AutodeskMoldflow Insight 2010 Performance Practice

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THIS PUBLICATION AND THE INFORMATION CONTAINED HEREIN IS MADE AVAILABLE BY AUTODESK, INC. "AS IS." AUTODESK, INC. DISCLAIMS ALL WARRANTIES, EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE REGARDING THESE MATERIALS.

About this manual

The Autodesk Moldflow Insight Performance, manual is designed with the new Moldflow experienced in mind. In creating this manual, our goal was to introduce you to analyses run with the Autodesk Moldflow Insight Performance tasks. This manual will concentrate on Cooling and Warpage, but will also have chapters that are Flow, Shrink, and Stress related.

There is a significant amount of information in this manual, more information than can be absorbed during the class. This manual should be useful as a handy desk reference when back in the office.

Using this manual

This manual is separated into several chapters and appendices. Each of the chapters covers a specific topic and includes the following sections:

Aim

Describes the learning objectives of the chapter.

Why Do It

Outlines the reasons for following the prescribed guidance, suggestions, and methodology within the chapter.

Overview

A complete outline of what will be covered within the chapter.

Practice

This section contains hands-on exercises used to reinforce what was learned. The practice section guides the user through the steps necessary to complete a project.

v

Formatting used in this manual

Tasks

: To perform a step on the computer

1. When the Task icon is shown, below it is a list of numbered steps to complete the task.

1.1. Tasks can have a sub-step,

A bulleted list provides information on a step, or a non-sequential actions to be done,

A second level bulleted list to provide information on a sub-step.

2. A task is used in the practice section of a chapter to indicate steps to be done on the computer.

Bulleted lists

A bulleted list contains a number of items that have no particular order.

It does not represent a list of steps that have to be followed in sequence.

Ruled paragraph

Tip

Note

Text from a computer screen is shown between ruled lines.

/ A tip is a useful piece of information that is normally associated with a task or procedure. Something that can be done to make a task easier or more efficient.

3 A note is generally used to highlight some background or theoretical information.

vi

Training files setup

The files required for the Autodesk Moldflow Insight Performance class are organized into several folders. Each folder has the files necessary for one chapter. The table below shows the required folders, study files, and results necessary for the class. In each folder, there will be a *.mpi file with the same name as the folder. The mpi file is the database of the Project pane in Synergy. All the results that need to be run will be provided in class. However if for some reason the results are not available, they can be obtained by analyzing the necessary studies.

Table 1: Files Required for the Autodesk Moldflow Insight Performance Class

Folder name Files Needed Results neededCooling_Analysis_Stratigies dustpan_specified.sdy

Radiator Tank Specified.sdyRadiator Tank Automatic.sdy

NoneCoolCool

Cooling_Optimization (empty project)Cooling_Results_Interpretation dustpan_cooling_interpretation.sdy

Radiator_tank_interpretation.sdyCoolCool

Core_Shift Syringe_Sub.sdySyringe_Edge.sdy

Fiber_Flow Cover_Fiber.sdyManifold_Fiber.sdy

Flow + Pack on both studies

Modeling_Cooling_Comp cap_wl_modeling.sdydustpan_wl_modeling.sdyRadiator Tank Fusion Insert.sdyRadiator Tank.sdy

Shrink cover_endg.sdycover_ping.sdySnap_cover_prof_1.sdy

Stress Bucket.sdystress_snapcover.sdy

Warpage_Diagnostics Cover_original.sdydustpan_original.sdyfood_tray_original.sdyradiator_tank_original.sdy

CFP CFPCFPCFPW

vii

Reduce_Warpage Cover 1 ShortCover 1 LongCover 3 LongCover 2 ShortCover 2 Short Each endCover Hot DropCover 2 Short Pack 65 MPaCover 2 Short Fill .5 Pack 65 MPaCover 2 Short Fill .5 Pack 85 MPaCover Hot Drop Pack 65 MPaCover Hot Drop Fill .4 Pack 65 MPaCover Hot Drop Fill .4 Pack 85 MPaFT Pack 50 MPaFT IPC 20 Pack 60 MPaFT IPC 20 PT 15 Pack 60 MPaFT IPC 25 PT 15 Pack 70 MPaFT CD3 IPC 20 PT 15 Pack 60 MPaFT CD35 IPC 20 PT 15 Pack 60 MPaFT CD3 IPC 25 VG7 60 MPaFT IPC 25 VG7 60 MPaFT IPC 25 VG7 50 MPaDP CS1 Pack 35 MPaDP CS2 Pack 35 MPaDP CS2 Pack 50 MPaDP CS2 Pack 50 MPa LongDP CS2 Pack 70 MPa LongDP CS2 Pack 70 MPa ProfDP CS2 Pack 70 MPa Prof2DP CS2 NG Pack 70 MPa LongDP CS2 NG Pack 35 MPa RT End 80% PackRT End 85 MPa PackRT Cent 80% PackRT Cent 85 MPa Pack

CFPW for all studies

Table 1: Files Required for the Autodesk Moldflow Insight Performance Class

Folder name Files Needed Results needed

viii

ContentsAbout this manual ........................................................................................................................vUsing this manual .........................................................................................................................vFormatting used in this manual .................................................................................................viTraining files setup .....................................................................................................................vii

CHAPTER 1Core Shift Analysis ................................................................................. 1

Practice - Core Deflection........................................................................................................... 3Syringe core modeling....................................................................................................... 5Syringe core shift analysis............................................................................................... 11

CHAPTER 2Fiber Flow Analysis ............................................................................... 19

Practice - Fiber Flow Analysis .................................................................................................. 21Cover Model..................................................................................................................... 23Manifold Model ............................................................................................................... 29Competency Check - Fiber Flow Analysis .................................................................. 33Evaluation Sheet - Fiber Flow Analysis ....................................................................... 35

CHAPTER 3Cooling Overview .................................................................................. 37

CHAPTER 4Cooling Results Interpretation ............................................................. 39

Practice - Cooling Results Interpretation................................................................................ 41Dustpan............................................................................................................................. 43Worksheet - Cooling Results ......................................................................................... 51Worksheet answers.......................................................................................................... 53Radiator end tank ............................................................................................................ 55Worksheet - Cooling Results ......................................................................................... 63Worksheet answers.......................................................................................................... 65Competency check - Cooling Results Interpretation................................................. 67Evaluation Sheet - Cooling Results Interpretation..................................................... 69

CHAPTER 5Cooling Analysis Modeling Requirements ......................................... 71

CHAPTER 6Modeling Cooling Components ........................................................... 73

Practice - Modeling Cooling Components ............................................................................. 75Modeling the mold components for the dustpan....................................................... 77Modeling the mold components for the cap............................................................... 91Creating an insert for a 3D radiator tank model...................................................... 111Creating and using a personal mold material database ........................................... 117

ix

CHAPTER 7Cooling Analysis Strategies ................................................................119

Practice - Cooling Analysis Strategies................................................................................... 121Dustpan.......................................................................................................................... 123Worksheet...................................................................................................................... 126Summarize results......................................................................................................... 127Worksheet answers....................................................................................................... 128Summary of the results ................................................................................................ 129Radiator tank ................................................................................................................. 131Worksheet .......................................................................................................................134Summarize results......................................................................................................... 135Worksheet answers....................................................................................................... 136Summary of the results ................................................................................................ 137

CHAPTER 8Cooling Optimization ...........................................................................139

Practice - Cooling Optimization............................................................................................ 141Dustpan.......................................................................................................................... 143Radiator end tank ......................................................................................................... 147

CHAPTER 9Warpage Overview ...............................................................................151

CHAPTER 10Design Influences on Warpage ...........................................................153

CHAPTER 11Warpage Analysis Process .................................................................155

CHAPTER 12Determine the Magnitude of Warpage ................................................157

