· PDF fileCustomized Cooling Channel Templates ... default for the next project. User...
Transcript of · PDF fileCustomized Cooling Channel Templates ... default for the next project. User...
1 CoreTech System Co., Ltd.
Contents
Advanced Support for Intelligent Workflow
Improved User Interface ……………………………………
Expanded Gate Types ………………………………………..
Enhanced Runner Wizard ………………………………….
Customized Cooling Channel Templates …………….
Parameterized Mesh Generator ………………...........
Mesh Engines Supports Multi-core ……………………
Accuracy Improvements for Simulations
Modeling for Crystalline Material ………………………
Added Support for HTC Effect …………………….........
Added Support for Heater-Sensor Coupling ……….
Added Support for Viscoelasticity ……………………..
Improved Analysis for RIM …………………………………
Improved Analysis for IC Packaging ……………………
Enhanced Efficiency for Simulations
Rendering Enhancement for Shell Project ………….
Enhanced Support for XY-Plot ……………………………
Improved Project Model Manager …………………….
User Defined Copy Run Contents ……………….........
Binary Format of Result Files ……………………………..
Remote Computing ……………………………………………
Material Database Updates ……………………………...
New Simulation Capabilities
Injection Compression Molding …………………………
Fluid-Assisted Injection Molding ………………………..
Stress Analysis on Injection-Molded Parts ……......
Industrial Vertical Integration
Optical Integration with CODE V ……………………....
NX Nastran Added into I2 Modules ……………………
Your Feedback Is Important to Us …………………....
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Moldex3D is a suite of professional CAE tools for plastic
part design validation and mold optimization. It not only
helps global manufacturers produce plastic parts with
better quality and lower cost, but also enables them to
implement a more efficient design-for-manufacturing
workflow.
The official release of Moldex3D R10.0 brings several
breakthroughs on developing solver capabilities and
improving user friendliness and efficiency, such as
enhanced workflow, added support for analysis, remote
computing, etc, to help users solve problems more easily
and more efficiently. In addition to the new modules
added for customers’ needs, Moldex3D has also integrated
with more industrial-leading software, including CODE V
and NX Nastran, to provide advanced CAE solutions for
design verification and optimization.
Moldex3D R10.0 builds upon the capabilities of past
releases and adds innovation for performance and
functionality, offering the following new features and
benefits:
Advanced Support for Intelligent Workflow
Accuracy Improvements for Simulations
Enhanced Efficiency for Simulations
Material Database Updates
New Simulation Capabilities
Industrial Vertical Integration
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Advanced Support for Intelligent Workflow
Moldex3D R10.0 highly improves user friendliness for the
pre-processing work and develops a variety of powerful
tools to help users handle the meshing work and mold
design settings, such as gates, runners, cooling, etc.
Improved User Interface
❙ The improved user interface provides an intuitive and
task-oriented workflow, improving its functionality and
shortening users’ learning curve.
The improved user interface of Moldex3D Designer
❙ The compact and easy-to-navigate tool menu provides
a consistent logic to guide users to access to the
simulation workflow step by step easily. With only a
few clicks, the improved user interface helps finish the
meshing process efficiently.
Expanded Gate Types
❙ New gate types are now available in the Gate Wizard,
including pin gate, sprue gate, edge gate, fan gate,
lapped edge gate, tunnel gate, cashew gate, tunnel
gate with ejector pin and cashew gate with ejector pin.
Using the gate-aware Runner Wizard, users can build
single or multiple gates quickly and consecutively.
Additionally, seeking for appropriate gate locations,
users can apply Gate Location Advisor to set up one or
more gate locations according to the part geometry.
The tool menu of Gate Wizard
Enhanced Runner Wizard
❙ More runner cross section types are added, including
trapezoidal, U-shape and semi-circular, to better
describe the real runner geometry with true 3D solid
mesh. To solve the mesh distortion problems of
curvature runners, Moldex3D R10.0 allows to use
curve objects as runners and to construct a complete
runner system with mixed STL topology and runner
lines. This feature will enhance mesh quality, modeling
flexibility and calculation efficiency.
