R12.0

Presentation for ANSYS Seminar:

Moldex3D FEA Interface for Workbench

Presenter: Jeff Kloberdanz

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Outline

> Company introduction

> Why use Moldex3D

> Fiber orientation and anisotropy: Isotropic

and Anisotropic

> FEA Integration Analysis with Workbench

> A case study: Tensile Bar

> Step-by-Step Example

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Company introduction

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CoreTech System and Moldex3D

The worlds largest injection molding CAE company

200 employees, 80% experienced engineering professionals

80 + Research and Development

80 + front-line technical sales and support engineers

9 global offices

Local support at Northville, Michigan

1,500+ global customers, 6,000+ users

10,000+ industrial projects validation

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> Adopted by many renowned companies and industries to

prove its capabilities of bringing quality solutions:

Moldex3D Reference Customers

Automobile High Tech/Electronics Material/Equipment

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Reference Customers in Automotive Industry

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Reference Customers in IC Industry

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Our commitment Your Benefits

2003: 1st complete 3D CAE for plastic molding(Solid)

2005: 1st Parallelized 3D CAE for plastic molding

2007: propriety automatic 3D meshing (eDesign)

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Fiber orientation and anisotropy

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Why Predict Fiber Orientation?

Processing

Properties

Structure

Flow induces fiber orientation

Poor orientation causes warpage

Orientation Modeling

Micromechanical Modeling

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Flow-Induced Fiber Alignment

> Shear flows align fibers in the direction of flow

> Stretching align fibers in the direction of stretch

shear flow fiber aligned along flow direction

shear-free flow Fiber aligned perpendicular to flow direction

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Shell-Core Structures of Fiber Orientation

> The shell-core structure of fiber orientation in injection

molded parts

velocity Shear rate

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Orientation Verification with Experiments

> Industrial connector with fiber-reinforced polymer

> Cross-section fiber orientation

Moldex3D R7 simulation Experiment (SEM)

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Case : Throttle Valve (DSM Engineering Plastics Korea)

Material = PET 35%GF

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Filling and Cooling Results

Melt Front Cooling Temperature

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Orientation and Melt Front

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Anisotropic Mechanical Properties

Major Modulus

Fiber Orientation

Color!

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Fiber-Induced Warpage

Total Deformation Orientation Effect

Color!

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Warpage Comparison

x20 x20

W/ Fiber Warpage W/O Fiber Warpage

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Concept Design

Production CAE

Structure Analysis

CAE

Injection molding

Ideal case by

assuming uniform

material properties

Since it is fabricated

with injection molding,

process induced

material properties

must be addressed!

Concept Design

CAE

Structure Analysis

Concept Design

CAE

Structure Analysis

Concept Design

CAE

Structure Analysis

Concept Design Concept Design

PLM and Injection Molding Process

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Moldex3D-Workbench Integration-

Flow Chart

eDesign

Setup Runner and

Cooling in Designer Structural mesh

Create user defined options

Static Structural

Use the structural mesh

as mapping target

Part Geometry

Workbench

Injection Molding

Analysis

FEA Interface Structural

Analysis

Export the results as

Workbench format

Moldex3D

Extension

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Moldex3D-Workbench Integration

The Moldex3D extension toolbar and Moldex3D button are now part of the ANSYS Mechanical user interface. The Moldex3D function is available from a drop-down menu to set analysis properties.

When solution done, user can open the post to view the result.

Moldex3D Output

Moldex3D

ANSYS

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How to Activate the Interfacing function

Open desired Moldex3D project

Click the shortcut Icon found in the Run toolbar

Or

Go through the main Toolbars.

Post->Interfacing function

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Interfacing Function Interface

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Selecting Solver - WorkBench

Click dropdown menu and select desired solver WorkBench.

