses.
Note:
MSC.Nastran doesn’t support pyramid elements. If pyramid elements exist, they will be removed.
12.3.5 Interface to NE/Nastran
Noran Engineering, Inc. is established in 1991, created with the idea of bringing a
true Nastran analysis tool from the mainframe to the desktop. NE/Nastran is a
comprehensive finite element analysis (FEA) tool based on NASA's popular
NASTRAN finite element analysis software. NE/Nastran offers structural analysis
software solutions including: linear static, buckling, pre-stress, modal dynamics,
nonlinear, steady state, and transient heat transfer. (More information please refer to
http://www.nenastran.com)
There are various file types that can be exported from Moldex3D/Solid-I2 NENASTRAN,
which are further described below:
(1) Original/ Warpage mesh with material properties of molded parts:
NENASTRAN_Part_Ori_*.nas/ NENASTRAN_Part_Wap_*.nas.
(2) User-specified mesh with material properties of molded part. The file is
*_NENASTRAN_ Part_MAPMESH_*.bdf.
After importing these files in NE/NASTRAN, users can further conduct other analyses.
Note:
NE/Nastran doesn’t support pyramid elements. If pyramid elements exist, they will be removed.
12.3.6 Interface to LS-DYNA
LS-DYNA, which is developed by the Livermore Software Technology Corporation
(LSTC), is being used by Automobile, Aerospace, Military, Manufacturing, and
Bioengineering companies. LS-DYNA has the capabilities from simple linear static
mechanical analysis up to advanced thermal and flow solving methods.(For more
information, please link to http://www2.lstc.com/)
There are various file types that can be exported from Moldex3D/Solid-I2 LS-DYNA, which
are further described below:
(1) Original/Warpage mesh with material properties of molded parts:
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LSDYNA_Part_Ori_*.dyn
LSDYNA_Part_Wap_*.dyn
(2) User-specified mesh with material properties of molded part:
LSDYNA_ Part_MAPMESH_*.bdf.
(3) Pressure outputs of multi-component models at various times:
LSDYNA_PartInsert_Pressure_Ori_*_EOF.dyn
LSDYNA_PartInsert_Pressure_Ori_*_EOP.dyn
LSDYNA_PartInsert_Pressure_Ori_*_00x.dyn
where x right presents the number of time steps, which ranges from 1 to the total amount of
time steps.
(4) Pressure outputs of moldbase at various times:
LSDYNA_Moldbase_Pressure_*_EOF.bdf
LSDYNA _Moldbase_Pressure_*_EOP.bdf
After importing these files in LS-DYNA, users can further conduct other analyses.
12.3.7 Interface to MSC.Marc
MSC.Software provides simulation technology and services to manufacturers and
research facilities in many fields. The MSC.Marc product family is a nonlinear FEA
program that enables you to assess the structural integrity and performance of parts
undergoing large permanent deformations as a result of thermal or structural load.
(More information please refer to http://www.mscsoftware.com)
There are various file type that can be exported from Moldex3D/Solid-I2 MSCMARC, which
are further described below:
(1) Original/Warpage mesh with material properties of molded parts:
MARC_Part_Ori_*.dat
MARC_Part_Wap_*.dat
(2) User-specified mesh with material properties of molded part:
MARC_ Part_MAPMESH_*.bdf.
(3) Pressure outputs of multi-component models at various times:
MARC_PartInsert_Pressure_Ori_*_EOF.dat
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MARC_PartInsert_Pressure_Ori_*_EOP.dat
MARC_PartInsert_Pressure_Ori_*_00x.dat
Where x right presents the number of time steps, which ranges from 1 to the total amount of
time steps.
(4) Pressure outputs of moldbase at various times:
MARC _Moldbase_Pressure_*_EOF.bdf
MARC _Moldbase_Pressure_*_EOP.bdf
After importing these files in MSCMARC, users can further conduct other analyses.
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Chapter 12
12.3.8 Interface to NX Nastran
NX Nastran is a premium computer-aided engineering (CAE) tool that major manufacturers
worldwide rely on to produce safe, reliable and optimized designs within increasingly shorter
design cycle times. (More information please refer to http://www.designviz.com)
There are various file type that can be exported from Moldex3D/Solid-I2 NXNASTRAN, which
are further described below:
(1) Original/Warpage mesh with material properties of molded parts:
NXNASTRAN_Part_Ori_*.dat/
NXNASTRAN_Part_Wap_*.dat.
(2) User-specified mesh with material properties of molded part:
NXNASTRAN_ Part_MAPMESH_*.dat.