Curvature runner and runner mesh displays
❙ When simulating multi-cavity models, users can apply
Runner Symmetrical Configuration to configure the
single cavity and associated runner system, with the
emulated symmetrical cavities displayed. It reduces the
effort to setup symmetric boundary conditions and
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avoids ambiguity. This feature supports half and
quarter symmetrical systems. Compared to a full
model, it provides better mesh resolution and reduces
memory requirement for multi-cavity analyses.
Multi-cavity symmetrical simulation
Customized Cooling Channel Templates
❙ The intelligent Cooling Wizard enables users to define
cooling channels by cavity side or by core side. New
cooling channels templates, including straight lines,
U-shape lines and auto-loop, help users quickly setup
essential cooling channels and save time of
restructuring the previously designed cooling system.
Edited cooling channels can be saved as users’
proprietary templates or as default directly for the
next design.
Settings of different cooling systems
Parameterized Mesh Generator
❙ In response to users’ expectation to create high quality
structure mesh for some generic geometry, the
parameterized mesh generator has been developed to
help users define the model parameters in 2D and
then generate 3D structure mesh. Furthermore, users
can specify nodal parameters on each edge of model
to optimize mesh density and result accuracy.
Parameterized mesh generator
Mesh Engines Support Multi-Core
❙ The meshing kernels, both in Designer and Mesh, will
automatically detect and fully utilize the modern
multi-core CPU to speed up meshing without any
additional settings. Users will save significant amount
of time on mesh preparation.
Accuracy Improvements for Simulations
Moldex3D R10.0 has improved and expanded its solver
capabilities to satisfy users’ demands to acquire more
accurate and more advanced CAE solutions for
manufacturing problems and industrial challenges.
Modeling for Crystalline Material
❙ An increasing cooling rate generally shifts the
transition temperature of semi-crystalline polymer
towards lower temperature and increases the final
specific volume of the material. In consideration of the
impact of cooling rate, Moldex3D solvers now support
the analysis of injection molding with high cooling rate
characteristics.
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Added Support for HTC Effect
❙ The thermal contact between polymer and mold varies
throughout the different phases of a typical injection
molding cycle. Heat Transfer Coefficient (HTC)
variations are now considered and well simulated
when the mold detachment happens in the packing
phase. This feature improves packing and warpage
prediction.
Added Support for Heater-Sensor Coupling
❙ An added support of Transient Cool analysis
capabilities is to provide the heater controller settings
to help users control the heaters by the sensor node
temperature. This enables more accurate simulations
for the realistic heater control system. Moldex3D R10.0
also supports the cooling analysis of hot runner effects
to provide more accurate part warpage prediction with
more precise moldbase temperature distribution.
Heater control system by sensor node temperature
Moldbase temperature distribution and part warpage
prediction
❙ Moldex3D R10.0 supports the pipe network analysis to
analyze the mold cooling efficiency with its coolant
flow rate and cooling channel design. Additionally,
users are able to define the convergence criteria for
different analysis purposes. The convergence condition
and cycle time will be logged in the log file for users to
observe the steady state of the cycle temperature
easily. Three tolerance criteria are available:
Average part surface temperature
Maximum variation of part surface temperature
Maximum variation of mold temperature
Cooling temperature distribution of the pipe network
analysis
Added Support for Viscoelasticity
❙ Moldex3D R10.0 supports multi-mode PTT and
Giesekus models. While the single mode is sometimes
inadequate to describe the viscoelasticity behaviors,
this feature can reflect the effects of multiple
relaxation times and bring more accurate polymer
viscoelasticity prediction.
The simulations of multi-mode PTT and Giesekus
compared with real viscoelasticity distributions
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Improved Analysis for Reactive Injection Molding (RIM)
❙ Moldex3D R10.0 provides the mold thermal analysis of
the RIM process. Its simulation results, cycle average
and transient approach, are well visualized for users to
revise their mold design. Moreover, the scorch-index
calculation enables users to simulate rubber injection
molding with long induction time by Deng-Isavev
model. It helps users optimize runner design and
process parameters to avoid premature vulcanization.
