HyperMold_12.0_Tutorials.pdf

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Manufacturing Solutions 12.0 HyperMold Tutorials iAltair Engineering

Proprietary Information of Altair Engineering

Manufacturing Solutions 12.0 HyperMold Tutorials

........................................................................................................................................... 1HyperMold

................................................................................................................................... 3MoldFlow........................................................................................................................................ 5MF-0010: Introduction to the Moldflow Macro Menu

........................................................................................................................................ 14MF-0020: Designing Feed Systems

........................................................................................................................................ 21MF-0030: Setting up a Basic Fusion Model

........................................................................................................................................ 26MF-0050: Creating a Solid 3D Mesh Starting from Solids for part

........................................................................................................................................ 32MF-0051: Creating a Solid 3D Mesh Starting from Surfaces

........................................................................................................................................ 37MF-0052: Creating a 3D Mesh Starting from a Surface Mesh................................................................................................................................... 41Moldex3D

........................................................................................................................................ 42MX-0010: Extracting Thickness Data from Midsurface

........................................................................................................................................ 52MX-0020: Setting Up an MSH Model with Part Using Thickness Extraction

........................................................................................................................................ 61MX-0030: Setting Up an MSH Model having Part and Runner

........................................................................................................................................ 72MX-0040: Setting Up an MSH Model for Complete Injection Analysis

........................................................................................................................................ 84MX-1010: Setting Up an MFE Model by Manual Meshing

........................................................................................................................................ 97MX-1020: Settng Up an MFE Model Using the Moldex3D Wizard........................................................................................................................................ 105MX-1030: Setting Up an MFE Model for Fast Cool Analysis........................................................................................................................................ 116MX-1040: Creating a Runner Mesh Using the Runner Meshing Wizard

Altair Engineering Manufacturing Solutions 12.0 HyperMold Tutorials 1


HyperMold

HyperMold provides a highly efficient and customized environment for setting up modelsfor injection molding simulation with Moldflow and Moldex3D. It gives you direct access toHyperMesh-based tools such as geometry cleanup, midsurface extraction and automeshgeneration in order to prepare data for analysis in and export it to native solver formats.The following tutorials and reference material enable you to use the features available inthe HyperMold user profile for setting models for Moldflow and Moldex3D.

MoldFlow

MF-0010: Introduction to the Moldflow Macro MenuMF-0020: Designing Feed Systems MF-0030: Setting up a Basic Fusion ModelMF-0050: Creating a Solid (3D) Mesh Starting from Solids (for part)MF-0051: Creating a Solid (3D) Mesh Starting from SurfacesMF-0052: Creating a 3D Mesh Starting from a Surface Mesh

Moldex3D

MX-0010 - Extracting Thickness Data from MidsurfaceMX-0020 - Setting Up an MSH Model with Part Using Thickness ExtractionMX-0030 - Setting Up an MSH Model having Part and RunnerMX-0040 - Setting Up an MSH Model for Complete Injection AnalysisMX-1010 - Setting Up an MFE Model by Manual MeshingMX-1020 - Settng Up an MFE Model Using the Moldex3D WizardMX-1030 - Setting Up an MFE Model for Fast Cool AnalysisMX-1040 Creating a Runner Mesh Using the Runner Meshing Wizard

2 Manufacturing Solutions 12.0 HyperMold Tutorials Altair Engineering




MoldFlow

HyperMold provides a highly efficient and customized environment for setting up modelsfor injection molding simulation with Moldflow. It gives you direct access to HyperMesh-based tools such as geometry cleanup, midsurface extraction and automesh generation inorder to prepare data for analysis in Moldflow and export it to native Moldflow formats. Youcan export data for all three model types supported by Moldflow such as, Midplane,Fusion, and Flow3D. Options for designing cooling circuits and feed systems are alsoincluded. In addition, HyperView makes it possible to visualize Moldflow results.

The following tutorials and reference material will give you hands-on experience usingMoldflow:

MF-0010: Introduction to the Moldflow Macro Menu

MF-0020: Designing Feed Systems

MF-0030: Setting up a Basic Fusion Model

MF-0050: Creating a Solid (3D) Mesh Starting from Solids (for part)

MF-0051: Creating a Solid (3D) Mesh Starting from Surfaces

MF-0052: Creating a 3D Mesh Starting from a Surface Mesh



MF-0010: Introduction to the Moldflow Macro Menu

This tutorial introduces you to the Moldflow macro menu available in ManufacturingSolutions. This tutorial steps you through the processes of loading a model, creating amesh, checking element quality, and exporting the data deck for Moldflow analysis.

The Moldflow macro menu simplifies the use of the Moldflow user profile in order to quicklyset up an analysis model. The buttons in the macro menu consist of customized panelsthat are specific to Moldflow and shortcuts to a few commonly-used HyperMesh panels.The buttons are presented in the same order as you need them, from top to bottom.

Overview

The following is a summary of steps followed in this tutorial:



1. Open a model

2. Create a midsurface

3. Generate mesh on the midsurface

4. Transfer thickness data from midsurface to elements

5. Check element quality

6. Inspect property cards

7. Organize elements

8. Select a color palette

9. Export the Moldflow data deck

Exercise: Moldflow Macro Menu

This exercise uses the model file MF_0010.hm.

Step 1: Load the model file1. From Altair HyperWorks -> Manufacturing Solutions choose the HyperMold user

profile.

2. To load the model, click on the open .hm file icon and browse to \tutorials\mfs\HyperMold\moldflow\MF_0010.hm

3. Click Open.

Note: The Moldflow interface supports three types of input file types: HyperMesh files,external CAD files (see the Import documentation for a listing of supported CADtypes), and Moldflow input decks (MPI files).



Step 2: Create a midsurfaceFollowing the order of the macro menu, you would first clean up the models geometry.However, in this simple example, the geometry is already acceptable. Next, extract themidsurface representation of the solid part.

1. Click Geometry > Create > Midsurfaces > Auto.

2. Click the yellow surfs button and select displayed from the extended selection menu.

3. Click extract to create the midsurface.



4. Click return to exit the panel.

Step 3: Generate mesh on the midsurfaceFor feed systems, you would now use the Create and Edit buttons in the Lines group tocreate lines. However, feed systems are not needed in this example. The next task is tocreate mesh elements on the midsurface you created in the last task. Please note thatonly linear triangular elements (trias/tria3) are supported

1. Click Mesh > Create > 2D Automesh open the Automesh panel.

2. Set the mesh type: field to trias.

3. In the graphics area, click on the midsurface to select it.

4. In the element size field, enter 0.5.5. Click mesh to create the mesh.




Step 4: Transfer thickness data from midsurface to elementsOnce the mesh has been created, you must extract the element thickness data from themidsurface plane to the elements.

