Professional Documents
Culture Documents
ANSYS, Inc.
Southpointe
2600 ANSYS Drive
Canonsburg, PA 15317
ansysinfo@ansys.com
http://www.ansys.com
(T) 724-746-3304
(F) 724-514-9494
Release 16.0
January 2015
ANSYS, Inc. is
certified to ISO
9001:2008.
Disclaimer Notice
THIS ANSYS SOFTWARE PRODUCT AND PROGRAM DOCUMENTATION INCLUDE TRADE SECRETS AND ARE CONFIDENTIAL AND PROPRIETARY PRODUCTS OF ANSYS, INC., ITS SUBSIDIARIES, OR LICENSORS. The software products
and documentation are furnished by ANSYS, Inc., its subsidiaries, or affiliates under a software license agreement
that contains provisions concerning non-disclosure, copying, length and nature of use, compliance with exporting
laws, warranties, disclaimers, limitations of liability, and remedies, and other provisions. The software products
and documentation may be used, disclosed, transferred, or copied only in accordance with the terms and conditions
of that software license agreement.
ANSYS, Inc. is certified to ISO 9001:2008.
Third-Party Software
See the legal information in the product help files for the complete Legal Notice for ANSYS proprietary software
and third-party software. If you are unable to access the Legal Notice, please contact ANSYS, Inc.
Published in the U.S.A.
Table of Contents
Using This Manual ........................................................................................................................................ ix
1. The Contents of This Manual ............................................................................................................... ix
2. The Contents of the ANSYS Polyflow Manuals ...................................................................................... ix
3. Contacting Technical Support ............................................................................................................. ix
I. Introduction to using Polyflow in Workbench ......................................................................................... 1
1. ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion .......................................................... 3
1.1. Introduction ............................................................................................................................... 3
1.2. Prerequisites ............................................................................................................................... 3
1.3. Problem Description ................................................................................................................... 3
1.4. Setup and Solution ..................................................................................................................... 5
1.4.1. Preparation ........................................................................................................................ 5
1.4.2. Creating a Fluid Flow Analysis System in ANSYS Workbench ................................................ 6
1.4.3. Preparing the Geometry in ANSYS DesignModeler ............................................................ 11
1.4.4. Meshing the Geometry in the ANSYS Meshing Application ................................................ 13
1.4.5. Setting Up the CFD Simulation in ANSYS Polydata ............................................................. 24
1.4.6. Solution ........................................................................................................................... 28
1.4.7. Postprocessing ................................................................................................................. 29
1.4.8. Exploring Additional Solutions ......................................................................................... 44
1.5. Summary .................................................................................................................................. 49
II. Extrusion ............................................................................................................................................... 51
1. 2.5D Axisymmetric Extrusion .......................................................................................................... 53
1.1. Introduction ............................................................................................................................. 53
1.2. Prerequisites ............................................................................................................................. 53
1.3. Problem Description ................................................................................................................. 53
1.4. Preparation ............................................................................................................................... 56
1.5. Setup and Solution ................................................................................................................... 56
1.5.1. Project and Mesh ............................................................................................................. 57
1.5.2. Define a Task .................................................................................................................... 59
1.5.3. Material Data ................................................................................................................... 61
1.5.4. Boundary Conditions ....................................................................................................... 63
1.5.5. Remeshing ....................................................................................................................... 68
1.5.6. Stream Function ............................................................................................................... 71
1.5.7. Outputs ........................................................................................................................... 73
1.5.8. Save and Exit Polydata ...................................................................................................... 73
1.5.9. Solution ........................................................................................................................... 75
1.5.10. Postprocessing ............................................................................................................... 75
1.6. Summary .................................................................................................................................. 88
2. Fluid Flow and Conjugate Heat Transfer ......................................................................................... 89
2.1. Introduction ............................................................................................................................. 89
2.2. Prerequisites ............................................................................................................................. 89
2.3. Problem Description ................................................................................................................. 89
2.4. Setup and Solution ................................................................................................................... 91
2.4.1. Preparation ...................................................................................................................... 91
2.4.2. Project and Mesh ............................................................................................................. 92
2.4.3. Create a Task for the Model ............................................................................................... 92
2.4.4. Fluid Sub-Task 1 ............................................................................................................... 93
2.4.5. Die Sub-Task .................................................................................................................. 101
2.4.6. Save and Exit Polydata .................................................................................................... 104
2.4.7. Solution ......................................................................................................................... 105
2.4.8. Postprocessing ............................................................................................................... 105
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iii
Tutorial Guide
2.5. Summary ................................................................................................................................ 114
3. Non-Isothermal Flow Through a Cooled Die ................................................................................. 115
3.1. Introduction ........................................................................................................................... 115
3.2. Prerequisites ........................................................................................................................... 115
3.3. Problem Description ............................................................................................................... 115
3.4. Setup and Solution ................................................................................................................. 118
3.4.1. Preparation .................................................................................................................... 118
3.4.2. Project and Mesh ........................................................................................................... 118
3.4.3. Create a Task for the Model ............................................................................................. 119
3.4.4. Fluid Sub-Task 1 ............................................................................................................. 119
3.4.5. Die Sub-Task .................................................................................................................. 131
3.4.6. Numerical Parameters .................................................................................................... 134
3.4.7. Outputs ......................................................................................................................... 134
3.4.8. Save and Exit Polydata .................................................................................................... 135
3.4.9. Solution ......................................................................................................................... 135
3.4.10. Postprocessing ............................................................................................................. 136
3.5. Summary ................................................................................................................................ 147
3.6. Appendix: Nonlinearity and Evolution ...................................................................................... 147
4. 3D Extrusion .................................................................................................................................. 149
4.1. Introduction ........................................................................................................................... 149
4.2. Prerequisites ........................................................................................................................... 149
4.3. Problem Description ............................................................................................................... 149
4.4. Preparation ............................................................................................................................. 151
4.5. Setup and Solution ................................................................................................................. 152
4.5.1. Project and Mesh ........................................................................................................... 152
4.5.2. Define a Task .................................................................................................................. 152
4.5.3. Material Data ................................................................................................................. 154
4.5.4. Boundary Conditions ...................................................................................................... 156
4.5.5. Remeshing ..................................................................................................................... 158
4.5.6. Save and Exit Polydata .................................................................................................... 161
4.5.7. Solution ......................................................................................................................... 162
4.5.8. Postprocessing ............................................................................................................... 163
4.6. Summary ................................................................................................................................ 176
5. Direct Extrusion ............................................................................................................................ 177
5.1. Introduction ........................................................................................................................... 177
5.2. Prerequisites ........................................................................................................................... 177
5.3. Problem Description ............................................................................................................... 177
5.4. Setup and Solution ................................................................................................................. 179
5.4.1. Preparation .................................................................................................................... 179
5.4.2. Project and Mesh ........................................................................................................... 180
5.4.3. Create a Task for the Model ............................................................................................. 180
5.4.4. Material Data ................................................................................................................. 181
5.4.5. Boundary Conditions ...................................................................................................... 182
5.4.6. Remeshing ..................................................................................................................... 184
5.4.7. Numerical Parameters .................................................................................................... 186
5.4.8. Outputs ......................................................................................................................... 187
5.4.9. Save and Exit Polydata .................................................................................................... 187
5.4.10. Solution ....................................................................................................................... 187
5.4.11. Postprocessing ............................................................................................................. 188
5.5. Summary ................................................................................................................................ 198
5.6. Appendix ................................................................................................................................ 198
5.6.1. Power Law ..................................................................................................................... 199
iv
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Tutorial Guide
5.6.2. Optimesh Remeshing Technique .................................................................................... 199
5.6.3. Evolution Scheme .......................................................................................................... 199
5.6.4. IGES Output ................................................................................................................... 199
6. Inverse Extrusion ........................................................................................................................... 201
6.1. Introduction ........................................................................................................................... 201
6.2. Prerequisites ........................................................................................................................... 201
6.3. Problem Description ............................................................................................................... 201
6.4. Setup and Solution ................................................................................................................. 203
6.4.1. Preparation .................................................................................................................... 203
6.4.2. Project and Mesh ........................................................................................................... 204
6.4.3. Create a Task for the Model ............................................................................................. 204
6.4.4. Material Data ................................................................................................................. 205
6.4.5. Boundary Conditions ...................................................................................................... 206
6.4.6. Remeshing ..................................................................................................................... 209
6.4.7. Numerical Parameters .................................................................................................... 211
6.4.8. Outputs ......................................................................................................................... 212
6.4.9. Save and Exit Polydata .................................................................................................... 212
6.4.10. Solution ....................................................................................................................... 213
6.4.11. Postprocessing ............................................................................................................. 213
6.5. Summary ................................................................................................................................ 225
6.6. Appendix ................................................................................................................................ 225
6.6.1. Power Law ..................................................................................................................... 225
6.6.2. Evolution Scheme .......................................................................................................... 225
6.6.3. Remeshing Technique .................................................................................................... 226
6.6.4. Optimesh Remeshing Technique .................................................................................... 226
6.6.5. IGES Output ................................................................................................................... 226
7. Flow of Two Immiscible Fluids ....................................................................................................... 227
7.1. Introduction ........................................................................................................................... 227
7.2. Prerequisites ........................................................................................................................... 227
7.3. Problem Description ............................................................................................................... 227
7.4. Setup and Solution ................................................................................................................. 230
7.4.1. Preparation .................................................................................................................... 230
7.4.2. Project and Mesh ........................................................................................................... 230
7.4.3. Create a Task for the Model ............................................................................................. 231
7.4.4. Fluid 1 Sub-Task ............................................................................................................. 231
7.4.5. Fluid 2 Sub-Task ............................................................................................................. 238
7.4.6. Save and Exit Polydata .................................................................................................... 242
7.4.7. Solution ......................................................................................................................... 243
7.4.8. Postprocessing ............................................................................................................... 243
7.5. Summary ................................................................................................................................ 249
8. Flow of Two Immiscible Fluids by Species Method ....................................................................... 251
8.1. Introduction ........................................................................................................................... 251
8.2. Prerequisites ........................................................................................................................... 251
8.3. Problem Description ............................................................................................................... 251
8.4. Setup and Solution ................................................................................................................. 254
8.4.1. Preparation .................................................................................................................... 254
8.4.2. Project and Mesh ........................................................................................................... 255
8.4.3. Create a Task for the Model ............................................................................................. 255
8.4.4. Species and Species Transport Sub-task .......................................................................... 255
8.4.5. Fluids Sub-task ............................................................................................................... 260
8.4.6. Save and Exit Polydata .................................................................................................... 265
8.4.7. Solution ......................................................................................................................... 266
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Tutorial Guide
8.4.8. Postprocessing ............................................................................................................... 266
8.5. Summary ................................................................................................................................ 273
III. Blow Molding ..................................................................................................................................... 275
1. 3D Thermoforming of a Blister ...................................................................................................... 277
1.1. Prerequisites ........................................................................................................................... 277
1.2. Problem Description ............................................................................................................... 277
1.3. Setup and Solution ................................................................................................................. 280
1.3.1. Preparation .................................................................................................................... 280
1.3.2. Project and Mesh ........................................................................................................... 281
1.3.3. Mold Sub-Task ................................................................................................................ 281
1.3.4. Film Sub-Task ................................................................................................................. 286
1.3.5. Postprocessing Sub-Tasks ............................................................................................... 291
1.3.6. Numerical Parameters .................................................................................................... 293
1.3.7. Outputs ......................................................................................................................... 294
1.3.8. Save and Exit Polydata .................................................................................................... 294
1.3.9. Solution ......................................................................................................................... 295
1.3.10. Postprocessing ............................................................................................................. 296
1.4. Summary ................................................................................................................................ 307
1.5. Further Improvements ............................................................................................................ 308
1.6. Appendix ................................................................................................................................ 309
1.6.1. Contact Boundary Conditions ......................................................................................... 309
1.6.2. Remark on the Penalty Coefficient .................................................................................. 310
1.6.3. Remeshing ..................................................................................................................... 310
2. 2D Axisymmetric Blow Molding .................................................................................................... 311
2.1. Introduction ........................................................................................................................... 311
2.2. Prerequisites ........................................................................................................................... 311
2.3. Problem Description ............................................................................................................... 312
2.4. Setup and Solution ................................................................................................................. 313
2.4.1. Preparation .................................................................................................................... 314
2.4.2. Project and Mesh ........................................................................................................... 314
2.4.3. Create a Task for the Model ............................................................................................. 314
2.4.4. Material Data ................................................................................................................. 317
2.4.5. Boundary Conditions ...................................................................................................... 319
2.4.6. Remeshing ..................................................................................................................... 322
2.4.7. Numerical Parameters .................................................................................................... 323
2.4.8. Outputs ......................................................................................................................... 325
2.4.9. Thickness Postprocessor ................................................................................................. 326
2.4.10. Save and Exit Polydata .................................................................................................. 327
2.4.11. Solution ....................................................................................................................... 327
2.4.12. Postprocessing ............................................................................................................. 327
2.5. Summary ................................................................................................................................ 339
2.6. Appendix ................................................................................................................................ 339
2.6.1. Remeshing Technique .................................................................................................... 340
2.6.2. Time Marching Scheme .................................................................................................. 340
3. Plug-Assisted Thermoforming of a Blister .................................................................................... 341
3.1. Prerequisites ........................................................................................................................... 341
3.2. Problem Description ............................................................................................................... 341
3.3. Setup and Solution ................................................................................................................. 344
3.3.1. Preparation .................................................................................................................... 344
3.3.2. Project and Mesh ........................................................................................................... 345
3.3.3. Mold Sub-Task ................................................................................................................ 345
3.3.4. Plug Sub-Task ................................................................................................................. 350
vi
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Tutorial Guide
3.3.5. Blister Sub-Task .............................................................................................................. 354
3.3.6. Numerical Parameters .................................................................................................... 361
3.3.7. Outputs ......................................................................................................................... 362
3.3.8. Save and Exit Polydata .................................................................................................... 362
3.3.9. Solution ......................................................................................................................... 362
3.3.10. Postprocessing ............................................................................................................. 363
3.4. Summary ................................................................................................................................ 374
3.5. Appendix ................................................................................................................................ 375
3.5.1. Contact Boundary Conditions ......................................................................................... 375
3.5.2. Remark on the Penalty Coefficient .................................................................................. 375
3.5.3. Remeshing ..................................................................................................................... 376
4. 3D Blow Molding of a Bottle ......................................................................................................... 377
4.1. Prerequisites ........................................................................................................................... 377
4.2. Description ............................................................................................................................. 377
4.3. Setup and Solution ................................................................................................................. 379
4.3.1. Preparation .................................................................................................................... 379
4.3.2. Project and Mesh ........................................................................................................... 380
4.3.3. Right Mold ..................................................................................................................... 380
4.3.4. Left Mold ....................................................................................................................... 385
4.3.5. Parison Sub-Task ............................................................................................................ 388
4.3.6. Numerical Parameters .................................................................................................... 396
4.3.7. Outputs ......................................................................................................................... 397
4.3.8. Save and Exit Polydata .................................................................................................... 397
4.3.9. Solution ......................................................................................................................... 397
4.3.10. Postprocessing ............................................................................................................. 398
4.4. Summary ................................................................................................................................ 407
4.5. Further Improvements ............................................................................................................ 408
4.6. Appendix ................................................................................................................................ 409
4.6.1. Contact Boundary Conditions ......................................................................................... 409
4.6.2. Remark on the Penalty Coefficient .................................................................................. 410
4.6.3. Remeshing ..................................................................................................................... 410
4.6.4. Evolutions ...................................................................................................................... 410
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
vii
viii
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
ix
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
xi
xii
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
1.2. Prerequisites
This tutorial assumes that you have little to no experience with ANSYS DesignModeler, ANSYS Meshing,
ANSYS Polyflow, CFD-Post, or the Parameter and Design Points view of ANSYS Workbench, and so
each step will be explicitly described.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two subdomains (as shown in Figure 1.1: Problem Description (p. 4))
so that a remeshing algorithm can be applied only to the portion of the mesh that will be deformed.
Subdomain 1 represents the die where the fluid is confined. Subdomain 2 corresponds to the extrudate
that is in contact with the air and can deform freely. The calculation will determine the location of the
free surface (the skin of the extrudate), as well as the velocity of the extrudate at the exit.
The boundary set for the problem is shown in Figure 1.2: The Boundary Set for the Problem (p. 5), and
the conditions at the boundaries of the domains are:
inlet: flow inlet, initial volumetric flow rate
cm3/s
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
1.4.1. Preparation
1.
Copy the file ext3d-workbench.zip to your working directory. To access this file, begin by pointing
your web browser to
For Windows:
path\ANSYS Inc\v160\polyflow\polyflow16.0. \help\index.htm
For Linux:
path/ansys_inc/v160/polyflow/polyflow16.0. /help/index.htm
where path is the directory in which ANSYS Polyflow has been installed and
propriate number for the release (for example, 0 for polyflow16.0.0).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Note
This zipped file can also be downloaded from the ANSYS Customer Portal, https://support.ansys.com/training.
2.
Unzip ext3d-workbench.zip.
The extracted files include the geometry file ext3d.x_t, the data file polyflow.dat, and a
solution_files folder that contains the solution files created during the preparation of the tutorial.
Note
This tutorial is prepared using ANSYS Polyflow on a Windows system. The screen shots and
graphic images that follow may be slightly different than the appearance on your system,
depending on the operating system or graphics card.
From the Windows Start menu, select Start > All Programs > ANSYS 16.0 > Workbench 16.0 to start
ANSYS Workbench.
The ANSYS Workbench application window will open, containing the Toolbox on the left and the
Project Schematic on the right. The Toolbox lists the various supported analyses and applications,
and the Project Schematic provides a space to display the components of the analysis systems you
select.
Note
When you first start ANSYS Workbench, the Getting Started message window is displayed, offering assistance through the online help for using the application. You can
keep the window open, or close it by clicking the red X icon in the upper right corner.
If you need to access the online help at any time, use the Help menu, or press the F1
key.
2.
Create a new fluid flow analysis system by double-clicking the Fluid Flow (Polyflow) option under Analysis Systems in the Toolbox.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Extra
You can also create a new fluid flow analysis system by dragging-and-dropping the
analysis system into the Project Schematic: a green dotted outline will indicate a potential
location in the Project Schematic for the new system, which will turn into a red box
when you attempt to drop it.
A new ANSYS Polyflow-based fluid flow analysis system will be displayed in the Project Schematic.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Note
The ANSYS Polyflow-based fluid flow analysis system is composed of various cells
(Geometry, Mesh, and so on) that represent the work flow for performing the analysis.
ANSYS Workbench is composed of multiple data-integrated (for example, ANSYS Polyflow)
and native applications into a single, seamless project flow, where individual cells can
obtain data from and provide data to other cells. ANSYS Workbench provides visual indications of a cells state at any given time via icons on the right side of each cell. Because
of the constant flow of data, a cells state can quickly change. Brief descriptions of the
various states are provided below. For more information about cell states, see the ANSYS
Workbench online help.
Unfulfilled ( ) indicates that required upstream data does not exist. For example, when you first
create a new Fluid Flow (Polyflow) analysis system, all cells downstream of the Geometry cell appear
as Unfulfilled because you have not yet specified a geometry for the system.