Improved Analysis for IC Packaging
❙ With the newly-developed Moldex3D stress solver,
users now can run full simulations for IC Packaging,
including wire sweep and paddle shift, without
accessing to external structural solvers. Additionally,
Moldex3D R10.0 expands supports to more drag force
models for wire sweep calculation.
Wire sweep prediction with Moldex3D-Stress
Enhanced Efficiency for Simulations
Moldex3D R10.0 improves user friendliness for the
pre-processing work and enhances user efficiency for the
post-processing work.
Rendering Enhancement for Shell Project
❙ The rendering efficiency for graphic performance of
Shell Project has been enhanced by 2-3 times with
entry-level graphic cards. Its performance increases
much more with high-end graphic cards.
Enhanced Support for XY-Plot
❙ The redeveloped user interface of XY-Plot function
helps users save different plot settings and review the
simulation analysis results more easily, especially for
sensor data. It also adds a toolbar for XY-Plot viewer.
Improved Project Model Manager
❙ The improved model manager enables users to control
the object display status faster and more easily. Users
are able to turn on/off each object and define their
colors; moreover, the settings can be directly saved as
default for the next project.
User Defined Copy Run Contents
❙ With this feature, users can choose to copy partial or
full run data for CAE analysis. The flexibility of copy run
contents will save disk space and copy time to build
additional runs for simulations.
Binary Format of Result Files
❙ The analysis result files have been changed from ASCII
to binary format in Moldex3D R10.0. Compared to
R9.1 Project, it is estimated to reduce 40-50% project
file size, highly improving the efficiency of result
loading and storage.
Remote Computing
❙ Moldex3D R10.0 expands supports of remote
computing to enable users to submit or download
analysis jobs from the client computer to the remote
computing server across intranet. With the parallel
computing cluster, the server can automatically assign
analysis jobs to different computing nodes, and the
completed jobs will be downloaded to the client
computers automatically. It not only saves users’ time
for running simulation analyses but also enhances the
calculation efficiency by the computing cluster.
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Material Database Updates
Moldex3D material database in R10.0 has been updated
with 437 thermoplastic materials modified and 98
materials added. Users can add a material from Moldex3D
material bank, user bank or Project settings into Material
Comparison List to easily compare its properties with
different materials. Additionally, Moldex3D R10.0 supports
Matereality 4.0. Users can directly download material
properties, including anisotropic mechanical properties,
from http://www.matereality.com.
Materials compared by Material Comparison List.
New Simulation Capabilities
Considering industrial customers’ demands for specific
simulation capabilities, Moldex3D R10.0 has developed
new modules to in-depth help users simulate the plastic
injection molding processes.
Injection Compression Molding (ICM)
❙ Moldex3D-ICM helps users accurately simulate the
injection compression molding process, which is
generally applied to thin and flat products such as light
guide plates or CD disks. The effects of key process
conditions, including delay time and compression gap,
on cavity pressure and volume shrinkage distribution
can be simulated and visualized.
More uniform volume shrinkage of ICM simulations
Fluid-Assisted Injection Molding (FAIM)
❙ Moldex3D-FAIM is a true 3D CAE simulation tool to
visualize flow behaviors when fluid (gas or water) is
injected directly into the cavity through melt entrances
or specific fluid entrances in the injection molding
process. Typical molding issues for FAIM, such as
fingering effect, blow-through, or corner effect, can be
predicted to help users investigate the real production
process and increase manufacturability.
Filling simulation of the FAIM process
Stress Analysis on Injection-Molded Parts
❙ Moldex3D-Stress provides users with the complete
stress simulation analyses for parts and part inserts.
This feature is especially useful when the fiber-filled
material is employed. As a result, mapping between
Moldex3D and other general purpose structural CAE is
no longer necessary.
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Simulation results of stress analysis
Industrial Vertical Integration
Moldex3D R10.0 has integrated with a wide variety of
industrial leading software to benefit users with advanced
CAE solutions for injection molded product design.
