Integrated Module for Structure Analysis: FEA Interface & Digimat Interface

March, 2013

R12.0

Moldex3D FEA Interface

> A series of interface modules to integrate Moldex3D and structure FEA Software, including ABAQUS, ANSYS, MSC. Nastran, NENastran, NX-Nastran, LS-Dyna, Marc, RADIOSS, and DIGIMAT > Helps users to introduce the process-induced properties, such as fiber orientation or residual stress, into structure FEA Software

Mesh, Material, Processetc

2

Flow/Pack/Cool Warp/Fiber Simulation

Deformed geometry, Fiber-reinforced Material propertiesetc

Structure analysis, Drop test analysis, Impact analysisetc.

Common Structural Analysis

>

Linear stress analysis Non-linear stress analysis Buckle analysis Modal analysis Shock and response analysis Frequency response analysis Impact analysis Crack analysis

> > > > > > >

Why Do We Need Moldex3D FEA Interface ?

Proper Mesh

Correct Material Properties

Structure Analysis Solver

Correct Boundary Condition

Accurate Results

Correct Initial Condition

What is FEA Interfaces Capability?

> Fiber orientation output > Material reduction > Mesh mapping > Residual stress output > EOP temperature output > Initial strain output (as temperature difference) > Multiple time step melt flow pressure output > Mold base related data output (pressure, temperature)

Technology Link of FEA Interface

Structure Analysis

Simulation

Ejection

Application

Flow

Pack

Cool

Warp

Warpage Mold Deform Core-Shift Modal Analysis Drop Test

FEARADIOSS

FEA-ANSYS

FEALS-DYNA

FEA-ABAQUS

FEANX Nastran

FEAMSC Nastran

Impact Paddle-Shift

FEAMSC Marc

Function List in Moldex3D R12.0

Structure FEA Software Material Reduction Residual Stress Initial Strain EOP Temperature Melt Flow Pressure Digimat Fiber Orientation Moldbase Output

ANSYS

ABAQUS

MARC

LSDYNA

MSC NASTRAN

NX NASTRAN

RADIOSS

Moldex3D FEA Interface Function Description

FEA Interface Function Description

(User Interface)
2. Select Output Mesh Type 3. Select Output Data 1. Select Structure FEA Software

4. Export File

FEA Interface Function Description

(Fiber Orientation Output)

> Fiber orientation effects

Usually higher strength and stiffness along fiber oriented direction; lower strength and stiffness perpendicular fiber oriented direction

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

10

FEA Interface Function Description

(Fiber Orientation Output (cont d))

> Isotropic material (identical material properties in all directions)

> Anisotropic material (material properties varied in different directions)

11

FEA Interface Function Description

(Material Reduction)

> Material Reduction

For fiber reinforced plastic (FRP), each element has its own material properties due to flow-induced non-uniform fiber orientation distribution

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

Total material number from 76,150 to 1,866

Total material number from 3,392 to 668

12

FEA Interface Function Description

(Material Reduction(cont d))

> Material Reduction Results

Moldex3D result

Moldex3D result

Moldex3D result

Material count: 11944

ABAQUS

Material count: 11944

ANSYS

Material count: 11944

LS-DYNA

Material count: 663

Material count: 663

Material count: 663

13

FEA Interface Function Description

(Density Output)

> Moldex3D FEA Interface can export the density distribution at the end of packing to Structural FEA software
Natural frequency Constant EOP 1 13.65 13.561 2 72.355 71.498 3 82.114 81.757 4 143.36 141.63 5 441.45 435.72 6 580.31 570.76

14

FEA Interface Function Description

(Mesh Mapping)

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

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

Moldex3D tetra mesh

Structure analysis 2nd order hexa mesh

15

FEA Interface Function Description

(Mesh Mapping(cont d))

> Output as high order element

After exporting as high order element (e.g. 2nd order), 1 additional node between every 2 original nodes will be generated

Original mesh

High order element mesh (2nd order)

16

FEA Interface Function Description

Residual Stress Output

> Residual stress

Flow induced residual stress: As the polymer is sheared and elongated, if solidification occurs before the polymer molecules are fully relaxed, molecular orientation is locked within the molded part Thermal stress: Because of non-uniform cooling, stress between molecule can not be released completely

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

LS-DYNA

17

FEA Interface Function Description

Residual Stress Output (cont d)

> Residual stress output results

Moldex3D result Moldex3D result Moldex3D result

von Mises stress: 0.856~161.198MPa ABAQUS

von Mises stress: 0.48~37.84MPa ANSYS

von Mises stress: 1.468~69.428MPa LS-DYNA

von Mises stress: 0.8563 ~161.2MPa

von Mises stress: 0.47~37.84MPa

von Mises stress: 1.469~69.39MPa

18

FEA Interface Function Description

Residual Stress Output (cont d)