Refresh Required ( ) indicates that upstream data has changed since the last refresh or update. For
example, after you assign a geometry to the Geometry cell in your new Fluid Flow (Polyflow) analysis
system, the Mesh cell appears as Refresh Required since the geometry data has not yet been passed
from the Geometry cell to the Mesh cell.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
) indicates that you have interrupted an update (or stopped an interactive calculation
that is in progress). For example, if you select the stop button ( ) in the Progress Monitor of ANSYS
Workbench at a point where ANSYS Polyflow has generated results but has not yet completed the calculation (such as during a transient simulation), then verify the action in the dialog box that opens,
ANSYS Polyflow is immediately stopped and the Solution cell appears as Interrupted.
Input Changes Pending ( ) indicates that the cell is locally up-to-date, but may change when next
updated as a result of changes made to upstream cells. For example, if you change the Mesh in an Upto-Date Fluid Flow (Polyflow) analysis system, the Setup cell appears as Refresh Required, and the
Solution and Results cells appear as Input Changes Pending.
Pending ( ) indicates that a batch or asynchronous solution is in progress. This icon will only appear
when the Solution cell is in background mode.
Refresh Failed, Refresh Required (
and so the cell must be refreshed.
) indicates that the last attempt to refresh cell input data failed,
Update Failed, Update Required ( ) indicates that the last attempt to update the cell and calculate
output data failed, and so the cell must be updated. For example, if you update the Solution cell and
the solver diverges during the calculation, the Solution cell appears as Update Failed, Update Required.
Update Failed, Attention Required ( ) indicates that the last attempt to update the cell and calculate
output data failed, and so the cell requires attention.
3.
4.
Double-click the Fluid Flow (Polyflow) label underneath the analysis system.
b.
Select the Save option under the File menu in ANSYS Workbench.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
5.
In your working directory, enter ext3d-wb as the project File name and click the Save button to
save the project. ANSYS Workbench saves the project with a .wbpj extension, as well as supporting
files for the project.
View the files generated by ANSYS Workbench, by enabling the Files option under the View menu.
View Files
The Files view is displayed in the Project Schematic.
Figure 1.5: Displaying the Files View after Adding an ANSYS Polyflow-Based Fluid Flow
Analysis System
ANSYS Workbench allows you to easily view the files associated with your project using the Files view.
You can see the name and type of file, the ID of the cell the file is associated with, the size of the file,
the location of the file, and other information. For more information about the Files view, see the separate Polyflow in Workbench User's Guide and the ANSYS Workbench online help.
10
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Note
ANSYS DesignModeler is licensed separately from ANSYS Polyflow. If you do not have access
to ANSYS DesignModeler, you can instead import a geometry file that does not need to be
modified, as noted in step 1.c.
1.
Right-click the Geometry cell in the ext3d fluid flow analysis system (cell A2 in the ANSYS Workbench
Project Schematic).
b.
Move your pointer over Import Geometry in the context menu that opens, and click Browse....
c.
Use the Open dialog box to browse to the folder you unzipped in a previous step, select ext3d.x_t,
and click Open.
Note
If you do not have access to ANSYS DesignModeler, select PFL.agdb in the Open
dialog box instead, then skip to Meshing the Geometry in the ANSYS Meshing Application (p. 13).
The state of the Geometry cell becomes Up-to-Date, indicating that there is a geometry now associated
with the fluid flow analysis system.
2.
Extra
You can also launch ANSYS DesignModeler by right-clicking the Geometry cell to display
the context menu then selecting the Edit Geometry... option.
3.
Finish importing the geometry file by clicking Generate in the ANSYS DesignModeler toolbar. The geometry
will be displayed in the Graphics window.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
11
Note that the scale at the bottom of the Graphics window can be used to confirm that the overall
length of the domain is 0.6 m.
4.
Modify the geometry so that the separate domains ("bodies") are treated as a single entity (a "part"), by
performing the following actions in the Tree Outline.
By uniting the multiple bodies of the geometry into a single part, you will create a conformal mesh
between the separate domains of the bodies.
12
a.
b.
c.
d.
Right-click the highlighted objects and click Form New Part in the menu that opens.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
6.
View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Note the addition of the geometry file (PFL.agdb, where PFL indicates a Polyflow-based fluid flow
system) to the list of files.
Extra
You can also right-click the Mesh cell to display the context menu where you can select
the Edit... option.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
13
2.
Group the faces and create named selections to match the boundary set shown in Figure 1.2: The
Boundary Set for the Problem (p. 5).
a.
Rotate the view to get your display similar to that shown in Figure 1.8: Rotated View (p. 15), by
holding the center mouse button and moving your pointer in the geometry window. (You can also
manipulate the view by clicking
Tip
14
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
Note
Note that since the ANSYS Meshing application automatically detects that you are
going to perform a CFD fluid flow analysis, CFD is selected from the Physics Preference drop-down list.
c.
Select the face that will represent the inlet, as shown highlighted in green in Figure 1.9: Selecting
the Inlet Face (p. 16).
Ensure
d.
Right-click and select the Create Named Selection option (from the menu that opens) to open the
Selection Name dialog box.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
15
16
e.
Enter inlet for the name in the Selection Name dialog box, and click OK.
f.
Hold down the Ctrl key, select the 2 faces that will represent the zero velocity boundary (as highlighted
in green in Figure 1.10: The Zero Velocity Faces Selected (p. 17)), then create a selection named die
wall in a manner similar to the previous steps.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
g.
Hold down the Ctrl key, select the 2 faces that will represent the free surface boundary (as highlighted
in green in Figure 1.11: The Free Surface Faces Selected (p. 18)), and create a selection named free
surface in a manner similar to the previous steps.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
17
h.
Rotate the view to get your display to be similar to that shown in Figure 1.12: Rotated View (p. 18),
by holding the center mouse button and moving your pointer in the geometry window.
Figure 1.12: Rotated View
18
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Hold down the Ctrl key, select the 2 faces that will represent one of the symmetry boundaries (as
highlighted in green in Figure 1.13: The First Pair of Symmetry Faces Selected (p. 19)), and create a
selection named symmetry 1 in a manner similar to the previous steps.
Figure 1.13: The First Pair of Symmetry Faces Selected
j.
Hold down the Ctrl key, select the 2 faces that will represent the other of the symmetry boundaries
(as highlighted in green in Figure 1.14: The Second Pair of Symmetry Faces Selected (p. 20)), and
create a selection named symmetry 2 in a manner similar to the previous steps.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
19
k.
20
Select the face that will represent the flow exit boundary (as highlighted in green in Figure 1.15: The
Flow Exit Face Selected (p. 21)), and create a selection named outlet in a manner similar to the
previous steps.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
3.
Set the appropriate meshing parameters for the ANSYS Meshing application in the Details view.
a.
Confirm that Polyflow is selected from the Solver Preference drop-down list under Defaults.
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
21
Select Off from the Use Advanced Size Function drop-down list.
Right-click Mesh in the Outline tree view, and select Update in the context menu.
The geometry window will display the generated mesh.
Note
Using the Generate Mesh option from the Mesh context menu creates the mesh,
but does not actually create the relevant mesh files for the project and is optional
if you already know that the mesh is acceptable. Using the Update option automatically generates the mesh and creates the relevant mesh files for your project and
updates the ANSYS Workbench cell that references this mesh.
b.
ii.
Right-click Mesh in the Outline tree view, and select Update in the context menu.
Extra
After the mesh is generated, you can view the mesh statistics by expanding the Statistics
node in the Details view to reveal information about the number of nodes, the number
of elements, and other details.
22
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
5.
6.
View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Note the addition of the mesh files (PFL.1.poly and PFL.mshdb) to the list of files. The
PFL.1.poly file was created when you updated the mesh, and the PFL.mshdb file was generated
when you closed the ANSYS Meshing application.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
23
Right-click the Setup cell in the ext3d fluid flow analysis system, and click Import Polyflow Dat ...
in the context menu that opens.
b.
Use the Open dialog box to browse to the folder you unzipped in a previous step, select polyflow.dat, and click Open.
The state of the Setup cell remains Refresh Required, indicating that even though there is a
data file now associated with the fluid flow analysis system, you still must perform an update for
the cell.
c.
Right-click the Setup cell and click Update in the context menu that opens.
After ANSYS Polydata checks for coherence between the mesh and data files, the state for the
Setup cell becomes Up-to-Date. At this point it would be possible to run the ANSYS Polyflow solver
for your simulation; however, for this tutorial you will first modify the data file.
2.
View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Note the addition of the data file (polyflow.dat) to the list of files.
3.
Extra
You can also launch ANSYS Polydata by right-clicking the Setup cell and clicking Edit...
in the context menu that opens.
Note
The mesh is automatically loaded and displayed in the Graphics Display window by
default.
24
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.
View the mesh information, in order to verify the unit that should be used for length when defining
your inputs for the simulation.
It is a good practice to always perform this step with new meshes. Polydata and Polyflow do not consider
units when calculating a solution, so it is your responsibility to ensure that you enter values for the velocity, material data, and other settings that are consistent with each other and with the mesh.
a.
b.
Click the Info button to open a panel that displays the mesh information.
c.
Verify that the Length Unit used to create the mesh was meters and that the dimensions of the
Bounding Box (which surrounds the mesh) are 0.1 x 0.1 x 0.6.
It is therefore recommended that you use meters for the length unit when specifying the inputs for
the simulation. Note that if you decided that you would rather work with a different length unit,
you could scale the mesh using Polyfuse, as described in the Polyflow User's Guide.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
25
Close the panel and click the Menus tab at the bottom of the Polydata window.
Modify the data file so that the inlet flow rate is flagged as modifiable in a user-defined template (UDT).
Note
UDTs are considered input parameters by ANSYS Workbench.
a.
b.
c.
26
d.
Select Inflow along INLET in the Flow boundary conditions menu and click Modify.
e.
Click the UPDT button at the top of the ANSYS Polydata application window, to enable template
inputs.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
g.
Retain the selections of Automatic and Volumetric flow rate in the Inflow calculation on
INLET menu, and note that the flow rate is already set to 1 x 10-5 (which, since you are using
meters for your length unit, is equal to 10 cm3/sthat is, the initial flow rate proposed in
Problem Description (p. 3)). Then click Upper level menu.
6.
h.
Click Create a new template entry in the Create template entry menu.
i.
Click the UPDT button again at the top of the ANSYS Polydata application window, to disable template
inputs.
j.
Click Upper level menu four times to return to the main Polydata menu.
Verify the system of units that will be passed to CFD-Post for postprocessing.
It is a good practice to always perform this step before running a new simulation, to ensure consistency
with the mesh and the units you used when defining the velocity, material data, and other settings.
Outputs
7.
a.
Note that the Current output(s) in the Outputs menu indicate that CFD-Post is currently selected
as the intended postprocessor.
b.
c.
Note that meter, kilogram, and second are currently selected for Length, Mass, and Time, respectively (which is consistent with the values used in setting up the data file).
d.
Click Upper level menu twice to return to the main Polydata menu.
b.
A Parameters cell will be added to the ext3d fluid flow analysis system in the ANSYS Workbench
Project Schematic (cell A7). Also, a Parameter Set bar will be added below the system with an inbound
arrow, indicating that an input parameter has been created.
8.
View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
27
Note the addition of the template file (templates.upd) to the list of files.
1.4.6. Solution
1.
2.
View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Note the addition of the listing file (polyflow.lst), the ANSYS Polyflow results file (res), the output
mesh file (res.msh), the CFD-Post file (cfx.res), and the automatically generated probe files (.prb)
to the list of files. For more information about ANSYS Polyflow (and the files associated with it), see Files
Written and Read by ANSYS Polydata and ANSYS Polyflow in the Polyflow User's Guide.
28
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
1.4.7. Postprocessing
In the following steps you will use ANSYS CFD-Post to view the results of your initial simulation, create
an expression that can be used as an output parameter for ANSYS Workbench, then review the list of
files generated by ANSYS Workbench.
1.
Extra
You can also start ANSYS CFD-Post by right-clicking the Results cell and selecting the
Edit... option in the context menu that opens.
The ANSYS CFD-Post application will launch with the extrusion geometry already loaded (displayed in
outline mode). Note that ANSYS Polyflow results are also automatically loaded into ANSYS CFD-Post.
Figure 1.18: The Extrusion Geometry Loaded into ANSYS CFD-Post
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
29
Obtain the view shown in Figure 1.19: Rotating the View (p. 30).
a.
Rotate the view, by holding the center mouse button and moving your pointer in the viewer area.
b.
Reduce the magnification of the view by clicking the Zoom icon at the top of the viewer area (
holding the left mouse button, and moving your pointer in the viewer area.
3.
Display contours of velocity magnitude on the boundaries (Figure 1.20: Contours of Velocity Magnitude (p. 33)).
a.
30
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
),
b.
Retain the default entry of Contour 1 for Name and click OK to close the dialog box.
Information about Contour 1 will be displayed in the Details view below the Tree view in ANSYS
CFD-Post. The Details view contains all of the settings for a contour object.
c.
Open the Location Selector dialog box by clicking the location editor button (
Locations drop-down list in the Geometry tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
) next to the
31
i.
Select all of the boundaries listed under ext3d by clicking the first one in the list
(PART_1_1_SOL_DIE_WALL), holding the Shift key, and clicking the last one in the list
(PART_1_2_SOL_SYMMETRY_2).
ii.
d.
e.
Click Apply.
The velocity is 0 along the die wall (as expected) and there is a fully developed profile at the inlet of the
die. At the die outlet, the velocity profile changes to become constant throughout the extrudate crosssection. The transition between these two states can be seen in the first third of the extrudate.
32
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.
Display contours of velocity in cross-sections (Figure 1.21: Velocity Profiles at cross-sections (p. 38)).
a.
Disable Contour 1 under User Locations and Plots in the Outline tab of the Tree view.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
33
b.
34
Select Plane from the Location drop-down menu, located in the toolbar.
ii.
Retain the default entry of Plane 1 for Name in the Insert Plane dialog box that opens, and
click OK.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iii.
Retain the default selection of XY Plane for Method in the Geometry tab of the Details view
for Plane 1.
iv.
v.
Click Apply
c.
In a similar manner, create cross-section planes at =0.08 m, 0.15 m, and 0.45 m named Plane 2,
Plane 3, and Plane 4 respectively. Note that you will retain the default selection of XY Plane for
Method and enter appropriate values for Z in the Details view.
d.
Disable Plane 1, Plane 2, Plane 3, and Plane 4 under User Locations and Plots in the Outline tab
of the Tree view, so that the planes are no longer colored gray in the viewer area.
e.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
35
f.
Retain the default entry of Contour 2 for Name and click OK to close the dialog box.
Information about Contour 2 will be displayed in the Details view below the Tree view.
g.
36
Open the Location Selector dialog box by clicking the location editor button (
Locations drop-down list in the Geometry tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
) next to the
i.
Select all of the planes listed under User Locations and Plots by clicking Plane 1, holding the
Shift key, and clicking Plane 4.
ii.
h.
i.
Click Apply.
Velocity profiles at the flow inlet, the flow outlet, and planes just before and just after the die exit are
displayed. Compare the velocity profile within the die to the velocity profile just after the die exit at the
end of the computational domain. In the die the flow is fully developed. The velocity profile is flat (that
is, all the particles in the cross-section are at the same velocity) in the extrudate, far away from the die
exit. In the transitional zone just beyond the die exit, the velocity profile is reorganized. The velocity
profile on the plane =0.15 m is no longer fully developed, but it is not yet flat either. The velocity rearrangement is the source of the deformation of the extrudate.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
37
5.
Create an expression for the maximum velocity at the flow exit, which can be used as an output parameter
in ANSYS Workbench.
a.
b.
Right-click anywhere in the Expressions tab and click New in the menu that opens to create a new
expression.
The New Expression dialog box will open.
38
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
ii.
c.
Right-click in the Definition tab of the Details view, move your pointer over Functions, move your
pointer over CFD-Post, and click maxVal, to specify that the function in the expression obtains the
maximum value.
d.
Make sure that the cursor is between the parentheses of maxVal()@, right-click in the Details view
again, move your pointer over Variables, and click VELOCITIES, to specify that the variables obtained
in the expression are velocities.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
39
e.
40
Move the cursor so that it is after the @ symbol of maxVal (VELOCITIES)@, right-click in the Details
view again, move your pointer over Locations, and click PART_1_2_SOL_OUTLET, to specify that
the variables are obtained for the expression at the flow exit.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
f.
Click Apply.
The expression in the Definition tab of the Details view will be defined as maxVal (VELOCITIES)@
PART_1_2_SOL_OUTLET with a Value of approximately 7.8 x 10-4 m/s, and maxvelocity will
be added to the list in the Expressions tab of the Tree view, as shown in Figure 1.22: Creating an
Expression for an Output Parameter (p. 42).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
41
g.
42
Right-click maxvelocity in the Expressions tab of the Tree view and select Use as Workbench
Output Parameter in the context menu that opens.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
An outbound arrow will be added from the Parameters cell to the Parameter Set bar in the
Project Schematic, indicating that an output parameter has been created.
6.
Note
Note that the ANSYS CFD-Post state files are automatically saved when you exit ANSYS
CFD-Post and return to ANSYS Workbench.
7.
8.
View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
43
Note the addition of the ANSYS CFD-Post state file (ext3d.cst) to the list of files. For more information
about ANSYS CFD-Post (and the files associated with it), see the ANSYS CFD-Post documentation.
Note
ANSYS DesignXplorer is licensed separately from ANSYS Polyflow. If you do not have access
to ANSYS DesignXplorer, you will not be able to perform some of the steps that follow, such
as computing multiple design points or plotting results in a chart.
1.
Open the Parameters Set tab, which contains the Parameters and Design Points view (Figure 1.24: The
Parameters and Design Points View (p. 45)).
In the ANSYS Workbench Project Schematic, double-click the Parameter Set bar below the ext3d
fluid flow analysis system.
Extra
You can also open the Parameters and Design Points view by right-clicking the Parameter Set bar and selecting the Edit... option in the context menu that opens.
44
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
If you do not see the panes shown in the previous figure, make them visible by enabling Outline,
Properties, Table, and Chart from the View menu.
2.
Run the calculation again with a new inlet flow rate for the current design point.
a.
Enter 8E-6 under P1 - flow rate for the DP0 (Current) design point (cell B3) in the Table of
Design Points.
An Update Required icon will be added to the cell under P2- maxvelocity for the DP0 (Current)
design point (cell C3).
b.
Right-click the cell under P2 - maxvelocity for the DP0 (Current) design point and select Update
Selected Design Points in the context menu that opens, to generate the maximum velocity at the
flow exit with the revised inlet flow rate.
Extra
You can also update the design point by clicking Update All Design Points in the
ANSYS Workbench toolbar.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
45
A dialog box may open to inform you that some open editors may close during this process. Click
OK to proceed.
ANSYS Polydata will update the data file based on the revised inlet flow rate and ANSYS Polyflow will
run again. When the calculation is complete, the Table of Design Points will display a new value of
approximately 6.2 x 10-4 m/s under P2 - maxvelocity for the DP0 (Current) design point.
3.
Click P1 under Input Parameters (cell A4) in the Outline of All Parameters.
The ANSYS Workbench Toolbox will display options for Parameter Charts.
b.
Double-click Parameters Chart P1 vs ? in the Toolbox to open the Properties of Outline A11:0
window at the bottom of the Parameters Set tab.
The Properties of Outline A11:0 window will display an initial setup for Parameter Chart 0,
in which P1 - flow rate is selected from the X-Axis (Bottom) drop-down list.
46
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
Select P2 - maxvelocity from the Y-Axis (Left) drop-down list in the Properties of Outline A11:0
window.
The current design point will be plotted in Parameter Chart 0 (Figure 1.25: The Chart of the Current
Design Point (p. 47)).