(3) Pressure outputs of multi-component models at various times:
NXNASTRAN_PartInsert_Pressure_Ori_*_00x.dat
NXNASTRAN_PartInsert_Pressure_Ori_*_EOF.dat
NXNASTRAN_PartInsert_Pressure_Ori_*_EOP.dat
Where x right presents the number of time steps, which ranges from 1 to the total amount of
time steps.
(4) Pressure outputs of moldbase at various times:
NXNASTRAN_Moldbase_Pressure_*_00x.dat
NXNASTRAN_Moldbase_Pressure_*_EOF.dat
NXNASTRAN_Moldbase_Pressure_*_EOP.dat
Where x right presents the number of time steps, which ranges from 1 to the total amount of
time steps.
After importing these files in NXNASTRAN, users can further conduct other analyses.
12.3.9 Interface to Radioss
Radioss is one of leading computer-aided engineering (CAE) tool that is applied widely in
analyzing product structure under high-speed impact. Its simulation can be used to
understand and predict product behavior in complex environments and further make sure the
reliability and optimization of product designs. (More information please refer to
http://www.radioss.com)
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Chapter 12
There are various file type that can be exported from Moldex3D/Solid-I2 Radioss, which are
further described below:
(1) Original/Warpage mesh with material properties of molded parts:
Radioss_Part_Ori_*.fem
Radioss _Part_Wap_*. fem
(2) User-specified mesh with material properties of molded part:
Radioss _ Part_MAPMESH_*. fem
(3) Packing phase temperature output
Radioss _Part_PackTemperature_ Ori_*.fem
Radioss _Part_PackTemperature_ MAPMESH_*.fem
(4) Initial strain output
Radioss _Part_InitialStrain_ Ori_*.fem
Radioss _Part_InitialStrain_ MAPMESH_*.fem
(5) Pressure outputs of multi-component models at various times:
Radioss _PartInsert_Pressure_Ori_*_00x. fem
Radioss _PartInsert_Pressure_Ori_*_EOF. fem
Radioss _PartInsert_Pressure_Ori_*_EOP. fem
(6) Pressure outputs of moldbase at various times:
Radioss _Moldbase_Pressure_*_00x. fem
Radioss _Moldbase_Pressure_*_EOF. fem
Radioss _Moldbase_Pressure_*_EOP. fem
Where x right presents the number of time steps, which ranges from 1 to the total amount of
time steps.
12.4 Application Tips
Moldex3D-I2 Interface modules provide a bridge between injection molding CAE and
other professional CAE. Users only need to import these interface files as initial
condition on other CAE platform and perform advanced simulations. These
simulations could be linear static, buckling, pre-stress, modal dynamics, nonlinear,
steady state, transient heat transfer … etc. This integration tool will be provided a
20 User’s Manual
Chapter 12
cost-effective total solution for related part/mold designers.
12.5 Moldex3D to Digimat Interfaces
1. Moldex3D to Digimat interfaces
Moldex3D to Digimat interface enables users to take material data resulted from
injection molding process, especially fiber orientation, into Digimat to gain readable
material parameters for further analyzing in structure softwares, such as ABAQUS
and ANSYS:
Moldex3D – DIGIMAT – ABAQUS
Moldex3D – DIGIMAT – ANSYS
1.1 Moldex3D – DIGIMAT – FE Software
Following is the detailed steps performing Moldex3D – DIGIMAT – FE software
analysis.
1.1.1 Moldex3D
Run Moldex3D analysis to obtain an orientation file (.o2d).
It is suggested to enter 1 in the box of Solver Accuracy/Performance Options to get
accurate orientation tensors. Other value for performance parameter may lead to
imprecise analysis in the following CAE calculation.
User’s Manual 21
Chapter 12
.o2d analysis example: the orientation file is presented as below.
In the first part, it shows related info, such as mesh file, material file, and process
condition file.
Second, it presents different parameters as Element Id, the number of the integration
point (IntegrationId), and the orientation tensors.
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Chapter 12
As for the last part of the file, the data in the first column presents the element
number after integration, the second column presents the number of the integration
point, and the rest columns are the value of the orientation tensors.
Note:
Moldex3D defines injection file (.o2d) for solid mesh only.
1.1.2 DIGIMAT to CAE
Step 1: Load this material file.
CAE interface: generate interface file. Select the desired software. Software with
Global axes orientation function, like Abaqus/Explicit, is included in the selection list
as well.
Inclusions' orientations given in: the axes system used to store the orientation
tensors in the orientation file.
