MDX3D R12 Features Intr FEA Interface en v1 Final

R12.0

Integrated Module for Structure Analysis:FEA Interface & Digimat Interface

March, 2013

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> A series of interface modules to integrate Moldex3D and structure FEA Software, including ABAQUS, ANSYS, MSC. Nastran, NENastran, NX-Nastran, LS-Dyna, Marc, RADIOSS, and DIGIMAT

> Helps users to introduce the process-induced properties, such as fiber orientation or residual stress, into structure FEA Software

Moldex3D FEA Interface

Mesh,Material,

Process…etc

Flow/Pack/CoolWarp/FiberSimulation

Deformed geometry,Fiber-reinforced

Material properties…etc

Structure analysis,Drop test analysis,

Impact analysis…etc.

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> Linear stress analysis

> Non-linear stress analysis

> Buckle analysis

> Modal analysis

> Shock and response analysis

> Frequency response analysis

> Impact analysis

> Crack analysis

Common Structural Analysis

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Why Do We Need Moldex3D FEA Interface ?

Moldex3D-FEA

Moldex3D-FEA

Correct Initial Condition

Correct Boundary Condition

StructureAnalysisSolver

AccurateResults

Moldex3D-FEA

Moldex3D-F

EA

Proper Mesh

Correct Material Properties

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> Fiber orientation output

> Material reduction

> Mesh mapping

> Residual stress output

> EOP temperature output

> Initial strain output (as temperature difference)

> Multiple time step melt flow pressure output

> Mold base related data output (pressure, temperature)

What is FEA Interface’s Capability?

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Technology Link of FEA Interface

Simulation EjectionStructure Analysis Application

Flow Pack Cool Warp

FEA-LS-DYNA

FEA-NX Nastran

FEA-ANSYS

FEA-ABAQUS

FEA-MSC Nastran

FEA-MSC Marc

FEA-RADIOSS

Warpage

Mold Deform

Core-Shift

Paddle-Shift

Modal Analysis

Drop Test

Impact

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Structure FEA Software

ANSYS ABAQUS MARCLS-

DYNAMSC

NASTRANNX

NASTRANRADIOSS

Material Reduction

◎ ◎ ◎ ◎ ◎ ◎ ◎

Residual Stress ◎ ◎ ◎ ◎

Initial Strain ◎ ◎ ◎ ◎ ◎ ◎ ◎

EOP Temperature ◎ ◎ ◎ ◎ ◎ ◎ ◎

Melt Flow Pressure

◎ ◎ ◎ ◎ ◎ ◎ ◎

Digimat Fiber Orientation

◎ ◎

Moldbase Output ◎ ◎ ◎ ◎ ◎ ◎ ◎

Function List in Moldex3D R12.0

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Moldex3D FEA InterfaceFunction Description

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FEA Interface Function Description (User Interface)

1. Select Structure

FEA Software

3. Select Output Data

4. Export File

2. Select Output Mesh Type

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> Fiber orientation effects– Usually higher strength and stiffness along fiber oriented

direction; lower strength and stiffness perpendicular fiber oriented direction

> Moldex3D FEA Interface can transfer fiber orientation effects to Structural FEA Software

FEA Interface Function Description (Fiber Orientation Output)

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> Isotropic material (identical material properties in all directions)

> Anisotropic material (material properties varied in different directions)

FEA Interface Function Description (Fiber Orientation Output (cont’ d))

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> Material Reduction– For fiber reinforced plastic (FRP), each element has its own

material properties due to flow-induced non-uniform fiber orientation distribution

– Moldex3D FEA Interface can reduce the quantity of material card by topological grouping method

FEA Interface Function Description (Material Reduction)

Total material number from 76,150 to 1,866

Total material number from 3,392 to 668

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> Material Reduction Results

FEA Interface Function Description (Material Reduction(cont’ d))

