Tutorial 16 - CEL - Bottle

Tutorial Number 16: CEL,moulding of a polymeric bottle

Stefano MorlacchiMay 2014

Strategic Simulation & Analysis LtdSouthill Barn, Southill Business Park, Cornbury Park, Charlbury, Oxfordshire, OX7 3EW

T. 01608 811777 F. 01608811770 [email protected] W. www.ssanalysis.co.uk

1. Introduction

In this tutorial, you will setup a Coupled-Eulerian-Lagrangian (CEL) model of the

moulding process of a polymeric bottle. Plastic bottles might be created by

moulding melt polymer within rigid frames. You will build the model using

Abaqus/CAE and then visualize the results of the simulation with Abaqus/Viewer.

Preliminaries

- Units. Before starting to define any model, you need to decide which system ofunits you will use. ABAQUS has no built-in system of units but all inputs must be

specified in consistent units. Some common systems of consistent units are

shown in Figure 1. In this tutorial, the unit system based on inches is used.

However, the international systems based on m or mm are kindly suggested for

all your future models!!!!!

Figure 1: Consistent sets of units available in Abaqus.

- Main assumptions and limitations. In order to keep the tutorial simple and fastto solve, the external and internal frames will be considered as rigid bodies while

the melt polymer will be modelled as a simple elastic material with very low

stiffness. Also, no 2D modelling is allowed with CEL so a thin layer of 3D elements is here considered.



2. Setting up the model

Import the file Tutorial 16.sat (File Import Part) containing the geometry of the different components of the system: the Eulerian region (green), the internal

(blue) and external (white) moulds and the initial region where the polymer is

defined at the beginning of the analysis (red). Import the file and then rename the

parts as Eulerian, External, Internal and Initial. In the model tree, click with the

right button on Eulerian, select edit and choose Eulerian as type of the part.Figure 2 shows the initial assembly of the model and its relevant dimensions in

inches.

Figure 2: Assembly of the model comprehending the internal (blue) and external (white)

moulds, the Eulerian region (green) and the initial state of the polymer (red). Measures

are in inches.

3. Material and section properties

Define two material models called polymer for the bottle and steel for theinternal and external moulds. Due to the rigid body definitions, the steel

mechanical properties in terms of Young modulus and Poisson ratio will not have

any influence on the actual solution while the density chosen will drive the

computational cost of the analysis due to the explicit solver used.

Consistently to the geometric dimensions, stresses are defined in lbf/in2 while

density is defined in lbf*s2/in4 where:

1 Pascal (Pa) = 1.4504e-4 lbf/in2

1 kg/m3 = 9.3572e-8 lbf s2/in4



1. Go into the Property Module and click the Create Material icon

a. In the Edit Material dialog box, name the material Polymer.b. From the material editors menu bar, select Mechanical Elasticity

Elasticc. Enter a Young modulus equal to 30.5 lbf/in2 (0.21 MPa) and a Poisson ration

equal to 0.35.

d. From the material editors menu bar, select General Density

e. Enter a density value equal to 0.0001345 lbf s2/in4 corresponding to 1455

kg/m3.

f. Click OK to exit the material editor

Repeat the same as above for a material called Steel using the following data:Young modulus = 30,450,000 lbf/in2 (~ 210 GPa)

Poisson Ration = 0.35

Density = 0.00072 lbf s2/in4 (7800 kg/m3)



2. Go into the Property Module and click the Create Section icon

Create a solid homogeneous section called Section-Steel using the Steel material

previously defined. Create another solid section called Section-Eulerian selecting

Eulerian as type and polymer as base material.

3. Go into the Property Module and click the Assign Section icon Assign Section-Steel to the internal and external moulds and the Eulerian section

to the Eulerian part. The initial part does not need any section assignment since it

will not be part of the actual simulation but only used to define the initial

conditions.



4. Assembly and Step definitions

1. Go into the Assemby module and select the Create Instance button on top ofthe toolbox. Create an instance for each of the four parts.

N.B. It is important that in every CEL analysis, all the parts in contact with the

Eulerian material overlap the Eulerian region at the contact surface.

2. Go into the Step module and select the Create Step button.Create a Dynamic Explicit step choosing 2 seconds as Time step and making

sure that the Nlgeom parameter is on.

3. In the model tree, explode the Field Output requests container and doubleclick on F-Output-1. Set the number of interval as 50, add EVF (Eulerian Volume

Fraction) as new element output in the Volume/thickness/coordinates container

and click OK.



5. Mesh

Go into the Mesh module to discretize the moulds and the Eulerian part. Selecthexahedral swept elements for all the parts.