Inclusions' orientations used in: the axes system that Digimat will use to perform the
homogenization.
Define the inclusions’ orientation: phase name, Orientation file format and File name.
Step 2: Run DIGIMAT to CAE job .
The job completed successfully is shown in Digimat log message space. Besides,
related files have been created in the Working directory:
.mat : with the material properties
.log : with the error and warning messages
When ABAQUS is selected as FE software, the file type created in the Working
directory is
.aba
When ANSYS is selected as FE software, the file type created in the Working
User’s Manual 23
Chapter 12
directory is
.ans
When LS-DYNA is selected as FE software, the file type created in the Working
directory is
.dyn
For further info, please refer to DIGIMAT to Abaqus, Ansys and Ls-Dyna
documentation.
Example :
.mat shows the data in which the link between Moldex3D and Digimat is done.
.log
24 User’s Manual
Chapter 12
.aba with the definition of the USER material card
and the meaning of every SDV in which the results of DIGIMAT calculation is stored
can be displayed in ABAQUS Postprocessor.
.ans with the definition of the USER material card
and the meaning of every SVAR in which the results of DIGIMAT calculation is stored
can be displayed in ABAQUS Postprocessor.
.dyn with the definition of the USER material card
User’s Manual 25
Chapter 12
And the meaning of every history variable in which the results of DIGIMAT calculation
is stored can be displayed in ABAQUS Postprocessor.
1.1.3 Use Digimat material file in FE – Software
Below shows how to use Digimat material file in FE software, such as ABAQUS,
ANSYS or LS-DYNA.
ABAQUS
1. Open model file
- Launch Abaqus
26 User’s Manual
Chapter 12
- Import Model (*.inp)
2. Open Plug-Ins
- Click Plug-Ins
- Select DIGIMAT
- Select 1. Add DIGIMAT material
A panel shows for users to load a DIGIMAT Material. Click Select, select the desired model,
and then click Add. Back to Abaqus.
Enter Property. Click Edit Job to change material as digimat material.
3. Run Jobs
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Chapter 12
Two words, assembly and part, are not allowed to use for the file name. These two words may
disorder the orientation tensor relationship between the original element and its corresponding
one in model renumbering phase at the beginning of running.
Add the output of SDV (state variables to have per-phase outputs)
*Output, field
*Element Output, directions=YES
E, S, SDV
Submit the job and use the sub-routine precisely.
*abaqus job=JobName user=C:\DIGIMAT\Digimat2CAE\3.0.1\exec\digi2aba\
*digi2abaStd.obj
*with Abaqus CAE submit options
ANSYS
Define a "user material" in your ANSYS model.
User material options are available in the material category: "Preprocessor – Material
Properties". The input file data can be read from DIGIMAT (.ans) there.
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Chapter 12
Two items, State variables and user constants, have been created under the material models.
Before starting the calculation, the name of the .mat file generated by DIGIMAT must be
modified to follow the generic name “DigimatMaterialID.mat”. ID has to be replaced by the
material ID in your ANSYS calculation. By default, it is 1. The name is therefore
“DigimatMaterial1.mat”.
Other running procedures are the same as the ones for running a general ANSYS job.
LS-DYNA
Define a user material card and a specific jobname for the LS-DYNA FE model.
A job name in LS-DYNA should be named following the rule: *KEYWORD_ID. All LS-DYNA
input files using DIGIMAT as a material model need to define this keyword and the name to
refer to the DIGIMAT mat file name.
An example of plate analysis is listed below:
User’s Manual 29
Chapter 12
The full .mat file name is name41.mat. 41 refers to the user material model number inside LS-
DYNA system. No. 41 to 50 are reserved in LS-DYNA for user to define material model. That
means 10 DIGIMAT material can be used in one LS-DYNA DIGIMAT coupled simulation.
In order to record history variables or state variables referring to DIGIMAT in LS-DYNA, the
following keyword in the LS-DYNA input file should be activated.
*DATABASE_EXTENT_BINARY. Look at the LS-DYNA keyword file for a complete
description.
*DATABASE_EXTENT_BINARY
$$FORCE SHELL HISTORY VARIABLE OUTPUT AT ALL 20 in-plane INTEGRATION POINT
**DATABASE_EXTENT_BINARY
$ neiph neips maxint strflg sigflg epsflg rltflg engflg
1
$# cmpflg ieverp beamip dcomp shge stssz n3thdt ialemat
0 0 0 0 0 0 0 0
30 User’s Manual
Chapter 12
Other running procedures are the same as the ones for running a general LS-DYNA job.