Practice - Determine the Magnitude of Warpage ............................................................... 159Warpage analysis on the cover ................................................................................... 161Warpage Analysis on the Food Tray ......................................................................... 167Warpage Analysis on the Dustpan............................................................................. 173Warpage Analysis on the Radiator Tank................................................................... 183Competency check - Determine the magnitude of warpage ................................. 193Evaluation Sheet - Determine the magnitude of warpage ..................................... 195

CHAPTER 13Determine the Cause of Warpage .......................................................197

Practice - Determine the Cause of Warpage ....................................................................... 199Warpage analysis on the cover ................................................................................... 201Warpage Analysis on the Food Tray ......................................................................... 207Warpage Analysis on the Dustpan............................................................................. 211Warpage Analysis on the Radiator Tank................................................................... 219Summary - Determine the cause of warpage results............................................... 224Competency check - Determine the Cause of Warpage ........................................ 227

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Evaluation Sheet - Determine the Cause of Warpage ............................................ 229

CHAPTER 14Reducing Warpage .............................................................................. 231

Practice - Reducing Warpage ................................................................................................. 233Warpage Analysis on the cover .................................................................................. 235Warpage Analysis on the food tray............................................................................ 243Warpage Analysis on the dustpan .............................................................................. 255Warpage Analysis on the radiator tank ..................................................................... 265Warpage Results............................................................................................................ 271Competency check - Chapter name........................................................................... 273Evaluation Sheet - Chapter name .............................................................................. 275

CHAPTER 15Shrink Analysis ................................................................................... 277

Practice - Shrink Analysis ....................................................................................................... 279Shrinkage Analysis on the cover ................................................................................ 281Shrinkage Analysis on the snap cover ....................................................................... 289Competency check - Shrink Analysis ........................................................................ 297Evaluation Sheet - Shrink Analysis ............................................................................ 299

CHAPTER 16Stress Analysis .................................................................................... 301

Practice - Stress Analysis ........................................................................................................ 303Stress Analysis on the Bucket ..................................................................................... 305Stress Analysis on the Snap Cover............................................................................. 311Competency check - Stress Analysis.......................................................................... 317Evaluation Sheet - Stress Analysis ............................................................................. 319

xi

CHAPTER 1

Core Shift Analysis

Aim

The aim of this chapter is to learn about core shift analysis capabilities within Autodesk Moldflow Insight. You will also learn how to prepare the models, run an analysis and interpret the results.

Why do it

Capabilities regarding core shift analysis depending on the mesh type. This chapter will review the capabilities and describe how to use them.

Overview

In this chapter you will:

Review the terms related to core shift and related technologies used in Moldflow.

Review the core shift capabilities.

Learn how to prepare models for core shift.

Learn how to run a core shift analysis.

Learn how to interpret results specific to a core shift analysis.

Core Shift Analysis 1

2 Chapter 1

Practice - Core Deflection

This chapter uses Dual Domain model for the practice and is described below.

Table 1: Model used for part insert overmolding

Description ModelSyringe core modeling: starts on page 5

The core for the Syringe will be constructed using elements from the Syringe. This core will be created in a separate study then added to two studies for analysis.

Syringe core shift analysis: starts on page 11

Using the core constructed in the previous practice, several core shift analyses are run to compare the results. An API script will be used to aid in the results interpretation. This part uses a Dual Domain mesh for the part.

Practice - Core Deflection 3

4 Chapter 1

Syringe core modeling

In this section, you will model the core of the syringe.

Design CriteriaThe Syringe is molded in an eight cavity tool. The cores are long and may move during molding. To determine the amount of movement of the cores, the core is modeled so a core shift analysis can be done. The part uses a Dual Domain mesh. This mesh is the starting point for the core mesh.

SetupThe project contains the necessary files for the syringe.

To open a project

1. Click (File Open Project), and navigate to the folder My MPI 6.1 Projects\MPIe Performance\Core Shift and double click the project file Core Shift.mpi.

2. Click File Preferences.

2.1. Ensure the active units are set to metric units.

To open the Syringe Sub model

1. Double click the Syringe Sub study in the Project View pane.

2. Rotate the model to review the geometry.

3. Click (File Save Study As) and enter Tet Core.

A copy of the Syringe Sub study called Core will be used to create the tetrahedral mesh with Core (3D) element properties. No entities in the original model will be maintained. The newly created core will be added back to the original study.

4. Review the layers in the study.

5. Rotate the model around to get familiar with it.

Model preparationMost of the entities in the model are not required to construct the core. The entities not required are first deleted by layers, then temporary layers are used to separate the required elements from those that are not required.

To delete layers not used

1. Right click on the Runners layer and select Hide All Other Layers.

2. Click on the IGES Surface layers.

Now only two layers are on, Runners and IGES Surface.


3. Band select around the entire model or click on the model and press CTRL + A.

4. Press the Delete key.

5. Click OK to accept the selection of multiple entities.

6. Click (Clean Layer) to remove layers with no entities on them.

To select core elements

1. Turn on the Body and Base layers and off the Part Nodes layer.

2. Click (Back view) to rotate the model to 0 180 0.

3. Click (New layer) to create a temporary layer.

4. Click (Select Enclosed items only) on the selection tool bar.

5. Click (Circle Select) on the selection tool bar.

6. Click in the center of the syringe and select around the core but dont enclose any elements on the bottom of the part as shown in Figure 1.

Figure 1: Circle selecting the core

7. Highlight the new layer and click (Assign) to move the selected elements to the new layer.

8. Right click on the New Layer and select Hide All Other Layers.

The entire core, and some of the cavity elements are now on this new layer. The elements that do not form the core must be moved back to the Body layer.

Band select tocircle the core

6 Chapter 1

To move edge entities back to the Body layer

1. Zoom and rotate on the small diameter at the end of the syringe.

Notice that the selection method also picked some of the elements on the cavity side of the syringe, as shown in Figure 2. These elements need to be moved back to the Body layer.

Figure 2: Elements remaining after selection

2. Click (Bottom View) to rotate the part to -90 0 0.

3. Band select the end of the syringe, as shown in Figure 3, to select the edge elements between the core and cavity side of the syringe.

Figure 3: Select end of the syringe

4. Highlight the Body and click (Assign) to move the selected elements to the layer.

Band select end Selected elements


To move cavity entities back to the body layer

1. Rotate the model so you can see that the edge elements are not on the New layer.

2. Click Mesh Mesh Diagnostics Connectivity Diagnostic.

2.1. Select one element on the cavity side of the syringe.

2.2. Check Place results in diagnostic layer.

2.3. Check Restrict to visible entities.

2.4. Click Show.

2.5. Notice that the entities on the cavity side are blue indicating the are connected, and the core elements are red. The new layer created Diagnostic results contains the connected elements.

2.6. Click Close.

3. Highlight the Body layer and click (Activate).

4. Highlight the Diagnostic results layer and click (Delete Layer).

4.1. Click Yes.

5. Click Mesh Show Diagnostics to turn off the diagnostic.

6. Ensure only the New Layer is on.

7. Check the model to ensure that the new layer has all the elements on the core side of the syringe and nothing else. Toggle other layers on and off as necessary.

To delete unused entities

Only the New Layer entities are needed for the core. All other entities will be deleted.

1. Right click on the Body layer and select Hide All Other Layers.

2. Click the Base layer to turn it on.

3. Band select around the entire model or click on the model and press CTRL + A.

4. Press the Delete key.

5. Click (Clean Layer) remove layers with no entities on them.

6. Click Mesh Mesh Tools Nodal Tools Purge Nodes.

7. Click Apply.

8. Click Close.

9. Click (File Save study).

The only entities left are the nodes and elements forming the core side of the syringe. These elements are used to make the core.

8 Chapter 1

Constructing the coreThe core is created by filling the holes on the existing mesh, creating the tetrahedral mesh, repairing any problems and assigning the Core (3D) properties.

