R10-UM_Ch12-SP2 (4)

User’s Manual Chapter 12, Introduction to Moldex3D-I2 Modules

Published: 2011-04-25_V03

Abstract

The application of CAE analysis in injection-molded plastic part is becoming popular in

the recent years, especially in part structure design and molding process optimization.

Users study the designs and experiments through numerous individual CAE tools. In

fact, these analyses and designs should be mutually dependent. The process-resulting

properties might be not favorable to the final products, such as fiber-induced anisotropic

mechanical property. Besides, the mesh requirement for different CAE analysis might be

different. In this chapter, an integrated approach from design phase to manufacturing

phase is proposed to seamlessly combine part structure analysis and injection molding

analysis through related-data linking and mesh property mapping. This developed

approach is proved from numerical experiments to be a cost-effective method for related

part/mold designers.

12........INTRODUCTION TO MOLDEX3D-I2 MODULES...................................................................................12-1

12.1 FUNCTION OVERVIEW................................................................................12-112.1.1 Thermal Residual Stress.......................................................................12-112.1.2 Anisotropic Material............................................................................12-212.1.3 Material Count Reduction....................................................................12-212.1.4 Map Function.......................................................................................12-312.1.5 High Order Element.............................................................................12-4

12.2 SHELL ANALYSIS OUTPUT.........................................................................12-512.2.1 Basic Procedures for Moldex3D/Shell-I2 Module...............................12-512.2.2 Interface to ABAQUS...........................................................................12-612.2.3 Interface to ANSYS...............................................................................12-712.2.4 Interface to MSC.Nastran....................................................................12-712.2.5 Interface to NE/Nastran.......................................................................12-712.2.6 Interface to LS-DYAN...........................................................................12-812.2.7 Interface to MSC.Marc.........................................................................12-812.2.8 Interface to NX Nastran.......................................................................12-9

12.3 SOLID ANALYSIS OUTPUT..........................................................................12-912.3.1 Basic Procedures for Moldex3D/Solid-I2 Module...............................12-912.3.2 Interface to ABAQUS.........................................................................12-1012.3.3 Interface to ANSYS.............................................................................12-1112.3.4 Interface to MSC.Nastran..................................................................12-1212.3.5 Interface to NE/Nastran.....................................................................12-1312.3.6 Interface to LS-DYNA.........................................................................12-1412.3.7 Interface to MSC.Marc.......................................................................12-1512.3.8 Interface to NX Nastran.....................................................................12-1612.3.9 Interface to Radioss............................................................................12-16

12.4 APPLICATION TIPS...................................................................................12-1712.5 MOLDEX3D TO DIGIMAT INTERFACES...................................................12-1812.6 MOLDEX3D-I2 FUNCTIONS TABLE.........................................................12-28

CONTENTS

Chapter 12

12. INTRODUCTION TO MOLDEX3D-I2 MODULES

12.1 Function Overview

The application of CAE analysis in injection-molded plastic part is becoming popular

in the recent years, especially in part structure design and molding process

optimization. Users usually study the designs and manufactures through numerous

individual CAE tools. An increasing number of industrial parts are made of plastic for

its low cost and superior material properties in the recent years. However, the

material characteristic of plastic part is extremely dependent on molding process.

The process-induced properties, such as fiber-induced anisotropic mechanical

properties, might not be favorable to the structural requirement of final products. The

traditional structure analysis is to perform CAE analysis based on the assumption of

one or several isotropic materials. But it neglects some molding effects. Sometimes

the results of analysis could be different from the real world.

Injection molding simulation is capable of simulating the filling, packing, and cooling

processes, as well as the part warpage after ejection. It has been widely applied in

industry and earns a fine reputation. Here we integrate injection molding and

structure analysis through an interfacing program to enhance structure analysis with

molding effects.

This chapter describes how to output relevant data of injection-molding analysis

through Moldex3D-I2 interface for other structure analysis software. Chapter12.1

describes function overview of Moldex3D-I2 interface, chapter 12.2 and 12.3

introduce how to output relevant data of injection molding analyses through

Moldex3D-I2 interface.

Moldex3D-I2 is the interface between Moldex3D and other CAE software. It

translates Moldex3D data to ABAQUS/ANSYS/MSC.Nastran/NASTRAN/LS-

DYNA/MSC.Marc/NX Nastran/Radioss data. These data include original/warpage

mesh and material properties. Original mesh describes the geometry before molding

process. Warpage mesh describes the geometry of molded part. The material

properties include material stiffness, thermal expansion coefficient, density etc. The

pure polymer is assumed as isotropic material. However, the material will be

anisotropic for fiber-filled polymer. These anisotropic material properties are related

to molding-induced fiber orientation. Moldex3D-I2 will translate these aniostropic

properties into other CAE software automatically. The following chapter will describe

more details.