Optical Integration with CODE V
❙ Integrated with CODE V, Moldex3D has developed
advanced optical solutions to help designers analyze
the manufacturing feasibility of part design by
injection molding simulation analyses and export the
deformed shape and refractive distribution into CODE
V for verification and optimization. This feature gives
designers the power to overcome the difficulties
between ideal product design and real production and
enables them to satisfy the market demands.
The process of the optical solution with CODE V
NX Nastran Added into I2 Modules
❙ The integration with NX Nastran provides users with a
CAE solution for structural analyses. Critical analysis
results, such as pressure, temperature, or material
reduction, can be precisely simulated and predicted for
different mesh types of parts and part inserts. More
features for I2-NXNastran are as the following:
Your Feedback Is Important to Us
Thank you for your continuous support of Moldex3D. We
added new and enhanced functionalities to Moldex3D
R10.0 to help you become more productive and more
competitive and return true value to your investment. We
sincerely invite you to provide feedback to Moldex3D
research and development team. Please don’t hesitate to
discuss with your Moldex3D authorized resellers and
support staffs near you. Alternatively, you can always
provide your feedback to [email protected].
© 2010 CoreTech System Co., Ltd. All rights reserved.
© 2010 CoreTech System Co., Ltd. All rights reserved.
True 3D CAE for Injection Molding
Moldex3D R10
New Temperature Results: Filling
Moldex3D – TIPs_10032
2010/08/20
True 3D CAE for Injection Molding
Filling: Maximum Temperature
Shows the maximum
temperature in the thickness
direction of the part.
True 3D CAE for Injection Molding
Filling: Center Temperature
Center temperature is the melt temperature of the middle layer (part line)
in the thickness direction at current instant. Center temperature is an
indicator of thermal energy supply of the fresh hot melt.
In general, the center
temperature is an indicator of
incomplete filling (short shot). If
the center temperature is too
low, flow hesitation happens and
there will be a short shot
problem.
True 3D CAE for Injection Molding
Filling: Average Temperature
Average temperature is the averaged temperature across the part thickness at current
instant. It considers the effect of mold cooling and viscous heating of melt. Therefore,
average temperature is representative for the part temperature
This data can be used to check
the combined effect of viscous
heating of polymer melt and
mold cooling. One should
examine if there is any hot spot
that will cause burning problem
and the possibility of short shot
due to flow hesitation and
excess mold cooling.
True 3D CAE for Injection Molding
Filling: Bulk Temperature
Bulk temperature is a velocity-weighted averaged temperature of plastic melt
across the thickness at current instant. The contribution from frozen layer that is
stationary is ignored in this data. The effect of heat convection and viscous
heating can be displayed from this data.
Therefore, it can apparently
demonstrate how heat convection
affects the melt temperature and
the temperature distribution of
hesitation area and viscous
heating area. Normally, bulk
temperature distribution can
reflect the trends or paths of
filling flow.
Moldex3D R10 New FunctionMoldex3D R10 New Function
Cooling Channel Layout Template
Moldex3D – TIPs_10033
2010/08/27
Introduction
In Moldex3D 10, Designer will support using Cooling Channel Layout Template to describe the cooling layout. There are three types of template, which are Straight line, U-Shape line and Auto-Loop.
Benefits:1. Users may create more complex cooling channel
automatically in Designer.2. Reduce the time for creating the cooling channel in
designer for initial verification.
Straight line
U-Shape line
Auto-Loop
True 3D CAE for Injection Molding
Moldex3D New Development:
3D Sink Mark prediction
Moldex3D – TIPs_10034
2010/09/03
True 3D CAE for Injection Molding
Introduction
Sink mark is important for the product appearance.
Therefore it is essential to understand the location
and the depth of sink mark.
These slides show the current progress on 3D sink
mark prediction. This function is scheduled to be
released in R10 SP1.
As is in Shell To be in 3D
True 3D CAE for Injection Molding
Some examples
T-shaped part:
Far from the gate, higher sink
mark value is observed
True 3D CAE for Injection Molding
Some examples
Mechanical part
(eDesign mesh)
Sink mark locations are
well predicted.