1. In the Utility Menu, under the Edit Attributes heading, click Extract Thickness.The Extract Midsurface Thickness dialog box appears.

2. In the Occurrence number field, type 4.3. In the Method field, select Average.

4. Select Actual for Grouping and type a value of 1 in the Tolerance field.

5. Click Extract.



Next, you will select a surface from which the elements thickness should beextracted.

6. In the element selector panel, click the yellow elems button. Choose the by collectoroption and select Middle Surface.

7. Click proceed to create property cards with thickness, eccentricity, and occurrencenumber and assign them the elements on the selected midsurfaces. In addition, acontour plot of element thicknesses will be displayed

8. Click return.

Step 5: Check element qualityAt this point in the process you could create feed systems or cooling circuits in the model.However, in this exercise you will skip to quality checks.

1. In the Utility Menu, click the Diagnostics>> button, which opens a sub-menu forelement diagnostics. This menu provides many checks, such as overlapping elements,element thickness distribution, aspect ration, element property.

2. Click the Aspect Ratio button. Aspect ratios are calculated based on Moldflowsformula, which is different from HyperMeshs formula. A contour plot appears thatdisplays the aspect ratios.



For midsurface models, Moldflow requires aspect ratios less than 10. You can see inthe contour plot that the largest aspect ratio in this model is 2.37.

3. Click the Summary button to view a list of statistics about the model. The informationappears in the Model Information dialog box.

4. Click Close to close the dialog box.

5. Click return to close the panel.



6. Click Back>> to return to the Moldflow Utility Menu.

Step 6: Inspect property cardsAt any time you can create or edit the property cards for the model by clicking the EditProp Cards>> button under the Edit Attributes group. From the submenu, click EditProperty Card to change an existing property or click Edit Element Data to change theproperty associated with an element.

Step 7: Organize elementsThis is an optional step. Sometimes you may be interested in grouping/organizing yourelements into component collectors based on its properties. With this dialog, you cancategorize elements into different groupings based on thickness or element type.

1. Click Diagnostics>>> followed by Organize Elements. The Organize Elementsdialog box appears.

2. In the Comp base name field, type plate. In the Organizing attribute field, selectThickness, and in select 1 for the Thickness tolerance field.

3. Click Organize. A selection panel appears from which you can specify which elementsto organize.

4. Select elems and select displayed. Click proceed. The elements are organized into13 new components based on thickness. The names of the new components aregenerated by combining both the component base name you provided and thethickness value for that grouping.

Step 8: Export the Moldflow data deckThe last task in this tutorial is to export the Moldflow data deck.

1. Under the Export Data group in the Utility Menu, click Moldflow. The ExportMoldflow Data File dialog box appears.



Export Data group of the macro menu

2. Click the button to browse to the location to save the file, specify a file name in the File Name field, and click Save.

3. Select the other parameters for the file, including the Moldflow version, units ofmeasure, which entities to export, and the type of the model.

4. Click Export. A Moldflow file (*.udm) is created in the location you specified. This datafile can be opened in Moldflow.



MF-0020: Designing Feed Systems

This tutorial steps you through a simple example of creating a feed system (also known asa runner system) for Moldflow using the Moldflow profile in HyperMold.

In this tutorial you will:

Load the model

Create beam elements

Create property cards

Review element data

Export data

Exercise

Step 1: Load the model file1. From the Start menu, select Altair HyperWorks, then select Manufacturing

Solutions, and click HyperMold.

2. Click the Import icon to open the Import tab.

3. Click the Import HM File icon .

4. Click on the file browser icon and browse to \tutorials\mfs\HyperMold\moldflow\MF_0020.hm. Please copy this file to your working directorybefore beginning the tutorial.

5. Click Close to close the Import tab.

This model already includes a midplane and lines that represent the feed system. Thesetwo steps are suggested as first steps to set up a feed system. For an example of how tocreate a midplane, refer to Introduction to the Moldflow Macro Menu tutorial.

The completed model will be a multi-cavity mold with four parts.



Step 2: Create beam elementsThis model includes lines that will be used to create a sprue, primary and secondaryrunners, and a gate. In this task, you will create the beam elements that comprise thefeed system.

1. Click Mesh > Create > Line Mesh.

The Line Mesh panel opens.

2. In the element config: field, ensure that rod is selected. This selection is required forMoldflow output.

3. Click lines, then click displayed.

4. Click mesh. Mesh is created for the lines in the model.

You can adjust mesh density and other common characteristics of mesh as usual.

5. Click return to accept the mesh and exit the panel.

Step 3: Create property cards1. On the Utility Menu, click Off for the Lines. This setting makes element

identification easier in the following steps.



2. Click Design Circuit>>> to open the sub-menu.

3. Under Create/Edit Feed System, click Create Feed System. The Create FeedSystem dialog box appears.

4. Set the following options on the dialog. These settings are for the first component ofthe feed system.

Feed element: Sprue

Hot or cold: Cold

Taper type: Ends

Occurrence number: 1

Cross-section: Circular

Diameter start: 0.7

Diameter end: 0.5 (where melt enters sprue from the extruder)

5. Click Create. You must now select elements in the main menu area.

6. Click elements >> by window. Create a closed shape around the elements in thesprue.

7. Click proceed. You must now select a starting element. The starting elementdetermines the direction of the taper, if you have created an element that tapers

8. Click proceed and this will create property cards for these elements. In addition, asolid is created depicting the shape of the solid. This solid is created only for thepurpose of visualization. If you delete the solid, the underlying elements are notdeleted and vice versa. However, when you use the macro menu to modify elements,



the solid and property cards are automatically re-created to reflect the changes.

9. Repeat steps 3 through 8, using the following settings for each additional feed systemcomponent:

Primary Runner:

Feed element: Runner

Hot or cold: Cold

Taper type: None


Cross-section: Rectangular

Width: 0.5

Height: 0.3

Secondary Runner:

Feed element: Runner

Hot or cold: Cold

Taper type: None


Cross-section: Rectangular

Width: 0.5

Height: 0.3

Gate:

Feed element: Gate

Hot or cold: Cold

Taper type: Ends


Cross-section: Circular

Start diameter: 0.3

End diameter: 0.7 (where it touches the part)

Height start: 0.3

Height end: 0.1

10. Equivalence any coincident nodes.



Step 4: Equivalence nodesThe node at the end of gate (where it touches the part) and the node it touches on thepart have to be equivalenced. This is because the feed system mesh was createdindependently of the part mesh and these two nodes are different. Hence, they have to beequivalenced. You can do this from the Edges panel.