12.1.1 Thermal Residual Stress

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Chapter 12

An injection-molding part is shaped from a high temperature melt to a solid state.

Variation of temperature and pressure will induce volumetric shrinkage and produce

internal forces. Thus, the internal forces cause warpage of a plastic part. In this

situation, this internal stress is also named residual stress. There are a lot of factors

that will affect plastics’ residual stress, such as material selection, part design, mold

design and processing. Through Moldex3D-I2 interface, Moldex3D can output

residual stress from injection molding analyses. Yet this function is not available in

Moldex3D/Shell-I2 module.

12.1.2 Cooling Temperature Distribution

冷卻不均會使成品收縮不平均，引起翹曲。User can use End-of-

cooling temperature to analysis tempering process and the

effective solutions to solve the warping problem can be

found. Yet this function is not available in Moldex3D/Shell-I2

module.

12.1.3 T he Strength in Weld-Line Region

Weld-lines or knit-lines are formed during the mold filling process when the split melt

flow fronts meet at the same downstream location. Weld-lines look like cracks on the

appearance of plastic parts. 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. Through Moldex3D-I2

interface, Moldex3D can transfer part geometry and weld-lines strength into stress

solver.User can define meeting angle and material parameter reduction

coefficients。Yet this function is not available in Moldex3D/Shell-I2 module.

12.1.4 D ensity Distribution

密度的分布，會影響模態分析的共振頻率；而塑膠的密度會隨著溫度及受壓縮程度的

變化而改變。溫度高時密度小，受壓縮程度大時密度大。User can use the density

distribution to do Modal analysis.Yet this function is not available in Moldex3D/Shell-

I2 module.

12.1.5 Anisotropic Material

If materials are fiber-contained, they will result in anisotropic mechanical properties

for fiber orientation. Moldex3D-I2 can also calculate and output the full stress-

strain relationship matrix relates terms ordered x, y, z, xy, yz, xz via. 21

2 User’s Manual

Symmetric

Chapter 12

constants as shown below:

同時，Moldex3D-I2 也支援輸出前一射含有非等向性質的 Part Insert 之材料，使用者

只要開啟計算參數精靈進行條件設定，Moldex3D-I2 在輸出時便會一起輸出前一射的

Part Insert 材料性質。

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Chapter 12

Fig 12-1 設定前一射的Part Insert run ID

12.1.6 Material Count Reduction

Because of fiber orientation and its strength, every element of a model has a different

material property. For most of professional CAE software, material settings in

structure analyses are quite limited. Consequently, Moldex3D-I2 reduces fiber-

contained materials in the outputs by sorting the materials with similar fiber

orientation and strength as a classification. A schematic diagram of fiber orientation

is shown in Fig.12-1, where θ and ψ are angles of fiber in the spherical coordinate.

Due to the lack of GUI interface, users have to update those parameters manually

from cmi files, which can be found in the folder where your project is located. Assume

that your project is located in D disc; this cmi file is under D:\R9.0 Manual\

MDXProject20080108\Analysis\Run01, where MDXProject20080108 is the folder of

your project, Run01 is the run where you export the results through Moldex3D-I2.

The function Moldex3D toolbar helps user find cmi files more easily.

The control parameters within this file is described as follows:

IsDoMaterialReduction: 0 or 1 (ON: 1, OFF: 0)

Parameter (Segment of θangle): 1~35 (Integer, Min=1, Max=35, Default=3)

Segment number of θangle. The θ angle is 0~900. This parameter is limited from

1~35, and must be an integer. The default parameter is 3.

Parameter (Segment ofψangle): 1~35 (Integer, Min=1, Max=35, Default=3)

Segment number of ψangle. The ψ angle is 0~900. This parameter is limited from

1~35, and must be an integer. The default parameter is 3.

Parameter (Segment of Orientation strength): 1~10(Integral, Min=1, Max=10,

Default=5)

This parameter is limited from 1~35, and must be an integer. The default parameter

is 5.

4 User’s Manual

Chapter 12

Fig 12-2 Sketch of fiber orientation

Users can get reasonable reduced material counts by the control parameters, but yet

only Moldex3D/Solid-I2 supports this function. Of course, users also have to

determine the rationality of this simplification by their engineering experience.

12.1.7 Map Function

The accuracy of finite element analysis or finite volume analysis is extremely

dependent on the mesh. Except for element qualities, the mesh structure is another

critical factor. The requirement of mesh structure for injection-molding analyses is

different from that for structure analyses due to different domains. Structure analyses

focus on the area of stress concentration while injection-molding analyses emphasize

the higher element resolution across the thickness direction. Injection molding

analyses typically need more elements and more diverse mesh densities than

structure analyses. Therefore, even though the meshes with molded properties in

injection-molding analyses are correctly taken into structure analyses, the accuracy

could not meet criterions.