12.6 Moldex3D-I2 Functions Table
Table 12-1 Moldex3D-I2 available functions for ANSYS
OptionANSYS
Original Mesh Deformed Mesh Mapped Mesh
Part
Mesh Output ○ ○ ○
Fiber Orientation - Material reduction ○ ○ ○
Weld line Output ○ ○ ○
Density Distribution Output ○ ○ ○
Thermal residual stress Output ○ ╳ ○
Flow residual stress Output ○ ╳ ○Initial strain Output(As
Temperature Difference)○ ╳ ○
Packing phase temperature output ○ ╳ ○
End of cooling temperature output ○ ╳ ○
Digimat option to export fiber orientation data ○ ○ ╳
Part Insert Flow Pressure Output ○ ╳ ○
Moldbase
Moldbase Output ○ ╳ ○Moldbase Pressure Output ○ ╳ ○
Moldbase Temperature Output ○ ╳ ○
Runner Output ○ ○ ○
Output as high order element ○ ○ ○
eDesign Mesh (*.mde) ╳ ╳ ○
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Chapter 12
Table 12-2 Moldex3D-I2 available functions for ABAQUS
OptionABAQUS
Original Mesh Deformed Mesh Mapped Mesh
Part
Mesh Output ○ ○ ○
Fiber Orientation - Material reduction ○ ○ ○
Weld line Output ○ ○ ○
Density Distribution Output ○ ○ ○
Thermal residual stress Output ○ ╳ ○
Flow residual stress Output ○ ╳ ○Initial strain Output(As
Temperature Difference)○ ╳ ○
Packing phase temperature output ○ ╳ ○
End of cooling temperature output ○ ╳ ○
Digimat option to export fiber orientation data ○ ○ ╳
Part Insert Flow Pressure Output ○ ╳ ○
Moldbase
Moldbase Output ○ ╳ ○Moldbase Pressure Output ○ ╳ ○
Moldbase Temperature Output ○ ╳ ○
Runner Output ○ ○ ○
Output as high order element ○ ○ ○
eDesign Mesh (*.mde) ╳ ╳ ○
32 User’s Manual
Chapter 12
13. Moldex3D-I2 available functions for LS-DYNA
OptionLS-DYNA
Original Mesh Deformed Mesh Mapped Mesh
Part
Mesh Output ○ ○ ○
Fiber Orientation - Material reduction ○ ○ ○
Weld line Output ○ ○ ○
Density Distribution Output ○ ○ ○
Thermal residual stress Output ○ ╳ ○
Flow residual stress Output ○ ╳ ○Initial strain Output(As
Temperature Difference)○ ╳ ○
Packing phase temperature output ○ ╳ ○
End of cooling temperature output ○ ╳ ○
Digimat option to export fiber orientation data ╳ ╳ ╳
Part Insert Flow Pressure Output ○ ╳ ○
Moldbase
Moldbase Output ○ ╳ ○Moldbase Pressure Output ○ ╳ ○
Moldbase Temperature Output ○ ╳ ○
Runner Output ○ ○ ○
Output as high order element ○ ○ ○
eDesign Mesh (*.mde) ╳ ╳ ╳
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Chapter 12
14. Moldex3D-I2 available functions for MSC.Nastran
OptionMSC-Nastran
Original Mesh Deformed Mesh Mapped Mesh
Part
Mesh Output ○ ○ ○
Fiber Orientation - Material reduction ○ ○ ○
Weld line Output ○ ○ ○
Density Distribution Output ○ ○ ○
Thermal residual stress Output ╳ ╳ ╳
Flow residual stress Output ╳ ╳ ╳Initial strain Output(As
Temperature Difference)○ ╳ ○
Packing phase temperature output ○ ╳ ○
End of cooling temperature output ○ ╳ ○
Digimat option to export fiber orientation data ╳ ╳ ╳
Part Insert Flow Pressure Output ○ ╳ ○
Moldbase
Moldbase Output ○ ╳ ○Moldbase Pressure Output ○ ╳ ○
Moldbase Temperature Output ○ ╳ ○
Runner Output ○ ○ ○
Output as high order element ○ ○ ○
eDesign Mesh (*.mde) ╳ ╳ ○
34 User’s Manual
Chapter 12
15. Moldex3D-I2 available functions for NE-Nastran
OptionNE-Nastran
Original Mesh Deformed Mesh Mapped Mesh
Part
Mesh Output ○ ○ ○
Fiber Orientation - Material reduction ○ ○ ○