1. Click on the Edges button from the main menu area.

2. Click the switch to elems (instead of comps) and pick the displayed elements.

3. Set the tolerance as 0.01.

4. Click on preview equiv to show the duplicate nodes.

5. Click on equivalence to merge these nodes.

Step 5: Review element data1. Return to the main Moldflow Utility Menu by clicking the



3. Return to the main Moldflow Utility Menu by clicking the



A Moldflow input file is now created in the location you specified. Import this file intoMoldflow.



MF-0030: Setting up a Basic Fusion Model

In this tutorial, you will:

Load the model and set the Moldflow user profile

Create component collectors and edit their card image

Trim the surface for enhancing mesh match

Create a fusion mesh

Check the model summary

Export data

In this tutorial you will go over the process of setting up a basic fusion model for export toMoldflow using the Manufacturing Solutions HyperMold user profile. This is a simplemodel and design of runner system is not included in this tutorial.

Exercise

Step 1: Load the model1. From the Start menu, select Altair HyperWorks, select Manufacturing Solutions,

and click HyperMold.

2. Click the Import icon to open the Import tab.

3. Click the Import HM File icon .

4. Click on the file browser icon and browse to \tutorials\mfs\HyperMold\moldflow\MF_0030.hm.

5. Click Open.

Step 2: Create the surface mesh This exercise will explain this process of creating component collectors for the shell



elements. For fusion mesh, the thickness value specified in the card is not used andmoldflow automatically estimates the thickness.

1. Click Mesh > Create > Automesh.

2. Set the mesh type to trias to create 3-noded tria elements.

3. Enter the element size at 5.04. Click surfs >> all.

5. Click mesh.

6. Click return twice to accept the mesh and exit the panel.

Step 3: Check the model for free edges1. Click Mesh > Check > Components > Edges.

2. Click the selector to change the option to elems. Click elems >> displayed.

3. Click on the find edges button to find the free edges in the model. It should comeback with the message:

Your model should not have any free edges and should enclose a volume. If yourmodel has free edges, you should inspect where the free edges are and correct it. This may happen if the elements are not connected or if you have non triangularelements.


Step 4: Check for element normal vectorsNormal vectors of the elements selected for computing mesh match ratio should pointinwards. If this requirement is not met, this computation will take a very long time beforeaborting.

1. Click Mesh > Assign > Element Normals to open the Element Normals panel.

2. Select the elements subpanel.

3. Switch the toggle to elems and click elems >> displayed.

4. In the size = field, enter 5. 5. Click display normals to display the normals and ensure all the elements normals

are inward.

6. You can complete the following optional steps, depending on the direction of thenormal vectors.

If all the normal vectors are outward, click on reverse normals to make allnormals inward

If some of the normals outward and some are inward, adjust all the normals inwardby clicking on the elems button under orientation and picking any one of the



elements with the inward normal. Click on adjust normals to make all the normalsinward.


Step 5: Check the mesh match ratio1. On the Utility Menu, click Diagnostics.

2. Click Mesh Match Ratio.

3. In the Mesh Match Ratio dialog, click the Show contours checkbox.

4. Click Apply. The estimated values and the contour plot is displayed, showing thematching, unmated and side elements.



5. Click Close to close the dialog, then click return to close the panel.

Step 6: Create and assign fusion property card1. In the Utility Menu, click on Edit Prop Card>>. A new tab with tools to create and

assign property cards opens.

2. Click on Create Property Card. A dialog opens to select the property card name andtype.

3. Set the following data:

4. Click Create. You are then prompted to select the elements and edit the propertycard.

5. Click elems >> displayed.

6. Click proceed.

7. In the card image, accept the default values and click return.



This assigns the fusion1 property card to all displayed elements.

Step 7: Export the data 1. Under the Export Data group, click Moldflow. The Export Moldflow Data Files

dialog box appears.

2. Enter MF_0030.udm in the Project file field and/or click the button to specify a path tosave the Moldflow file.

3. Select the format of Moldflow for which to create the file.

4. Select Millimeters for the HM model units field.

5. Select Displayed for the Export entities field.

6. Select Midplane for the Model type field.

7. Click Export.

A Moldflow input file is now created in the location you specified. Import this file intoMoldflow.



MF-0050: Creating a Solid 3D Mesh Starting from Solids forpart

In this tutorial, you will set up a Solid 3D mesh model for Moldflow. During this tutorial,you will also learn how to use the Flow3D Wizard to quickly set up the model. You willstart from solids to create this mesh. By appropriately merging the solids and/or sharingthe common surfaces, you can control how the mesh is generated. For example if thegate is modeled as a solid, then the gate solid should only share the surface with the partsolid. This way the mesh generated for the gate will be in a separate component and itcan be excluded for the warpage calculations.

Exercise



2. Click the File Open icon and browse to \tutorials\mfs\HyperMold\moldflow\MF_0050.hm.

3. Click Open.

Step 2: Launch the Flow3D Wizard1. On the Utility Menu, click on Flow3D Wizard.



Step 3: Set the project directory1. In the tab, click Set Project Directory. Specify the project directory and project

name and click OK.

Step 4: Set the model units1. In the tab, click Set Model Unit. Select the model length unit in the dialog and click

OK.

Step 5: Solid Edit1. In the tab, click Solid Edit to do share/merge operations on the solids in the model.

2. Click Merge to select the solids and merge them into single solid.

3. The selector panel opens. Select the solids in the collectors base and bosses_merge.

4. Click proceed.



The merged solids are placed in either base or bosses_merge.

5. In the Model Browser, rename the collector that has the solid (in this case, it shouldbe bosses_merge) as part and delete the other (empty) collector.

6. The Solid Edit dialog reopens after each Merge/Share operation to provideadditional solid edit opportunities. Click on Share to create shared surfaces betweenpart and the solids in collector bosses_share. The purpose of this exercise is to showthat even with the part, you can have multiple solids, and thereby meshes can becreated in multiple collectors.

7. Click Merge again select the collectors part and bosses_share.

8. Click proceed to create shared surfaces between the solids.

9. The Solid Edit dialog opens again. Click on Share to chare shared surfaces betweenthe part and the sprue. It is mandatory that the feed system mesh remains separatefrom the part mesh.

10. When the selector panel opens, select the solids in the part and sprue.

11. Click proceed to create the shared surfaces between the solids.

12. Click Close to close the Solid Edit dialog.

Step 6: Set the model information1. Click Set Model Info. Set the options as shown below and click OK.

In this model, there are only solids. One advantage of starting with solids is that youcan mesh the feed system with tet4 elements using this macro. However, this optionis not supported if you start with either surfaces or surface mesh.