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Extensions Manager

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Moldex3D Interface in WorkBench

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Example: Tensile Bar

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Tensile Bar Filling Animation

Weld Line Location

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Tensile Bar Fiber Orientation

Weld Line Location

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Tensile Bar Major Modulus

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Tensile Bar Minor Modulus

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Tensile Bar Stress 30MPa Load Applied

Yield at 80 Mpa

Yield at 80 Mpa

79 MPa

47 MPa

30 MPa Load

30 MPa Load

0-80 MPa Range displayed

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Tensile Bar Stress 40MPa Load Applied

Yield at 80 Mpa

Yield at 80 Mpa

63 MPa

105 MPa

40 MPa Load

40 MPa Load

0-105 MPa Range displayed

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Tensile Bar Stress 50MPa Load Applied

Yield at 80 Mpa

Yield at 80 Mpa

79 MPa

132 MPa

50 MPa Load

50 MPa Load

0-132 MPa Range displayed

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Tensile Bar Stress Yield stress comparison

0-80 MPa Range displayed

Yield at 80 Mpa

Yield at 80 Mpa

79 MPa

79 MPa

50 MPa Load

30 MPa Load

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Tensile Bar Conclusions

> The isotropic model assumes uniform mechanical

properties and can lead to inaccurate predictions and in

this case leads to an over prediction in part strength.

> The isotropic model shows the onset of yield at a load of

50 Mpa while the anisotropic model shows the yielding

will start at a load of 30 Mpa.

> Distributions of the peak stresses differ greatly when

considering the molding conditions for the weld line.

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Step-by-Step Example

> Step1:

> Injection Molding Analysis with eDesign

> Generate structural mesh on workbench

> Export the Workbench mesh to FEA interface

> Step2: Export the eDesign Data for Workbench

> Use commands(APDL)

> Use the ACT extension for a Project

> Step3:

> Prepare a Workbench Project

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Step1: Injection Molding Analysis with eDesign

> Open the geometry in Moldex3D Designer, build up the

runners and cooling system, generate a 3D mesh.

> Open the mesh in Moldex3D Project, setup the process

conditions, then launch the injection molding analysis.

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Step1-2 : Generate structural mesh on workbench

Generate mesh

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Step1-3 :Export the Workbench mesh to FEA interface

1.Choose Static Structural

2.Tools Write Inputs File

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Step1-4: Export the eDesign Data for Workbench

> Run Moldex3D FEA Interface to generate ACT extension

and output data

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Step2: Export the eDesign Data for Workbench (cont)

> You can integrate in ANSYS Workbench by two ways

1) Use commands(APDL)

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Step2: Export the eDesign Data for Workbench (cont)

2) Use the ACT extension for a Project

Move the output data to current working directory.

By default, the Extension Manager contains the extensions located in the installation repository of ANSYS:

You can place the Moldex3DtoANSYS extension folders and files in the extensions folder of a users Applications Data folder, C:\Documents and Settings\\Application

Data\Ansys\v140\ AdvancedAddinPackage. When

extensions are installed in a users Applications Data folder, only the owner of that folder has access to the extensions.

%ANSYS140_DIR%\..\Addins\AdvancedAddinPackage\extensions

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Step3: Prepare a Workbench Project

1. Copy the installer zip file to WB 14 installation area (%AWP_ROOT140%)

e.g.: C:\Program Files\ANSYS Inc\v140

2. Close all WB 14 sessions

3. Extract the zip file in the same path

If prompted about replacing any files, click Yes

4. Start a new WB 14 session

5. Activate the Beta options in the Project page.

6. Activate the Debug Mode for ACT

1

2

3

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Step3: Prepare a Workbench Project

> Generate the mesh and load your Moldex3D extension

Extension Manager to Load / Unload available extensions

ANSYS mesh for mapping the Moldex3D results

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Step3: Prepare a Workbench Project (cont)

> Set your BC conditions

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Step3: Prepare a Workbench Project (cont)

> The context of the Moldex3D

extension and button has

been set to Mechanical. Consequently, this extension

was loaded with the

Mechanical application.

> Click Moldex3D icon

The Moldex3D function is available from a drop-down

menu to set the analysis

properties.

Information provided by Moldex3D FEA Interface

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Step3: Prepare a Workbench Project (cont)

If you choose many items to output in Moldex3D FEA Interface, you will see more items appearing in the Definition list.

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Step4: Run the Structural Analysis

Including Initial strain (warpage) Without Initial strain