Figure 1.25: The Chart of the Current Design Point
4.
Enter 1E-5 for P1 - flow rate in the row beneath the DP0 (Current) design point (cell B*) in
the Table of Design Points, so that a new row is added (4) with DP 1 as the Name.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
47
In a similar manner, create additional design points DP 2 and DP 3 with a P1 - flow rate of
1.1E-5 and 1.2E-5, respectively.
Extra
By default, Workbench only saves the calculated data for the design point in the
row labeled Current. You can specify that the data generated for any other design
points is saved within the project by enabling the Retain option in column D. After
the design points are updated, you can then right-click a design point in the Table
of Design Points and select Set as Current to access the data.
5.
Generate the values for the maximum velocity at the flow exit for all of the new design points.
Click Update All Design Points in the ANSYS Workbench toolbar.
ANSYS Polydata will update and ANSYS Polyflow will run repeatedly to solve for each of the design
points. As each calculation completes, the Table of Design Points (Figure 1.26: Displaying Values for
All of the Design Points (p. 48)) and Parameter Chart 0 (Figure 1.27: The Chart of All of the Design
Points (p. 49)) will be updated.
Figure 1.26: Displaying Values for All of the Design Points
48
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Summary
Figure 1.27: The Chart of All of the Design Points
6.
7.
Return to the Project Schematic view by clicking the Project tab above the ANSYS Workbench toolbar.
8.
View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Figure 1.28: Displaying the Files View after Exploring Solutions
Note that the list of files shows that the design point file (designPoint.wbdp) was updated. For
more information about the files associated with ANSYS Workbench, see the ANSYS Workbench documentation.
1.5. Summary
In this tutorial, portions of ANSYS Workbench were used to simulate a 3D extrusion and to compare
the flow exit velocities associated with a range of inlet flow rates.
ANSYS DesignModeler was used to prepare the geometry, ANSYS Meshing was used to create a computational mesh, ANSYS Polydata was used to set up the simulation, ANSYS Polyflow was used to calculate
the fluid flow throughout the geometry using the computational mesh, and CFD-Post was used to
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
49
50
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
1.1. Introduction
This tutorial illustrates the setup and solution of a 2.5D axisymmetric extrusion problem. The problem
corresponds to a simplified 2D simulation of a swirling flow that occurs around the head of an extrusion
screw. The fluid is forced through the die and exits the extruder after a short die land. The model involves
a free surface, the position of which is unknown.
In this tutorial you will learn how to:
Create a project in ANSYS Workbench.
Start Polydata from ANSYS Workbench.
Create a new task.
Create a sub-task.
Set material properties and boundary conditions for a 2.5D axisymmetric extrusion problem.
Select a remeshing method.
Specify output for CFD-Post.
1.2. Prerequisites
This tutorial assumes that you have little experience with Polyflow and its associated modules.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
53
Since the problem involves a free surface, the domain is divided into two subdomains: one for the region
near the free surface and the other for the rest of the domain, as shown in Figure 1.2: Subdomains and
Boundary Sets for the Problem (p. 55)
54
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Problem Description
Figure 1.2: Subdomains and Boundary Sets for the Problem
The boundary sets for the problem are also shown in Figure 1.2: Subdomains and Boundary Sets for the
Problem (p. 55), and the conditions at the boundaries of the domains are:
BS1: flow inlet
BS2: outer wall
BS3: free surface
BS4: flow exit
BS5: symmetry axis
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
55
1.4. Preparation
To prepare for running this tutorial:
1.
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the 25-Axi-Extrusion_R160.zip file you have downloaded to your working folder.
The mesh file ext2d.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
56
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
a. Rename the project name to Tutorial 1 by double-clicking and editing the text Fluid Flow (Polyflow).
b. Save the ANSYS Workbench project using File Save.
c. Enter 2.5-axi-extrusion as the name of the ANSYS Workbench project.
This will create a 2.5-axi-extrusion.wbpj file and a folder named 2.5-axi-extrusion_files in the working directory. To reopen this project in a later ANSYS Workbench session,
use File Open.
2. Import the mesh file for the Polydata session.
Right-click the Mesh cell, hover over Import Mesh File and click Browse....
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
57
a. Select ext2d.msh.
b. Click Open.
3. Double-click the Setup cell to start Polydata and read in the mesh. When Polydata starts, the Create a new
task menu item appears in bold text, and the geometry for the problem is displayed in the Graphics Display
window.
Note
At this point (when Create a new task appears in bold text) if you realize that you have
read the wrong mesh file, click STOP at the top of the Polydata menu and repeat the
process to access the correct mesh file.
58
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
59
Note
At this point (when Create a sub-task appears in bold text) if you realize that you
have made a mistake in the creation of the task and you need to return to that menu,
do the following:
i.
ii. Select Redefine global parameters of a task and make the necessary changes.
iii. Click Accept the current setup when you are satisfied with the corrected settings.
iv. Select F.E.M. Task 1.
Note
At this point (when Domain of the sub-task appears in bold text) if you realize that
you have made a mistake in the creation of the sub-task and you need to return to
that menu, do the following:
i.
ii. Select Redefine global parameters of a sub-task and make the necessary changes.
iii. Click Upper level menu.
60
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Accept the default selection of both subdomains by clicking Upper level menu.
The Material data menu item appears in bold text.
61
Enter 85000 [units: poise] as the New value and click OK.
4. Specify the value for , referred to as tnat in the graphical user interface.
Modify tnat
62
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Modify expom
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
63
64
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Note
Do not select the Outlet option. It is only applicable for die design problems.
j.
Click Upper level menu to return to the Flow boundary conditions menu.
65
i.
5. Retain the default condition at the symmetry axis (Axis of symmetry along BS_5).
For axisymmetric models, the axis of symmetry is always the y axis. Polydata determines the axis of
symmetry from the mesh file, and automatically imposes the symmetry condition along the line r=0
(x=0).
6. Set the conditions at the boundary of the rotating screw (BS_6).
66
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
e. Click Velocity w imposed and select 'w' velocity = linear function of coordinates.
f.
Accept the default value of 0 [units: cm/s] for the constant A by clicking OK.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
67
g. Enter 6.2832 [units: rad/s] as the New value for the constant B and click OK.
h. Accept the default value of 0 [units: rad/s] for the constant C by clicking OK.
i.
j.
Click Upper level menu at the top of the Flow boundary conditions menu.
The Global remeshing menu item appears in bold text.
1.5.5. Remeshing
This model involves a free surface for which the position is unknown. A portion of the mesh is affected by
this unknown boundary. Hence a remeshing technique is applied on this part of the mesh. The free surface
is entirely contained within subdomain 2, and hence only subdomain 2 will be affected by the relocation of
the free surface.
Global remeshing
1. Specify the region where the remeshing is to be performed (SD_2).
In some cases, when the mesh is geometrically complex, it may be necessary to split it into additional
subdomains in order to define a specific remeshing method on each of them. For this purpose, Polydata
allows you to create several local remeshings. For the current problem, a single local remeshing is sufficient.
1-st local remeshing
68
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
If you accidentally remove the wrong subdomain, select it and click Add to restore it. Then, follow
the instructions to remove the correct subdomain.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
69
70
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
71
72
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
1.5.7. Outputs
After Polyflow calculates a solution, it can save the results in several different formats. Choose the format
that is appropriate for your postprocessor. In this case, save the outputs in the default format for ANSYS
CFD-Post.
Outputs
1. Select Listing: max.
2. Accept the default output option for CFD-Post by clicking Upper level menu.
When exiting the menu, Polydata asks you to confirm the current system units and fields that are to be
saved to the results file for postprocessing.
3. Specify the system of units for the simulation.
a. Click Modify system of units.
b. Select Set to metric_cm/g/s/A+Celsius.
c. Click Upper level menu twice.
If you do not enter the menu Outputs, Polydata will ask you to confirm the current system units at
the end of the session, if it is a new session.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
73
1. Click Accept.
This confirms that the default Current field(s) are correct.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postprocessing, and for the Polyflow format results file (res).
74
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
1.5.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update from the shortcut
menu.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2. Check for convergence in the listing file.
a. Right-click the Solution cell and select Listing Viewer.
ANSYS Workbench opens the View listing file dialog box, which displays the listing file.
b. In the View listing file dialog box, disable the Show only last 200 lines option and click the Manual
refresh button. Then find the SOLVER section that relates to F.E.M. Task 1; at the end of this
section, a message Convergence assumed is displayed. This indicates that the solution has converged. See the Polyflow User's Guide for more information on convergence.
1.5.10. Postprocessing
ANSYS CFD-Post has similar interfaces for UNIX and Windows, the postprocessing steps are illustrated for
Windows.
1. Double-click the Results cell in the ANSYS Workbench analysis and read the results files saved by Polyflow.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
75
The central mouse button allows you to zoom in and zoom out. The left mouse button allows rotating
the image. The right mouse button allows you zoom to an area.
b. Also, right-click a blank area anywhere in the graphical window and deselect Ruler, if needed.
3. Display contours of pressure.
a. Click the Insert menu and select Contour or click the Contour button (
).
b. Click OK to accept the default name (Contour 1) and open the details view below the Outline tab.
76
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c. In the details view for Contour 1, specify the following settings under Geometry:
i.
) on the right
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
77
78
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
The details view of Default Transform will open below the Outline tab.
ii. In the details view of Default Transform, disable Instancing Info From Domain.
iii. Increase Number of Graphical Instances to 2.
iv. Select Y from the Axis drop-down list in the Axis Definition group box.
v. Decrease the Number of Passages to 2 in the Instance Definition group box.
vi. Retain the rest of the default settings.
vii. Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
79
button.
ii. Click OK to accept the default name (Text 1) and open the details view below the Outline tab.
80
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iii. Enter Polyflow Results for Text String in the Definition tab of the details view.
iv. In the Location tab, select Top for Y Justification.
v. Possibly check the Appearance tab.
vi. Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
81
).
c. Click OK to accept the default name (Vector 1) and open the details view below the Outline tab.
82
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
ii. Select VELOCITIES from the Variable drop-down list, or click the ellipsis button (
and select VELOCITIES.
) on the right
Deselect Text 1 in the Outline tab, under User locations and plots.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
83
f.
Rotate to the isometric view by clicking the cyan-blue dot in the axis triad (bottom right of the
graphics window).
This allows you to better visualize the magnitude of the velocity vectors.
84
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
ii. Enable Normalize Symbols in the Symbol tab of the details view for Vector 1.
This allows you to better visualize the direction of the velocity vectors.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
85
The velocity vectors take all components of the velocity into account. Along the screw tip, the
rotational component is important, leading to long vectors that are not in the xy plane. After the
die exit, a rearrangement of the velocity field takes place. The flow slows down along the axis of
symmetry and accelerates on the outside. This makes the particles go toward the free surface,
creating the swelling.
g. Display the mesh.
i.
86
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
ii. Under Render tab, deselect Show Faces and select Show Mesh Lines.
iii. Under Color tab, click the ellipsis (
Double-click Vector 1 under User Locations and Plots in the Outline tab.
Right-click a blank area in the graphics window, hover over Predefined Camera in the context menu,
and select View from +Z.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
87
j.
Move the mouse to the left-hand border of the graphic window until the cursor suggests a rotation
along a vertical line.
ii. Click and move the mouse slowly to the right-hand side.
1.6. Summary
This tutorial demonstrated how to set up and solve a 2.5D axisymmetric extrusion problem. It showed
how to set up a free surface problem and the associated remeshing, and demonstrated the use of CFDPost to examine the flow behavior associated with the problem.
88
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
2.1. Introduction
This tutorial illustrates the setup and solution of a problem involving heat transfer between a Newtonian
fluid and a cooled circular die. Along with a good die design, rheological and thermo physical properties
of the melt and the thermal settings in the die are very important in obtaining a geometrically welldefined polymer product. The heat transfer calculation is important when temperature-sensitive polymers
are shaped and when product surface qualities are of critical importance. The temperature field at the
die exit influences the swelling and drawing behavior of the product.
In this tutorial, you will solve the non-isothermal flow problem for the fluid and the heat conduction
in the die, making some assumptions regarding the rheological and thermo physical properties of the
melt.
In this tutorial you will learn how to:
Start Polydata from Workbench.
Create a new task.
Create multiple sub-tasks.
Define a Newtonian non-isothermal flow problem.
Define a Heat conduction problem.
Set material properties and boundary conditions for a fluid-solid heat conduction and flow problem.
2.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the set up procedure
will not be shown explicitly.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
89
Viscous heating is taken into account. For the solid region, the thermal conductivity
is 35 W/m-C.
The boundary sets for the problem are shown in Figure 2.2: Boundaries and Sub-domains (p. 91), and
the conditions at the boundaries of the domains are as follows:
boundary 1: flow inlet,
90
= 180C,
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
= 100C
boundary 4: insulated
boundary 5: flow exit
boundary 6: symmetry axis
Figure 2.2: Boundaries and Sub-domains
2.4.1. Preparation
To prepare for running this tutorial:
1.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
91
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the Fluid-Solid_R160.zip file you have downloaded to your working folder.
The mesh file flusol.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow (Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering fluid_solid as the name of the project.
3.
4.
2.
92
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Note
Be sure you are selecting the non-isothermal flow problem.
A dialog box appears asking for the title of the problem.
b.
2.
93
SUBDOMAIN_2 is moved from the top list to the bottom list, indicating that subtask 1 is defined
on SUBDOMAIN_1.
b.
3.
94
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
ii.
Specify the value for , referred to as fac in the graphical user interface.
Modify fac
Polydata prompts for the new value of .
b.
iii.
Enter 2500 [units: Pas] as the New value and click OK.
iv.
Click Upper level menu two times to continue the Material Data specification.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
95
c.
ii.
Click OK.
iii.
Click Density.
In this problem, specify a constant value for the density.
Modification of density
d.
i.
Enter 950 [units: kg/m3] as the New value and click OK.
ii.
is a reference temperature.
In this problem, the thermal conductivity is assumed to be a constant for the fluid so only the
constant coefficient is modified.
Modify a
96
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
e.
i.
Enter 0.5 [units: W/m-C] as the New value and click OK.
ii.
Click Upper level menu to continue with the Material Data specification.
is a reference temperature.
The temperature variation of differs with the nature of the polymer melts. In this problem,
assumed to be constant, so only the constant coefficient is modified.
is
Modify a
f.
i.
Enter 2300 [units: J/kg-C] as the New value and click OK.
ii.
Click Upper level menu to continue with the Material Data specification.
g.
i.
ii.
4.
97
a.
b.
98
Retain the default condition Zero wall velocity (vn=vs=0) along SUBDOMAIN_2.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
ii.
Click Inflow.
iii.
iv.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
v.
Enter 0.6e-06 [units: m3/s] as the New value in the dialog box that appears, and click OK.
The flow rate of the melt is very low due to the highly viscous nature of the melt.
When the Automatic option is selected, Polydata automatically chooses the most appropriate
method to compute the inflow condition.
vi.
c.
d.
i.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_5 and click Modify.
ii.
Click Outflow.
e.
Click Upper level menu at the top of the Flow boundary conditions menu to return to the fluid
menu.
The Thermal boundary conditions menu item is highlighted.
5.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
99
a.
ii.
Click Interface.
iii.
Click Upper level menu to accept the default setting (continuous heat flux along the interface).
In the case of an interface condition, both the heat flux and temperature are usually continuous
along the interface. It is possible to specify a nonzero value for the heat flux jump ( ), but
this is mainly used in problems where internal radiation is simulated. Here, accept the default
value for the definition of heat flux discontinuity,
= 0.
b.
100
i.
ii.
iii.
Select Constant.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
iv.
v.
Click Upper level menu to return to the Thermal boundary conditions menu.
ii.
Click Outflow.
d.
e.
Click Upper level menu twice to return to the F.E.M. Task 1 menu.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
101
Click No, since this sub-task has different parameters associated with it.
c.
d.
2.
b.
3.
102
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
4.
i.
Select Modify a.
ii.
Click Upper level menu two times to return to the solid menu.
b.
i.
ii.
Click Interface.
iii.
Click Upper level menu to accept the default option for continuity of temperature and heat
flux.
c.
i.
ii.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
103
ii.
iii.
Select Constant.
Polydata prompts you for the new value of the constant temperature.
d.
iv.
v.
Click Upper level menu to return to the Thermal boundary conditions menu.
e.
i.
ii.
Click Upper level menu three times to return to the top-level Polydata menu.
2.
3.
104
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click No.
In this instance, the convergence strategy will not assist Polyflow in reaching a solution as the problem
is quasi-linear.
5.
Click Accept.
This confirms that the default Current field(s) are correct.
6.
Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postprocessing, and for the Polyflow format results file (res).
2.4.7. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
2.4.8. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
Double-click the Results cell in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
2.
3.
Click the Insert menu and select Contour or click the Contour button (
).
b.
Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
105
c.
In the details view for Contour 1, specify the following settings under Geometry:
i.
ii.
Select PRESSURE from the Variable drop-down list, or click the ellipsis button (
right and select PRESSURE.
iii.
Click Apply.
) on the
Most of the pressure drop occurs in the upper part of the die where the cross-section is smallest (Figure 2.3: Pressure Contours (p. 107)). The pressure is linear except in the contraction zone. The isobars are
perpendicular to the flow direction, as expected for the fully developed flow that occurs in the second
part of the die.
106
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.
In the details of Contour 1, select VELOCITIES from the Variable drop-down list.
b.
Click Apply.
The velocity is higher in the second part of the die where the cross-section is smaller (Figure 2.4: Velocity
Distribution (p. 108)). It reaches a maximum value in the center of the thin tube.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
107
5.
108
In the Outline tab, under User Locations and Plots, deselect Contour 1.
b.
button.
ii.
iii.
iv.
Select the location SUBDOMAIN_1 and click OK to close the Location Selector dialog box.
v.
In the Symbol tab, select Arrow 3D and increase the Symbol Size to 3.
vi.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
The flow is fully developed in the downstream part of the die (Figure 2.5: Velocity Vectors (p. 109)). Observe
the classical parabolic velocity profile. The Poiseuille flow is rapidly reached after the contraction because
inertia is not taken into account here.
6.
Display of the temperature distribution in the solid and the fluid regions.
a.
Deselect Vector 1 in the Outline tab under User Locations and plots.
b.
Double-click Contour 1 (in the Outline tab under User Locations and plots.
c.
In the details view for Contour 1, specify the following settings under Geometry:
i.
Ensure SUBDOMAIN_1_surf and SUBDOMAIN_2_surf are selected for Locations, (click the
ellipsis button
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
109
ii.
Select Temperature from the Variable drop-down list, or click the ellipsis button (
right and select Temperature.
iii.
Click Apply.
110
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
) on the
As expected, the temperature gradients are larger in the fluid than in the die, (the isolines are closer
together in the fluid than in the diesee Figure 2.6: Temperature Distribution (Celsius) (p. 110)). This is
because the conductivity of the fluid is much lower than the conductivity of the solid. The temperature
isolines are perpendicular to the boundaries where the (normal) flux becomes zero. The heating of the
fluid due to viscous dissipation can be clearly seen. In order to visualize contours in Kelvin, select the
Edit/Options... menu item, click Units under Common, select K from the Temperature drop-down
menu, and click OK.
7.
).
ii.
Click OK to accept the default name (Line 1) and display the details view below the Outline
tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
111
iii.
iv.
Enter 0, 0.006, and 0 for Point 1 and enter 0.008, 0.006, and 0 for Point 2.