To fill the holes in the core

1. Zoom and rotate to the small end of the syringe.

2. Click Mesh Mesh Tools Edge Tools Fill Hole

3. Select one node on the edge of the hole.

4. Click Search.

5. Click Apply.

6. Rotate to the large end of the syringe and fill the hole.

7. Close the tool when done.


To create the tetrahedral mesh

1. Right click on (Dual Domain Mesh) in the study tasks list.

2. Select Set Mesh Type 3D.

3. Click Mesh Generate Mesh.

4. Click the Tetra Refinement tab.

5. Ensure 6 is entered for the number of layers.

6. Click Mesh now.

To check the mesh

1. Close the log file.

2. Click Mesh Mesh Repair Wizard.

3. Go through the wizard and ensure there are no problems with the mesh. Use the default settings as a guide.


To clean up the layers

There should be only two layers when done, one for the elements, and one for the nodes.

1. Right click on any layer and select Show All Layers.

2. Move all nodes to one layer.

2.1. Click Edit Select by Properties, or CTRL+B.

2.2. Ensure the entity type is Node.

2.3. Click OK.

2.4. Highlight a Part Nodes layer.

There may be more than one Part Nodes layer. pick any one.

2.5. Click (Assign) to move the selected nodes to the layer.

3. Move all Tetrahedral elements to one layer.

3.1. Click on the model and press CTRL+B.

3.2. Select Tetrahedral element as the entity type.

3.3. Click OK.

3.4. Highlight the New Tetras layer and click (Assign) to move the selected elements to the layer.

4. Click (Clean Layer) to remove layers with no entities on them.

5. Rename the layers.

5.1. Change the name of the New Tetras layer to Core.

5.2. Change the name of the Part Nodes layer to Core Nodes.

6. Move the layers so the Core layer is at the top of the list.

If you need to move a layer, right click and select Move Up or Move Down.

To assign properties

1. Select all the elements in the model.

2. Click Edit Change Property Type.

3. Select Core (3D) from the list.

4. Click OK.

5. Ensure the elements are still selected.

6. Click Edit Properties

7. Click Select

8. Ensure P-20 is the Mold material.

9. Click OK twice to exit.


10 Chapter 1

Syringe core shift analysis

In this section, you will run a core shift analysis the syringe. You must complete the previous practice before doing this one.

Design CriteriaThe Syringe is molded in an eight cavity tool. The cores are long and may move during molding. To determine the amount of movement of the cores, several core shift analyses are run done. The core must not deflect more than 0.1 mm tolerance to maintain an acceptable wall thickness in the neck of the syringe.

SetupOpen the project and reserve the tasks as necessary. The same project is used for this practice as it is for the modeling of the core.

To open the Syringe Sub model

1. Double click the Syringe Sub study in the Project View pane.


3. Click (File Save Study As) and enter Syringe Orig.

This will represent the original conditions used. Previous analysis work optimized: the fill time, mold and melt temperatures, feed system, cycle time. The model represents an eight cavity tool. The packing profile has been modified from defaults but has not been modified specifically to optimize the volumetric shrinkage.

4. Review the layers in the study.

5. Rotate the model around to get familiar with it.

To add the core


2. Check Default to Project directory, if necessary, and click OK.

3. Ensure all layers are off except Body and Base.

4. Click File Add.

5. Select the study Core and click Open

6. Rotate the model as necessary to see the core has been added.


Running the analysis

To check the core properties

1. Select an element in the core.

2. Click Edit Properties.

3. Ensure all the properties are properly set using Table 2 as a guide.

To set the constraints

1. Right click on the Core layer and select Hide All Other Layers.

2. Check the Core nodes layer.

3. Click Analysis Set Constraints Fixed Constraints.

4. Click in the Select field.

5. Click (Bottom View) to rotate the part to -90 0 0.

6. Click (Select Enclosed items only) on the selection tool bar.

7. Band select the nodes on the bottom of the core.

8. Set the Use Constraint in field to Core-shift Analysis.

9. Click Apply.

10. Click Close.

11. Turn off the Core Nodes and Fixed nodal constraints layers.


Table 2: Core(3D) property settings

Parameter ValueMaterial Metal, P-20Local mold surface temperature control Use global settings in advanced optionsMold material Use global settings in advanced options

12 Chapter 1

To set the analysis properties

1. Open the process setting wizard and ensure the parameters are set as shown in Table 3.

2. Click the Advanced options button.

3. Click the Edit button in the solver parameters frame.

4. Click the Core shift tab.

5. Set the core deflection properties are set as shown in Table 4.

6. Double-click Start Analysis.

The analysis should only take a few minutes to run.

Table 3: Syringe analysis parameters

Parameter ValueMaterial Moplen EP301K (KMT6100): Basell AustraliaMold Temperature 40 CMelt Temperature 230 CFilling control Flow rateFlow rate 54 cm^3/sVelocity/pressure switch-over AutomaticPack/holding control %Filling pressure vs timePacking profile 0.2

41

80800

Cooling time 4 seconds

Table 4: Syringe core shift analysis parameters

Parameter DescriptionPerform core shift analysis Checked Frequency of core shift, Maximum volume increment between analyses

2%

Frequency of core shift, Maximum time step between analyses

0.25s.

Analyze core using 4-noded tetrahedra Perform core shift analysis during pressure iteration During filling and packingSurface matching 0.2 mmPercentage frozen layer that makes node constrained 90%Use AMG matrix solver Yes


Review the resultsOnce the analysis has run, results relating to the core deflection are reviewed. To aid in the viewing of the results, an API script was written to summarize key information about the results. The information includes:

The number of animation frames for the core deflection results.

This is used to show how many core shift analyses were done during the cycle. Changing the frequency values will have a direct i

The maximum core deflection and the time it occurred.

The core deflection at the end of the cycle.

The minimum volumetric shrinkage at ejection for triangular elements.

The maximum volumetric shrinkage at ejection for triangular elements.

The average volumetric shrinkage at ejection for triangular elements.

The script should be in the My MPI ...Projects/Scripts folder. If it is not there, check the current project folder. If the script is not available, the information can be obtained by traditional methods. The script will take some time to run. The longest component is determining the volumetric shrinkage values on triangular elements. The script must compare a list of elements (all triangles) to the results and only compare the triangular entities. The script is well documented so it can be used to learn how the script runs and to customize scripts for your own use.

To run the API script view a summary of the results

1. Click Tools Play Macro.

2. Navigate to the scripts location to find the file Core Shift Practice.

It should be in either the My MPI ...Projects/Scripts folder or the current project folder.

3. Highlight the script then click Open.

The script will take a few seconds to run.

4. Record the results in Table 7 on page 18.

The results show that the deflection of the core at the end of the cycle is above the tolerance of 0.1 mm. Now the results are reviewed in more detail.

To plot the core deflection as a shaded image

1. Ensure that only the following layers are on:

Body.

Base.

Core.

2. Click the Displacements, core result.

14 Chapter 1

3. Click (Results Plot Properties).

3.1. Click the Mesh Display tab and ensure Transparent is selected.

3.2. Click the Deflection tab and set the Scale Factor Value to 10.

3.3. Click OK.

4. Rotate the model so the top of the core (unsupported end) can be easily seen.

5. Click (Animate).

The animation shows that during much of the filling phase, the core deflection is rather low and through most of the packing the core does not move. The API script shows that the maximum deflection is not the final deflection. The core moves significantly around the time the part fills. An XY plot can be used to see this.

To create an XY plot of the core deflection

1. Click (Front View) to rotate the model to 0 0 0.

2. Zoom up on the core, as shown in Figure 4.

3. Click Results New Plot.

3.1. Select Displacements, core in the Available results list.

3.2. Click XY Plot in the Plot type list.

3.3. Click OK.

4. Click on a node of the core at its edge, as shown in Figure 4.

5. Click (Select) to stop selecting other node locations for the XY plot.

There is a significant change in the core deflection between about 0.8 and 1.2 seconds.

Figure 4: Selecting the location of the node use to show core deflection


To review volumetric shrinkage

1. Click the result Volumetric shrinkage at ejection.

2. Ensure the Body and Base layers are on, and the Runners layer is off.

The volumetric shrinkage results reported by the script show the minimum, maximum, and average shrinkage for just the parts by including only triangular elements in the calculation. The script was written because these numbers are a quick way to get a sense on the influence of the packing profile on the volumetric shrinkage. The subsequent analyses will changes the packing profile.