2. Click on Next to open the Select Components dialog.

3. Select the part and bosses_share components in the left panel and click on Add toPart button.

4. Select sprue and click on Add to Feed .

5. Click Pick Inlet Surfaces and pick the melt entry surface on the top of sprue solidand click on Proceed.



6. Click on Apply to close the dialog.

Step 7: Surface mesh1. In the tab, click on Surface Mesh. This will open the Surface Mesh dialog.

2. Set the size as shown in the image above and click on Mesh to create a surface mesh.

Step 8: Flow3D mesh1. In the Flow3D Wizard tab, click on Volume Mesh. The Flow3D Mesh dialog opens.



2. Accept the default values and click on Mesh.

Step 9: Export data1. Click Export Data in the Flow3D Wizard. The Export Moldflow Data Files dialog

appears.

2. Click Export to export the model.

3. Click Close to close the Flow3D Wizard.

This deck can be imported in Moldflow Plastics Insight(MPI) and solved.



MF-0051: Creating a Solid 3D Mesh Starting from Surfaces

In this tutorial, you will set up a solid (3D) model for Moldflow starting from a CAD filehaving surfaces. For generating the solid mesh, a closed set of surfaces always need to beconsidered. If the surfaces selected dont form a closed loop, the boundary layergeneration will fail. During this exercise, you will also learn how to use the Flow3DWizard to quickly set up the model.

Exercise




3. Click Open.

Step 2: Launch the Flow3D Wizard1. On the Utility Menu, click on Flow3D Wizard.

Step 3: Set the project directory1. In the tab, click Set Project Directory. Specify a project directory and a project

name and click OK.

Step 4: Set the model unit1. In the tab, click Set Model Unit. Select the model length unit in the dialog and click

OK.



Step 5: Set the model information1. Click Set Model Info. Set the options as shown below and click Next.

Step 6: Select the surfaces1. Select the surface components and add them as volumes in the Select Components

dialog.

Select base1, boss1_shared, and boss2_shared as a new volume

Select boss1 and boss1_shared and add them as a new volume

Select boss2 and boss2_shared and add as a new volume



2. Click on Apply to save the information and close the dialog.

Step 7: Surface mesh1. In the tab, click Surface Mesh. The Surface Mesh dialog opens.

2. Select the minimum and maximum size as 1 and 3 mm; and then click on Mesh. Thiswill create a surface mesh on the surfaces of the selected volumes.

3. Click Mesh. Notice a surface mesh on all the surfaces in the model.

Step 8: Flow3D mesh1. In the tab, click on Volume Mesh. The Flow3D Mesh dialog opens.

2. Accept the default value and click on Mesh. The actual layer thickness to be used willbe automatically recomputed if the selected value is too high. It will take few secondsto create the 3D mesh. The newly created 3D mesh is placed in the componentcollectors flow3d_mesh0, flow3d_mesh1 and flow3d_mesh2.

3. Click on the Model Browser tab and expand the Component folder.

4. Right-click on the components flow3d_mesh0, flow3d_mesh1 and flow3d_mesh2



and click Show.

All the 3D elements are shown.

Step 9: Export the data1. Click Export in the Flow3D Wizard. The Export Moldflow Data Files dialog

appears.





MF-0052: Creating a 3D Mesh Starting from a Surface Mesh

In this tutorial you will learn how to use the Flow3D Wizard to create a 3D mesh startingfrom a surface mesh. The size and quality of the surface mesh will determine the qualityof the created solid mesh. The size of the tetrahedral elements created in the core (that isinside the layered mesh) is directly determined by the size of the surface mesh. Hence, itis important to have reasonably fine and uniform mesh on the surface.

Exercise:




3. Click Open..

Step 2: Set the project directory1. On the Utility Menu, click on Flow3D Wizard.

2. In the tab, click Set Project Directory. Specify a project directory and a projectname and click OK.

Step 3: Set the model unit1. In the tab, click Set Model Unit. Select the model length unit in the dialog and click

OK.



Step 4: Set the model information1. Click Set Model Info. Set the options as shown below and click OK.

Step 5: Select the surfaces1. Select the surface components and add them as volumes in the Select Components

dialog.

Select base1, boss1_shared, and boss2_shared as a new volume

Select boss1 and boss1_shared and add them as a new volume

Select boss2 and boss2_shared and add as a new volume



2. Click on Apply to save the information and close the dialog.

Step 6: Flow3D mesh1. In the tab, click Volume Mesh. The Flow3D Mesh dialog opens.

2. Click Mesh. It will take few seconds to create the 3D mesh. The newly created 3Dmesh is placed in the components flow3d_mesh0, flow3d_mesh1 andflow3d_mesh2.

3. Click on the Model Browser tab and expand the Component folder.

4. Right-click on the components flow3d_mesh0, flow3d_mesh1 and flow3d_mesh2and click Show.

All the 3D elements are shown.

Step 7: Export the data1. Click Export in the Flow3D Wizard. The Export Moldflow Data Files dialog

appears.





Moldex3D

The following tutorials are available:

MX-0010: Extracting Thickness Data from MidsurfaceMX-0020: Setting Up an MSH Model with Part Using Thickness ExtractionMX-0030: Setting Up an MSH Model having Part and RunnerMX-0040: Setting Up an MSH Model for Complete Injection AnalysisMX-1010: Setting Up an MFE Model by Manual MeshingMX-1020: Settng Up an MFE Model Using the Moldex3D WizardMX-1030: Setting Up an MFE Model for Fast Cool AnalysisMX-1040: Creating a Runner Mesh Using the Runner Meshing Wizard



MX-0010: Extracting Thickness Data from Midsurface

In this tutorial, you will learn how to:

Load Moldex3D/Shell user profile

Load a HyperMesh file containing geometry of a part

Extract midsurface from the part geometry

Mesh the part

Assign property card(s) to the part

Inspect mesh quality and thickness contour

Define melt entrance boundary condition

Export the model as a Moldex3D MSH file

All files referenced in this tutorial are located in the HyperWorks installation folder\tutorials\mfs\HyperMold\Moldex3D\MX_0010. If you do not knowthe location of the HyperWorks installation folder on your system, please contact yoursystems administrator.

To work on this tutorial, it is recommended that you copy this folder to your local harddrive where you store your HyperXtrude data, for example, C:\Users\Moldex3D\ on aWindows machine. This will enable you to edit and modify these files without affecting theoriginal data. In addition, it is best to keep the data on a local disk attached to themachine to improve the I/O performance of the software.

Step 1: Load the Moldex3D/Shell user profile1. Launch HyperMesh.

2. On the Preferences menu, click User Profiles.

3. In the Application field, select Manufacturing Solutions.

4. Select HyperMold and Moldex3D/Shell.

5. Click OK.

Step 2: Load the HyperMesh file1. From the File menu, click Open.