Note
You will need to ensure that your unit of length is set to meter in CFD-Post.
v.
b.
112
Click Apply.
Create a plot.
i.
Click the Insert menu and select Chart or click the Chart button (
).
ii.
Click OK to accept the default name (Chart 1) and display the details view below the Outline
tab tree.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iii.
In the General tab, ensure XY is selected for the Chart Type and enter Temperature Profile
for the Title.
iv.
In the Data Series tab, select Line 1 from the Location drop-down list.
v.
vi.
In the Y Axis tab, select Temperature from the Variable drop-down list.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
113
The thermal boundary layer located along the die wall is clearly visible. This boundary layer is the result
of the low thermal conductivity and high heat capacity of the fluid. The temperature of the fluid at the
center is not affected by the low temperature of the solid. The heat does not diffuse quickly enough
through the fluid layer to reach the axis of symmetry, before the fluid exits the die.
2.5. Summary
This tutorial introduced the coupling of sub-tasks of different types: a non-isothermal flow problem and
a heat conduction problem in a solid. Coupled calculations like this are very useful in polymer processing
applications where thermal effects are critical (for example: extrusion, coating, fiber spinning). Coupling
can also be applied through fields other than temperature (for example: electrical potential and pressure
in porous media).
114
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
3.1. Introduction
This tutorial examines the flow of a polymer melt through a die. The temperature of the melt increases
due to viscous dissipation caused by the shearing taking place in the die. The temperature of the fluid
is critical for the process. The viscosity of the fluid changes with temperature, which leads to the
modification of the shape of the extrudate. The polymer might degrade if the temperature is too high,
so a numerical simulation is of great interest to optimize the operating conditions.
In this tutorial, you will learn how to:
Define an evolution problem.
Create multiple sub-tasks to define a 2D axisymmetric contraction flow problem.
Set material properties and boundary conditions for the contraction flow problem.
3.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the set up procedure
will not be shown explicitly.
115
The high flow rate introduces strong nonlinearity in the problem, which can lead to a loss of convergence
in the iterative scheme. In Polyflow an evolution scheme is available to solve such highly nonlinear
problems. In this problem, the evolution scheme is applied to the flow rate, which is increased from a
low value to the desired value. This leads to a simultaneous increase of viscous dissipation and inertia
effects.
The material properties of the generalized Newtonian fluid are:
= density (950 kg/m3)
= heat capacity per unit mass (2300 J/kg-C)
= thermal conductivity (0.5 W/m-C)
Viscous heating is taken into account and the shear-rate dependence of viscosity obeys the Bird-Carreau
law. For the solid region, the thermal conductivity ( ) is 30 W/m-C.
116
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Problem Description
The boundary sets for the problem are shown in Figure 3.2: Boundaries and Subdomains (p. 117), and
the flow and thermal conditions for the fluid and the die at the boundaries of the domains are:
intersection of SUBDOMAIN_1 and SUBDOMAIN_3: interface
boundary 1: flow inlet ( =200C,
= 5 10-6 m3/s)
20C)
20C)
20C)
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
117
3.4.1. Preparation
To prepare for running this tutorial:
1.
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the Non-Iso-Flow_R160.zip file you have downloaded to your working folder.
The mesh file die.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow (Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering non-iso-flow as the name of the
project.
118
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.
2.
Note
Be sure you are selecting the non-isothermal flow problem.
A panel appears, asking for the title of the problem.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
119
b.
2.
120
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
SUBDOMAIN_3 is moved from the top list to the bottom list, indicating that subtask 1 is defined
on SUBDOMAIN_1 and SUBDOMAIN_2.
b.
Click Upper level menu at the top of the Domain of the sub-task menu.
The Material data menu item is highlighted.
3.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
121
index, and
ii.
Specify the value , referred to as fac in the graphical user interface (compare the equation
at the top of the Bird-Carreau law menu to Equation 3.1 (p. 122)).
Modify fac
Enter 5000 [units: Pas] as the New value and click OK.
iii.
iv.
Modify expo
Enter 0.41 as the New Value and click OK.
v.
122
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
For this tutorial, you will use an evolution function for the flow rate (the third recommended
method).
vi.
Click OK to continue.
vii. Click Upper level menu again to continue with the Material Data specification.
b.
ii.
Specify the value for , referred to as alfa in the graphical user interface (compare the equation
at the top of the Temperature dependence of viscosity menu to Equation 3.2 (p. 123)).
Modify alfa
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
123
Modify talfa
Enter 200 [units: C] as the New Value and click OK.
iv.
Modify t0
Enter -273 [units: C] as the New Value and click OK.
v.
c.
Click Upper level menu two times to continue with the Material Data specification.
Click Density.
Specify a constant value for density.
Modification of density
d.
i.
Enter 950 [units: kg/m3] as the New value and click OK.
ii.
Click Upper level menu to continue with the Material Data specification.
e.
i.
Enter 0.5 [units: W/m-C] as the New Value and click OK.
ii.
Click Upper level menu to continue with the Material Data specification.
124
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
f.
i.
Enter 2300 [units: J/kg-C] as the New value and click OK.
ii.
Click Upper level menu to continue with the Material Data specification.
g.
i.
ii.
4.
Retain the default condition Zero wall velocity (vn=vs=0) along SUBDOMAIN_3 at the intersection
of SUBDOMAIN_1 and SUBDOMAIN_3.
The liquid is assumed to stick to the wall, since at a solid-liquid interface the velocity of the liquid
is that of the solid surface. This is known as the no-slip assumption because the liquid is assumed
to adhere to the wall, and hence, has no velocity relative to the wall.
By default, Polydata imposes
default condition.
b.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
ii.
Click EVOL at the top of the Polydata menu to enable the evolution inputs for the flow rate.
For information on nonlinearity and evolution, see Appendix: Nonlinearity and Evolution (p. 147).
iii.
Click Inflow.
iv.
v.
vi.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
125
c.
ix.
Click EVOL at the top of the Polydata menu to disable the evolution inputs.
x.
Click Upper level menu to return to the Flow boundary conditions menu.
d.
e.
i.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_3 and click Modify.
ii.
iii.
Click Upper level menu to accept the default value of 0 [units: Pa] for
iv.
Click Upper level menu to accept the default value of 0 [units: Pa] for
Select Zero wall velocity (vn=vs=0) along BOUNDARY_4 and click Modify.
ii.
iii.
iv.
v.
vi.
vii. Click Upper level menu to return to the Kinematic condition menu.
126
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
x.
xi.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
127
a.
ii.
Click Interface.
iii.
Click Upper level menu to accept the default setting (continuous heat flux along the interface).
For an interface condition, both the heat flux and temperature are usually continuous along
the interface. It is possible to specify a nonzero value for the heat flux jump ( ), but this is
mainly used in problems where internal radiation is simulated. Accept the default value for
the definition of heat flux discontinuity ( =0).
b.
ii.
iii.
Select Constant.
Polydata prompts for the value of the temperature.
128
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
v.
Click Upper level menu to return to the Thermal boundary conditions menu.
c.
d.
e.
i.
ii.
ii.
iii.
iv.
Modification of Talpha
Enter 20 [units: C] as the New value and click OK.
v.
f.
Click Upper level menu to return to the Thermal boundary conditions menu.
6.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
129
SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that only SUBDOMAIN_2
will be remeshed.
ii.
b.
130
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Specify the inlet for the system of spines by selecting Intersection with SUBDOMAIN_1 and
clicking Confirm.
ii.
Specify the outlet for the system of spines by selecting Intersection with BOUNDARY_3 and
clicking Confirm.
iii.
Click Accept the current setup in the Element distortion check menu.
The finite-element mesh can undergo great deformations. The Element distortion check
menu deals with the detection of all possible distortions of the elements.
For this problem, accept the default options and proceed to the next step.
c.
7.
Scroll down to select 4x4 element for temperature in the Interpolation menu.
The Current setup (at the top of the menu) is updated to reflect your selection.
b.
Click Upper level menu two times to return to the F.E.M. Task 1 menu.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
131
b.
Click No, since this sub-task has different parameters associated with it.
c.
d.
2.
b.
c.
Click Upper level menu at the top of the Domain of the sub-task menu.
The Material data menu item is highlighted.
3.
Material data
a.
b.
Select Modify a.
c.
d.
Click Upper level menu two times to return to the solid menu.
The Thermal boundary conditions menu item is highlighted.
132
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
i.
ii.
Click Interface.
iii.
Click Upper level menu to accept the default option for continuity of temperature and heat
flux.
ii.
iii.
iv.
Modification of Talpha
Enter 20 [units: C] as the New Value and click OK.
v.
c.
Click Upper level menu to return to the Thermal boundary conditions menu.
ii.
iii.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
133
Modification of Talpha
Enter 20 [units: C] as the New Value and click OK.
v.
5.
Click Upper level menu to return to the Thermal boundary conditions menu.
Click Upper level menu twice to return to the F.E.M. Task 1 menu.
Define the starting solution for the iterative scheme in the calculation of the inflow condition.
Modify the initial value of delta-S
Retain the default of 0.01 by clicking OK.
2.
Click Upper level menu three times to return to the top-level Polydata menu.
3.4.7. Outputs
Outputs
1.
b.
134
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click Upper level menu three times to return to the top-level Polydata menu.
Click No, as you have already defined an evolution strategy on the flow rate.
1.
Click Accept.
This confirms that the default Current field(s) are correct.
2.
Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postprocessing, and for the Polyflow format results file (res).
3.4.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Ten CFD-Post files are created, corresponding to the ten evolution steps in the problem.
2.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
135
3.4.10. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
Double-click the Results cell in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
2.
3.
136
a.
Right-click in the graphical window and select View from +Z under Predefined Camera.
b.
To remove the ruler right-click in the graphical window, select Viewer Options, and disable Ruler
Visibility.
button.
b.
In the panel that opens, click OK to accept the default name (Contour 1) display the details view
below the Outline tab.
c.
Perform the following steps In the Geometry tab of the details view for Contour 1:
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
i.
Select PRESSURE from the Variable drop-down list, or click the ellipsis button (
right and select PRESSURE.
iii.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
) on the
137
4.
138
In the details view of Contour 1, select VELOCITIES from the Variable drop-down list.
b.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
The fluid experiences high velocity gradients in the narrow section of the die. This leads to important
viscous dissipation effects that cause the temperature of the melt to increase.
5.
In the Outline tab under User Locations and Plots, disable Contour 1.
b.
c.
Click OK to accept the default name (Vector 1) and open the details view below the Outline tab.
button.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
139
d.
ii.
140
iii.
In the Symbol tab, select Arrow3D and retain the default Symbol Size of 1.0.
iv.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
The velocity vectors in the wide section of the die are very small compared to those in the narrow section
of the die (Figure 3.5: Velocity Vectors (p. 141)). Also, the important velocity re-arrangement takes place
at the die exit. This leads to the swelling of the extrudate.
6.
Display the temperature distribution in the solid and the fluid regions.
a.
In the Outline tab, under User Locations and Plots, disable Vector 1, and enable and double-click
Contour 1.
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
141
i.
142
ii.
iii.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
143
Figure 3.7: Temperature Profile Near the Die Exit (p. 144) shows a magnified view of the temperature
contours near the die exit. The high velocity gradients near the die exit lead to an important viscous
dissipation effect. The temperature of the polymer melt increases from the converging zone to the die
lip. This increase in temperature must be monitored to avoid melt degradation. The simulation helps
optimize the geometry of the die, the flow section for the cooling fluid, and other conditions in order
to maximize the flow rate and the extrudate speed.
7.
Verify that you have millimeters selected as your units for length in CFD-Post.
Edit Options... Units
b.
144
Define the line for the plot with the points (0, 1, 0) and (15, 1, 0).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
i.
).
ii.
Click OK to accept the default name (Line 1) and display the details view below the Outline
tab.
iii.
iv.
v.
Click Apply.
Create a plot.
i.
ii.
Click OK to accept the default name (Chart 1) and display the details view below the Outline
tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
145
iii.
In the General tab of the details view, ensure XY is selected for the chart Type and disable
Display Title.
iv.
In the Data Series tab, select Line 1 from the Locations drop-down list for Series 1.
v.
vi.
In the Y Axis tab, select TEMPERATURE from the Variable drop-down list.
vii. With Series 1 (Line 1) enabled under the Line Display tab, select Rectangle from the Symbols
drop-down list. Retain the default Symbol Color (green).
viii. Click Apply.
146
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
3.5. Summary
In this tutorial, you solved the non-isothermal flow of a polymer melt through a cooled die. You set the
material properties for the melt and supplied suitable boundary conditions. A specific interpolation
scheme was used for the temperature in order to cope with the important gradients. You applied an
evolution scheme to solve the convergence problems caused by the viscous dissipation coupled with
the temperature-dependent viscosity law.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
147
148
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Chapter 4: 3D Extrusion
This tutorial is divided into the following sections:
4.1. Introduction
4.2. Prerequisites
4.3. Problem Description
4.4. Preparation
4.5. Setup and Solution
4.6. Summary
4.1. Introduction
This tutorial illustrates the simulation of a 3D extrusion process. Due to the velocity rearrangement that
occurs at the die exit, the shape of the extrudate is usually different from the die lip cross-section.
Polyflow is capable of handling 3D free surfaces, so it can predict the extrudate shape that corresponds
to a given die geometry under prescribed operating conditions.
In this tutorial you will learn how to:
Create a sub-task to define a 3D extrusion problem.
Set material properties and boundary conditions for a 3D extrusion problem.
Select a remeshing method.
4.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the setup procedure
will not be shown explicitly.
= 10
cm /s (a quarter of the actual flow rate) and the extrudate is obtained at the exit. At the end of the
computational domain, it is assumed that the extrudate is fully deformed and that it will not deform
any further. It is assumed that subdomain 2 is long enough to account for all the deformation of the
extrudate.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
149
3D Extrusion
Figure 4.1: Problem Description
The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two subdomains (as shown in Figure 4.1: Problem Description (p. 150))
so that the remeshing algorithm can be applied only to the portion of the mesh that will be deformed.
The subdomain 1 represents the die where the fluid is confined. The subdomain 2 corresponds to the
extrudate that is in contact with the air and can deform freely. The main aim of the calculation is to
find the location of the free surface (the skin of the extrudate).
The boundary sets for the problem are shown in Figure 4.2: Boundary Sets for the Problem (p. 151), and
the conditions at the boundaries of the domains are as follows.
boundary 1: flow inlet, volumetric flow rate
= 10 cm3/s
150
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Preparation
Figure 4.2: Boundary Sets for the Problem
4.4. Preparation
To prepare for running this tutorial:
1.
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the 3D-Extrusion_R160.zip file you have downloaded to your working folder.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
151
3D Extrusion
The mesh file ext3d.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow (Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering 3D-extrusion as the name of the
project.
3.
4.
b.
152
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
3.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
153
3D Extrusion
Accept the default selection of both subdomains (SUBDOMAIN_1 and SUBDOMAIN_2) by clicking
Upper level menu.
The Material data menu item is highlighted.
2.
154
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Specify the value , referred to as fac in the graphical user interface (compare the equation at the top
of the Cross law menu to Equation 4.1 (p. 154)).
Modify fac
Enter 85000 [units: poise] as the New value and click OK.
4.
Specify the value for , referred to as tnat in the graphical user interface.
Modify tnat
Modify expom
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
155
3D Extrusion
Select Upper level menu three times to return to the 3D die swell menu.
The Flow boundary conditions menu item is highlighted.
1.
156
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
b.
Click Inflow.
c.
d.
Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY_2 at the wall of SUBDOMAIN_1 (BOUNDARY_2).
At a solid-liquid interface, the velocity of the liquid is that of the solid surface. Hence the fluid is assumed
to stick to the wall. This is known as the no-slip condition because the liquid is assumed to adhere to
the wall, and hence, has no velocity relative to the wall.
By default, Polydata imposes
condition.
3.
4.
a.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_3 and click Modify.
b.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_4 and click Modify.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
157
3D Extrusion
b.
5.
6.
a.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_5 and click Modify.
b.
c.
d.
e.
f.
g.
h.
Click Upper level menu to return to the Flow boundary conditions panel.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_6 and click Modify.
b.
c.
d.
e.
Click Upper level menu at the top of the Flow boundary conditions panel.
4.5.5. Remeshing
This model involves a free surface, whose shape is unknown a priori, which will be calculated together with
the flow equations. A portion of the mesh is affected by the relocation of this boundary, so a remeshing
technique is applied on this part of the mesh. The free surface is entirely contained within subdomain 2,
therefore only subdomain 2 is affected by the relocation of the free surface.
Global remeshing
1.
158
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
2.
159
3D Extrusion
Optimesh-3D (extrusion only)
160
a.
Specify the initial plane for the optimesh remeshing technique, by selecting Intersection with
SUBDOMAIN_1 and clicking Confirm.
b.
Specify the final plane for the optimesh remeshing technique, by selecting Intersection with
BOUNDARY_6 and clicking Confirm.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Polydata asks if you want to change from the surface kinematic condition to the line kinematic
condition.
c.
d.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
161
3D Extrusion
Polydata asks you to confirm the current system units and fields that are to be saved to the results file for
postprocessing.
1.
2.
b.
c.
Click Accept.
This confirms that the default Current field(s) are correct.
3.
Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postprocessing, and for the Polyflow format results file (res).
4.5.7. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2.
b.
162
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.5.8. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
Double-click the Results cell in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
2.
button.
b.
Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
c.
In the Outline tree tab, under User Locations and Plots, deselect Wireframe.
d.
ii.
Select all topological entities under PFL in the Location Selector dialog box (use Shift) and
click OK.
iii.
iv.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
).
163
3D Extrusion
v.
Click Apply.
In Figure 4.3: Contours of Velocity Magnitude (p. 164), the velocity is zero along the die wall (as expected)
and there is a fully developed profile at the inlet of the die. At the die outlet, the velocity profile changes
to become constant throughout the extrudate cross-section. The transition between these two states
can be seen in the beginning section of the extrudate.
Figure 4.3: Contours of Velocity Magnitude
3.
164
Deselect Contour 1 in the Outline tree tab under User Locations and Plots.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
).
ii.
Click OK to accept the default name (Plane 1) and display the details view below the Outline
tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
165
3D Extrusion
iii.
In the Geometry tab of the details view of Plane 1, ensure XY Plane is selected from the
Method drop-down list.
iv.
Enter 0 for Z.
v.
Click Apply.
vi.
Repeat steps 3.b.i.v. for the other planes, at Z = 0.08, 0.15, and 0.45 m.
vii. In the Outline tree tab, under User Locations and Plots, deselect Plane 1, Plane 2, Plane 3,
and Plane 4.
c.
d.
Click OK to accept the default name (Contour 2) and display the details view below the Outline tab.
e.
In the Outline tree tab under User Locations and Plots, select Wireframe.
f.
166
button.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
ii.
Select all planes under User Locations and Plots (use Shift for multiple selection).
iii.
Click OK.
iv.
v.
vi.
Click Apply.
).
Velocity profiles at the flow inlet, the flow outlet, and planes just before and just after the die exit are
displayed (Figure 4.4: Velocity Profiles at Cross-Sections (p. 168)). Compare the velocity profile within the
die to the velocity profile just after the die exit at the end of the computational domain. In the die the
flow is fully developed. The velocity profile is flat in the extrudate, far away from the die exit; all the
particles in the cross-section plane are at the same velocity. Just beyond the die exit, in the transitional
zone, the velocity profile is reorganized. The velocity profile on the plane = 15 is no longer fully developed, but it is not yet flat either. The velocity rearrangement is the source of the deformation of the
extrudate.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
167
3D Extrusion
Figure 4.4: Velocity Profiles at Cross-Sections
4.
b.