3. Click off the Base layer to see the shrinkage directly on the barrel of the syringe.

Notice the maximum shrinkage, on the syringe body layer, is near the top of the syringe and only on one side. This is a result of the core deflecting. The core movement influences the shrinkage results.

To review other results

1. Review any other results as desired to see the influence of the core shifting or results that will show why the core is shifting.

Summarize the first analysis results

The API script showed all that was necessary to show that the results were not acceptable. The deflection at the end of the cycle is greater than the tolerance. The deflection XY plot is useful for showing how and when the deflection happens. The volumetric shrinkage plots can be compared with future analyses to see how packing influences the core deflection and the shrinkage.

Run a second analysis

To run a second analysis

1. Save the Syringe Orig study.

2. Click (File Save Study As) and enter Syringe 100%.

3. Open the Process Settings wizard and change the packing profile as shown in Table 5.


5. Double click Start Analysis.

Table 5: Syringe analysis parameters increased packing pressure

Parameter ValuePack/holding control %Filling pressure vs timePacking profile 0.2

41

1001000

16 Chapter 1

To review results

1. Ensure that both the Syringe Orig and Syringe 100% are open.

2. Click Window Tile Vertically.

The windows can be tiled horizontally.

3. Activate the Syringe 100% study and execute the Core Shift Practice script and record the results in Table 7 on page 18.

4. Click View Lock

All Views.

All Animations.

All Plots.

5. Click in the Syringe Orig study to activate it.

6. Click the result Displacements, core:XY Plot.

This should create this result in the Syringe 100% study.

Summarize the second analysis results

The core deflection results have not gotten much better with a higher packing pressure. The next analysis will lower the packing pressure.

Run a third analysis

To run a third analysis

1. Save the Syringe Orig study.

2. Click (File Save Study As) and enter Syringe 50%.

3. Open the Process Settings wizard and change the packing profile as shown in Table 5.


5. Double click Start Analysis.

To review results

1. Ensure that both the Syringe Orig and Syringe 50% are open.

2. Click Window Tile Vertically.

The windows can be tiled horizontally.

Table 6: Syringe analysis parameters increased packing pressure

Parameter ValuePack/holding control %Filling pressure vs timePacking profile 0.2

41

50500


3. Activate the Syringe 50% study and execute the Core Shift Practice script and record the results in Table 7 on page 18.

4. Click View Lock

All Views.

All Animations.

All Plots.

5. Click in the Syringe Orig study to activate it.

6. Click the result Displacements, core:XY Plot.

This should create this result in the Syringe 50% study.

Summarize the third analysis results

With the lower packing pressure, the core deflection is now closer to the design tolerance. However, the maximum deflection should be well within the tolerance. Also the average volumetric shrinkage has gone up with the lower packing pressure. Plot the volumetric shrinkage results to get a better understanding of the shrinkage results.

Continued workThe third analysis is close to the core deflection tolerance but should be lower. Continue to run some analyses as time permits to continue to improve the warpage. Investigate changing processing conditions such as changing the mold or melt temperatures or injection time. A study with an edge gate (Syringe Edge) is provided so a gate location not on the core can be investigated.

Table 7: Core deflection results for the syringe

Deflections [mm] Volumetric Shrinkage [%]Study Name Max EOC Min Max Avg

Syringe OrigSyringe 100%Syringe 50%

18 Chapter 1

CHAPTER 2

Fiber Flow Analysis

Aim

The aim of this chapter is to be introduced to the Fiber analysis program. This includes background theory about fibers, why the fiber-orientation analysis is important, and how to run an analysis and interpret the results.

Why do it

A fiber flow analysis is a standard flow analysis plus an algorithm that calculates the distribution of short fibers in a polymer matrix. For conducting a warpage or stress analysis of a filled material, it is critical that the distribution of the fibers be considered as they dominate the physical properties of the material.

Overview

Running a fiber flow analysis is a simple task. If the material is a fiber filled material, the database contains all of the additional data necessary to run this material. By default, a fiber flow analysis is run unless you indicate that the fiber-orientation flow analysis should not be run. In this chapter, you will review fiber flow analysis results on a Dual Domain or 3D part.

Fiber Flow Analysis 19

20 Chapter 2

Practice - Fiber Flow Analysis

This chapter has two models to choose from and are described below. Pick one to work on.

Table 8: Models used for Fiber flow analysis

Description ModelCover: starts on page 23

The cover is the same part that is used in other chapters, however in this version; the feed system has been added to the model. This is a Dual Domain model. Running a fiber analysis and looking at fiber results is the same for both Midplane and Dual Domain mesh types. If you primarily use Midplane models, use this example. Manifold: starts on page 29

The manifold is a 3D model. This is the same model used for the translation chapter, however a feed system has been added.

3 To save time, the results are provided for both models.

Practice - Fiber Flow Analysis 21

22 Chapter 2

Cover Model

Design CriteriaFor the cover, only the initial fiber flow analysis will be run, and the results will be viewed. In this practice, you are only working on reviewing the fiber results. The whole project involves solving the warpage problems with this part.

The cover will be assembled with other components along the bottom edge of the part. To meet assembly requirements, the bottom edge needs to be flat within the warpage specifications. If changes need to be made to reduce the warpage, the part design cannot change but the gate location and processing conditions can be modified. The current gate location is through a pin on the underside of the part. Subgates can also be used in the side of the part.

For the cover, you will review the results for the fiber flow analysis and form an opinion on whether the part will warp due to the fiber orientation.

Setup

To open a project

1. Click (File Open Project), and navigate to the folder My AMI 2010 Projects\AMI Standard 1\Fiber_Flow.

2. Double click the project file Fiber_Flow.mpi.



To open the cover model

1. Double click the Cover_Fiber study in the Project View pane.


Project/Design Parameters:Model Type Dual DomainMaterial 33% Glass Filled NylonMinimum warpage criteria Part bottom edge must be flat within 1.0 mm


Viewing Results

To view the fill time results

1. Click Fill time in the study tasks list.


2.1. Click on the Methods tab.

2.2. Select the Contour radio button.

2.3. Click OK.

3. Click (Animate result) to watch the filling pattern.

Notice where the flow front is primarily radial and where it is mostly straight.

To view the Pressure result

1. Click Pressure in the study tasks list.


2.1. Click the Optional Settings tab.

2.2. Select Banded in the Color field.

2.3. Click OK.

3. Click (Animate result) watch how the pressure changes over time.

Interpreting fiber orientation results

There are two results that show the fiber orientation: Average fiber orientation and Fiber orientation tensor.

Tensor plots

The default method for displaying the Average fiber orientation and Fiber orientation tensor is Tensor as axes. Other methods of display are possible including shaded and contour.

The plots by default use tensor as First Principal value. This means that the highest probability percentage of the fibers is in the direction indicated by the tensor axis, as shown in Figure 5.

The scale for the first principal value goes from ~0.5 (blue) to ~1.0 (red).

The blue values indicate that the fibers are randomly oriented in plane. A value of 0.5 would mean that all the fibers are oriented in the plane of the element. Below 0.5 indicates some alignment in the element thickness direction.

The red value indicates that fibers are highly aligned. A value of 1.0 indicates that all fibers are aligned in one direction.

3 To save time, the flow analysis has been run for you.

24 Chapter 2

The tensor axis (two lines crossing) will have the legs at the same length with a random distribution, and a very short secondary leg when the tensor value is high. Refer to Figure 5.

Figure 5: Fiber orientation tensors

Average fiber orientation

Average fiber orientation shows how the fibers are oriented on average through the thickness of the part over time.

Animation is done through time.

Fiber orientation tensor

This plot represents the fiber orientation at a specific location in the cross section at the end of the analysis.

For a Flow analysis, the time is at the end of the cycle. If this were a fill analysis, it would represent the results at the end of fill.