Material count: 11944

Moldex3D result Moldex3D result Moldex3D result

ABAQUS ANSYS LS-DYNA

Material count: 11944 Material count: 11944

Material count: 663 Material count: 663 Material count: 663

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> Moldex3D FEA Interface can export the density distribution at the end of packing to Structural FEA software

FEA Interface Function Description(Density Output)

Natural frequencyConstant EOP

1 13.65 13.5612 72.355 71.4983 82.114 81.7574 143.36 141.635 441.45 435.726 580.31 570.76

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> Due to different application fields, mesh requirements are varied. Thus users need to map the injection molding results to suitable mesh for further structural analysis

> Moldex3D FEA Interface can map material properties and analysis result between different meshes

FEA Interface Function Description (Mesh Mapping)

Moldex3D tetra mesh

Structure analysis 2nd order hexa mesh

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> Output as high order element– After exporting as high order element (e.g. 2nd order), 1 additional

node between every 2 original nodes will be generated

FEA Interface Function Description (Mesh Mapping(cont’ d))

Original mesh High order element mesh (2nd order)

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> Residual stress– Flow induced residual stress: As the polymer is sheared and

elongated, if solidification occurs before the polymer molecules are fully relaxed, molecular orientation is locked within the molded part

– Thermal stress: Because of non-uniform cooling, stress between molecule can not be released completely

> Moldex3D FEA Interface can transfer residual stress effects to Structural FEA Software

FEA Interface Function Description Residual Stress Output

LS-DYNA

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> Residual stress output results

FEA Interface Function Description Residual Stress Output (cont’ d)



von Mises stress: 0.856~161.198MPa

von Mises stress: 0.8563 ~161.2MPa

von Mises stress: 0.48~37.84MPa von Mises stress: 1.468~69.428MPa

von Mises stress: 0.47~37.84MPa von Mises stress: 1.469~69.39MPa

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Fiber Orientation

von Mises stressvon Mises stress

Material count reduced to 127

To ABAQUSTo ABAQUS


> Moldex3D FEA Interface ABAQUS– Residual Stress Data Output

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> Moldex3D FEA Interface ABAQUS– Residual Stress Data Output

• Notes: Before runningABAQUS, make sure the workspace includes two filetypes

– *.inp

– *.sts

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> Moldex3D FEA Interface ANSYS– Residual Stress Data Output

• Only SOLID186 supportsboth pyramid element &initial stress.

• Before running ANSYS, makesure the workspace includestwo file types, *.cdb & *.ist.

• Max. material reference number = 100,000

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To ANSYSTo ANSYS

No reduced, material count 28584 Material count reduced to 152


Fiber Orientationvon Mises stress

Material reductionMaterial reduction

> Moldex3D FEA Interface ANSYS– Residual Stress Data Output

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> EOP temperature output results

FEA Interface Function Description EOP Temperature Output



Range: 33.41~169.6˚C

Range: 33.6~169.55˚C Range: 31.287~227.876˚C

Range: 31.287~227.876˚C

Range: 35.251~ 226.218˚C

Range: 35.3~226.0˚C

Moldex3D result

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> EOC temperature output results

FEA Interface Function Description EOC Temperature Output

Moldex3D result ANSYS

Range: 60.489~62.004˚C Range: 60.489~62.004˚C

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> Initial strain output results

FEA Interface Function Description Initial Strain Output



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> Initial strain output results in shell module

FEA Interface Function Description Initial Strain Output (cont’ d)

Moldex3D result

ABAQUS

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Transfer part geometry and weld-lines strength into ANSYS

1000N-1000N

> The local mechanical strength in the weld line area could be significantly weaker

> It could be one of the most significant problems for structural applications due to the potential failure in the weld line areas

FEA Interface Function DescriptionWeld Line Effect

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> Y-Component of displacement

FEA Interface Function DescriptionWeld Line Effect (cont’d)

Including weld line effect

UYMX=505.09

NormalUYMX=341.18

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> Through this function, users can observe the deformation of part insert at different time step during mold filling stage