2. Browse to the file MX_0010.hm.3. Click Open.

Step 3: Extract the midsurface from the part geometry 1. Click Geometry > Create > Midsurfaces > Auto.



2. Click on the yellow surfs button and select displayed from the extended selectionmenu.

3. Click on the extract button to create the midsurface.


Step 4: Mesh the part1. Click Mesh > Create > 2D AutoMesh.

2. From the graphics area, select the midsurface.

3. In the element size field, enter 0.5.4. Click on the mesh button to create the mesh.

5. Click return twice to exit the panels.



Step 5: Assign property card(s) to the part1. In the Utility Menu, under the Model Setup section, click on Create Property

Cards.

A new macro page is displayed.

2. Click on the Assign Thickness macro button.

The Extract/Assign Cavity Thickness dialog appears.

3. Keep the default values and click Extract. A surface selection panel is displayed.

4. In the graphics area, select the midsurface click proceed.

The thickness is computed and a property card is assigned for each element. Acontour plot appears in the graphics area that shows the distribution of elementthicknesses.




6. Click on the Back macro button to return to the main Utility Menu.

Step 6: Inspect mesh quality and thickness contour1. On the Utility Menu, click on the Diagnostics macro button. A new macro page is

displayed.

2. Click on the Show Quality Table macro button to see the mesh quality.



3. Click on the Show Elements button to see elements based on their Aspect Ratiovalues.



4. Click Cancel to close the dialog.

5. In the Utility Menu, click on Plot Thickness to see the thickness contour.



Step 7: Define melt entrance boundary condition 1. From the Utility Menu, click Create Property Cards.

2. Click on the BCs macro button. A panel to select node(s) will appear.

3. Select a node on the part from the graphic area and click on the proceed button.

The Create Boundary Condition dialog will appear.



4. Select Melt Entrance for BC type and click on the OK button. Notice the boundarycondition created on the selected node. When you apply the melt entrance directly onthe mesh, the direction of the load vector created depends on the direction of thenormal. However, this should matter in the simulation.


Step 8: Export the model as MSH file1. On the Utility Menu, click on the Export macro button. A new tab called Moldex3D

MSH Export displays.



2. In the File: field, specify the file path and name to write the MSH file, and clickExport. The status of export is shown in the status bar at the bottom.

Step 9 (optional): Load the model in Moldex3D solver1. Load the exported MSH file in Moldex3D solver.



2. Solve the model and post-process.



MX-0020: Setting Up an MSH Model with Part UsingThickness Extraction


Load Moldex3D/Shell user profile

Load a HyperMesh file containing geometry of a part

Extract midsurface from the part geometry

Mesh the part











5. Click OK.





Step 3: Assign property card(s) to the part1. In the Utility Menu, under the Model Setup section, click on the Create Property

Cards macro button. A new macro page is displayed.

2. Click on the Assign Thickness macro button. The Extract/Assign Cavity Thicknessdialog appears.



3. Set the Method: field to Manual. Enter a value of 2.0 in the Thickness field.

4. Click Assign.

The element selection panel is displayed.

5. With the yellow elems button activated, select any element on the top face. Thenclick on the elems button and pick by face in the extended selection menu.

6. Click proceed.

7. In the panel, click Assign.

8. The thickness is computed and a property card is assigned for each element. Acontour plot appears in the graphics area that shows the distribution of elementthicknesses.




10. Click again on the Assign Thickness macro button. Set the Method to Manual andThickness to 2.2. Click on the Assign button. Select one element on one of the facesadjacent to the top face.

11. Click elems and select the option by face from the extended selection. Click on theproceed button.

12. Click return to close the panel. Repeat steps 10 and 11, selecting each the remainingsides until all sides are completed.

13. Notice the contour.



Step 4: Inspect the mesh quality and thickness contour1. In the Utility Menu, click on Diagnostics. It will open a new macro page.

2. Click on Show Quality Table macro button to see the mesh quality.



3. Click on Show Elements to see elements based on their Aspect Ratio values.



4. Click on Plot Thickness to see the thickness contour. Click return to close this panel.

5. Click Back to return to the main Utility Menu.

Step 5: Define melt entrance boundary condition 1. In the Utility Menu, click Create Property Cards.

2. Click on BCs macro button. A panel to select the node will appear.

3. In the graphics area, select a node on the part and click proceed.

The Create Boundary Condition dialog appears.

4. Select Melt Entrance for BC type. Click OK. Notice the boundary condition on thenode.




Step 6: Export the model as MSH file1. Click on the Export macro button.

2. The Moldex3D MSH Export tab opens up.

3. Specify the file path and name to write the MSH file and click Export.

The export status is shown in the status bar.





MX-0030: Setting Up an MSH Model having Part and Runner


Load a HyperMesh file containing mesh of the part and geometry of the runner


Create the runner system










5. Click OK.





4. Click on the tab Model to display the Model Browser and view the contents of thefile. The part mesh is in the component collector part. Lines that constitute the hotrunner are in the component RH and lines that constitute the cold runner are in thecomponent RC.

Step 3: Assign property card(s) to the part1. In the Utility Menu, under the Model Setup section, click on Create Property

Cards. A new macro page is displayed.

2. Click on Assign Thickness. The Extract/Assign Cavity Thickness dialog appears.

3. Set the Method to Manual. Specify the Thickness as 2.0.



4. Click Assign.

5. A panel to select elements will appear in the panel area. Select any element on thetop face, then click on the elems button and pick by face in the extended selectionmenu. Click proceed.

The thickness is computed and a property card is assigned for each element. Acontour plot appears in the graphics area that shows the distribution of elementthicknesses.


7. Click again on Assign Thickness macro button. Set the Method to Manual andThickness to 2.5. Click Assign.

8. Select one element on one of the faces adjacent to the top face. Click the elemsbutton and select the option by face from the extended selection. Click proceed.

9. Repeat steps 7 and 8 until all four sides adjacent to the top face have been selected.Notice the contour.



10. Click return to close the panel, and click Back in the Utility Menu to return to themain menu.

Step 4: Create the runner system1. In Moldex3D/Shell, the runner system is defined by 1D-beam elements. Click on the

Model tab to open the Model Browser. Right-click on the component RC and selectthe option Make Current as shown below.

2. Click on Utility tab to view the Utility Menu. Under the Generate Mesh section,click on the macro button Runner System Mesh . This will open the Line Meshpanel.



3. Click on the lines button to open the extended selection menu. Click the option bycollector and pick RC and click select.

4. Set the element size= field to 4.0. Click on the mesh button and then click returnto accept the mesh. Notice the mesh.