Animation is done by Normalized thickness or through the cross section. A normalized thickness of 0.0 is the center line, with 1.0 and -1.0 at the mold wall.


To plot average fiber orientation

1. Click Average fiber orientation in the study tasks list.


2.1. Click on the Mesh Display tab.

2.2. Select the Opaque radio button.

2.3. Click OK.

3. Click (Animate result).

Notice how the orientation of an area changes over time. Most of the change goes from less aligned to more aligned.

Change the mesh display if desired.

4. Animate so the whole model can be seen then zoom up to concentrate on an area of interest.

What can you conclude about the orientation? Is the changing orientation good or bad?

To make fiber orientation results easier to see

1. Change the glyph size.

1.1. Click (Results Plot Properties).

1.2. Click the Tensor tab.

1.3. Enter 0.5 in the Glyph Size Scale Factor.

1.4. Click Apply.

If desired, change the glyph to other sizes and see the effect on the model.

2. Change the scale.

2.1. Click Specified.

2.2. Enter 0.4 as the min.

2.3. Enter 1.0 as the Max.

2.4. Click Apply.

3 This next step is optional. It will set the mesh display. Some people like the part transparent others like it opaque. Adjust setting to see the difference if you wish.

26 Chapter 2

3. Change the Animation value range.

3.1. Click on the Animation tab.

3.2. Set the Animate result over to Single Dataset.

3.3. Set the time to the maximum.

3.4. Click the Value range to 0.05.

3.5. Click Current frame only.

4. Set the mesh display to transparent.

4.1. Click on the Mesh Display tab.

4.2. Select the Transparent radio button.

4.3. Click OK.

5. Click (Step forward) to animate the result one frame at a time.

To plot fiber orientation tensor

1. Click Fiber orientation tensor in the study tasks list.


Watch how the orientation changes through the thickness. What does this correlate to?

What conclusions can be made about the fiber orientation? What is your opinion on fiber orientations effect on warpage?

3 The same modification can be done with the fiber orientation tensor that was done with the average fiber orientation. For both plots, the Animate result at value can be changed to see the influence at different times, or locations within the cross section.


28 Chapter 2

Manifold Model

Design CriteriaFor the manifold, only the initial fiber flow analysis results will be viewed. In this practice, you are only working on reviewing the fiber results. The whole project involves solving the warpage problems with this part.

The manifold will be assembled with other components along the bottom face of the part. To meet assembly requirements, the bottom face needs to be flat within the warpage specifications so the seal to be used will work properly. If changes need to be made to reduce the warpage, the part design cannot change but the gate location and processing conditions can. The current gate location is an edge gate through the side of the part.

Setup

To open a project

1. Click (File Open Project), and navigate to the folder My AMI 2010 Projects\AMI Standard 1\Fiber_Flow.

2. Double click the project file Fiber_Flow.mpi.



To open the manifold model

1. Double click the Manifold_Fiber study in the Project View pane.


3. Turn on and off the layers.

There is only one layer for the tetrahedral mesh of the part. To see the mesh inside the part, create a new layer select and assign elements to the new layer.

Project/Design Parameters:Model Type 3D Tetrahedral meshMaterial 33% Glass Filled NylonMinimum warpage criteria Part bottom edge must be flat within 0.2 mm


Viewing Results

To view the fill time results

1. Click Fill time in the study tasks list.

2. Click (Animate result) to watch the filling pattern.

To view the Pressure result

1. Click Pressure in the study tasks list.

2. Click (Animate result) and watch how the pressure changes over time.

Interpreting fiber orientation results

Fiber orientation tensor indicates how the fibers are oriented in an element at the end of the cycle.

The default method for displaying the results in a Shaded plot. Using Tensor as axes is also a common method of display.

The tensor by default is plotted by First Principal value. This means that the highest value will be in the direction where most of the fibers are oriented. When plotting as a shaded image, you can see the values on the part, with the tensor as axes method you can see the direction and magnitude.

The scale for the first principal value goes from 0.33 (blue) to 1.0 (red).

A value of 1.0 (red) would indicate all the fibers are oriented in one direction.

Planar random orientation means a11 and a22 are equal to 0.5.

Three dimensional random orientation means a11 = a22 = a33 = 1/3.

Zero in any component means there is no percentage of fibers in this direction.

The tensor symbol (three lines crossing) will have the legs at the same length with a random distribution, and very short secondary legs when the tensor value is high.

The symbol used to show the fiber orientation is called a glyph. The default size is based on the element. Changing its size will help with the orientation.

Viewing Fiber Results

To plot fiber orientation tensor as a shaded image

1. Click Fiber orientation tensor in the study tasks list.


2.1. Click Shaded on the Methods tab.

2.2. Click OK.

3 To save time, the flow analysis has been run for you.

30 Chapter 2


The image will go from low values (~0.33) to high values (~1.0). Generally the highest values in the cross section are near the surface of the part and the plot is animated from low to high values so you may be able to see the areas of greatest orientation.

This method makes it difficult to see the location in the cross section of all orientations, and you cant see the direction.

3.1. Stop the animation.

4. Click (Edit cutting plane).

4.1. Check the Plane YZ box and close the dialog.

4.2. Rotate the part so you can see the cutting plane.

4.3. Click (Move cutting plane).

4.4. Drag the mouse up and down to see various locations within the cross section.

Notice how the orientation is higher at the mold wall and lower in the center of the cross section.

You may uncheck Show active plane box to visualize the part better.

4.5. When done, close the Move Cutting Plane dialog

4.6. Click (Edit cutting plane) and uncheck the Plane YZ box.

4.7. Click Close.


5.1. Click the Scaling tab.

5.2. Click Specified and set the Min to 0.3 and the Max to 1.0.

5.3. Click the Animation tab.

5.4. Click the Value range button and set the value to 0.05.

5.5. Click the Current frame only button.

5.6. Click OK.


The result only plots information in 0.05 increments through the range specified in the scale. This will help you isolate where in the part various magnitudes of orientation are.

Because this is a shaded plot, you cant see the direction of the orientation. Plotting the result as a tensor will allow you to see the direction.


To plot the fiber orientation results as a tensor

1. Ensure the Fiber orientation tensor plot is displayed.


3. Change the method of display.

3.1. Click the Methods tab.

3.2. Click the Tensor as axes button.

4. Change the glyph size.

4.1. Click the Tensor tab.

4.2. Enter 0.15 in the Glyph Size Scale Factor.

4.3. Click Apply.

If desired, change the glyph to other sizes and see the effect on the model.

5. Verify the Animation value range.

5.1. Click on the Animation tab.

5.2. Ensure the Value range is 0.05.

5.3. Ensure Current frame only is clicked.

6. Verify the scale.


6.2. Ensure Specified is clicked.

6.3. Ensure 0.3 is the min.

6.4. Ensure 1.0 is the Max.

6.5. Click OK.


Now by using the Tensor method, the direction of the orientation can be seen. By using the value range with the tensor orientations at various levels can be isolated.

The cutting planes can also be used with the tensor to further isolate the area of the part being viewed.

What can you conclude about the orientation?

Is the changing orientation good or bad?

32 Chapter 2

Competency Check - Fiber Flow Analysis

1. What 3 things need to happen for a fiber analysis to run?

2. What is the definition of the value of 0.5 on an Average fiber orientation plot with the tensor set to First principal, on a Dual Domain or Midplane model?


34 Chapter 2

Evaluation Sheet - Fiber Flow Analysis

1. What 3 things need to happen for a fiber analysis to run?

Licenses must be available.

A fiber filled material must be selected.

The Fiber orientation check box must be checked on the Process settings wizard.

2. What is the definition of the value of 0.5 on an Average fiber orientation plot with the tensor set to First principal, on a Dual Domain or Midplane model?

A value of 0.5 would indicate the fibers are randomly oriented in the plane of the element.


36 Chapter 2

CHAPTER 3

Cooling Overview

There is no practice for this subject.