> Moldex3D FEA Interface ABAQUS

Residual Stress Data Output
Fiber Orientation

To ABAQUS

von Mises stress

Material count reduced to 127

19

FEA Interface Function Description

Residual Stress Output (cont d)

> Moldex3D FEA Interface ABAQUS

Residual Stress Data Output Notes: Before running ABAQUS, make sure the workspace includes two file types
*.inp *.sts

von Mises stress

20

FEA Interface Function Description

Residual Stress Output (cont d)

> Moldex3D FEA Interface ANSYS

Residual Stress Data Output Only SOLID186 supports both pyramid element & initial stress. Before running ANSYS, make sure the workspace includes two file types, *.cdb & *.ist. Max. material reference number = 100,000
von Mises stress

21

FEA Interface Function Description

Residual Stress Output (cont d)

> Moldex3D FEA Interface ANSYS

Residual Stress Data Output
von Mises stress

Fiber Orientation

To ANSYS

von Mises stress

Material reduction

22

No reduced, material count 28584 reduced to 152

Material count

FEA Interface Function Description

EOP Temperature Output

> EOP temperature output results

Moldex3D Moldex3D result result Moldex3D result Moldex3D result

Range: 33.6~169.55C
ABAQUS

Range: 31.287~227.876C
ANSYS

Range: 35.251~ 226.218C

LS-DYNA

Range: 33.41~169.6C

Range: 31.287~227.876C

Range: 35.3~226.0C

23

FEA Interface Function Description

EOC Temperature Output

> EOC temperature output results

Moldex3D result

ANSYS

Range: 60.489~62.004C

Range: 60.489~62.004C

24

FEA Interface Function Description

Initial Strain Output

> Initial strain output results

Moldex3D result Moldex3D result Moldex3D result

ABAQUS

ANSYS

LS-DYNA

25

FEA Interface Function Description

Initial Strain Output (cont d)

> Initial strain output results in shell module

Moldex3D result

ABAQUS

26

FEA Interface Function Description

Weld Line Effect

> The local mechanical strength in the weld line area could be significantly weaker > It could be one of the most significant problems for structural applications due to the potential failure in the weld line areas

-1000N

1000N

Transfer part geometry and weld-lines strength into ANSYS

27

FEA Interface Function Description

Weld Line Effect (contd)

> Y-Component of displacement

Including weld line effect UYMX=505.09

28

Normal UYMX=341.18

FEA Interface Function Description

Multiple Time Step Melt Flow Pressure Output

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

29

FEA Interface Function Description

Multiple Time Step Melt Flow Pressure Output (cont d)

> Multiple time step melt flow pressure output results

Moldex3D result Moldex3D result Moldex3D result

ABAQUS

ANSYS

LS-DYNA

30

FEA Interface Function Description

Moldbase Related Data Output

> EOC temperature output results

Moldex3D result Moldex3D result

Range: 30.056~36.98C
ABAQUS

Range: 30.056~36.98C
ANSYS

Range: 30.06~39C

Range: 30.062~36.98C

31

FEA Interface Function Description

Moldbase Related Data Output (cont d)

> This function can be utilized for monitoring the core shift behavior of moldbase, which has significant influence on the product accuracy
Moldex3D result Moldex3D result

Pressure: 59.999~117.6MPa ABAQUS

Pressure: 110.351~120.208MPa

ANSYS

32

ABAQUS Interface Output Enhancement

33

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

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

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

34

ABAQUS Interface Output Enhancement

New in R12
As shown in figure, the total element number:776800 Choose *Distribution format and export to improve the efficiency of file reading.

FEA Interface Output Time Moldex3D R12.0 Moldex3D R11.0 (Medium-Level Material reduction) Moldex3D R11.0 (No Material reduction)
35

Output File Size 786MB

ABAQUS Analysis Time Solve 30mins (2G memory is enough) Solve 1 day (Huge memory needed) Solve 1 day (Huge memory needed)

CPU Time = 467.00 sec

CPU Time = 51598.89 sec.

393MB

CPU Time = 458.00 sec.

