Cooling Analysis Strategies
Cooling Analysis Objectives
Cooling analyses are performed to determine (in part)
Cooling line placement Minimum cycle time Minimum temperature
distribution on cavity and/or core Minimum temperature distribution
between cavity and core Whether high thermal conductivity inserts
should be used
Analysis Type
Objectives determines are cooling analyses are run There are two
analysis types
Manual analysis A cycle time is input into the analysis Best if
there is a known cycle time Best if the cooling layout is poor
Automatic analysis Calculates the cycle time for you Best for
minimizing cycle time Automatic analysis should not be run if the
cooling layout is poor, because cycle times will be extended.
Automatic Analysis
Cycle time is calculated by
Making sure the part is 100% frozen 100% frozen is the default,
but the value can be defined
Average of mold surface temperatures (top and bottom) for all
elements is within 1C of the target mold temperature
Analysis Advanced Parameters
Mold temperature convergence tolerance Maximum number of mold
temperature iterations Geometric influence
Geometry Influence Parameter (GIP)
Geometric influence option
Automatic The software calculates the minimum number of
surrounding elements required to produce accurate cooling results
for each element, which is faster and requires less computing
time.Automatic
Ideal The calculation for each element takes into account all
other elements in the modelIdeal
Geometry Influence Parameter (GIP)
How it is used
Geometry Influence Parameter (GIP) Tips
Use default automatic setting unless an issue arises
Good to use when optimizing water lines
Ideal should be used if going on to warpage Parameter can be
used but not typically recommended for warpage
Automatic ~ GIP 10, so for large models you can set the
parameter lower Reduces memory requirements but may affect accuracy
of results
Set to a high number (20-30) if Ideal gives problems
Cooling Memory Errors
ERROR 702270 Disk Space Free up more disk space for both job
manger temp and project directories Change GIP, especially if
running Ideal If using a large model, change GIP to 6-10 Upgrade to
higher amount of disk space ERROR 700080 Memory (RAM + SWAP)
Increase swap size Swapping to hard drive increases analysis time
significantly Watch CPU usage when swapping, normally under 10%
Upgrade to higher amount of RAM Try to lower element count
Remesh Convert Fusion > Midplane model
Fusion Thickness Change Issue
MPI allow you to manually change element thickness
properties
Does not move mesh OK for Flow
Issue for cooling as solver (Boundary Element Method) relies
partially on mesh location Heat flux calculations do use thickness
property
Typically gives accurate results
This issue affects warp results Most accurate results obtained
by making changes in CAD and re-importing Fusion mesh
When to Run Cooling
Model part & mold Fill
Warp
Optimize filling of the part Balance/size feed system Possible
packing
Cooling
Determine type (midplane only) Determine magnitude Determine
cause Reduce warpage
Minimize temp differences DONT run filling as input to
coolOptimize packing if necessary, Use cooling as input to Flow,
cooling may have strong influence on packing
Flow
Exercise
Run a cooling analysis on the dustpan
Set inlets locations with Reynolds number Water temperature
10,000 25 C 40 C 225 C 5 sec Specified 15 sec Ideal
Run analysis with the following inputs Mold surface temp: Melt
temp: Mold-open: Inj + Pack + Cooling: Geometry influence:
Run a second cooling analysis with Automatic IPC Compare the
results from the two analyses
Results SummaryTarget Mold Temperature 40 C
Automatic AnalysisSummary of Cavity Temperature Results
===================================== Cavity temperature - maximum
Cavity temperature - minimum Cavity temperature - average Average
mold exterior temperature Cycle time = = = = = 54.6 29.4 39.8 26.9
66.0 C C C C s
Specified AnalysisSummary of Cavity Temperature Results
===================================== Cavity temperature - maximum
Cavity temperature - minimum Cavity temperature - average Average
mold exterior temperature Cycle time= = = = = 91.2 35.6 59.0 29.2
20.0 C C C C s
Top Temperatures
Max Temp 54.6 C
Specified analysis Cycle time 20 sec. Avg. cavity temp.
59.0C
Automatic analysis Cycle time 66.0 sec. Avg. cavity temp. 39.8C
Target mold temp. 40C
Maximum Temperature
Max Temp 54.6 C
Manual analysis Cycle time 20 sec. Avg. cavity temp.
59.0CEjection temperature 107C
Automatic analysis Cycle time 66.0 sec. Avg. cavity temp. 39.8C
Target mold temp. 40C
Average Temperature
Max. Value 46.0 Manual analysis Cycle time 20 sec. Automatic
analysis Cycle time 66.0 sec. Target mold temp. 40C
Time to Freeze
Max. Value 15.7 secManual analysis Cycle time 20 sec. Automatic
analysis Cycle time 65.6 sec.
Coolant Temperature
Max. Value 26.0Manual analysis Cycle time 20 sec. Automatic
analysis Cycle time 65.6 sec.
QUESTIONS?