1. Mesh of the moulds. For each mould select 0.075 as global element size and 0.04 as local element

size for the edges shown in the following picture. Lastly, set 2 as the number of

elements in the thickness of the moulds and 0.02 as local element size at the top

of the internal mould. Select Hexahedral elements, Sweep technique and Medial

axis algorithm in the mesh controls, then mesh the parts.



2. Mesh of the Eulerian Body. Set the Global element size of the Eulerian body as 0.03 and mesh it with

hexahedral elements.



6. Interactions

Go into the Interaction modules. Three main tasks have to be performed here.

1. Create a new General Contact Interaction. Click on the first button of the toolbox to create a new interaction. Select Initial as

step and General contact as contact type.

In the General Contact window, select All* with self as contact domain andclick on the Create Interaction property button close to the Global property

Assignment. Select Contact in the new window that appears and create a contact

property with a Hard Contact normal behaviour and a frictionless tangentialbehaviour. Click OK to go back to the edit Interaction window, select the new

interaction property in the global property assignment menu and click OK to exit.

2. Create two new rigid bodies constraints. First, click on Tool Reference Point from the menu toolbar to create a new

reference point for each mould.



Click on the third button of the toolboxs left column to create two new rigid bodyconstraints for the internal and external moulds. Select Rigid Body as ContraintType, Body(Elements) as region Type and the new Reference Points as the

control points.

3. This step is fundamental for any CEL analysis where the Eulerian mesh does

not conform to the initial material boundaries and aims at identifying which part of

the Eulerian region initially contains the material. To achieve this goal, you have

to first click on Tools Discrete Field Volume Fraction Tool . Follow theinstruction and select the Eulerian part first and then the Initial part as the

reference instance. This operation will create a discrete field that will then be

associated to the Eulerian part in terms of predefined field in the initial step. At

this point you have to remove the instance of the Initial part from the assembly.It might be useful to only suppress it since every change in the mesh of the

Eulerian body will require a new calculation of the initial discrete field.

7. Load module



Go into the Load module.

1. Create the boundary conditions for the external and internal moulds. Because of the rigid boy constraints previously defined, the boundary conditions

have to be applied to the Reference points.

a. Click on the Create Boundary condition Icon, and create an encastre at thereference point of the external mould to fix all its degrees of freedom.

b. Create a displacement boundary condition at the reference point of the internal

mould. Click on the Create Boundary condition Icon, select Step-1 as the stepand displacement/rotation as type. Select the Reference point of the internal

mould, enter 1.45 in the U1 degree of freedom and 0 in all the others. Then, click

on the Create Amplitude Icon on the right and create a tabular amplitudereplicating a standard ramp and apply it to the displacement condition.

2. Create the boundary conditions for the Eulerian Region. a. Click on the Create Boundary condition Icon, select Velocity/Angular velocityas Type, select the two faces of the Eulerian region with face normal to the Z axisand select the v3 degree of freedom to fix the normal velocity on this faces.

b. repeat the same operation by constraining the normal velocity (V2) at thesurfaces normal to the Y axis.

3. Click on the Create Predefined Field Icon, select the Initial step, Other ascategory and Material Assignment as Type than click continue. Select the

Eulerian part in the viewport and the option Discrete Fields in the Volume fraction

definition. At this point Select the whole Eulerian part and the Discrete Field

previously created from the menu option.

8. Job module

1. Create and Run the job.

a. Go into the Job Module. Click the Job Manager icon.



b. In the Job Manager dialog box, click Create to create the job namedCEL_BOTTLE.

c. In the Edit Job window, go to Parallelization and select at least 2 processors(4 if available) and domain as parallelization method. Then, click OK.

d. In the Job Manager dialog box, select the job created, click Submit andmonitor the solution.

9. Results visualization

At the end of the simulation, enter the Visualization module by clicking results inthe Job manager.

a. Colour the parts by part instances by selecting the colouring strategy in the

horizontal toolbar and click on the View cut Manager in the vertical toolbar.

Here, click on EVF_VOID to only show the elements of the Eulerian partcontaining material. Then, animate the solution to view the results.



b. In the vertical Toolbar, select the Plot contours on deformed shape icon and

view the SVAVG Mises contour map, then Animate the solution. From theResult options menu select the option Compute scalars before averaging

and then put 100% the averaging threshold.

c. As you will notice, parts of the polymer overlap the rigid moulds in the contact

surfaces. This error is due to the rough discretization used. In the following

picture, you can see the results with a more refined mesh. If time and



computational resources are available, please refine the mesh of youEulerian body and rerun the simulation. Rememeber to recalculate a new

Discrete Field with the volume fraction tool!!!!



Documents

Tutorial 16 - CEL - Bottle