Moldflow User Meeting

Hanno van RaalteProduct Manager for Moldflow

22 June, 2017

What’s New in Moldflow

Franco CostaSenior Research Leader

Agenda

▸ Quarterly Update Releases▸ 2017R2

▸ 2017.3

▸ Moldflow & Helius 2018.0

▸ Moldflow Ecosystem update▸ New Products & Technology

▸ Outlook

Moldflow | Quarterly Cadance

2016

Jan Mar Apr

2017 FCS

* Cloud access for Insight users* Foaming with Core Back

* Foaming with Blowing Agent

* Design Optimization• Adviser Re-stack

• Improved Fiber Orientation• 3D Residual Stres

Oct Jan

2017.3

* One Click Mesh+ SolveMulti-barrel inj. Molding

2017 R2 2018.0

July

2018.1

Oct

2018.2

Jan

2018.3

2017 2018

2017 SP1(Linux)

2017 SP2(SJM)

* MIM/CIM* Mesh generation

improvements

2019.0

Apr

Moldflow 2017

Year Review

Moldflow 2017 releases

Local, Network and Cloud Solves for Moldflow Insight

2016

2017

Moldflow Insight

Moldflow Flex

Moldflow Insight

Moldflow Job Manager

Simulation Job Manager

Moldflow Job Manager

Simulation Job Manager

Moldflow Insight Standard (1 solve)

Moldflow Insight Premium (3 solves)

Moldflow Insight Ultimate (3 solves)

Named User license with Moldflow Insight Ultimate level functionality (many solves, consumes Cloud Credits)

Moldflow Insight Standard (1 solve)

Moldflow Insight Premium (3 solves)

Moldflow Insight Ultimate (3 solves)

Capabilities at the same license level as available at the local and remote solves. Named user model and will require Cloud Credits.

Workflow Efficiency Improvements

Customizable Legend Bar

Ribbon Customization

Cutting Plane Synchronization

New Meshing Tools

Local Mesh Refinement Advanced Surface Mesh Modification Tools

1. Original 2. Offset operation 3. Extrude operation

6

1

Vector (0 0 -15)

2

Normal 1.5

3

Normal -1.5

4

Vector (35 0 0)

5

Normal (-10 0 0)

Direct Geometry Modification

Direct Geometry Modification

Parametric Geometry Optimization

Parametric Geometry Optimization

▸ Automated local edge length control

▸ Users can adjust edge length by a “scale factor”

▸ User defined settings override automatic options

▸ Fillets are ignored

▸ Large elements on external Mold boundaries, smaller elements on internal boundaries

▸ Same edge length on surface meshes of assembly contact interfaces

Auto-sizing for CAD Surface Mesh Generation

Improved abilities working with CAD models

▸ Improvement in CAD model handling in Moldflow Synergy and new CAD export format

▸ Delete components of an assembly or mold that are not needed.

▸ Copy and move individual CAD bodies.

▸ Export Warped or Windage model in .step format

Reflect and Translate

Model preparation Quality and Speedup Mold Meshes

▸ Mold setup wizard can now create a Solid model of a Mold around a model for Cool(FEM)

▸ Overall improved quality, robustness and workflow.

▸ User does not need to stitch contact surface manually

Valve Gate Trigger node Enhancement

▸ New Fiber Orientation Model for 3D Flow

▸ Powder Injection Molding (PIM)

▸ RTM in 3D

▸ Residual Stress based 3D Warp

▸ Wall Slip option with Friction

New Solver Features

Powder concentration

Expand Linux HPC Support

▸ Expanded support for Moldflow Insight on Linux to further support

▸ Meshing can now be done on Linux

▸ The new job manager now has a distribution queue for Linux

Moldflow & Helius PFA 2018.0

▸ Improve design change and Parametric optimization:▸ Success with much larger deformations

▸ API support for model changes

▸ Design Optimization study support on Linux

Moldflow Insight 2018.0 | DOE/Parametric Study Improvements

Moldflow Insight 2018.0 | Auto-mesh analysis

▸ Simulate the Multi-barrel Injection Molding process:

▸ Multiple independently controlled injection molding barrels injecting into the same mold cavity.