168
).
ii.
Click OK to accept the default name (Polyline 1) and display the details view below the Outline
tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iii.
In the Geometry tab of the details view, select Boundary Intersection from the Method dropdown list.
iv.
Click
next to Boundary List and select SUBDOMAIN_1_BOUNDARY_2, SUBDOMAIN_1_BOUNDARY_3, SUBDOMAIN_1_BOUNDARY_4 (use Shift for multiple selection).
Click OK to close the Location Selector dialog box.
v.
vi.
).
ii.
Click OK to accept the default name (Polyline 2) and display the details view below the Outline
tab.
iii.
In the Geometry tab of the details view, select Boundary Intersection from the Method dropdown list.
iv.
Click
next to Boundary List and select SUBDOMAIN_2_BOUNDARY_3, SUBDOMAIN_2_BOUNDARY_4, SUBDOMAIN_2_BOUNDARY_5 (use Shift for multiple selection).
v.
vi.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
169
3D Extrusion
d.
On the axis triad in the graphics window click +Z to view from Z-direction.
This allows you to compare the size and shape of the flow inlet with that of the flow outlet without
distortion due to perspective.
Since the model involves a generalized Newtonian fluid, there are no viscoelastic effects. The swelling
(Figure 4.5: Swelling of the Extrudate (p. 170)) is only due to reorganization of the velocity profile at the
die exit. Fluid from the high-speed region moves to the low-speed region and pushes the free surface
to the exterior.
5.
Define the line of the plot with the points (0.0, 0.1, 0.1) and (0.1, 0.0, 0.1).
These values are in meters.
i.
170
).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
ii.
Click OK to accept the default name (Line 1) and display the details view below the Outline
tab.
iii.
Enter 0, 0.1, 0.1 for Point 1 and 0.1, 0, 0.1 for Point 2.
iv.
Click Apply.
Create a plot.
i.
ii.
Click OK to accept the default name (Chart 1) and display the details view below the Outline
tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
171
3D Extrusion
iii.
In the General tab of the details view, ensure XY is selected for Type, and enter 3D Extrusion
for Title.
iv.
In the Data Series tab, for Series 1, select Line 1 from the Locations drop-down list (or by
clicking the
button).
v.
vi.
In the Y Axis tab, select VELOCITIES from the Variable drop-down list.
172
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
The shear-thinning introduced by the Cross law is not clearly visible in Figure 4.6: Velocity Magnitude
Along a Diagonal of Die Exit Section (p. 173) due to the large finite elements along the die wall. The
mesh should be refined in that zone.
6.
b.
Define the line of the plot with the points (0.08, 0.02, 0.00) and (0.08, 0.02, 0.50).
i.
).
ii.
Click OK to accept the default name (Line 2) and display the details view below the Outline
tab.
iii.
Enter 0.08, 0.02, 0 for Point 1 and 0.08, 0.02, 0.5 for Point 2.
iv.
Click Apply.
Create a plot.
i.
ii.
Click OK to accept the default name (Chart 2) and display the details view below the Outline
tab.
iii.
In the General tab of the details view, ensure XY is selected for Type, and disable Display Title.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
173
3D Extrusion
iv.
In the Data Series tab, select Line 2 from the Locations drop-down list for Series 1.
v.
vi.
In the Y Axis tab, select VELOCITIES X from the Variable drop-down list.
7.
174
In the Y Axis tab of the details of Chart 2, select VELOCITIES Y from the Variable drop-down list.
b.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
8.
In the Y Axis tab of the details view of Chart 2, select VELOCITIES Z from the Variable drop-down
list.
b.
Click Apply.
Figure 4.9: Velocities Along a Line Close to the Center of the Die (p. 176) shows that the flow
slows down ( decreases) after the die exit. Meanwhile, particles travel from the center of
the extrudate toward the edge, creating the swelling of the extrudate. Figure 4.7: X-Velocities
Along a Line Close to the Center of the Die (p. 174) and Figure 4.8: Y-Velocities Along a Line
Close to the Center of the Die (p. 175) show that the peak values of
and
are located at
the very beginning of the extrudate, and vanish at the end of the free jet.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
175
3D Extrusion
Figure 4.9: Velocities Along a Line Close to the Center of the Die
4.6. Summary
This tutorial introduced the concept of a 3D extrusion problem. You solved the problem using a specific
3D geometry for the die and made suitable assumptions about the physics of the problem. You analyzed
the factors affecting the extrudate shape. In Polydata you learned how to use the optimesh remeshing
method, which is recommended for 3D extrusion problems.
176
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
5.1. Introduction
This tutorial is similar to the 3D extrusion problem solved in 3D Extrusion (p. 149), where the shape of
the extrudate was computed from the die geometry. In this tutorial, a complex geometry (free surface)
is associated with the exit section of the die and undergoes large deformations during the extrusion
process. Consequently, the problem becomes highly nonlinear and special convergence techniques are
required to obtain a solution. This tutorial introduces the evolution procedure in Polyflow that is used
to handle nonlinear problems.
In this tutorial you will learn how to:
Define an evolution problem.
Create a sub-task to define a direct extrusion problem.
Set material properties and boundary conditions for a direct extrusion problem.
5.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the set up procedure
will not be shown explicitly.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
177
Direct Extrusion
Figure 5.1: Problem Description
The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two subdomains (as shown in Figure 5.1: Problem Description (p. 178))
so that the remeshing algorithm can be applied only to the portion of the mesh that is deformed.
Subdomain 1 represents the fluid as it enters and is confined by the die. Subdomain 2 corresponds to
the extrudate that is in contact with the air (and can deform freely). The main aim of the calculation is
to find the location of the free surface (the skin of the extrudate).
The boundary set for the problem are shown in Figure 5.2: Boundary Set for the Problem (p. 179), and
the conditions at the boundaries of the domains are:
boundary 1: flow inlet, volumetric flow rate
= 10 cm3/s
178
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
5.4.1. Preparation
To prepare for running this tutorial:
1.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
179
Direct Extrusion
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the Direct-Extrusion_R160.zip file you have downloaded to your working folder.
The mesh file dirext.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow - Extrusion (Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering direct-extrusion as the name of
the project.
3.
4.
180
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
2.
b.
3.
2.
3.
Specify the value for , referred to as fac in the graphical user interface (compare the equation at the
top of the Power law menu to the equation shown in the Appendix (p. 198)).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
181
Direct Extrusion
Modify fac
Enter 3e+05 [units: poise] as the New value and click OK.
4.
Retain the default value for , referred to as tnat in the graphical user interface.
Modify tnat
Click OK to retain the default value of 1 [units: s].
5.
Specify the value for , referred to as expo in the graphical user interface.
Modify expo
Click Upper level menu three times to return to the Direct extrusion menu.
The Flow boundary conditions menu item is highlighted.
182
Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
b.
Click Inflow.
c.
Ensure Volumetric flow rate is selected and click Modify volumetric flow rate.
Polydata prompts you for the volumetric flow rate.
d.
e.
2.
3.
4.
a.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_2 and click Modify.
b.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_3 and click Modify.
b.
Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY_4 at the wall of SUBDOMAIN_1 (BOUNDARY_4).
At a solid-liquid interface, the velocity of the liquid is that of the solid surface. Hence the velocity the
fluid is assumed to stick to the wall. This is known as the no-slip assumption because the liquid is assumed
to adhere to the wall, and hence, has no velocity relative to the wall.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
183
Direct Extrusion
By default, Polydata imposes
condition.
5.
6.
a.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_5 and click Modify.
b.
c.
d.
Select No condition along BOUNDARY_4 (the boundary where the free surface starts) and click
Modify.
e.
f.
Click Upper level menu to return to the Boundary conditions on the moving surface menu.
g.
Click Upper level menu two times to return to the Flow boundary conditions menu.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_6 and click Modify.
b.
c.
d.
e.
5.4.6. Remeshing
This model involves a free surface, whose shape is unknown a priori, which will be calculated together with
the flow equations. A portion of the mesh is affected by the relocation of this boundary, so a remeshing
technique is applied on this part of the mesh. The free surface is entirely contained within subdomain 2,
therefore only subdomain 2 is affected by the relocation of the free surface.
Global remeshing
1.
184
b.
2.
Specify the initial plane for the optimesh remeshing technique, by selecting Intersection with
SUBDOMAIN_1 and clicking Confirm.
b.
Specify the final plane for remeshing technique, by selecting Intersection with BOUNDARY_6 and
clicking Confirm.
Polydata asks if you want to change from the surface kinematic condition to the line kinematic
condition.
c.
d.
Click Accept the current setup in the Element distortion check menu.
In complex extrusion simulations, the finite element mesh can undergo great deformations. The
Element distortion check menu deals with the detection of all possible distortions of the elements.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
185
Direct Extrusion
e.
2.
Define the starting solution for the iterative scheme in the calculation of the free surface location.
The first calculation is performed at . Increase the value of the initial increment of
the number of evolution steps and to speed up the calculation.
Modify the initial value of delta-S
Polydata prompts you for the initial value of
3.
186
b.
c.
Click Upper level menu two times to return to the top-level Polydata menu.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
) to reduce
5.4.8. Outputs
After Polyflow calculates a solution, it can save the results in several different formats. Choose the one that
is appropriate for your postprocessor. In this case, save the outputs in IGES format, as well as the default
format for CFD-Post.
Outputs
1.
Retain the default output (CFD-Post) and click Enable Iges file output.
The default CFD-Post output is used for postprocessing with CFD-Post. The IGES output contains the
modified geometry of the extrudate (after remeshing) calculated at every step of the evolution procedure.
For information on IGES output, see Appendix (p. 198).
Polydata asks you to confirm the current system units and fields that are to be saved to the results file
for postprocessing.
2.
b.
c.
Click Accept.
This confirms that the default Current field(s) are correct.
2.
Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postprocessing, and for the Polyflow format results file (res).
5.4.10. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
187
Direct Extrusion
a.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
5.4.11. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
Double-click the Results tab in the Polyflow analysis system. This will start CFD-Post and read the results
files saved by Polyflow. CFD-Post reads the mesh information and the solution fields that were saved to
the results file.
2.
b.
Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
c.
Perform the following steps in the Geometry tab of the details view of Contour 1:
i.
188
Click the
button.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
d.
ii.
Select all topological entities under Fluid Flow Extrusion Polyflow in the Location Selector
dialog box (use Shift for multiple selection) and click OK.
iii.
iv.
Click Apply.
).
Rotate the image so that you can see the fluid at the inlet of the die, as shown in Figure 5.3: Contours
of Velocity Magnitude (p. 189).
Observe that the velocity is zero along the die wall, as expected, and there is a fully developed profile
at the inlet of the die. At the die outlet, the velocity profile changes to become constant throughout the
extrudate cross-section. The transition between these two states can be seen in the first third of the extrudate.
3.
189
Direct Extrusion
a.
In the Outline tree tab, under User Locations and Plots, deselect Contour 1.
b.
190
).
ii.
Click OK to accept the default name (Plane 1) and display the details view below the Outline
tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iii.
In the Geometry tab of the details view, ensure XY Plane is selected from the Method dropdown list.
iv.
Enter 0 for Z.
v.
Click Apply.
vi.
Repeat steps 3.b.i.v. for the other planes, at Z = 0.03, 0.07, and 0.1999 m.
vii. In the Outline tree tab, under User Locations and Plots, deselect Plane 1, Plane 2, Plane 3,
and Plane 4.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
191
Direct Extrusion
c.
192
button.
ii.
Click OK to accept the default name (Contour 2) and display the details view below the Outline
tab.
iii.
In the Outline tree tab under User Locations and Plots, select Wireframe.
iv.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
v.
Select all planes under User Locations and Plots (use Shift for multiple selection).
vi.
Click OK.
vii. Select VELOCITIES from the Variable drop-down list (or click
).
Click Apply.
Figure 5.4: Velocity Profiles at Cross-Sections (p. 194) shows the velocity profiles at the flow inlet, the flow
outlet, and at the planes just before and just after the die exit.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
193
Direct Extrusion
Figure 5.4: Velocity Profiles at Cross-Sections
Compare the velocity profile within the die to the velocity profile just after the die exit at the end of the
computational domain. In the die the flow is fully developed. In the extrudate, far away from the die
exit, the velocity profile is flat. That is, all the particles in a cross-sectional plane are at the same speed.
Just after the die exit, there is a transitional zone where the velocity profile is reorganized. The velocity
profile on the plane Z = 7 cm is no longer fully developed, but it is not yet flat either. The velocity rearrangement is the source of the deformation of the extrudate.
4.
194
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
).
ii.
Click OK to accept the default name (Polyline 1) and display the details view below the Outline
tab.
iii.
In Geometry tab of the details view, select Boundary Intersection from the Method drop-down
list.
iv.
Click
next to Boundary List and select SUBDOMAIN_1_BOUNDARY_4. Click OK to close
the Location Selector dialog box.
v.
vi.
).
ii.
Click OK to accept the default name (Polyline 2) and display the details view below the Outline
tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
195
Direct Extrusion
d.
iii.
In Geometry tab of the details view, select Boundary Intersection from the Method drop-down
list.
iv.
v.
vi.
Click Apply.
Right-click in the graphic window and select View From +Z under Predefined Camera.
This allows you to compare the size and shape of the flow inlet with that of the flow outlet without
distortion due to perspective.
5.
196
Click the Insert menu and select Instance Transform, or click the
b.
Click OK to accept the default name (Instance Transform 1) and display the details view below the
Outline tab.
c.
ii.
button.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iv.
Ensure Method is set to Principal Axis and Z is selected from the Axis drop-down list.
v.
vi.
Click Apply.
d.
In the Outline tree tab, under User Locations and Plots, right-click Polyline 1 and click Edit (or
double-click Polyline 1).
e.
In the View tab, scroll down and enable Apply Instancing Transform.
f.
g.
Click Apply.
h.
In the Outline tree tab, under User Locations and Plots, right-click Polyline 2 and click Edit (or
double-click Polyline 2).
i.
You can use the central-mouse button to zoom in and out. This allows you to compare the size and
shape of the flow inlet with that of the flow outlet without distortion due to perspective.
You can also click the fit view button (
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
197
Direct Extrusion
Figure 5.5: Swelling of the Extrudate
The deformations come from the rearrangement of the velocity profile. Particles coming from highspeed regions in the die must slow down, while particles coming from low-speed regions must
accelerate. Observe that the central part of the cross, where the fluid easily flows in the die, is enlarged in the extrudate, while the extremities of the branches are smaller in the extrudate. Since
the combined effect of cross-sectional expansions and reductions is very difficult to guess, a numerical simulation is necessary for a moderate to high complexity die.
5.5. Summary
This tutorial introduced the concept of a direct extrusion problem. You solved the problem using a
specific 3D geometry for the die, made suitable assumptions about the physics of the problem, and
analyzed the factors affecting the extrudate shape. The nonlinear problem was solved using an evolution
technique to reach the convergence.
5.6. Appendix
The appendix contains the following sections:
198
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Appendix
5.6.1. Power Law
5.6.2. Optimesh Remeshing Technique
5.6.3. Evolution Scheme
5.6.4. IGES Output
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
199
200
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
6.1. Introduction
Inverse extrusion deals with the computation of the shape of a die that produces an extrudate of the
desired shape. This tutorial illustrates how to handle a complex inverse extrusion problem. In this tutorial,
slip conditions along the die walls are considered and evolution on the slip coefficient is enabled to
aid convergence.
In this tutorial you will learn how to:
Define an evolution problem.
Create a sub-task to define an inverse extrusion problem.
Set material properties and boundary conditions for a inverse extrusion problem.
Specify multiple local remeshing regions.
6.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the set up procedure
will not be shown explicitly.
= 10 cm3/s
The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two sub-domains (as shown in Figure 6.1: Problem Description (p. 202))
so that specific remeshing algorithms can be applied in each sub-domain to accurately predict the die
profile. Subdomain 1 represents the fluid as it enters and is confined by the die. Subdomain 2 corresponds
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
201
Inverse Extrusion
to the extrudate that is in contact with the air (and can deform freely). The main aim of the calculation
is to compute the geometry of the die to obtain the desired extrudate.
Figure 6.1: Problem Description
The boundary set for the problem are shown in Figure 6.2: Boundary Set for the Problem (p. 202), and
the conditions at the boundaries of the domains are given below
boundaries of the domains are:
boundary 1: flow inlet, volumetric flow rate
202
= 10 cm3/s
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
6.4.1. Preparation
To prepare for running this tutorial:
1.
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the Inverse-Extrusion_R160.zip file you have downloaded to your working folder.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
203
Inverse Extrusion
The mesh file invext.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow - Extrusion(Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering inverse-extrusion as the name of
the project.
3.
4.
b.
2.
204
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
3.
2.
3.
Specify the value of , referred to as fac in the graphical user interface (compare the equation at the
top of the Power law menu to the equation shown in the Power Law (p. 225)).
Modify fac
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
205
Inverse Extrusion
Enter 300000 [units: poise] as the New value and click OK.
4.
Retain the default value for , referred to as tnat in the graphical user interface.
Modify tnat
Click OK to retain the default value of 1.
5.
Specify the value for , referred to as expo in the graphical user interface.
Modify expo
Enter 0.75 as the New value and click OK.
6.
Click Upper level menu three times to return to the Inverse Extrusion menu.
The Flow boundary conditions menu item is highlighted.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
b.
Click Inflow.
c.
206
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
d.
e.
f.
2.
3.
4.
a.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_2 and click Modify.
b.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_3 and click Modify.
b.
Set the conditions along the outer wall of the die (BOUNDARY_4).
a.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_4 and click Modify.
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
207
Inverse Extrusion
wall slows down, which increases the velocity of the fluid in the center of the die. For more information on the evolution scheme, see Evolution Scheme (p. 225).
i.
Click EVOL at the top of the Polydata menu to enable the evolution inputs for the slip coefficient.
ii.
iii.
iv.
Modify k
A dialog box appears asking you for the value of .
v.
vi.
x.
xi.
Click EVOL at the top of the Polydata menu to disable the evolution inputs.
).
xiv. Click Upper level menu two times to return to the Flow boundary conditions menu.
5.
208
Select Zero wall velocity (vn=vs=0) along BOUNDARY_5 and click Modify.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
d.
Select No condition along BOUNDARY_4 (the boundary where the free surface starts) and click
Modify.
e.
f.
Click Upper level menu to return to the Boundary conditions on the moving surface menu.
g.
h.
Click Outlet (Inv. prediction) to define the outlet of the moving surface.
In inverse extrusion problems, you have to predict the appropriate die exit cross-section to obtain
a given extrudate cross-section. By defining the outlet of a free surface, inform Polyflow the desired
extrudate shape. Hence, you impose the outlet of the moving surface along the last section of the
free jet as the outlet of the free surface. This section will not be modified during the calculation.
6.
i.
Select BOUNDARY_6 as the outlet of the moving surface and click Confirm.
j.
Click Upper level menu to return to the Flow boundary conditions menu.
7.
a.
Select Zero wall velocity (vn=vs=0) along BOUNDARY_6 and click Modify.
b.
c.
d.
Click Upper level menu at the top of the Flow boundary conditions menu.
The Global remeshing menu item is highlighted.
6.4.6. Remeshing
The purpose of the remeshing technique is to relocate internal nodes according to the displacement of
boundary nodes due to the motion of the free surface, since a part of the mesh is deformed. For information
on remeshing technique, see Appendix (p. 225).