5. Set the collector RH as the current collector. Repeat the steps 3-4 for hot runner.




7. Click on the edges button in the panel area. It will open the Edges panel.

8. Click the selector to change the option to elems. Click on the yellow elems buttonand select displayed option.

9. Click on the preview equivalence button to find out any coincident nodes.

10. Click on the equivalence button to remove coincident nodes.


12. On the Utility Menu, click Create Property Cards under Model Setup.

13. Click on the Create Runner macro button. It will open the Create Feed Systemdialog.

14. Set the options as shown below and click Create.



15. After clicking Create, a panel appears to select the elements. Click elems and selectby collector in the extended selection menu. Select the collector RC.

16. Click select and then click proceed. Surfaces are drawn for visualization of therunner.

17. Click on the Create Runner macro button again. Set the options as shown below, andclick Create.



18. After clicking Create, a panel appears to select the elements. Click elems and selectby collector in the extended selection menu. Select the collector RH.

19. Click select and then click proceed.

20. After clicking proceed, another panel is opened to select the start node. Select thetop most node of the hot runner and click proceed. The runner creation is complete.

21. Click Back in the Utility Menu to return to the main menu.

Step 5: Inspect mesh quality and thickness contour1. Click on Diagnostics macro button. It will open a new macro page.

2. Click on Show Quality Table macro button to see the mesh quality.




Step 6: Define melt entrance boundary condition 1. Click Create Property Cards.

2. Click on the BCs macro button. A panel to select the node will appear.

3. In the graphics area, select the top most node on the hot runner and click proceed.The Create Boundary Condition dialog will appear.

4. Select Melt Entrance for BC type. Click OK. Notice the boundary condition on thenode.




Step 7: Export the model as MSH file1. Click on the Export macro button.

2. The Moldex3D MSH Export tab opens up.

3. Specify the file path and name to write the MSH file and click Export.

The export status is shown in the status bar.





MX-0040: Setting Up an MSH Model for Complete InjectionAnalysis


Load a HyperMesh file containing geometries of the part, runner, coolant channel andmoldbase

Mesh the part, runner, coolant channel and the moldbase

Assign property card to the part and moldbase

Create the runner system

Create the coolant channel system


Define melt entrance and coolant entrance/exit boundary conditions








5. Click OK.





4. Click on the Model tab to view the contents of the file. The part geometry is in thecomponent collector geom_Part and the component Middle Surface contains themidsurface of this part. Lines that constitute the runner are in the component geom_Runner and lines that constitute the cooling channel are in the componentgeom_CoolingChannel. The moldbase geometry is in the componentgeom_Moldbase.

Step 3: Midsurface for the part geometryThe following steps outline how the middle surface was created. You do not have to repeatthese steps as the model you started with already contains the middle surface.

1. Click Geometry > Create > Midsurfaces > Auto.

2. Click on the surfs button and select the option by collector.

3. Select the collector geom_Part. Click on the select button and then on the extractbutton.

Midsurface extraction takes a couple of seconds. The midsurface is placed in a new



collector name Middle Surface.


The created midsurface will have some errors; by using surface edit and Autocleanupfunctions, these errors were corrected. These steps are not presented here as they willdistract the focus of this tutorial. Hence, the corrected midsurface was included in themodel provided.

Step 4: Mesh the part, runner, coolant channel and moldbase1. From the Model Browser, right-click on the component geom_Part and select Make

Current. Right-click again and select Isolate. Click the icon to make sure thecomponent displays completely.

2. To generate surface mesh on the part, click Mesh > Create > 2D Automesh.

The Automesh panel opens.

3. Click on the yellow surfs collector to open the extended selection menu. Click theoption by collector and pick Middle Surface and click on the select button.

4. Set the element size field to 1.0. 5. Set the mesh type field to trias.

6. Set the switch to elems to current comp.

7. Click on the mesh button to generate the mesh.

8. Click on the return button twice to exit the panel.

8. In the Model Browser, set the collector geom_Moldbase as the current collectorand isolate it in the view.

9. Click Mesh > Create > 2D Automesh again. Click surfs and select the surfaces inthe collector geom_Moldbase.

10. Set the element size to 30.0 and the mesh type to trias.11. Click on the mesh button.

12. Click on the return button twice to exit the panel.



13. From the Model Browser, set the collector geom_Runner as the current collector.Show both the geom_Runner and geom_Part components in the view.

14. In the Utility Menu, click on the Runner System Mesh button to open the LineMesh panel.

14. Click the lines button and select the collector geom_Runner.

15. Set the element size field to 5. Click on the mesh button in the Line Mesh panel.Click on the return button twice to exit the panel.

16. From the Model Browser, set the collector geom_CoolingChannel as the currentcollector and display it. From the Utility Menu, click on the Coolant System Meshbutton to open the Line Mesh panel.

17. Pick the lines in the collector geom_CoolingChannel. Set the element size to 30.0and click on the mesh button.

18. Click return twice to close the panel.



Step 5: Assign property cards to the part and moldbase1. In the Utility Menu, click on Create Property Cards under the Model Setup header.

A new dialog opens.

2. Click on Assign Thickness. The Extract/Assign Cavity Thickness dialog appears.

3. Keep the default values and click Extract. A panel to select the surface(s) thatconstitute the part will appear.

4. Select the surfaces in the collector Middle Surface. Click on the proceed button.

Thickness information is retrieved from the nodes of the part mesh and is stored inproperty cards(s). At the end of thickness extraction, a thickness contour for the partis plotted.



5. Click on the Shell Mesh macro button again. It will open a panel to select elements.Select the elements in the collector geom_Moldbase and click on the proceedbutton.

The Create/Assign Surface Mesh Properties dialog opens up.

6. Retain the default options. Click on the OK button to complete the property cardassignment for Moldbase surface mesh.


Step 6: Create the runner system1. In the Model Browser, right-click on geom_Runner and make it the current

component.

2. In the Utility Menu, click on the Create Runner macro button. It will open a newdialog.



3. Set the diameter as 5.0 and click on the Create button. A panel to select the runnerelements will open up.

4. Select the elements in the collector geom_Runner. Click on the proceed button.

Step 7: Create the coolant channel system 1. In the Model Browser, right-click on geom_CoolingChannel and make it the

current component and display it.

2. Click on the Coolant Channel macro button. A panel to select the coolant channelelements will open. Select the elements in the collector geom_CoolingChannel.Click on the proceed button. The Create Coolant Channel dialog will display.



3. Set the options as shown in the image above and click on the Create button. Surfacegeneration for coolant channel visualization takes couple of seconds to complete.