Cooling Overview 37

38 Chapter 3

CHAPTER 4

Cooling Results Interpretation

Aim

The aim of this chapter is to learn about the different types of cooling results and how to use them. This chapter applies to all mesh types.

Why do it

To make effective use of a cooling analysis, it is important to know which results are most important, and how to interpret them. Once results are understood, then they can be compared to the objectives of the analysis and a decision can be made on how to proceed.

Overview

The cooling results are classified in two basic categories:

Key results

Key results are results that are almost always the most important results no matter what the objectives are for your cooling analysis.

Secondary results

They may be important for understanding some objectives of a cooling analysis.

They are used to help you fully understand the information shown in the key results.

Cooling Results Interpretation 39

40 Chapter 4

Practice - Cooling Results Interpretation

This chapter has two models that are used for practice and are described below. One is a Dual Domain model the other is 3D. Do the practice for the model of the mesh type you use most. Do the other as time permits.

Table 9: Models used for cooling results interpretation

Description Model

Dustpan: starts on page 43

This part uses a Dual Domain mesh. Use this part if your primary mesh type you use is Dual Domain or midplane.

Radiator end tank: starts on page 55

This part uses a 3D tetrahedral mesh. Use this part if your primary mesh type you use is 3D.

Practice - Cooling Results Interpretation 41

42 Chapter 4

Dustpan

Design criteriaThe cooling lines, water flow rate and temperature must be optimized to provide the lowest possible distribution in mold surface temperature. The initial water line design has been analyzed and provided. Determine recommendations for improvement including.

What changes in the cooling line geometry should be investigated to lower the temperature variation with the defined cycle time?

What changes (if any) should be made to the water flow rate or temperature to help solve the problems?

Project setup

To open a project

1. Click (File Open Project), and navigate to the folder My MPI 6.2 Projects\MPIe Performance\Cooling_Results_Interpretation.

2. Double click the project file Cooling_Results_Interpretation.mpi.



3.2. Click on the Directories tab.

3.3. Ensure the Default to project directory box is checked.

By having the box checked, the import dialog will open in the project directory.

To review the model

1. Open the model Dustpan cooling interpretation.

2. Investigate the model geometry using the model manipulation tools.


Notice there is several layers for the part itself.

This will be helpful when you are interpreting the results.

Analysis parameters

The analysis was run for you to save time.


To review the analysis parameters

1. Review the analysis parameters used to run the analysis as shown in Table 10.

Viewing the key results

To review the Analysis Log

1. Click the Logs box in the Study Tasks list.

2. Click on the Analysis Log tab.

3. Find the Circuit information and record the following for each circuit in Table 11 on page 51.

3.1. Flow rates.

3.2. Reynolds numbers.

3.3. Pressure drops.

3.4. Coolant temperature rises.

4. Find the Summary of Cavity Temperature Results and record the following for each circuit in Table 11 on page 51.

4.1. Cavity surface temperature - maximum

4.2. Cavity surface temperature - minimum.

4.3. Cavity surface temperature - average.

5. Uncheck the Logs box to close the logs window.

The maximum and minimum cavity surface temperature values correlate to the Temperature, mold results you will view next.

The Average value is the average of the mold surface temperatures. This is compared to the mold temperature entered in the Process Settings wizard. This is also called the target mold temperature. In this case the target mold temperature is 50C.

If the Cavity surface temperature - average is higher than the target, then either there are hot spots within the tool, or the water temperatures are too high, or both.

Table 10: Analysis input parameters

Project/Design Parameters ValueModel type: Dual DomainMaterial: Noblen BZE62F2 PolypropyleneMold temperature: 50CMelt temperature: 215CMold open time: 5.0 secondsInj + pack + Cool: 11.0 secondsGeometry influence: IdealMesh Aggregation: Unchecked (not used)Water temperature: 35CReynolds number: 10,000

44 Chapter 4

Analysis log results interpretation

The coolant flow rate was determined by Reynolds number and the flow rate is not too high. The coolant temperature rise is OK, although circuit 3 could be a little lower. The range of cavity surface temperatures is rather large. The target temperature is 50C and the average is well above this value. Preferably, the surface temperature range should be between 45C and 55C. and the results are no where near that range.

To review the Temperature, mold result

1. Ensure the following layers part layers are on and all others off.

Bottom.

Inside.

Handle.

Sides.

Edge.

Lip.

2. Click the result Temperature, mold.

2.1. Enter the range in Table 11 on page 51 in the entire part range field.

3. Rotate the model around to see where the hotter and colder areas are.

4. Rotate the model so you can see in the core of the dustpan.

A rotation of about 140 -40 -40 is good.

You can use the Enter Rotation Angles field on the Viewpoint toolbar to enter the exact rotation.

5. Turn off all the layers except the Inside layer.

This shows only the temperature distribution in the core of the dustpan body itself.

Notice how the temperature range automatically scaled based on the displayed layers.

5.1. Record the results in Table 11 on page 51.

6. Turn on the Bottom layer and the Inside layer off.

This is the cavity side of the dustpan body.

6.1. Record these results in Table 11 on page 51.

As you have turned on and off the layers and have noticed the temperature scale change you can see easily that the core is much warmer than the cavity.

6.2. Record any additional observations you have about the top temperature in Table 11 on page 51.

7. When you are finished, turn all the part layers on again.

/ Synergy responds faster when turning on and off layers if no results are being displayed. It is faster to turn the result off first, and to then turn the layers on and off.


Temperature, mold results interpretation

The entire part range goes from ~46C to ~98C. The inside corners in the core side of the part is by far the hottest area. However, even the temperature distribution on the Bottom side has a range greater than +/- 5C from the target temperature of 50C.

Most of the optimization should be done on the core, but all the part could be improved.

To review the Temperature Profile, Part:XY Plot result

1. Click (Results Create New Plot).

2. Select Temperature profile, part in the Available Plots list.

3. Click XY Plot in the Plot Type list.

4. Click OK.

5. Enter 2117, 1965 in the Entity ID dialog then hit Enter.

On the X-axis, the 1 value at the right represents the triangular element you chose, and the -1 value at the left represents the matched element on the other surface of the Dual Domain mesh.

6. Click (Select) to stop picking nodes to enter.

Temperature profile results interpretation

Element 2117 is in the corner of the core and element 1965 is in the center of the core. You can see that the temperature in the corner of the core is much warmer than the cavity side for element 2117. You can also see the maximum temperature is about 130C. Element 1965 is much more symmetrical shape because the mold surface temperatures are close together compared to element 2117. The plastic surface temperatures are at data points -1.0 and 1.0. This supports the previous results that the core is the hottest and needs the most attention.

7. Click (Results Examine Results) to find the temperatures at the cavity and the core for element 2117.

7.1. Click on the curve to query for exact values at 1 and -1.

7.2. Record the values in Table 11 on page 51.

Viewing the secondary results

To review the Temperature maximum, part result

1. Click the Temperature maximum, part result.

1.1. Examine the results.

1.2. Record the results in Table 12 on page 52.

46 Chapter 4

2. Right-click (Select Material) in the Study Tasks pane and select Details

2.1. Click the Recommended Processing tab.

2.2. Locate the Ejection temperature.

2.3. Record it in Table 12 on page 52.

2.4. Click OK to close the material dialog.

Maximum temperature part results interpretation

Some of the part has a maximum temperature that is above the ejection temperature. Because there are no thick sections of the part, this suggests the cycle time is too short, the coolant temperature is to high, the cooling is poor, or a combination of the 3. This cooling analysis was run at the desired cycle time for this part. We know from the key results that the cooling, particularly in the core, is poor. The maximum temperature result further suggests the cooling is poor. It also suggests that the coolant temperature may be a bit high.

To review the Percentage frozen layer, part (top) result

1. Click the Percentage frozen layer, part (top) result.

2. Examine the results.

Preferably, there should be no results less than 100%. If this were the case, all of the part would be blue.