Global remeshing
1.
209
Inverse Extrusion
a.
b.
2.
Specify the initial plane for the optimesh remeshing technique, by selecting Intersection with
SUBDOMAIN_1 and clicking Confirm.
b.
Specify the final plane for the remeshing technique, by selecting Intersection with BOUNDARY_6
and clicking Confirm.
Polydata asks if you want to change from the surface kinematic condition to the line kinematic
condition.
c.
d.
Click Accept the current setup in the Element distortion check menu.
In complex extrusion simulations, the finite element mesh can undergo great deformations. The
Element distortion check menu deals with the detection of all possible distortions of the elements.
Accept default options.
3.
210
5.
b.
c.
d.
e.
Note
Setting the final value of equal to 20 creates a large enough slip coefficient that
it is equivalent to a no-slip condition at the die wall (BOUNDARY_4, as discussed
in a previous step).
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
211
Inverse Extrusion
c.
2.
Click Upper level menu three times to return to the top-level Polydata menu.
6.4.8. Outputs
After Polyflow calculates a solution, it can save the results in several different formats. Choose the one that
is appropriate for your postprocessor. In this case, save the outputs in IGES format, as well as the default
format for CFD-Post.
Outputs
1.
Retain the default output (CFD-Post) and click Enable Iges file output.
The default CFD-Post output is used for postprocessing with CFD-Post. The IGES output contains the
modified geometry of the extrudate (after remeshing) calculated at every step of the evolution procedure.
For information on IGES output, see Appendix (p. 225).
Polydata asks you to confirm the current system units and fields that are to be saved to the results file
for postprocessing.
2.
b.
c.
212
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click Accept.
This confirms that the default Current field(s) are correct.
2.
Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postprocessing, and for the Polyflow format results file (res).
6.4.10. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
A cfx.res file (corresponding to the eight evolution steps of the flow case) will be created.
2.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
6.4.11. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
Double-click the Results tab in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
2.
Deselect Wireframe in the Outline tree tab, under User Locations and Plots.
b.
c.
Click OK to accept the default name (Contour 1) and open the details view below the Outline tab.
d.
Perform the following steps In the Geometry tab of the details view.
i.
Click the
button.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
213
Inverse Extrusion
ii.
Select all topological entities under PFL in the Location Selector dialog box (use Shift for
multiple selection) and click OK.
iii.
iv.
Click Apply.
).
You can see in Figure 6.3: Contours of Velocity Magnitude (p. 215) that the velocity is zero along the die
wall, as expected, and there is a fully developed profile at the inlet of the die. At the die outlet, the velocity
profile changes to become constant throughout the extrudate cross-section. The transition between
these two states can be seen at the beginning of extrudate section.
214
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
3.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
215
Inverse Extrusion
In the Outline tree tab, under User Locations and Plots deselect Contour 1.
b.
216
).
ii.
Click OK to accept the default name (Plane 1) and display the details view below the Outline
tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iii.
In the Geometry tab of the details view, select XY Plane from the Method drop-down list.
iv.
Enter 0 for Z.
v.
Click Apply.
vi.
Repeat steps 3.b.i.v. to create the other planes at Z = 0.03, 0.07, and 0.1999 m.
vii. In the Outline tree tab, under User Locations and Plots, deselect Plane 1, Plane 2, Plane 3,
and Plane 4.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
217
Inverse Extrusion
c.
d.
Click OK to accept the default name (Contour 2) and open the details view below the Outline tree
tab.
e.
In the Outline tree tab under User Locations and Plots, select Wireframe.
f.
218
button.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
ii.
Select all planes under User Locations and Plots (use Shift for multiple selection).
iii.
Click OK.
iv.
v.
vi.
Click Apply.
).
The velocity profiles planes are located at the flow inlet, the flow outlet, and planes just before and after
the die exit as shown in Figure 6.4: Velocity Profile Planes (p. 220).
Compare the velocity profile within the die to the velocity profile just after the die exit at the end of the
computational domain.
The flow is fully developed in the die.
The velocity profile is flat in the extrudate, far away from the die exit. All particles in the cross-section plane
are at the same velocity.
Just after the die exit, there is a transitional zone where the velocity profile is reorganized.
The velocity profile on the plane
219
Inverse Extrusion
Figure 6.4: Velocity Profile Planes
4.
b.
220
).
ii.
Click OK to accept the default name (Polyline 1) and display the details view below the Outline
tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iii.
In the Geometry tab of the details view, select Boundary Intersection from the Method dropdown list.
iv.
Click
next to Boundary List and select SUBDOMAIN_1_BOUNDARY_4. Click OK to close
the Location Selector dialog box.
v.
vi.
d.
).
ii.
Click OK to accept the default name (Polyline 2) and display the details view below the Outline
tab.
iii.
In the Geometry tab of the details view, select Boundary Intersection from the Method dropdown list.
iv.
v.
vi.
Click Apply.
Right-click in the graphic window and select View From +Z under Predefined Camera.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
221
Inverse Extrusion
5.
222
Click the Insert menu and select Instance Transform, or click the
button.
b.
Click OK to accept the default name (Instance Transform 1) and display the details view below the
Outline tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
Perform the following steps in the Definition tab of the details view of Instance Transform 1:
i.
ii.
iii.
iv.
Ensure Principal Axis and Z are selected for Method and Axis in the Axis Definition group
box.
v.
vi.
Click Apply.
d.
In the Outline tree tab, under User Locations and Plots, right-click Polyline 1 and click Edit (or
double-click Polyline 1).
e.
In the View tab of the details view, scroll down and enable Apply Instancing Transform.
f.
g.
Click Apply.
h.
In the Outline tree tab, under User Locations and Plots, right-click Polyline 2 and click Edit (or
double-click Polyline 2).
i.
You can use the central-mouse button to zoom in and out. This allows you to compare the size and
shape of the flow inlet with that of the flow outlet without distortion due to perspective.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
223
Inverse Extrusion
The deformation of the extrudate is the result of the rearrangement taking place at the die exit. Particle
coming from high-speed regions in the die must slow down, while particles coming from low-speed regions must accelerate. You can change the speed by enlarging the flowing section. A tube of fluid at
high speed in the die will enlarge its cross-section in the extrudate to decrease its average velocity. A
tube of fluid at low speed in the die will reduce its cross-section in the extrudate in order to increase
average speed. In Figure 6.5: Swelling of the Extrudate (p. 224), you can see that the die design tool
compensated for these effects. The central part of the cross-section where the fluid easily flowed in the
original die has been reduced by the die design tool, while the extremities of the branches were enlarged
because the flow was much slower in the original die. Since the combined effects of the cross-sectional
enlargements and reductions are very difficult to guess, the numerical simulation is necessary to help
the die designer reduce the number of trial-and-error iterations.
224
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Appendix
6.5. Summary
This tutorial introduced the concept of an inverse extrusion problem. You solved the problem assuming
suitable conditions for the physics of the problem and Polyflow predicted the shape of the die. You
used multiple domain calculations with remeshing methods most suited to 3D inverse extrusion problems.
The nonlinear problem was solved using an evolution technique to aid convergence.
6.6. Appendix
The appendix contains the following sections:
6.6.1. Power Law
6.6.2. Evolution Scheme
6.6.3. Remeshing Technique
6.6.4. Optimesh Remeshing Technique
6.6.5. IGES Output
225
Inverse Extrusion
= tangential velocity of the wall
= material parameters
= material parameters
= 0 (assumed zero, by default
226
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
7.1. Introduction
This tutorial examines the flow of two fluids in a single die. Two polymer melts with distinct physical
properties are fed through different channels into a die. The aim of the calculation is to predict the
location of the interface between the two fluids.
In this tutorial you will learn how to:
Define a moving interface problem.
Create multiple sub-tasks.
Set material properties and boundary conditions for a moving interface problem.
Select a remeshing method.
7.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the set up procedure
will not be shown explicitly.
227
= 5000 poise.
The boundary sets for the problem are shown in Figure 7.2: Boundary Sets and Subdomains for the
Problem (p. 229).
228
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Problem Description
Figure 7.2: Boundary Sets and Subdomains for the Problem
= 3 cm3/s
= 1 cm3/s
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
229
7.4.1. Preparation
To prepare for running this tutorial:
1.
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the Two-Fluids_R160.zip file you have downloaded to your working folder.
The mesh file fluids.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow - Extrusion (Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering two-fluids as the name of the project.
3.
4.
230
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
2.
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
231
b.
c.
3.
232
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
5.
Specify the value for , referred to as fac in the graphical user interface.
Modify fac
Polydata prompts for a new value of .
Enter 10000 [units: poise] as the New value and click OK.
6.
Click Upper level menu three times to return to the fluid 1 menu.
The Flow boundary conditions menu item is highlighted.
7.
Specify the flow boundary conditions for fluid 1 (SUBDOMAIN1 and SUBDOMAIN2).
Flow boundary conditions
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
233
a.
ii.
Click Interface.
iii.
iv.
v.
234
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
vi.
b.
ix.
x.
Click Accept the current setup to return to the Flow boundary conditions menu.
Select Zero wall velocity (vn=vs=0) along BOUNDARY1 and click Modify.
ii.
Click Inflow.
iii.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
235
iv.
v.
vi.
Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY2 at the outer
wall of SUBDOMAIN1 (BOUNDARY2).
At a solid-liquid interface, the velocity of the liquid is that of the solid surface. Hence the fluid
is assumed to stick to the wall. This is known as the no-slip assumption because the liquid is
assumed to adhere to the wall, and therefore has no velocity relative to the wall.
By default, Polydata imposes Zero wall velocity (
c.
d.
i.
Select Zero wall velocity (vn=vs=0) along BOUNDARY5 and click Modify.
ii.
Click Outflow.
Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY6 at the outer wall
common to SUBDOMAIN1 and SUBDOMAIN2 (BOUNDARY6).
The fluid is assumed to stick to the wall, since at a solid-liquid interface the velocity of the liquid
is that of the solid surface.
e.
8.
236
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
ii.
b.
237
To specify the inlet for the system of spines, select Intersection with SUBDOMAIN1 and click
Confirm.
ii.
Specify the outlet for the system of spines, select Intersection with BOUNDARY5 and click
Confirm.
iii.
238
Polydata asks you if you want to copy data from an existing sub-task.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
Click No, since this sub-task has different parameters associated with it.
c.
d.
2.
b.
c.
3.
b.
c.
Specify the value for , referred to as fac in the graphical user interface.
Modify fac
Polydata prompts for a new value of .
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
239
Enter 5000 [units: poise] as the New value and click OK.
d.
Click Upper level menu three times to return to the fluid 2 menu.
The Flow boundary conditions menu item is highlighted.
4.
Specify the flow boundary conditions for fluid 2 (SUBDOMAIN3 and SUBDOMAIN4).
Flow boundary conditions
a.
Select Zero wall velocity (vn=vs=0) along SUBDOMAIN2 and click Modify.
ii.
Click Interface.
The interface condition was defined as a moving interface when setting the boundary conditions for fluid 1. So further inputs are not required to define the moving interface for fluid 2.
Surface tension effects are neglected in this problem.
iii.
b.
Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY2 at the outer wall of
SUBDOMAIN3 (BOUNDARY2).
c.
Select Zero wall velocity (vn=vs=0) along BOUNDARY3 and click Modify.
ii.
Click Inflow.
iii.
240
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iv.
Accept the default value of 1 [units: cm3/s] for the flow rate by clicking OK.
v.
d.
Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY4 at the outer wall
common to SUBDOMAIN3 and SUBDOMAIN4 (BOUNDARY4).
e.
f.
i.
Select Zero wall velocity (vn=vs=0) along BOUNDARY5 and click Modify.
ii.
Click Outflow.
Click Upper level menu to return to the Flow boundary conditions menu.
The Global remeshing menu item is highlighted.
5.
ii.
b.
241
c.
i.
Specify the inlet for the system of spines by selecting Intersection with SUBDOMAIN3 and
click Confirm.
ii.
Specify the outlet for the system of spines by selecting Intersection with BOUNDARY5 and
click Confirm.
2.
b.
c.
Click Accept.
This confirms that the default Current field(s) are correct.
3.
242
Click Continue.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
7.4.7. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
7.4.8. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
Double-click the Results tab in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
2.
3.
In the graphical window, right-click, and select the option Predefined Camera.
b.
button.
b.
Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
243
c.
244
ii.
In the Location Selector dialog box that opens, select SUBDOMAIN1_surf, SUBDOMAIN2_surf,
SUBDOMAIN3_surf, and SUBDOMAIN4_surf (use Ctrl for multiple selection) and then click
OK.
iii.
iv.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
).
The velocity is much larger at the inlet of fluid 1 than at the inlet of fluid 2. There are two reasons for
this:
The flow rate is three times larger for fluid 1 than for fluid 2.
You are modeling an annular die. Hence the flow section is smaller for the interior channel than for the exterior channel.
When the two fluids come into contact with each other, the interface between the two fluids is pushed
towards the exterior of the annular die.
There are three reasons for this:
The flow rate for fluid 1 is higher than for fluid 2.
The die is annular, so even identical flow rates cause the interface to move in order to equilibrate the flow
sections.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
245
In the Outline tree tab, under User Locations and Plots deselect Contour 1.
246
b.
button.
c.
Click OK to accept the default name (Vector 1) and display the details view below the Outline tab.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
d.
ii.
In the Location Selector dialog box that opens, select SUBDOMAIN1_surf, SUBDOMAIN2_surf,
SUBDOMAIN3_surf, and SUBDOMAIN4_surf (use Ctrl for multiple selection) and click OK.
iii.
iv.
In the Symbol tab, set Symbol to Arrow3D and increase the Symbol Size to 3.
v.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
247
248
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Summary
Figure 7.5: Magnified View of Velocity Vectors
You can see that the velocity is continuous across the interface. As both the fluids are Newtonian, the
velocity profile is a parabola on both sides of the interface. Since the force must be continuous across
the interface, the shear stress generated within fluid 1 is equal to the shear stress generated within fluid
2 along the interface.
7.5. Summary
This tutorial introduced the concept of fluid layers flowing in the same duct. In Polydata, you learned
how to set up a multiple-domain calculation, including the definition of a moving interface and associated
remeshing methods.
The location of the interface depends largely on the physical properties of the fluids involved, the
geometry of the channels, and the operating conditions (for example: flow rates of the fluids). A CFD
simulation with Polyflow allows you to test different setups (for example: in order to optimize the
feeding of a coextrusion die).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
249
250
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
8.1. Introduction
This tutorial examines the flow of two fluids in a single die. Two polymer melts with distinct physical
properties are fed through different channels into a die. The aim of the calculation is to predict the
location of the interface between the two fluids.
In this tutorial you will learn how to:
Define a species.
Define a species transport problem.
Create multiple sub-tasks.
Define a PMAT function.
Define an EVOLUTION task.
8.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the set up procedure
will not be shown explicitly.
251
= 5000 poise.
The boundary sets for the problem are shown in Figure 8.2: Boundary Sets and Subdomains for the
Problem (p. 253).
252
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Problem Description
Figure 8.2: Boundary Sets and Subdomains for the Problem
= 3 cm3/s
= 1 cm3/s
253
8.4.1. Preparation
To prepare for running this tutorial:
1.
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the Two-Fluids-Species_R160.zip file you have downloaded to your working folder.
The mesh file fluids.msh can be found in the unzipped folder.
8.
254
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Create a Fluid Flow - Extrusion(Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering two-fluids-species as the name
of the project.
3.
4.
2.
3.
Create a species A.
Define species
2.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
255
a.
b.
c.
3.
b.
Click SpeciesA.
The Domain of the sub-task menu item is highlighted.
4.
5.
256
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
a.
Click Diffusivity.
b.
Click EVOL button at the top of Polydata menu to enable evolution inputs.
c.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
257
d.
e.
f.
g.
h.
Click the EVOL button at the top of the Polydata menu to disable evolution inputs.
i.
Click Upper level menu twice to return to the Transport of SpeciesA menu.
Boundary conditions of the species must be defined at all of the boundaries.
6.
Specify the concentration boundary conditions for fluid 1 (SUBDOMAIN1 and SUBDOMAIN2).
Concentration boundary conditions
258
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
a.
ii.
iii.
Click Constant.
A dialog box appears asking for the new value of concentration.
iv.
v.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
259
c.
ii.
ii.
iii.
Click Constant.
A dialog box appears asking for the new value of concentration.
d.
iv.
v.
ii.
iii.
Repeat step (i) and step (ii) for BOUNDARY5 and BOUNDARY6.
iv.
260
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
2.
3.
b.
c.
d.
Specify the value for , referred to as fac in the graphical user interface.
Modify fac
Polydata prompts for the new value of .
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
261
f.
g.
Click f1(...).
h.
262
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Enter 0.495 for X1( 1), and 5000 for f(X1)( 1).
j.
k.
l.
Select SpeciesA.
o.
p.
Click Upper level menu six times to return to the fluid 1 and 2 menu.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
263
a.
Select Zero wall velocity (vn=vs=0) along BOUNDARY1 and click Modify.
ii.
Click Inflow.
iii.
264
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
v.
b.
Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY2.
At a solid-liquid interface, the velocity of the liquid is that of the solid surface. Hence the fluid is
assumed to stick to the wall. This is known as the no-slip assumption because the liquid is assumed
to adhere to the wall, and so has no velocity relative to the wall.
By default, Polydata imposes Zero wall velocity (
c.
Select Zero wall velocity (vn=vs=0) along BOUNDARY3 and click Modify.
ii.
Click Inflow.
iii.
iv.
Click OK to accept the default value of 1 [units: cm3/s] for New Value.
v.
d.
Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY4.
e.
f.
i.
Select Zero wall velocity (vn=vs=0) along BOUNDARY5 and click Modify.
ii.
Click Outflow.
Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY6.
The fluid is assumed to stick to the wall, since at a solid-liquid interface the velocity of the liquid
is that of the solid surface.
g.
Click Upper level menu three times to return to the top-level Polydata menu.
265
2.
b.
c.
Click Accept.
This confirms that the default Current field(s) are correct..
3.
Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postprocessing, and the Polyflow format results file (res).
8.4.7. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
8.4.8. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
Double-click the Results tab in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
2.
3.
266
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
a.
Click the Insert menu and select Contour or click the Contour button (
).
b.
Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
c.
ii.
In the Location Selector dialog box that opens, select SUBDOMAIN1_surf, SUBDOMAIN2_surf,
SUBDOMAIN3_surf, and SUBDOMAIN4_surf (use Ctrl for multiple selection) and click OK.
iii.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
267
Click Apply.
The velocity is much larger at the inlet of fluid 1 than at the inlet of fluid 2. There are two reasons for
this:
The flow rate is three times larger for fluid 1 than for fluid 2.
You are modeling an annular die. Hence the flow section is smaller for the interior channel than for the exterior channel.
When the two fluids come into contact with each other, the interface between the two fluids is pushed
towards the exterior of the annular die.
There are three reasons for this:
The flow rate for fluid 1 is higher than for fluid 2.
268
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
In Outline tree tab, under User Locations and Plots, deselect Contour 1.
b.
c.
Click OK to accept the default name (Vector 1) and display the details view below the Outline tab.
d.
button.
i.
ii.
In the Location Selector dialog box that opens, select the locations SUBDOMAIN1_surf, SUBDOMAIN2_surf, SUBDOMAIN3_surf and SUBDOMAIN4_surf (use ctrl for multiple selections)
and click OK.
iii.