4. In the Utility Menu, click on the Back macro button to return to the main UtilityMenu.

Step 8: Inspect mesh quality and thickness contour1. Click on the Diagnostics macro button. A new macro page will open up.

2. Click on the Show Quality Table macro button. The mesh quality plot comes up.



3. Based on the plot, we can conclude that mesh is of good quality and can be exported.Click Cancel to close the dialog.

4. Click on the Back macro button to return to the main Utility Menu, and click returnto close the panel.

Step 9: Define melt entrance1. Click on the Create Property Cards macro button. It will open a new macro page.

2. Click on the BCs macro button. A panel to select the node(s) will open up. Select thetop most node of the runner as shown below. Click on the proceed button.

3. The Create Boundary Condition dialog opens up. Click on the OK button tocomplete the Melt Entrance Boundary condition creation.



Step 10: Define Coolant Inlet/Outlet 1. Click on the Create Property Cards macro button. It will open a new macro page.

2. Click on the BCs macro button. A panel to select the node(s) will open up. Select thefour left extremes nodes of the coolant channel as shown below and click on the proceed button.

3. The Create Boundary Condition dialog opens up. Click on switch on the BC type to



Coolant Entrance and click the OK button to create coolant entrance BC.

4. Click on the BCs macro button again and pick the nodes on the other side for coolantexit.

5. In the BC panel, select Coolant Exit and click on OK to create the exit BC.

Step 11: Equivalence coincident nodes 1. Click on edges button in the panel area. It will open the Edges panel.

2. If necessary, click the switch from comps to elems.

3. Click on the yellow elems button and select all. Click on the preview equivalencebutton to find coincident nodes. In this model, you will find one coincident nodebetween the runner mesh and the part mesh.

4. Click on the equivalence button to remove the coincident node.



5. Click return to close the panel, and click Back to return to the main Utility Menu.

Step 10: Export the model as MSH file1. Click on the Export macro button. The Moldex3D MSH Export tab displays.

2. Specify the file path and name to write the MSH file and click Export. The status ofexport is shown in the status bar.



MX-1010: Setting Up an MFE Model by Manual Meshing


Load a HyperMesh file containing solid mesh of the part and the runner

Mesh the runner using solid map

Mesh the part using CFD BL mesh

Assign property card(s) to the part and the runner

Inspect mesh quality


Export the model as a Moldex3D MFE file

All files referenced in this tutorial are located in the HyperWorks installation folder \tutorials\mfs\HyperMold\Moldex3D\MX_1010. If you do not knowthe location of the HyperWorks installation folder on your system, please contact yoursystems administrator.


Step 1: Load the Moldex3D/Solid user profile1. Launch HyperMesh.



4. Select HyperMold and Moldex3D/Solid.

5. Click OK.



4. Click on the Shaded Geometry icon to display the model as shaded.



5. Click on the Model tab to open the Model Browser and view the contents of the file.The part solid geometry is in the component collector part. The runner solid geometryis in the component collector runner.

6. Click the Geometry Color Mode icon to switch the mode to By 3D Topo to checkfor the shared surface(s) between the part and the runner as shown below.

7. In the Model Browser, right click in the white space and select Create >Component. Enter the component name as shown below to create a new componentthat will have the solid mesh for both the part and the runner.



Step 3: Mesh the runner using solid map1. In the Model Browser, right-click on the component runner and select the option

Make Current. The component name will become bold.

2. Click Mesh > Create > 2D AutoMesh. The Automesh panel opens.

3. Pick the topmost surface of the runner as shown below. Set the mesh type to R-trias. Set the element size to 0.2.



4. Click the mesh button to generate surface mesh on the top most surface. Click onthe return button twice to exit the panel.

5. In the Model Browser, set the component runnersolidmesh as the currentcollector.

6. Click on the solid map button in the main menu. It will open the Solid Map panel.

7. Select the one volume subpanel.

8. With the solid button under the option volume to mesh highlighted, select therunner solid from the graphics area.

9. Click on the surfs button under the option source hint, and select the top mostsurface of the runner.

10. Click the switch for the source shells option, and select R-trias.

11. Set the switch from elems to solid/surf comp to elems to current comp.

12. Set the elem size field to 0.5. 13. Click the mesh button to generate the solid mesh for the runner. Click return to close

the panel.



14. From the main menu, click on the faces button.

15. Select the component runnersolidmesh either by picking from the graphics area orby clicking the comps button and selecting it from the component list. Click the findfaces button to generate the faces, then click return to close the panel.

16. The face elements are placed in the component ^faces. Use the Model Browser toswitch off all other components except ^faces and the runner.

17. From the top menu bar, click on Mesh > Delete > Elements. The Delete panel willopen up.



18. Select any element on the bottom most face of the runner as shown below. Then click elems >> by face.

19. Click again on the yellow elems button and select the reverse option.

20. Click on the delete entity button to delete the elements. Click on the return buttonto exit from the panel.

21. Click on the project button.

22. Select the to surface subpanel.

23. Click on the selector and change it to elems.

24. For the option along vector, click on the toggle button and set it to surface normal.

25. Click on the yellow elems button and select displayed.



26. Click on the yellow surf button and pick the bottom most surface of the runner.

27. Click on the project button to project the face elements. Click on the return buttonto exit the panel.

Step 4: Mesh the part using CFD BL mesh1. Switch on the part geometry and mesh from the Model Browser by clicking on the

icons and next to the component part. Switch off the runner geometry and meshfrom the Model Browser by clicking on the same icons next to the componentrunner.

2. Click on the organize button.

3. Click elems >> displayed.

4. Click on dest component = and select the component part.



5. Click move to move the elements to the component part. Click return to close thepanel.

6. In the Model Browser, make the part component the current component.

7. Click on the Surface Mesh macro button in the Utility Menu. It will open theAutomesh panel.

8. Select the surface where the runner meets the part as shown below. Click on theyellow surfs button and pick the reverse option to select the remaining surfaces.

9. Set the element size field to 0.5 and click mesh. Click return twice to exit thepanel.

10. In the Utility Menu, click on the Layered Tet Mesh macro button. It will open a newmacro page.

11. Click on the Def BL Thickness macro button. It will open a new dialog as showbelow:



12. Click on the Add collectors with surface elements button. It will open a panel toselect components.

13. Select the component part and click proceed.

14. Set the number of layers field to 2.

15. Set the first layer thickness field to 0.1.

16. Click on the button Generate Distributed BL Thickness Ratio to generatedistributed BL information. A message will appear to confirm the BL informationgeneration. Click the OK button.

17. Click on the Close button to close the dialog.

18. Click on the CFD Tet Mesh macro button in the same macro page. It will open theCFD Tetramesh panel.

19. In the Boundary selection subpanel, select the component part from the graphicsfor elements with boundary layer (fixed).