405MB

ABAQUS/Standard v.s ABAQUS/CAE

Abaqus/Standard

Abaqus/CAE

Now Support

36

Moldex3D R12 Integration with ANSYS Workbench

37

What is ACT?
> The Application Customization Toolkit is a full-featured scripting interface to customize Applications in Workbench
In ANSYS R14, ACT allows customization in the Mechanical application (Beta)

Define customized boundary conditions and postprocessing

Replace command snippets with interactive objects Do much more than what the standard features in Mechanical offer
Access node/element information, material, solution, results data

Even replace the APDL solver with your customer solver

> ACT provides an option to migrate APDL users to Mechanical

Allow reusing legacy APDL developments in user-friendly way Gets the best of the two worlds
38

Moldex3D-Workbench Integration
> Moldex3D extension toolbar and Moldex3D button are now part of ANSYS Mechanical user interface
Moldex3D function is available from the drop-down menu to set analysis properties When solution done, users can open the post to view the result

ANSYS

Moldex3D
39

Moldex3D Output

Moldex3D-Workbench Integration (contd)

> Moldex3D-FEA Interface is integrated in ANSYS Workbench > To cover the process-induced variation during the processes
Map material properties between different meshes Thermal / Flow Residual stress output EOP /EOC Temperature output Initial strain output

40

Moldex3D-Workbench Integration - Flow Chart

Part Geometry

eDesign

Workbench

Setup Runner and Cooling in Designer

Use the structural mesh as mapping target

Structural mesh

Injection Molding Analysis Moldex3D Extension FEA Interface

Export the results as Workbench format

Create user defined options

Static Structural

Structural Analysis

41

Moldex3D-Workbench Integration (contd)

New in R12

42

More Options of Digimat Output

43

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

Moldex3D

ANSYS/ABAQUS/LSDYNA

44

Moldex3D - DIGIMAT - ABAQUS

> Moldex3D - DIGIMAT - ABAQUS
Supported file types can be exported from Moldex3D FEA interface to ABAQUS, which are further described below : Original mesh file of molded parts:
*_ABAQUS_Part_Ori.inp

User-specified mesh of molded parts:

*_ABAQUS_Part_MAPMESH.inp

Export the fiber orientation data for further analysis to view characteristics of fiber orientation:
*.o2d (Original mesh) *Map.o2d (User-specified mesh)

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

45

Moldex3D - DIGIMAT - ANSYS

> Moldex3D - DIGIMAT - ANSYS
Supported file types can be exported from Moldex3D FEA interface to ANSYS, which are further described below: Original mesh file of molded parts:
*_ANSYS_Part_Ori.ans *_ANSYS_Part_Ori.cdb

User-specified mesh of molded parts:

*_ANSYS_Part_MAPMESH.cdb

Export the fiber orientation data for further analysis to view characteristics of fiber orientation:
*o2d (Original mesh) *Map.o2d (User-specified mesh)

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

46

Moldex3D - DIGIMAT - LS-DYNA

> Moldex3D - DIGIMAT - LS-DYNA
Supported file types can be exported from Moldex3D FEA interface to LS-DYNA, which are further described below: Original mesh file of molded parts:
*_LSDYNA_Part_Ori.dyn

User-specified mesh of molded parts:

*_LSDYNA_Part_MAPMESH.dyn

Export the fiber orientation data for further analysis to view characteristics of fiber orientation:
*.o2d (Original mesh) *Map.o2d (User-specified mesh)

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

47

FEA Interface Step-by-Step Analysis Setting

48

1. Injection Molding Analysis with eDesign

> Open the geometry in Moldex3D Designer, build up the runner and cooling system, and generate a 3D mesh. > Open the mesh in Moldex3D Project, setup the process conditions, then launch the injection molding analysis.

49

1-2. Generate Structural Mesh on Workbench

Generate mesh

50

1-3. Export the Workbench Mesh to FEA Interface

1.Choose Static Structural 2.Tools Write Inputs File

51

2. Interface Function Dialog Setting

2. Select Output Mesh Type

1. Select Structure FEA Software

3. Select Output Data

4. Export File

52

3. Export the eDesign Data for Workbench (cont)

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

53

4. Export the eDesign Data for Workbench (cont)

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

> Move the output data to current working directory. > By default, the Extension Manager contains the extensions located in the installation repository of ANSYS: %ANSYS140_DIR%\..\Addins\AdvancedAddinPackage\extensions > You can place the Moldex3DtoANSYS extension folders and files in the extensions folder of a users Applications Data folder, C:\Documents and Settings\<USER>\Application Data\Ansys\v140\ AdvancedAddinPackage. When extensions are installed in a users Applications Data folder, only the owner of that folder has access to the extensions.

54

4-1. Prepare a Workbench Project

> Generate the mesh and load your Moldex3D extension.

Extension Manager to Load / Unload available extensions

ANSYS mesh for mapping the Moldex3D results

55

4-2. Prepare a Workbench Project (cont)

> Set your BC conditions.

56

4-3. Prepare a Workbench Project (cont)

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

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

Information provided by Moldex3D FEA Interface

57

4-4. Prepare a Workbench Project (cont)

If you choose many items to output in Moldex3D FEA Interface, you will see more items appearing in the Definition list.
58

5. Run the Structural Analysis

Including Initial strain (warpage) Without Initial strain

59

Thank you for your attention!