In the Symbol tab, select Arrow 3D from the Symbol drop-down list.
iv.
v.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
269
You can see that the velocity is continuous across the interface. As both the fluids are Newtonian, the
velocity profile is a parabola on both sides of the interface. Since the force must be continuous across
the interface, the shear stress generated within fluid 1 is equal to the shear stress generated within fluid
2 along the interface.
5.
In Outline tree tab, under User Locations and Plots, deselect Vector 1.
b.
Click the Insert menu and select Contour or click the Contour button (
c.
Click OK to accept the default name (Contour 2) and display the details view below the Outline tab.
d.
270
Click the
).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
In the Location Selector dialog box that opens, select SUBDOMAIN1_surf, SUBDOMAIN2_surf,
SUBDOMAIN3_surf, and SUBDOMAIN4_surf (use Ctrl for multiple selection), and then click
OK.
iii.
Click the
iv.
In the Variable Selector dialog box that opens, select SpeciesA, and then click OK.
v.
vi.
6.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
271
272
a.
In Outline tree tab, under User Locations and Plots, deselect Contour 2.
b.
c.
Click OK to accept the default name (Isosurface 1) and display the details view below the Outline
tab.
d.
).
i.
ii.
iii.
In the Color tab, select Constant from the Mode drop-down list and select pink by clicking
next to Color.
iv.
In the Render tab, select Draw As Lines from the Draw Mode drop-down list.
v.
Click Apply.
vi.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Summary
Figure 8.6: Location of Interface
8.5. Summary
This tutorial introduced the concept of fluid layers flowing in the same duct. In Polydata, you learned
how to set up a species transport equation, a PMAT function, and you learned how to define a coextrusion
problem using species transport and PMAT functions. This method avoids the use of the remeshing
method, which is computationally expensive.
The species method, although less accurate, can help in quickly finding a solution when the die has a
complex shape. For more accurate results, the interface tracking method, as demonstrated in Flow of
Two Immiscible Fluids (p. 227), should be used. Generating a mesh for a complex die may be an issue
with the interface tracking method.
The location of the interface depends largely on the physical properties of the fluids involved, the
geometry of the channels, and the operating conditions (for example: flow rates of the fluids). A CFD
simulation with Polyflow allows you to test different setups (for example: in order to optimize the
feeding of a coextrusion die).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
273
274
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
1.1. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the setup procedure
will not be shown explicitly.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
277
3D Thermoforming of a Blister
Figure 1.1: Thermoforming of a Blister, Sheet (blue) and Mold (red)
To reduce the computational run time, and utilizing the symmetric nature of the blister, only one quarter
of the blister/mold is modeled, Figure 1.1: Thermoforming of a Blister, Sheet (blue) and Mold (red) (p. 278).
From a geometric point of view, the initial (1/4) film has the following dimensions:
Length = 15 mm
Width = 5 mm
Initial thickness = 0.35 mm
Dimensions are intentionally given in millimeters due to the small size of the object. The simulation will be
built around the system of units consisting of millimeters, grams and seconds.
The thickness compared to the length/width of the blister is rather small. This allows for the use of the
membrane (shell) element, which is suited for the analysis of 3D blow molding and thermoforming
simulations. The use of the membrane element is presently restricted to time-dependent flows and is
combined with Lagrangian representation (each mesh node is a material point). Node displacement
results from the time integration of nodal velocity.
278
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Problem Description
The finite element mesh and the boundary conditions are displayed in Figure 1.2: Finite Element Mesh,
Subdomains and Boundary Sets (p. 279). A 3D surface mesh has been generated for both the mold and
the film. The most important aspect is the proper description of the inner mold surfaces that will shape
the blister.
The film has the following material properties:
Viscosity = 105
Density = 10-3 g/mm3
Initial thickness = 0.35 mm
Figure 1.2: Finite Element Mesh, Subdomains and Boundary Sets
As seen in Figure 1.2: Finite Element Mesh, Subdomains and Boundary Sets (p. 279), the topology involves
two subdomains:
Subdomain 1 = film
Subdomain 2 = mold
and four boundary sets:
Boundary 1: will be fixed (clamped boundary)
Boundary 2: will be fixed (clamped boundary)
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
279
3D Thermoforming of a Blister
Boundary 3: symmetry boundary condition with respect to the x-axis
Boundary 4: symmetry boundary condition with respect to the y-axis
The inflation pressure will be defined on the subdomain representing the film (Subdomain 1).
An important new concept is introduced in this tutorial: contact with a mold. Typically, two cases may
be encountered:
The moving mold comes in contact with the shell and the shell acquires the mold velocity.
The shell is inflated according to a certain rate and eventually comes into contact with the mold, acquiring
its shape.
Often, both types of contact are encountered in a given application.
1.3.1. Preparation
To prepare for running this tutorial:
1.
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
5.
280
a.
b.
7.
Unzip the 3D-Thermo-Blister_R160.zip file you have downloaded to your working folder.
The mesh file blister.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow - Blow Molding (Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering blister as the name of the project.
3.
4.
b.
2.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
281
3D Thermoforming of a Blister
b.
3.
4.
282
a.
b.
Click Upper level menu at the top of the Domain of the mold menu.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
5.
a.
b.
Enter 1 as the New value to impose a translation velocity, and click OK.
b.
Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
283
3D Thermoforming of a Blister
c.
Click OK to accept the default value of 0 for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x-direction.
ii.
284
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iv.
v.
Define the coordinate pairs (a,b) and (c,d) for the points that define the ramp function.
Click Modify the value of a.
In a similar manner, set the values for b, c, and d to 1.0, 0.103, and 0, respectively.
Figure 1.3: Ramp Function for Mold Velocity
Figure 1.3: Ramp Function for Mold Velocity (p. 285) shows the ramp function you just defined.
Click Upper level menu to return to the Mold motion menu.
vii. Click the EVOL button at the top of the menu to disable evolution inputs.
viii. Click Upper level menu three times to return to the F.E.M. Task 1 menu.
The Create a sub-task menu item is highlighted.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
285
3D Thermoforming of a Blister
b.
2.
b.
Click Upper level menu button at the top of the Domain of the sub-task menu.
The Flow boundary conditions menu item is highlighted.
3.
286
a.
b.
Select Zero wall velocity (vn=vs=0) along Boundary 3 and click Modify.
i.
ii.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Select Zero wall velocity (vn=vs=0) along Boundary 4 and click Modify.
i.
ii.
iii.
Click Upper level menu to return to the Flow boundary conditions menu.
d.
Click Inflation pressure imposed at the bottom of the Flow boundary conditions menu.
e.
Enter 100000 [units: Pa] as the New value and click OK.
f.
Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
g.
ii.
Click Modify the value of a, and enter 0.1 as the New value.
iii.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
287
3D Thermoforming of a Blister
Figure 1.4: Ramp Function for Pressure
Figure 1.4: Ramp Function for Pressure (p. 288) shows the ramp function you just defined.
h.
i.
4.
b.
c.
ii.
ii.
iii.
288
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Magnify the view of the mold to ensure that you can see the darts that will be displayed.
Alternatively, you can increase the size of the darts:
Graphical window Sizing Darts Size up.
ii.
iii.
Click No in the dialog box that opens, to specify that the darts are not pointing towards the
mold body.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
289
3D Thermoforming of a Blister
If the direction of the darts is not clear to you, you can close the dialog box, rotate the view
and/or change the magnification, click Specify mold side / cavity side again, and then
answer the question appropriately.
e.
Click OK.
The Define layers menu item is highlighted.
5.
b.
290
i.
ii.
iii.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iv.
Click Upper level menu twice to continue with material data specification.
v.
Click Density.
vi.
vii. Click Upper level menu to continue with the material data specification.
viii. Click Inertia terms.
Select Inertia will be taken into account and click Upper level menu to continue with
material data specification.
ix.
x.
xi.
c.
Click Constant.
Enter 0.35 [units: mm] as the New value and click OK.
ii.
Click Upper level menu four times to return to the F.E.M. Task 1 menu.
Click Postprocessor.
Enter Mass of product as the New value in the dialog box that asks for the title of the
sub-task and click OK.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
291
3D Thermoforming of a Blister
b.
c.
Confirm that the Density of layer [blister] is set to 1.00E-03, and click Upper level menu.
d.
2.
e.
f.
g.
Click Postprocessor.
Enter Permeability of product as the New value in the dialog box that asks for the
title of the sub-task and click OK.
b.
c.
Confirm that the Permeability of layer [blister] is set to 5.00E-12, and click Upper level menu.
d.
3.
292
e.
f.
g.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click Postprocessor.
Enter Volume of product as the New value in the dialog box that asks for the title of
the sub-task and click OK.
b.
c.
d.
e.
f.
Click Upper level menu to ignore contact with Subdomain 2 and return to F.E.M. Task 1.
2.
3.
4.
5.
6.
7.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
293
3D Thermoforming of a Blister
Click OK to retain the default of 0.01 [units: s] as the New value.
8.
9.
Click Upper level menu three times to return to the top-level Polydata menu.
1.3.7. Outputs
Outputs
1.
b.
2.
Click Upper level menu two times to return to the Outputs menu.
a.
b.
c.
3.
Click Upper level menu twice to return to the top-level Polydata menu.
294
Click Accept.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postprocessing, and the Polyflow format results file (res).
1.3.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
3.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
295
3D Thermoforming of a Blister
1.3.10. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
2.
296
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
3.
b.
In the dialog box that opens, click OK to accept the default name (Contour 1) and display the details
of Contour 1 below the Outline tree.
button.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
297
3D Thermoforming of a Blister
c.
298
ii.
iii.
iv.
v.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.
Double-click Default Transform in the Outline tree tab, under User Locations and Plots (or rightclick Default Transform and select Edit).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
299
3D Thermoforming of a Blister
300
b.
Disable Instancing Info From Domain under the Definition tab in the details of Default Transform.
c.
d.
Select Value from the Determine Angle From drop-down list in the Instance Definition group box.
e.
f.
Enable Apply Reflection, and select ZX Plane from the Method drop-down list.
g.
h.
Click Apply and revise the magnification of the view to show the whole mold.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
5.
).
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
301
3D Thermoforming of a Blister
c.
302
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
d.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
303
3D Thermoforming of a Blister
Figure 1.8: Contours of Thickness at Time = 0.2338 s
304
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
305
3D Thermoforming of a Blister
Figure 1.10: Contours of Thickness at Time = 0.6000 s
6.
306
).
b.
c.
Select Timesteps.
d.
To save the animation, expand the dialog box by clicking the button at the lower-right.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Summary
i.
ii.
Click the file icon to the right and enter the path where you would like to save the animation.
Enter Thickness.wmv for the name of the file and click Save to close the Save Movie
dialog box.
wmv and mpg are the recommended formats.
iii.
Disable
iv.
Click the play button, to play the animation and save it as a file.
1.4. Summary
This tutorial introduced the concept of a blow molding problem. The mold moved into contact with
the film, where a constant pressure was applied to the film. This blew the film into the mold where it
assumed the shape of the mold.
You represented the film by a shell geometry under the valid assumption that the thickness of the film
was much smaller than the other two dimensions. Polyflow linearly interpolated the process vari-
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
307
3D Thermoforming of a Blister
ablesthickness, velocity and position. By reporting the individual time steps to CFD-Post you were
able to view the thickness of the product as a function of time.
308
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Appendix
Figure 1.11: Effect of Adaption on Final Mesh and Thickness Variation
1.6. Appendix
The appendix contains the following topics:
1.6.1. Contact Boundary Conditions
1.6.2. Remark on the Penalty Coefficient
1.6.3. Remeshing
309
3D Thermoforming of a Blister
with the (moving) molds. In all forming applications (blow molding and thermoforming for example),
the definition of the contact is an important aspect, as it will eventually lead to the desired shape. The
contact involves a what and a how. The what describes the geometry of the film/sheet and the
mold surface it may get in contact with (contact problem). The how refers to other process parameters
such as a moving mold. In this case, a velocity (possibly time-dependant) must be specified for the
mold. In some cases, the material may slip along the contact wall, which can also be taken into account.
Next to these operating attributes, some numerical parameters must be specified. A geometrical algorithm
is applied for detecting the occurrence of contact, while a penalty formation is used for the treatment
of contact. A penalty coefficient ensures that a geometrical contact is detected. It should not be too
small. A coefficient is also specified in the tangential direction. If the fluid sticks along the wall, this
tangential coefficient should preferably receive the same value as the penalty coefficient. Two additional
coefficients are also needed; a tolerance on penetration accuracy and an element dilatation.
Presently, the penalty coefficient has been set to 1010, while the same value has been selected for the
coefficient along the tangential direction (slipping coefficient). The tolerance on penetration and element
dilatation equal 0.05 and 0.05 mm, respectively.
1.6.3. Remeshing
No remeshing must be specified. In the context of the membrane element, a Lagrangian representation
is applied where all mesh nodes are considered material points.
310
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
2.1. Introduction
Molding is a process of forcing a preform or a parison (preshaped sleeve) into a mold cavity so that the
preform assumes the shape of the cavity. There are numerous molding methods, including blow
molding, compression and transfer molding, and slush and rotational molding. These methods differ
in the formation of the preform and the filling of the mold cavity. Also, each processing method is
suitable for a specific class of polymers.
Blow molding is an important processing method for molding hollow articles such as bottles. The preform
is usually made by extrusion and forced between the mold halves by pressurization (blowing air). The
polymer solidifies upon contact with the cold mold and the finished product is then ejected. The homogeneity and rheological properties of the preform along with the operating conditions (temperature
and pressure variations) are crucial in this step and will affect the design of the processing machinery.
This process reflects all facets of polymer processing the isothermal and transient flow of Newtonian
fluids in complex geometries with simultaneous structuring and solidification.
In this tutorial you will learn how to:
Define a time-dependent problem.
Set material properties and boundary conditions for a 2D axisymmetric blow molding problem.
Set numerical parameters available in Polydata for a time-dependent problem.
2.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the setup procedure
will not be shown explicitly.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
311
The domain for the problem is divided into two subdomains: one for the fluid preform (subdomain 1)
and the other for the mold (subdomain 2). Incompressibility and momentum equations are solved in
subdomain 1 (the fluid preform). The problem involves two free surfaces (boundary 2 and boundary 4,
shown in Figure 2). boundary 2 will eventually come into contact with the mold, and its position is
calculated as a part of the solution.
The fluid preform has a density of =1 g/cm3 and a viscosity of
the effects of gravity will be included in the calculation.
The boundary sets for the problem are shown in Figure 2.2: Boundary Set for the Problem (p. 313), and
the conditions at the boundaries of the domain (for the preform) are:
boundary 1: symmetry axis
312
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
313
2.4.1. Preparation
To prepare for running this tutorial:
1.
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the 2D-Axi-Blow-Molding_R160.zip file you have downloaded to your working folder.
The mesh file 2d-axi-blowmold.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow - Blow Molding (Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering Final-blow-mold as the name of the
project.
3.
4.
314
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
2.
Create a mold.
Create a new mold
b.
c.
When prompted, click OK to retain the default name for the mold (Mold 1).
d.
ii.
e.
Specify the boundary that represents the part of the mold that comes into contact with the fluid.
Polyflow uses this information to determine the penetration distance (into the mold) of every
point of the free surface (BOUNDARY2).
Contact conditions
i.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
315
ii.
f.
3.
Select Contact.
Click Upper level menu four times to return to the F.E.M. Task 1 menu.
316
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.
SUBDOMAIN_2 is moved from the top list to the bottom list, indicating that the sub-task is
defined on SUBDOMAIN_1.
b.
317
b.
c.
Click Modify fac to specify the value of , which is referred to as fac in the graphical user interface.
Polydata prompts for the new value of the viscosity.
2.
d.
Enter 100000 [units: poise] as the New value and click OK.
e.
Click Upper level menu two times to continue with the Material Data specification.
Click Density.
b.
3.
318
c.
d.
Click Upper level menu to continue with the Material Data specification.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.
a.
b.
c.
Click Upper level menu to continue with the Material Data specification.
Click Gravity.
b.
c.
Enter -981 [units: cm/s2] as the New value and click OK.
d.
Click Upper level menu two times to return to the blow molding menu.
The Flow boundary conditions menu item is highlighted.
2.
319
Select Zero wall velocity (vn=vs=0) along BOUNDARY2 and click Modify.
b.
c.
ii.
iii.
iv.
v.
vi.
vii. Click Upper level menu two times to return to the Kinematic condition menu.
d.
Click Upper level menu to return to the Flow boundary conditions panel.
In contact detection problems, abrupt changes in the velocity field occur at the contact points
between the fluid preform and the mold. Polydata gives the warning message shown below. Since
320
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
e.
3.
4.
Select Zero wall velocity (vn=vs=0) along BOUNDARY3 and click Modify.
b.
c.
Click Upper level menu to accept the default value of 0 for the normal velocity,
d.
Click Upper level menu to accept the default value of 0 for the tangential force,
.
.
Select Zero wall velocity (vn=vs=0) along BOUNDARY4 and click Modify.
b.
c.
ii.
Select Constant.
Polydata prompts for the new value of the normal force.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
321
d.
5.
iii.
iv.
Click Upper level menu to return to the Flow boundary conditions menu.
2.4.6. Remeshing
This model involves free surfaces for which the positions are unknown. A portion of the mesh is affected by
the relocation of these boundaries. Hence a remeshing technique is applied on this part of the mesh. The
free surfaces are entirely contained within SUBDOMAIN_1, and hence only SUBDOMAIN_1 is affected by the
relocation of the free surfaces.
Global remeshing
1.
322
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click Accept the current setup in the Element distortion check menu.
In blow molding simulations, the finite-element mesh can undergo great deformations. The Element
distortion check menu deals with the detection of all possible distortions of the elements. In this
problem, you can accept the default options and proceed to the next step.
b.
Click Upper level menu two times to return to the F.E.M. Task 1 menu.
Specify the parameters for the iterative scheme in the calculation of the free surface.
Modify the transient iterative parameters
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
323
b.
c.
324
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
e.
f.
g.
2.
Click Upper level menu three times to return to the top-level Polydata menu.
2.4.8. Outputs
You can specify how often Polyflow saves the solution data when it calculates a solution. In this tutorial,
save the results at every 4 time steps.
Outputs
1.
b.
2.
3.
325
Click Upper level menu twice to return to the top-level Polydata menu.
b.
Click Postprocessor.
c.
Enter parison thickness as the New value for the title and click OK.
2.
3.
4.
5.
6.
Specify the boundary sets representing the starting and ending borders to be used in the thickness calculation.
Polyflow evaluates the distance between these borders at a point between them to determine the
thickness at that location.
Borders for thickness calculation
326
a.
b.
c.
d.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click Upper level menu five times to return to the top-level Polydata menu.
Click Accept.
This confirms that the default Current field(s) are correct.
2.
Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postprocessing, and the Polyflow format results file is (res).
2.4.11. Solution
In the following steps you will run Polyflow to calculate a solution for the model you just defined using
Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
2.4.12. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
2.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
327
3.
328
button.
b.
In the box that opens, click OK to accept the default name (Contour 1) and display the details below
the Outline tree.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
d.
ii.
Select estim. THICKNESS from the Variable drop-down list, or click the ellipsis button (
on the right and select estim. THICKNESS.
iii.
Click Apply.
button.
ii.
Click OK to accept the default name (Text 1) and display the details view below the Outline
tab.
iii.
iv.
v.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
329
4.