Moldex3D R10 New FunctionMoldex3D R10 New Function
AutoProfile Function
Moldex3D – TIPs_10036
2010/09/24
Introduction
In Moldex3D R10, Project will support AutoProfile Function. Theprogram will provide suggested Flow rate and Packing pressure profiles based on the analysis result . This function is available in Shell, eDesign and Solid modules.
Benefits:1. A reference for us to optimize the Filing and Pac king
profiles, and reduce the number of trial and error for process condition setting.
AutoProfile Results
Original flow rate Suggested flow rate
Original packing pressure Suggested packing pressure
Moldex3D R10 New FunctionMoldex3D R10 New Function
Cooling Channel Layout Template
Part II
Moldex3D – TIPs_10039
2010/10/22
Introduction
• In Moldex3D R10, Moldex3D-Designer supports users to apply cooling channel layout template. When designing cooling channel system, users can load the templates in the database and modify its dimension more conveniently. There are 3 template types as default, including Straight Line, U-Shape, and Auto-Loop. However, users can follow below steps to design their own cooling channel layout can follow below steps to design their own cooling channel layout template.
Main Concept
• The main concept used in Moldex3D for cooling channel layout creation is vector. Below figure is a simple example displaying three vectors and lengths represented cooling channel layout.
Cooling Channel Layout File Format
• To create a cooling channel template, follow the procedures listed below.– Step 1: Create Cooling channel template csv files
Open a new Microsoft Excel file or word pad file. Enter following required values for each item.
• Cooling channel layout file format:• Cooling channel layout file format:– Head:
» VERSION: template file version.» NAME: template name display on UI.» CCTYPE: define cavity/core side or slider side» CAVITY: along parting direction» SLIDER: perpendicular to parting direction
Cooling Channel Layout File Format cont.
– PATH:» ID: path ID» VECTOR: path vector» LENGTH: path length» TYPE: path type» LINE: straight line path type
– CONSTRAINT:– CONSTRAINT:» DUPLICATE: silder side layout directions
+X1, -X1, +X2, -X2: the silder side layout direction definitions are depending on the parting direction, as shown in the table
Cooling Channel Layout File Format cont.
• View the setting:
Apply Template to Moldex3D-Designer
• After setting all values, save it as a *.csv file in Moldex3Ddestination folder where Moldex3D main programs install. For example, if Moldex3D main programs are installed in C disk. The path for the saved *.csv file should be “C:\Moldex3D\R10.0\Moldex3D-Designer\templates.
• Note: if there is no folder named templates in Moldex3D-Designerfolder, create one manually and name it “templates” by lowercase. folder, create one manually and name it “templates” by lowercase. *.csv must be saved in template folder to be read by Moldex3D-Designer .
– Step 2: Cooling channel template bitmap:• Create a bitmap (*.bmp). The *.bmp is just a symbolic figure for
cooling channel layout, which will be displayed on UI of the cooling channel template. It is not restricted to figure content, but the file type must be *.bmp.
Apply Template in Designer cont.
• Note: The file name for both the cooling channel template file (*.csv) and the bitmap (*.bmp) must be the same and both of these two files must be save in the same folder.
• After finishing the above template steps, the file info and UI figure will shown as below.
• After setting all related properties of the cooling channel, click to go back the main setting panel for other setting.
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Moldex3D R10 Viewer is
Officially Released
Moldex3D – TIPs_10040
2010/10/29
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Introduction
> Moldex3D Viewer is the light version of “Project” which allows
any users without a license to open a Moldex3D simulation case.
> The projects opened with Viewer will be in “Read Only” mode,
but users can still create a HTML or PPT report.
> For any prospects interested in Moldex3D Viewer, we suggest
that they get the download link through our website after
registering.
> For all our resellers, our support teams could provide the
download link directly. There is no need to register.
> The R10 Viewer download link will be put on our official website
on November 10. If you would like to have it upfront, please
contact your support team.
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Moldex3D R10 Viewer
The “Read Only” will be shown on the title
Report Generator available
New R10 results display
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Thank you!