Percentage frozen layer (top), part results interpretation

The area of the part that is NOT at 100% represent areas that are above the ejection temperature. These are the areas that need the most attention to keep the cycle time the same and to improve the cooling.

To review the Average Temperature, part result

1. Click the Average temperature, part result.


The average temperature should be as uniform as possible.


4. Record any observations in Table 12 on page 52.

/ If the maximum temperature were above the ejection temperature by more than a few degrees, it could mean that the cooling time used in the analysis was too short.

/ If the ejection temperature was more than a few degrees higher than the maximum temperature, the cooling time might be too long.


Average temperature, part results interpretation

The more uniform the average temperature is, the better. The area of the part with a lower average is the thinner front lip of the part. The area with the highest average are the areas already identified as problem areas.

To review the Time to reach ejection temperature, Part result

1. Click the Time to reach ejection temperature, part result.


As a rule, the time to freeze should be less than the injection + packing + cooling time (IPC) that you set in the process settings.

3. Record the range in Table 12 on page 52.

If there are very thick local sections in the part, a freeze time longer than the injection + packing + cooling time might be acceptable.

4. Record the result in Table 12 on page 52 the IPC time found in the process settings wizard.

5. Scale the results to identify any areas that have a time to freeze that is longer than the IPC time.

What other result does this look like?

Time to freeze, part results interpretation

The maximum freeze time for the part is slightly higher than the IPC time entered in the analysis. The area that is over the 11 second IPC time is the same area that has a maximum temperature higher than 125C and percentage frozen of less than 100%. This is another plot that shows where the cooling optimization must be concentrated.

To review the Circuit pressure result

1. Turn on the three water line layers:

Core WL.

Side WL.

Cavity WL.


3. Select Circuit Pressure from the Available Plots list and click OK.


You have already written down the circuit pressures (they were listed in the Analysis Log). If the circuit were complex, with different channel diameters or shapes, you could use this plot to see where the major pressure build-up is.

Circuit pressure results interpretation

The maximum value for circuit pressure should be significantly less than the capacity of the pumping equipment or coolant source.

48 Chapter 4

To review the Circuit coolant temperature result

1. Click the Circuit coolant temperature.


3. Record your observations in Table 12 on page 52.

Circuit coolant temperature results interpretation

Ideally, the rise in temperature over a cooling circuit should be no more than 3C. All the circuits have a temperature rise of less than 3C, however the core has a rise that is nearly 3 degrees. This would suggest that the flow rate should be higher to lower the temperature rise.

To review the Circuit metal temperature result

1. Click the Circuit metal temperature result.


2.1. Identify the areas, if any, where the circuit metal temperature exceeds the coolant entrance temperature by more than 5C.

Circuit metal temperatures are highest in the areas where the circuit is pulling the most heat out of the mold.


Circuit metal temperature results interpretation

Ideally, the metal temperature should be no more than 5C higher than the coolant inlet temperature. Only small areas in the core circuit closest to the inside corner of the dustpan have more than a 5C

To review the Circuit Flow Rate result

1. Click the Circuit flow rate result.

Circuit flow rate results interpretation

In this case, the flow rates are constant because the cooling line diameters are the same and the flow control input was a Reynolds number of 10,000 for each circuit. However, in cases where the circuit input is a Reynolds number value and there are cross-section variations in the circuits, the flow rate varies. This result is also useful if a circuit has parallel branches.


Recommending improvementsYou have now seen the results of the cooling analysis. You should now determine what changes need to be made to the model or the cooling system. To help determine what changes need to be made, answer the following questions.

The ideas you list here will be implemented in Cooling Optimization chapter.

What area of the part is the warmest?

Is there some area of the part that is too cold?

What is the main problem with the results?

The cooling line layout, water flow rate and water temperatures can be changed. List three things that could be done in the order of preference to address the problem areas of the part. Be specific.

1.

2.

3.

50 Chapter 4

Worksheet - Cooling Results

Answers for this worksheet can be found on page 53.

Table 11: Key Results Work sheet

Key Results Values & ObservationsFlow Rate l/min

First inlet node:Second inlet node:

Third inlet node:

Reynolds NumberFirst inlet node:

Second inlet node:Third inlet node:

Pressure Drop MPaFirst inlet node:


Coolant Temp. Rise CFirst inlet node:


Cavity Temperature CMaximum:Minimum:

Average:

Temperature (top), part CEntire part rangeInside layer range

Bottom layer rangeObservations

Temperature profile, part CAt element 2117 +1At element 2117 -1

Observations


Answers for this worksheet can be found on page 54.

Table 12: Secondary results

Secondary Results Values & observationsMaximum temp, part C

Ejection temperatureRange:

Observations:

Percentage frozen layer (top), part %

Range:

Observations:

Average temp, part C

Range:

Observations:

Time to reach ejection temperature Sec.

IPC TimeRange:

Observations:

Circuit pressure MPa

Observations:

Circuit coolant temp C

Observations

Circuit metal temp C

Observations

Circuit flow rate l/min

Observations

52 Chapter 4

Worksheet answersTable 13: Key Results Work sheet

Key Results Values & ObservationsFlow Rate l/min

First inlet node: 3.41Second inlet node: 3.41

Third inlet node: 3.41

Reynolds NumberFirst inlet node: 10,000

Second inlet node: 10,000Third inlet node: 10,000

Pressure Drop MPaFirst inlet node: 0.0040

Second inlet node: 0.0018Third inlet node: 0.0055

Coolant Temp. Rise CFirst inlet node: 1.6

Second inlet node: 1.1Third inlet node: 2.6

Cavity Temperature CMaximum: 97.5Minimum: 46.1

Average: 67.7

Temperature, mold CEntire part range ~46 to ~97Inside layer range ~52 to ~97

Bottom layer range ~47 to ~73

Observations: The inside layer, (the core) is the hottest area of the part and needs the most attention.

Temperature profile, part CAt element 2117 +1 ~103At element 2117 -1 ~68

Observations: The hot inner corner of the core will be a main factor for warpage on the part, due to differential cooling and needs to be addressed.


Table 14: Secondary results

Secondary Results Values & observationsMaximum temp, part C

Ejection temperature 125Range: ~69 to 130

Observations:Most of the part is near or above the ejection temperature of the material. The cooling must be fixed. The coolant temperature may be too warm as well

Percentage frozen layer (top), part %

Range: ~25 to 100

Observations: The areas that are not 100% frozen are the areas that have a maximum temperature higher than 125C.

Average temp, part C

Range: ~64 to ~112

Observations:

Most of the part is at the high end of the range, but is below the ejection temperature. The average temperature should be lower and the distribution more uniform

Time to reach ejection temperature Sec.

IPC Time 11.0Range: ~4 to ~11.7

Observations: Most of the inside corners have a cooling time higher than the IPC time.

Circuit pressure MPa

Observations: No, problems, the max pressure is well below pump capacities

Circuit coolant temp C

Observations Below the limit, but the core circuit is doing a lot of work.

Circuit metal temp C

Observations Some of the Core circuit is too high, primarily in the corners. Need higher flow rate or more circuits.

Circuit flow rate l/min

Observations No problems

54 Chapter 4

Radiator end tank

Design criteriaThe cooling lines, water flow rate and temperature must be optimized to provide the lowest possible distribution in mold surface temperature. The initial water line design has been analyzed and provided. Determine recommendations for improvement including.

What changes in the cooling line geometry should be investigated to lower the temperature variation with the defined cycle time?

What changes (if any) should be made to the water flow rate or temperature to help solve the problems?

Project setup

To open a project

1. Click (File Open Project), and navigate to the folder My MPI 6.2 Projects\MPIe Performance\Cooling_Results_Interpretation.

2. Double click the project file Cooling_Results_Interpretation.mpi.



3.2. Click on the Directories tab.

3.3. Ensure the Default to project directory box is checked.

By having the box checked, the import dialog will open in the project directory.

To review the model

1. Open the model Radiator tank interpretation.

2. Investigate the model geometry using the model manipulation tools.


Notice there is several layers for the part itself.