20. In the BL parameters subpanel, set the number of layers field to 2.

21. Set the first layer thickness field to 0.1 and BL growth rate field to 1.00.

22. Click on the mesh button to start the CFD BL meshing. CFD BL meshing will takecouple of seconds to complete. When finished, click on the return button to exit thepanel.

23. The CFD BL mesh for the part is placed in two newly created components CFD_boundary_layer and CFD_tetramesh_core. Switch off the display of thecomponent part to visualize the CFD BL mesh of the part. You can also use the Maskpanel to display the newly created mesh.

24. In the Model Browser, create a new component collector called partsolidmesh.

25. Click on the organize button and move the elements from the collectorsCFD_boundary_layer and CFD_tetramesh_core to the collector partsolidmesh.Now the collectors you created have the solid meshes for the runner and the part.

26. In the Utility Menu, click on Back.

Step 5: Assign property card(s) to the part and the runner1. In the Utility Menu, click on Create Property Cards under Model Setup.

2. Click on Solid Mesh. It will open a panel to select the elements. Select the elementsin the collector runnersolidmesh and click proceed.

3. The Create/Assign Solid Mesh Properties dialog displays. Select the option ColdRunner solid mesh from the drop down menu and click OK.

4. Repeat the steps 2-3. This time select the collector partsolidmesh and select Cavity(Part) solid mesh from the drop down menu.

5. Click on the Back macro button to return to the Utility Menu.

Step 6: Inspect mesh quality 1. Click on the Diagnostics macro button.

The Mesh Quality Table displays, showing the quality. Click on each tab to view thedistribution. Using the button Show Elements, you can see the elements falling in



the range selected.

2. Click Cancel to close the table.

Step 7: Define melt entrance boundary condition 1. Click on the Create Property Cards macro button.

2. Under the BCs header, click the Points macro button. A panel to select the node(s)will appear.

3. Select a node on the cold runner from the graphic area as shown below and click onthe proceed button. The Create Boundary Condition dialog will appear.



4. Select Melt Entrance for BC type. Click on the OK button. Notice the boundarycondition on the node.

5. Click on the Back macro button to return to the Utility Menu.

Step 8: Export the model as MSH file1. Click on the Export macro button. The Moldex3D MSH Export tab displays.

2. Specify the file path and name to write the MSH file and click Export. The status ofexport is shown in the status bar.



MX-1020: Settng Up an MFE Model Using the Moldex3DWizard


Load a HyperMesh file containing solid geometry of the part and the runner

Create CFD mesh for the part and runner using Moldex3D Wizard

Assign property card(s) to the part and the runner

Inspect mesh quality


Export the model as a Moldex3D MFE file



Step 1: Load the Moldex3D/Solid user profile1. Launch HyperMesh.



4. Select HyperMold and Moldex3D/Solid.

5. Click OK.



4. Click on the Shaded Geometry icon to display the model as shaded.



5. Click on the tab Model to display the Model Browser and view the contents of thefile. The part geometry is in the component collector part. The runner geometry is inthe component collector runner.

Step 3: Create a CFD mesh for the part and runner using Moldex3DWizard1. Click on the Moldex3D Wizard macro button in the Utility Menu. It will open a new

tab named Moldex3D Wizard.

2. Click on the checkbox Set Project Directory in the Moldex3D Wizard. It will openthe Set Project Directory dialog. Specify the Project Directory and the ProjectName. Click on the OK button.

3. Click on the checkbox Set Model Unit. It will open the Set Model Unit dialog. Selectthe appropriate unit from the drop down field. Click on the OK button.

4. Click the Geometry Color Mode icon and set the display to By 3D Topo mode.

5. Click on the checkbox Solid Edit. It will open the Solid Edit dialog. Using this dialog,



you can merge or share solids. As there is no shared surface between the part and therunner, we need to create shared surface between these two solids.

6. Click on the button Share. It will open a panel to select the solids. Select both thesolids from the graphics area and click on the proceed button. Notice the yellow areathat represent the shared surface between the part and runner. Click on the Closebutton.

7. Click on the checkbox Set Model Info. It will open the Set Model Info dialog.Information about the model is set in this step. Set the options as shown below andclick on the Next button.

8. After clicking the Next button, a new dialog named Select Components appears.Using this dialog, you can specify the components that contain the geometry of partand the feed (runner) system. On the left side is the list of components in the modelwith solids. On the right side, components are shown under part and feed categoriesbased on the selection.

9. Select the component part and click on the Add to Part -> button. Select thecomponent runner and click on the Add to Feed-> button.



10. Click on the Pick Inlet Surfaces button to specify the feed inlet surface. It will opena panel to select the surfaces. Select the top most surface of the runner as shownbelow. Click on the proceed button. Click on the Apply button to set the informationand close the dialog.

11. Click on the checkbox Surface Mesh. It will open the Surface Mesh dialog. In thisdialog, you can specify minimum and maximum element sizes separately for the partand the runner. Surface meshing is done progressively from surface(s) with thesmallest area until the surface with the largest area. A good surface mesh yields agood quality solid mesh. Specify the sizes as shown below.



12. Click on the Mesh button to generate the surface mesh.

13. Click on the checkbox Volume Mesh. It will open the Volume Mesh dialog. Specifythe Number of Layers as 2 as required in the solid mesh and the First LayerThickness as 0.3.



14. Click on the Mesh button to generate the solid mesh. Switch off the collectors partand runner from the Model Browser to visualize the solid mesh. Click on the Closebutton in the Moldex3D Wizard.

Step 4: Assign property card(s) to the part and the runner1. In the Utility Menu, click on the Create Property Cards macro button under Model

Setup. It will open a new tab.

2. Click on the Solid Mesh macro button. It will open a panel to select the elements.Select the elements in the collector flow3d_mesh0. Click on the proceed button.

3. After clicking proceed, the Create/Assign Solid Mesh Properties dialog comes up.Select the option Cold Runner solid mesh from the drop down and click on the OKbutton.

4. Repeat steps 2 and 3. This time select flow3d_mesh1 and Cavity (Part) solidmesh.


Step 5: Inspect mesh quality 1. Click on the Diagnostics macro button.

The Mesh Quality Table will appear showing the quality. Click on each tab to viewthe distribution. Using the button Show Elements, you can see the elements fallingin the range selected.



Step 6: Define melt entrance boundary condition 1. Click on the Create Property Cards macro button.

2. Under the BCs header, click the Points macro button. A panel to select the node(s)will appear.

3. Select a node on the cold runner from the graphic area as shown below and click onthe proceed button. The C

Documents

HyperMold_12.0_Tutorials.pdf