▸ Supported for Midplane, Dual Domain and 3D models.

Multiple Barrel Injection Molding Simulation

▸ Restored 3D Connection devices. Updated to Driver version 10.x

▸ Thermoplastic overmolding with Injection-Compression molding

▸ Pre-conditioning analysis for thermoset compression molding

▸ New Solver API for solidification behavior

▸ Average Fiber Orientation Result for 3D

Other Improvements

▸ Insight Ultimate users with a subscription license (MUS) will automatically be entitled to Helius PFA

▸ Access Helius PFA installation from Autodesk Account

▸ Helius PFA will check for a Helius PFA or Insight Ultimate MUS license

Helius PFA entitlement for Moldflow Insight 2018.0 Ultimate subscription users

▸ Helius PFA 2018 adds support for:

▸ Abaqus 2017

▸ ANSYS 17.2 and 18.0

Current FEA platforms are supported

▸ The fiber orientation model used by Insight needs to be consistent with the fiber orientation model used to compute the RO parameters in Advanced Material Exchange

▸ Helius 2018 uses the Rotation Diffusion model to compute the RO parameters

▸ Insight 2018 defaults to Rotation Diffusion

▸ Previous Insight releases defaulted to other models (Folgar-Tucker, RSC, and Rotation Diffusion)

Synchronization of fiber orientation model

▸ New Polynomial Stress rupture model

▸ Replaces MCT as default criteria

▸ Material characterization improvements

▸ Failure coefficients are functions of the orientation tensor

▸ Result: Improved accuracy and more stable rupture behavior

Rupture criteria and material characterization

Moldflow Ecosystem Update

Generative Design

Dreamcatcher Workflow

Define Generate Explore Refine Validate Make

700N

700N

Generative | Example

Generative | Example

Generative | Example

Generative | Learning System

Preference

Simulation

MFG & Cost

NetFabbSimulation

▸ Additive manufacturing does not produce the desired net shape without significant process optimization

▸ Iteration is required on designs to produce the desired combination of shape, materials and processes

▸ Commonly 10 iterations are required and each iteration is very expensive

▸ Parts are expensive, commonly ranging from $1k to over $10k per part

Additive Manufacturing | Current Challenge

Additive process simulation assesses manufacturing process implications in order to predict deformations and allow design iteration before a physical part is built.

Benefits:

▸ Reduces the number of iterations required

▸ Saves production costs (time & Material)

▸ Reduces lead time to produce a part

Additive Manufacturing | Process Simulation

Desired geometry Production resultsPredicted deformation

© 2015 Autodesk

Additive Manufacturing | Process Simulation

© 2015 Autodesk

Additive Manufacturing | Process Simulation

Delcam

PREPARE MODEL FOR MANUFACTURE

Delcam Subtractive Manufacturing Tools

MANIPULATE TOOL AXES WITHOUT RECALCULATION

EDIT TOOLPATHS FOR OPTIMISED USE WITHOUT RECALCULATION

QUICK AND EASY ELECTRODE DESIGN; INCLUDING IMPORTED

DATA

Electrode Design and Inspection tools

ELIMINATE HUMAN ERROR WITH ELECTRODES

AUTOMATED TOOLPATHS USING CUSTOMISATION

INSPECTION DATA AUTOMATICALLY USED FOR ELECTRODE USE

Outlook

Moldflow | Quarterly Cadance

2016

Jan Mar Apr

2017 FCS

* Cloud access for Insight users* Foaming with Core Back

* Foaming with Blowing Agent

* Design Optimization• Adviser Re-stack

• Improved Fiber Orientation• 3D Residual Stres

Oct Jan

2017.3

* One Click Mesh+ SolveMulti-barrel inj. Molding

2017 R2 2018.0

July

2018.1

Oct

2018.2

Jan

2018.3

2017 2018

2017 SP1(Linux)

2017 SP2(SJM)

* MIM/CIM* Mesh generation

improvements

2019.0

Apr

Areas of Focus

Efficiency improvements

Optimization and Automation

Components

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