330
Double-click Default Transform in the Outline tree tab, under User Locations and Plots (or rightclick Default Transform and select Edit).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
Disable Instancing Info From Domain under the Definition tab in the details of Default Transform.
c.
Enable Apply Reflection, and select YZ Plane from the Method drop-down list.
d.
e.
Click Apply.
f.
Click the
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
331
5.
332
button.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
a.
b.
c.
d.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
333
334
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
335
336
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
6.
button.
b.
Enable Quick Animation and select Timesteps in the Animation dialog box.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
337
7.
c.
d.
Disable
e.
Double-click Contour 1 under the Outline tab to display the details view.
b.
Select VELOCITIES from the Variable drop-down list and click Apply.
There is zero velocity at the contact between the parison and the mold, but the velocity magnitude
is still important where the fluid does not yet touch the mold. At the final time of the simulation,
the velocity is near zero, which indicates that the contact is completed. The residual value originates
from the penalty formulation used for the contact, as explained in 3D Thermoforming of a
Blister (p. 277).
338
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Appendix
Figure 2.9: Final Velocity Distribution
2.5. Summary
This tutorial introduced a time-dependent problem with a 2D axisymmetric geometry for the mold.
Suitable assumptions were made regarding the nature of the preform and the operating conditions.
You analyzed the factors affecting the process in the postprocessing section. An optimization of the
preform shape could be performed in order to minimize the weight of the bottle while avoiding weak
(too thin) bottle walls.
You used a remeshing method that is most suited for contact detection problems. This problem also
introduced the concept of the calculation of free surfaces for contact detection problems. You used
efficient numerical techniques to more accurately solve a time-dependent problem.
2.6. Appendix
The appendix covers the following topics:
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
339
340
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
3.1. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the setup procedure
will not be shown explicitly.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
341
To reduce the computational run time, and utilizing the symmetric nature of the blister, only one quarter
of the blister/plug/mold is modeled, Figure 3.1: Plug-Assisted Thermoforming of a Blister: Plug (Orange),
Sheet (Blue), and Mold (Green) in the Initial Configuration (p. 342). From a geometric point of view, the
initial (1/4) film has the following dimensions:
length = 15 mm
width = 5 mm
initial thickness = 0.35 mm
Dimensions are intentionally given in millimeters due to the small size of the object. The simulation will be
built around the system of units consisting of millimeters, grams and seconds.
342
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Problem Description
The thickness compared to the length/width of the blister is rather small. This allows the use of the
membrane (shell) element, which is suited for the analysis of 3D blow molding and thermoforming
simulations. The use of the membrane element is presently restricted to time-dependant flows and is
combined with Lagrangian representation. That is, each mesh node is a material point.
The finite element mesh and the boundary conditions are displayed in Figure 3.2: Finite Element Mesh,
Subdomains and Boundary Sets (p. 343). As shown, a full 3D finite element is built for the mold, the plug
and the film. Only a surface mesh is required for the three subdomains, but the most important aspect
remains the proper description of the inner mold surfaces which will shape the blister.
The film has the following material properties:
model: shell model, Gen. Newtonian isothermal
viscosity = 105
density = 10-3 g/mm3
inertial terms taken into account
initial thickness = 0.35 mm
Figure 3.2: Finite Element Mesh, Subdomains and Boundary Sets
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
343
3.3.1. Preparation
To prepare for running this tutorial:
1.
2.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
344
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the Plug-Thermo-Blister_R160.zip file you have downloaded to your working folder.
The mesh file plugblister.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow - Blow Molding (Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering Blister-plug-assist as the name
of the project.
3.
4.
b.
2.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
345
b.
c.
3.
346
a.
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
4.
Click Upper level menu at the top of the Domain of the mold menu.
5.
a.
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
347
Enter 1 as the New value, to impose a translation velocity, and click OK.
b.
Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
c.
348
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click OK to accept the default value of 0 [units: mm/s] for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x direction.
ii.
iii.
iv.
v.
Define the coordinate pairs (a,b) and (c,d) for the points that define the ramp function.
Click Modify the value of a.
In a similar manner, set the values for b, c, and d to 1.0, 0.103, and 0, respectively.
Figure 3.3: Ramp Function for Mold Velocity (p. 350) shows the ramp function you just defined.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
349
Click No.
a.
b.
350
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
3.
a.
b.
c.
Click Upper level menu at the top of the Domain of the mold menu.
4.
a.
b.
Enter 1 as the New value, to impose a translation velocity, and click OK.
b.
Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
c.
351
Click OK to accept the default value of 0 [units: mm/s] for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x direction.
ii.
iii.
iv.
v.
Enter 0.11 as the New value for time( 1) and click OK.
352
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Retain the default, 0 as the New value for f(time)( 1) and click OK.
vi.
Click Insert new pair, and in a similar manner, define the following three pairs: (0.12, 1),
(0.13, 1), and (0.14, 0).
Figure 3.4: Multi-Ramp Function for Plug Velocity (p. 353) shows the multi-ramp function you
just defined.
Figure 3.4: Multi-Ramp Function for Plug Velocity
Click Upper level menu three times to return the Mold motion menu.
vii. Click the EVOL button at the top of the menu to disable evolution inputs.
viii. Click Upper level menu three times to return to the F.E.M. Task 1 menu.
The Create a sub-task menu item is highlighted.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
353
b.
2.
b.
c.
Click Upper level menu button at the top of the Domain of the sub-task menu.
The Flow boundary conditions menu item is highlighted.
3.
b.
Select Zero wall velocity (vn=vs=0) along Boundary 3 and click Modify.
i.
354
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
ii.
iii.
Select Zero wall velocity (vn=vs=0) along Boundary 4 and click Modify.
i.
ii.
iii.
Click Upper level menu to return to the Flow boundary conditions menu.
d.
Click Inflation pressure imposed at the bottom of the Flow boundary conditions menu.
e.
Enter 1e05 [units: Pa] as the New value and click OK.
f.
Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
g.
ii.
Click Modify the value of a, and enter 0.14 as the New value.
iii.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
355
h.
i.
4.
b.
c.
ii.
ii.
356
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
d.
Increase the size of the darts that will be used to display the orientation, to ensure that they are
visible.
Graphical window Sizing Darts Size up
ii.
iii.
iv.
Click No in the dialog box that opens, to specify that the darts are not pointing towards the
mold body.
If the direction of the darts is not clear to you, you can close the dialog box, rotate the view
and/or change the magnification, click Specify mold side / cavity side again, and then
answer the question appropriately.
v.
357
b.
ii.
ii.
iii.
iv.
c.
Rotate the view and change the magnification so that you can see the plug.
ii.
358
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iii.
Click Yes in the dialog box that opens, to verify that the darts are pointing toward the plug body
(away from contact with the film).
If the direction of the darts is not clear to you, you can close the dialog box, rotate the view
and/or change the magnification, click Specify mold side / cavity side again, and then
answer the question appropriately.
iv.
d.
e.
Click OK in the warning box that opens, saying that velocity prediction must be disabled.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
359
6.
b.
ii.
iii.
iv.
Click Upper level menu twice to continue with material data specification.
v.
Click Density.
vi.
vii. Click Upper level menu to continue with the material data specification.
360
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
ix.
x.
Click Constant.
Enter 0.35 [units: mm] as the New value and click OK.
ii.
Click Upper level menu four times to return to the F.E.M. Task 1 menu.
2.
3.
4.
5.
6.
7.
8.
361
3.3.7. Outputs
Outputs
1.
2.
3.
4.
Click Upper level menu three times to return to the top-level Polydata menu.
Click Accept.
2.
Click Continue.
This accepts the default names for the graphical output files (cfx.res) that are to be saved for postprocessing, and the Polyflow format results file (res).
3.3.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2.
362
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
3.3.10. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
2.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
363
3.
364
button.
b.
In the box that opens, click OK to accept the default name (Contour 1) and display the details view
below the Outline tree.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
ii.
Select THICKNESS from the Variable drop-down list, or click the ellipsis button (
right and select THICKNESS.
iii.
iv.
v.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
) on the
365
4.
366
Double-click Default Transform in the Outline tree tab, under User Locations and Plots (or rightclick Default Transform and select Edit).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
The details view of Default Transform will be displayed below the Outline tab.
b.
Perform the following steps in the Definition tab of the details view.
i.
ii.
iii.
Select Value from the Determine Angle From drop-down list in the Instance Definition group
box.
iv.
v.
Enable Apply Reflection, and select ZX Plane from the Method drop-down list.
vi.
Rotate the view and change the magnification, as shown in Figure 3.7: Contours of Thickness on the
Whole Thermoformed Blister (p. 368).
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
367
5.
368
a.
).
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
369
d.
370
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
371
372
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
6.
).
b.
c.
Select Timesteps.
d.
To save the animation, expand the dialog box by clicking the button at the lower-right.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
373
i.
ii.
Click the file icon to the right and enter the path where you would like to save the animation.
Enter Thickness.wmv for the name of the file and click Save to close the Save Movie
dialog box.
wmv and mpg are the recommended formats.
iii.
Disable
iv.
Click the play button, to play the animation and save it as a file.
3.4. Summary
This tutorial introduced the concept of a plug-assisted blow molding problem. The mold moved into
contact with the film, where a plug guided the film into the mold, and a constant pressure was applied
to the film. This blew the film into the mold where it assumed the shape of the mold.
You represented the film by a shell geometry under the valid assumption that the thickness of the film
was much smaller than the other two dimensions. Polyflow linearly interpolated the process vari-
374
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Appendix
ablesthickness, velocity and position. By reporting the individual time steps to CFD-Post you were
able to view the thickness of the product as a function of time.
3.5. Appendix
The appendix covers the following topics:
3.5.1. Contact Boundary Conditions
3.5.2. Remark on the Penalty Coefficient
3.5.3. Remeshing
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
375
3.5.3. Remeshing
The results of this tutorial could be refined and improved with the use of adaptive meshing.
In the context of the membrane element, a Lagrangian representation is applied where all mesh nodes
are considered material points. Therefore, the only available remeshing technique is Lagrangian and is
the one that should be specified for this case.
376
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
4.1. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 53). Some steps in the setup procedure
will not be shown explicitly.
4.2. Description
This tutorial simulates a typical blow molding situation for a bottle. In the present case, it is assumed
that a cylindrical parison with uniform thickness distribution has been extruded. The present calculation
involves two major steps; parison pinch-off due to mold closing, and inflation. Figure 4.1: Blow Molding
Initial Configuration (p. 378) shows a sketch of the process in the initial configuration, before the pinchoff and parison inflation.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
377
From a geometric point of view, the initial parison has the following dimensions:
height = 0.276 m
radius = 0.0225 m
initial thickness = 0.003 m
The thickness of the fluid parison is much smaller than the other two dimensions of the bottle, which
allows for the use of the membrane (shell) element, which is suited for the analysis of 3D blow molding
simulations. It is important to remember when preparing the surface mesh, that the mesh elements on
the mold should not be the same order of magnitude as the expected final local thickness. The use of
the membrane element is presently restricted to time-dependant flows and is combined with Lagrangian
representation. That is, each mesh node is a material point.
The finite element mesh and the boundary conditions are displayed in Figure 4.2: Finite Element Mesh,
Subdomains, and Boundary Sets (p. 379). As shown, a full 3D finite element is built for both the mold
and the parison. Only a surface mesh is needed for both the mold and the parison, but the most important aspect remains the proper description of the inner mold surfaces that will shape the bottle.
The parison has the following material properties in SI units:
model: shell model, Gen. Newtonian isothermal
viscosity = 104
density = 900 kg/m3
inertial terms taken into account
378
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
As seen in Figure 4.2: Finite Element Mesh, Subdomains, and Boundary Sets (p. 379), the mesh topology
involves three subdomains (MoldLeft, parison, and Moldright) and two boundary sets (TopEdge and
BottomEdge). The fluid parison is covered by the subdomain named parison while MoldLeft and
MoldRight will be defined as molds. Along boundary sets TopEdge and BottomEdge, a symmetry
boundary condition will be imposed. The inflation pressure will be defined on the subdomain representing the parison.
4.3.1. Preparation
To prepare for running this tutorial:
1.
379
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3.
4.
Narrow the results by using the filter on the left side of the page.
a.
b.
5.
6.
7.
Unzip the 3D-Blow-Molding-Bottle_R160.zip file you have downloaded to your working folder.
The mesh file bottle.msh can be found in the unzipped folder.
8.
Start Workbench from Start > All Programs > ANSYS 16.0 > Workbench 16.0.
Create a Fluid Flow - Blow Molding (Polyflow) analysis system by drag and drop in Workbench.
2.
Save the ANSYS Workbench project using File Save, entering instanet-PF-only as the name of
the project.
3.
4.
380
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
3.
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
381
c.
4.
Click Upper level menu at the top of the Domain of the mold menu.
5.
a.
b.
382
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Enter 1 as the New value, to impose a translation velocity, and click OK.
b.
Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
c.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
383
Click OK to accept the default value of 0 for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x direction.
ii.
iii.
iv.
v.
Define the coordinate pairs (a,b) and (c,d) for the points that define the ramp function.
Click Modify the value of a.
In a similar manner, set the values for b, c, and d to -1.0, 0.1, and 0, respectively.
Figure 4.3: Ramp Function for Right Mold Velocity (p. 385) shows the ramp function you just
defined.
384
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click No.
a.
385
2.
3.
a.
b.
c.
Click Upper level menu at the top of the Domain of the mold menu.
4.
a.
b.
Enter 1 as the New value, to impose a translation velocity, and click OK.
b.
Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
c.
386
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click OK to accept the default value of 0 for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x direction.
ii.
iii.
iv.
v.
Define the coordinate pairs (a,b) and (c,d) for the points that define the ramp function.
Click Modify the value of a.
In a similar manner, set the values for b, c, and d to 1.0, 0.1, and 0, respectively.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
387
vii. Click Upper level menu to return the Mold motion menu.
d.
Click the EVOL button at the top of the menu to disable evolution inputs.
e.
Click Upper level menu three times to return to the F.E.M. Task 1 menu.
The Create a sub-task menu item is highlighted.
388
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
2.
b.
c.
Click Upper level menu button at the top of the Domain of the sub-task menu.
The Flow boundary conditions menu item is highlighted.
3.
b.
c.
Select Zero wall velocity (vn=vs=0) along BOTTOMEDGE and click Modify.
i.
ii.
iii.
Select Zero wall velocity (vn=vs=0) along TOPEDGE and click Modify.
i.
ii.
iii.
Click Upper level menu to return to the Flow boundary conditions menu.
Click Inflation pressure imposed at the bottom of the Flow boundary conditions menu.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
389
e.
Enter -1e4 [units: Pa] as the New value and click OK.
390
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
g.
h.
Define the settings in the Time dependence of inflation pressure menu that opens.
i.
ii.
Click Modify the value of a, enter 0.1 as the New value, and click OK.
iii.
In a similar manner, set the values for b, c, and d to 0, 0.2, and 1.0, respectively.
Figure 4.5: Ramp Function for Pressure (p. 391) shows the ramp function you just defined.
Figure 4.5: Ramp Function for Pressure
4.
i.
j.
Click the EVOL button at the top of the Polydata menu to disable evolution inputs.
k.
391
c.
ii.
ii.
iii.
d.
Increase the size of the darts that will be used to display the orientation, to ensure that they are
visible.
Graphical window Sizing Darts Size up
ii.
iii.
392
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
iv.
Click No in the dialog box that opens, to specify that the darts are not pointing towards the
mold body.
If the direction of the darts is not clear to you, you can close the dialog box, rotate the view
and/or change the magnification, click Specify mold side / cavity side again, and then
answer the question appropriately.
v.
5.
b.
ii.
393
ii.
iii.
c.
Rotate the view slightly to display the bottle-shaped cavity from an oblique angle.
ii.
iii.
394
Click No in the dialog box that opens, to specify that the darts are not pointing towards the
mold body.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
6.
d.
e.
Click OK in the warning box that opens, to acknowledge that the velocity prediction must be disabled.
b.
ii.
iii.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
395
iv.
Click Upper level menu twice to continue with material data specification.
v.
Click Density.
vi.
vii. Click Upper level menu to continue with the material data specification.
viii. Click Inertia terms.
ix.
c.
Select Inertia will be taken into account and click Upper level menu twice to return to the
parison menu.
Click Constant.
Enter 0.003 [units: m] as the New value and click OK.
ii.
Click Upper level menu four times to return to the F.E.M. Task 1 menu.
2.
3.
4.
5.
6.
396
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
8.
9.
Click Upper level menu three times to return to the top-level Polydata menu.
4.3.7. Outputs
Outputs
1.
2.
3.
Click Upper level menu twice to return to the top-level Polydata menu.
Click Accept.
2.
Click Continue.
This accepts the default names for the graphical output files (cfx.res) that are to be saved for postprocessing, and the Polyflow format results file (res).
4.3.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1.
Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2.
b.
It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
397
4.3.10. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1.
2.
Change the view in the Graphics Display window as shown in the figure that follows.
3.
398
a.
button.
b.
In the dialog box that opens, click OK to accept the default name (Contour 1) and display the details
view below the Outline tree.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
c.
d.
ii.
iii.
iv.
v.
Click Apply.
Disable the Wireframe in the Outline tree tab, under User Locations and Plots.
This makes for a cleaner image by removing the Wireframe lines.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
399
4.
400
Enable and double-click MOLDLEFT_surf in the Outline tree tab, under Fluid Flow Blow Molding
Polyflow at 2s.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
b.
Enter 0.7 for Transparency in the Render tab in the details view of MOLDLEFT_surf.
The contours of thickness on the parison would not be visible without increasing the transparency
of the mold.
5.
c.
Click Apply.
d.
).
b.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
401
c.
402
Click Apply.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
d.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
403
404
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
405
6.
406
).
b.
c.
Select Timesteps.
d.
To save the animation, expand the dialog box by clicking the button at the lower-right.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Summary
i.
ii.
Click the file icon to the right and enter the path where you would like to save the animation.
Enter Thickness.wmv for the name of the file and click Save to close the Save Movie
dialog box.
wmv and mpg are the recommended formats.
iii.
Disable
iv.
Click the play button, to play the animation and save it as a file.
4.4. Summary
This tutorial introduced the concept of a parison blow molding problem. The two halves of the mold
moved into contact with the parison, where it became pinched, and a vacuum was applied to the parison. This blew the parison into the mold where it assumed the shape of the mold, which was a bottle
in this case.
You represented the parison by a shell geometry under the valid assumption that the thickness of the
parison was much smaller than the other two dimensions (diameter and height). Polyflow linearly interRelease 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
407
408
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Appendix
Figure 4.11: Effect of Adaption on Final Mesh and Thickness Variation
4.6. Appendix
The appendix contains the following topics:
4.6.1. Contact Boundary Conditions
4.6.2. Remark on the Penalty Coefficient
4.6.3. Remeshing
4.6.4. Evolutions
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
409
4.6.3. Remeshing
In the context of the membrane element, a Lagrangian representation is applied where all mesh nodes
are considered material points. Therefore, the only available remeshing technique is Lagrangian and is
the one that should be specified for this case.
4.6.4. Evolutions
The present case involves a mold motion followed by inflation.
For the mold motion, the x and y-components are zeros. The two mold halves move only in the z direction at the same speed but in opposite directions. The two mold halves move at 0.736842 m/s in the
z direction. To control the duration and the direction of the motion, a simple ramp function is applied
410
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
Appendix
on the mold speed. The ramp function is multiplied by the z-velocity component to give each half of
the mold the proper speed in the appropriate direction.
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.
411
412
Release 16.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.