Weld line Output ○ ○ ○
Density Distribution Output ○ ○ ○
Thermal residual stress Output ╳ ╳ ╳
Flow residual stress Output ╳ ╳ ╳Initial strain Output(As
Temperature Difference)○ ╳ ○
Packing phase temperature output ○ ╳ ○
End of cooling temperature output ○ ╳ ○
Digimat option to export fiber orientation data ╳ ╳ ╳
Part Insert Flow Pressure Output ○ ╳ ○
Moldbase
Moldbase Output ○ ╳ ○Moldbase Pressure Output ○ ╳ ○
Moldbase Temperature Output ○ ╳ ○
Runner Output ○ ○ ○
Output as high order element ○ ○ ○
eDesign Mesh (*.mde) ╳ ╳ ○
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Chapter 12
16. Moldex3D-I2 available functions for MSC.Marc
OptionMSC-Marc
Original Mesh Deformed Mesh Mapped Mesh
Part
Mesh Output ○ ○ ○
Fiber Orientation - Material reduction ○ ○ ○
Weld line Output ○ ○ ○
Density Distribution Output ○ ○ ○
Thermal residual stress Output ○ ╳ ○
Flow residual stress Output ○ ╳ ○Initial strain Output(As
Temperature Difference)○ ╳ ○
Packing phase temperature output ○ ╳ ○
End of cooling temperature output ○ ╳ ○
Digimat option to export fiber orientation data ╳ ╳ ╳
Part Insert Flow Pressure Output ○ ╳ ○
Moldbase
Moldbase Output ○ ╳ ○Moldbase Pressure Output ○ ╳ ○
Moldbase Temperature Output ○ ╳ ○
Runner Output ○ ○ ○
Output as high order element ○ ○ ○
eDesign Mesh (*.mde) ╳ ╳ ○
36 User’s Manual
Chapter 12
17. Moldex3D-I2 available functions for NX Nastran
OptionNX Nastran
Original Mesh Deformed Mesh Mapped Mesh
Part
Mesh Output ○ ○ ○
Fiber Orientation - Material reduction ○ ○ ○
Weld line Output ○ ○ ○
Density Distribution Output ○ ○ ○
Thermal residual stress Output ╳ ╳ ╳
Flow residual stress Output ╳ ╳ ╳Initial strain Output(As
Temperature Difference)○ ╳ ○
Packing phase temperature output ○ ╳ ○
End of cooling temperature output ○ ╳ ○
Digimat option to export fiber orientation data ╳ ╳ ╳
Part Insert Flow Pressure Output ○ ╳ ○
Moldbase
Moldbase Output ○ ╳ ○Moldbase Pressure Output ○ ╳ ○
Moldbase Temperature Output ○ ╳ ○
Runner Output ○ ○ ○
Output as high order element ○ ○ ○
eDesign Mesh (*.mde) ╳ ╳ ○
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Chapter 12
18. Moldex3D-I2 available functions for Radioss
OptionRadioss
Original Mesh Deformed Mesh Mapped Mesh
Part
Mesh Output ○ ○ ○
Fiber Orientation - Material reduction ○ ○ ○
Weld line Output ○ ○ ○
Density Distribution Output ○ ○ ○
Thermal residual stress Output ╳ ╳ ╳
Flow residual stress Output ╳ ╳ ╳Initial strain Output(As
Temperature Difference)○ ╳ ○
Packing phase temperature output ○ ╳ ○
End of cooling temperature output ○ ╳ ○
Digimat option to export fiber orientation data ╳ ╳ ╳
Part Insert Flow Pressure Output ○ ╳ ○Moldbase Moldbase Output ○ ╳ ○
Moldbase Pressure Output ○ ╳ ○
Moldbase Temperature Output ○ ╳ ○
Runner Output ○ ○ ○
Output as high order element ○ ○ ○
eDesign Mesh (*.mde) ╳ ╳ ○
38 User’s Manual
Chapter 12
19. The software versions of each stress solver supported by Moldex3D-I2:
ANSYS ANSYS 10, ANSYS 11 , and ANSYS 12.1 and
ANSYS13
ABAQUS ABAQUS 6.8, ABAQUS 6.9 and ABAQUS 6.10
LS-DYNA LS-DYNA v9.71 R4.2
MSC.Marc Msc.Marc2010
MSC.Nastran Msc.Nastran2010
NE Nastran NE Nastran V8.3
NX Nastran UGS NX 7.0
User’s Manual 39
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