This will be helpful when you are interpreting the results.

Analysis parameters

The analysis was run for you to save time.


To review the analysis parameters

1. Review the analysis parameters used to run the analysis as shown in Table 15.

Viewing the key results

To review the Analysis Log

1. Click the Logs box in the Study Tasks list.

2. Click on the Analysis Log tab.

3. Find the Circuit information and record the following for each circuit in Table 16 on page 63.

3.1. Flow rates.

3.2. Reynolds numbers.

3.3. Pressure drops.

3.4. Coolant temperature rises.

4. Find the Summary of Cavity Temperature Results and record the following for each circuit in Table 16 on page 63.

4.1. Cavity surface temperature - maximum

4.2. Cavity surface temperature - minimum.

4.3. Cavity surface temperature - average.

5. Uncheck the Logs box to close the logs window.

The maximum and minimum values correlate to the Temperature, mold results you will view next.

The Average value is the average of the mold surface temperatures. This is compared to the mold temperature entered in the Process Settings wizard. This is also called the target mold temperature. In this case the target mold temperature is 90C.

Table 15: Analysis input parameters

Project/Design Parameters ValueModel type: 3DMaterial: Ultramid 8333GHI, Glass filled NylonMold temperature 90CMelt temperature 280CMold open time: 5.0 secondsInj + pack + Cool: 70.0 secondsGeometry influence IdealMesh Aggregation CheckedCalculate internal mold temperatures CheckedGrid resolution 50 divisions in all directionsWater temperature: 50CReynolds number 10,000

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If the Cavity surface temperature - average is higher than the target, then either there are hot spots within the tool, or the water temperatures are too high, or both.

Analysis log results interpretation

The coolant flow rate was determined by Reynolds number and the flow rate is not too high. The coolant temperature rise is OK, although circuit 2 could be a little lower. The range of cavity surface temperatures is rather large. The target temperature is 90C and the average is well below this value. Preferably, the surface temperature range should be between 85C and 95C. and the results are no where near that range. There appears to be spots on the part that are way too cold as well as too warm.

To review the Temperature, mold result

1. Ensure only the Part layer is on and all others off.

2. Click the result Temperature, mold.

3. Rotate the model around to see where the hotter and colder areas are.

4. Record the range of the entire part and record any additional observations you have about the mold temperature in Table 16 on page 63.

Temperature, mold results interpretation

The entire part range goes from ~58C to ~107C. The core has the hottest region of the part. much of the cavity side is well below the target temperature, with a very cold area at the top of the mounting rib on the top of the part. The distribution suggests there must be much better cooling in the core and the coolant temperature must be raised to get the average mold temperature to be within 1C of the target temperature.

To review the Temperature, part result


2. Select Temperature, part in the Available Plots list.

3. Click Probe XY Plot in the Plot Type list.

4. Click OK.

5. Click on the locations shown in Figure 6

Curve 1, top of the tank at the end by the filler port.

Curve 2, in the mounting rib half way between the tank and slot.

Curve 3, in the smaller diameter of the filler port.

Curve 4, in the left hose port.

Curve 5, in the thick sensor port near the center of the part.

6. Click (Select) to stop picking probe locations.


Figure 6: Probe locations

7. Click (Plot properties) and set the Y-axis scale to 60C to 300C in the plot properties.


9. Right-click (Select material) in the Study Tasks pane and select Details

9.1. Click the Recommended Processing.

9.2. Locate the Ejection temperature.

9.3. Record it in Table 16 on page 63.

9.4. Click OK to close the material dialog.

10. Scale the Y-axis from 60C to 110C.

11. Click (Results Examine Results) to find the temperatures (Y-axis value) at lowest and highest X-value on the graphs.

11.1.Record the values in Table 16 on page 63.

Temperature, part probe results interpretation

The X-axis represents the thickness of the cross section at the location of the curve. Notice how curve 5 is about 10 mm thick, and all the other curves are about 3.8 mm thick. When animating, notice how the first and last data point on any curve does not change in temperature. This is due to the steady state analysis assumptions. The number of animation steps through time is determined by the solver parameter, Number of time steps for 3D cooling flux calculation. The default is 6, this analysis was set to 7.

The shape of the curve should be symmetrical with both the first and last data points being the target mold temperature and the maximum temperature in the center and just at the ejection temperature for the material.

/ If the maximum temperature on the curve is above the ejection temperature by more than a few degrees, it could mean that the cooling time used in the analysis was too short.

/ If the ejection temperature on the curve is more than a few degrees higher than the maximum temperature, the cooling time might be too long.

1

2 3

4 5

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Only curve 2 is symmetrical, but the maximum temperature is way below the ejection temperature. Most of the curves are much hotter on one end which correlates to the core side of the part. Curve 5 has much of its cross-section above the ejection temperature for the material.

Viewing the secondary results

To review the Mold internal temperature result

1. Uncheck any result that is displayed.

2. Click (Edit cutting plane) and check Plane ZX then click Close.

3. Click the Temperature internal mold result.

3.1. Click (Move cutting plane).

3.2. Uncheck the Show Active plane box.

3.3. Click and drag the left mouse button up and down to move the plane.

3.4. Notice how temperature gradient is highest in the core.

3.5. Click (Edit cutting plane) to turn on another plane if desired.

4. When done:

4.1. Close (Move cutting plane) dialog.

4.2. Uncheck the Mold internal temperature result.

4.3. Click (Edit cutting plane) to turn off any planes that or on then close the dialog.

Mold internal temperature results interpretation

This result does not add much new information, but it does support the Temperature, mold result to highlight where the hottest areas of the part are.

To review the Percentage molten layer result

1. Click the Percentage molten layer result.

2. Click (Results Plot properties).


2.2. Select the Contour button.

2.3. Check the Single contour box.

2.4. Enter a contour value of 100.

2.5. Click OK.



Preferably, there should be no results at the last time step. This would indicate the part is completely frozen.


Percentage molten layer results interpretation

The area of the part that is NOT at 100% represent areas that are above the ejection temperature. These are the areas that need the most attention to keep the cycle time the same and to improve the cooling.

To review the Time to reach ejection temperature, Part result

1. Click the Time to reach ejection temperature, part result.

2. Click (Results Plot properties).


2.2. Select the Contour button.

2.3. Check the Single contour box.


2.5. Set the scale from 0 to 70 seconds.

2.6. Click the Animation tab.

2.7. Select Single dataset in the Animate result over combo box.

2.8. Select 70 seconds for the Animate results at combo box.

2.9. Click the Value range button.

2.10.Enter 10 seconds as the value range time.

2.11.Click the Current frame only button.

2.12.Click OK.

3. Click (Step Forward) to animate the results one frame at a time.


Time to Freeze, Part results interpretation

The final time step at 70 seconds does not have any results even though there are areas that are not frozen. The reason for this is because no freeze time is recorded if the node is not frozen yet. At 40 seconds, most of the part is frozen except for the heavy rim, a ring in the inlet port, in a solid boss, and in the thick sensor port. In these areas, the area that is not frozen reduces, but as shown in the Percentage molten plot, the sensor port and rim do not completely freeze off.

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To review the Circuit Pressure result

1. Turn on the WL (water line) layer.


3. Select Circuit Pressure from the Available Plots list and click OK.

4. Review the results.

You have already written down the circuit pressures (they were listed in the Analysis Log). If the circuit were complex, with different channel diameters or shapes, you could use this plot to see where the major pressure build-up is.

Circuit pressure results interpretation

The maximum value for circuit pressure should be significantly less than the capacity of the pumping equipment or coolant source.

To review the Circuit Coolant Temperature result

1. Click the Circuit coolant temperature.

2. Review the results.


Circuit coolant temperature results interpretation

Ideally, the rise in temperature over a cooling circuit should be no more than 3C. All the circuits have a temperature rise of less than 3C, however the core has a rise that is nearly 3C. This would suggest that the flow rate should be high

Documents

AutodeskMoldflow Insight 2010 Performance Practice