FEA Interface Function Description Multiple Time Step Melt Flow Pressure Output

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> Multiple time step melt flow pressure output results

FEA Interface Function Description Multiple Time Step Melt Flow Pressure Output (cont’ d)



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> EOC temperature output results

FEA Interface Function Description Moldbase Related Data Output

Range: 30.056~36.98˚C

Range: 30.06~39˚C

Moldex3D result Moldex3D result

ABAQUS ANSYS

Range: 30.056~36.98˚C

Range: 30.062~36.98˚C

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> This function can be utilized for monitoring the core shift behavior of moldbase, which has significant influence on the product accuracy

FEA Interface Function Description Moldbase Related Data Output (cont’ d)

Moldex3D result Moldex3D result

ABAQUS ANSYS

Pressure: 110.351~120.208MPa Pressure: 59.999~117.6MPa

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ABAQUS Interface Output Enhancement

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> Users sometimes met a trouble if they would like to transfer a mesh from Moldex3D to ABAQUS for fiber-filled plastic parts

> They need to wait for several hours only for loading .inp file in ABAQUS even though the model has only hundred thousand solid elements

> In Moldex3D R12, we provide a suitable way to improve the efficiency of file reading

ABAQUS

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ABAQUS Interface Output Enhancement

FEA Interface Output Time Output File Size ABAQUS Analysis Time

Moldex3D R12.0 CPU Time = 467.00 sec 786MBSolve 30mins

(2G memory is enough)

Moldex3D R11.0(Medium-Level Material reduction)

CPU Time = 51598.89 sec. 393MBSolve 1 day ↑

(Huge memory needed)

Moldex3D R11.0(No Material reduction)

CPU Time = 458.00 sec. 405MBSolve 1 day ↑

(Huge memory needed)

As shown in figure, the total element number:776800Choose *Distribution format and export to improve the efficiency of file reading.

New in R12

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Abaqus/Standard Abaqus/CAE

Now Support

ABAQUS/Standard v.s ABAQUS/CAE

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Moldex3D R12 Integration with ANSYS Workbench

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What is ACT?

> The Application Customization Toolkit is a full-featured scripting interface to customize Applications in Workbench– In ANSYS R14, ACT allows customization in the Mechanical

application (Beta)

• Define customized boundary conditions and post-processing

• Replace command snippets with interactive objects

• Do much more than what the standard features in Mechanical offer

– Access node/element information, material, solution, results data……

• Even replace the APDL solver with your customer solver

> ACT provides an option to migrate APDL users to Mechanical– Allow reusing legacy APDL developments in user-friendly way

– Gets the best of the two worlds

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> Moldex3D extension toolbar and Moldex3D button arenow part of ANSYS Mechanical user interface– Moldex3D function is

available from the drop-downmenu to set analysis properties

– When solution done, users can open the post to view theresult

Moldex3D-Workbench Integration

Moldex3D OutputMoldex3D

ANSYS

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> Moldex3D-FEA Interface is integrated in ANSYS Workbench

> To cover the process-induced variation during the processes– Map material properties between different meshes

– Thermal / Flow Residual stress output

– EOP /EOC Temperature output

– Initial strain output

Moldex3D-Workbench Integration (cont’d)

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Moldex3D-Workbench Integration - Flow Chart

eDesign

Setup Runner and Cooling in Designer Structural mesh

Create user defined optionsStatic Structural

Use the structural mesh as mapping target

Part Geometry

Workbench

Injection Molding Analysis

FEA Interface Structural Analysis

Export the results as Workbench format

Moldex3D Extension

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Moldex3D-Workbench Integration (cont’d)

New in R12

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More Options of Digimat Output

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> The link between Digimat and Moldex3D interface enables to consider the results of injection molding and the orientation of fibers in your structural FE analysis

Digimat-CAE/Moldex3D

Moldex3D ANSYS/ABAQUS/LSDYNA

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> Moldex3D - DIGIMAT - ABAQUS– Supported file types can be exported from Moldex3D FEA

interface to ABAQUS, which are further described below:

• Original mesh file of molded parts:– *_ABAQUS_Part_Ori.inp

• User-specified mesh of molded parts:– *_ABAQUS_Part_MAPMESH.inp

• Export the fiber orientation data for further analysis to view characteristics of fiber orientation:

– *.o2d (Original mesh)

– *Map.o2d (User-specified mesh)

– Note: If you want to get DIGIMAT material result, it needs to go with the input mesh file(.inp) and orientation file (.o2d)

Moldex3D - DIGIMAT - ABAQUS

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> Moldex3D - DIGIMAT - ANSYS– Supported file types can be exported from Moldex3D FEA

interface to ANSYS, which are further described below:

• Original mesh file of molded parts:– *_ANSYS_Part_Ori.ans

– *_ANSYS_Part_Ori.cdb

• User-specified mesh of molded parts:– *_ANSYS_Part_MAPMESH.cdb


– *o2d (Original mesh)


– Note: If you want to get DIGIMAT material result, it needs to go with the input mesh file(.ans/.cdb) and orientation file (.o2d)

Moldex3D - DIGIMAT - ANSYS

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> Moldex3D - DIGIMAT - LS-DYNA– Supported file types can be exported from Moldex3D FEA

interface to LS-DYNA, which are further described below:

• Original mesh file of molded parts:– *_LSDYNA_Part_Ori.dyn

• User-specified mesh of molded parts:– *_LSDYNA_Part_MAPMESH.dyn


– *.o2d (Original mesh)


– Note: If you want to get DIGIMAT material result, it needs to go with the input mesh file(.dyn) and orientation file (.o2d)

Moldex3D - DIGIMAT - LS-DYNA

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FEA Interface -Step-by-Step Analysis Setting

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1. Injection Molding Analysis with eDesign

> Open the geometry in Moldex3D Designer, build up the runner and cooling system, and generate a 3D mesh.

> Open the mesh in Moldex3D Project, setup the process conditions, then launch the injection molding analysis.

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1-2. Generate Structural Mesh on Workbench

Generate mesh

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1-3. Export the Workbench Mesh to FEA Interface

1.Choose Static Structural2.Tools → Write Inputs File

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1. Select Structure FEA Software

2. Interface Function Dialog Setting

2. Select Output Mesh Type

3. Select Output Data

4. Export File

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3. Export the eDesign Data for Workbench (con’t)

> You can integrate in ANSYS Workbench by two ways: (1) Use commands (APDL)

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4. Export the eDesign Data for Workbench (con’t)

> You can integrate in ANSYS Workbench by two ways: (2) Use the ACT extension for a Project

> Move the output data to current working directory.

> By default, the Extension Manager contains the extensions located in the installation repository of ANSYS:

%ANSYS140_DIR%\..\Addins\AdvancedAddinPackage\extensions

> You can place the Moldex3DtoANSYS extension folders and files in the extensions folder of a user’s Applications Data folder, C:\Documents and Settings\<USER>\Application Data\Ansys\v140\ AdvancedAddinPackage. When extensions are installed in a user’s Applications Data folder, only the owner of that folder has access to the extensions.

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4-1. Prepare a Workbench Project

Extension Manager to Load / Unload available extensions

ANSYS mesh for mapping the Moldex3D results

> Generate the mesh and load your Moldex3D extension.

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4-2. Prepare a Workbench Project (con’t)

> Set your BC conditions.

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Information provided by Moldex3D FEA Interface

> The context of Moldex3D extension and button has been set to “Mechanical”. Consequently, this extension was loaded with the Mechanical application.

> Click Moldex3D icon. The Moldex3D function is available from a drop-down menu to set the analysis properties.

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If you choose many items to output in Moldex3D FEA Interface, you will see more items appearing in the “Definition” list.

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5. Run the Structural Analysis

Including Initial strain (warpage) Without Initial strain

Thank you for your attention!

MDX3D R12 Features Intr FEA Interface en v1 Final

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