In order to solve this awkward situation, a function to map element properties

between Moldex3D mesh and user-specified mesh is developed. This approach is to

look for matched elements between two meshes and assign proper element

properties into the specified mesh. Afterward users only need to import this mesh on

the platform of structure CAE and proceed advanced analyses.

Currently, Moldex3D/Shell-I2 supports three kinds of file formats for user-specified

mesh.

Moldex3D shell mesh file (*.msh)

ABAQUS mesh file (*.inp)

NASTRAN mesh file (*.bdf;*.dat;*.nas)

User’s Manual 5

Chapter 12

For solid element, Moldex3D/Solid-I2 supports various file formats for user-specified

mesh.

Moldex3D solid mesh file (*.mfe)

ABAQUS mesh file (*.inp)

ANSYS mesh file (*.ans)

NASTRAN mesh file (*.bdf;*.dat;*.nas)

Marc mesh file created by Mentat (*.dat)

LS-DYNA mesh file(*.dyn)

In Interfacing Function Option, to map element properties to other mesh files, firstly

select Mapped in Output mesh as: list, and then selecting a mesh file which the

original data will be mapped to in Mesh file box. After selecting the items you would

like to map along with the original mesh in Function options list, click Export, and

all the element data will be mapped to the chosen mesh file.

12.1.8 High Order Element

Sometimes user would like to use high order element (Quadratic element) for more

accurate simulation. Therefore, Moldex3D-I2 further supports the auto-translation of

6 User’s Manual

Chapter 12

normal element to high order element. In order to meet such demands, Moldex3D-I2

provides a function to output high order element. Users can select linear/output as

higher order element in Element type list. It should be noted that ANSYS stress

solver takes element of Solid-185 as linear and Solid-186 as higher order element.

While “Output as high order element” is selected, Moldex3D-I2 will translate the

element type automatically.

Fig 12-3 Interfacing Function Dialog

12.2 Shell Analysis Output

12.2.1 Basic Procedures for Moldex3D/Shell-I2 Module

The basic procedures of Moldex3D/Shell-I2 Module analysis are described as

follows.

Step 1: Create a new project

Step 2: Import a new mesh

Step 3: Select/import a new material

Step 4: Generate a new process condition

Step 5: Set the Computation parameter

Step 6: Check the requirement Run data

Step 7: Perform Flow/Pack/Cool/Warp analyses first

Step 8: Perform Interfacing function to output these interface files

User’s Manual 7

Chapter 12

Step 9: Load these interface files on other CAE platform and perform advanced

analyses

As pointed in item 8, users have to assign the requirement in Interfacing Function

Option dialog as shown in Fig. 12-3.


12.2.2 Interface to ABAQUS

ABAQUS was founded in 1978 by David Hibbitt, Bengt Karlsson, and Paul Sorensen.

The ABAQUS suite of software for finite element modeling and solution is able to

solve many kinds of challenging simulations. ABAQUS provides a powerful and

unified system for engineering analysis and digital prototyping in support of design

and manufacturing. (More information please refer to http://www.hks.com)

There are various file types that can be exported from Moldex3D/Shell-I2 ABAQUS,

which are further described below:

Original/Warpage mesh files with material properties of molded parts:

* _ABAQUS_Part_Ori.inp/ *_ABAQUS_Part_Wap.inp.

User-specified mesh with material properties of molded parts:

8 User’s Manual

http://www.hks.com/

Chapter 12

*_ABAQUS_ Part_MAPMESH.inp.

After importing these files in ABAQUS, users can further conduct other analyses.

12.2.3 Interface to ANSYS

ANSYS is committed to developing simulation solutions — from mechanical to

computational fluid dynamics (CFD) — that illustrate realistic and accurate modeling

and simulation of components, subsystems, and systems. Replacing hardware

prototyping and testing, ANSYS solutions drive product designs from concept to

reality, providing an engineering simulation system for a fast, efficient and cost-

conscious information-based development process. (More information please refer to

http://www.ansys.com)

There are various file types that can be exported from Moldex3D/Shell-I2 ANSYS,


Original/Warpage mesh files with material properties of molded parts:

*_ANSYS_Part_Ori.ans/ *_ANSYS_Part_Wap.ans.


*_ANSYS_ Part_MAPMESH.ans.

After importing these files in ANSYS, users can further conduct other analyses.

12.2.4 Interface to MSC.Nastran

MSC.Software provides simulation technology and services to manufacturers and

research facilities in many fields. The MSC.Nastran product family is modular,

enabling you to analyze products ranging from simple components to complex

structures and systems. (More information please refer to

http://www.mscsoftware.com)

There are various file types that can be exported from Moldex3D/Shell- I2

MSCNASTRAN, which are further described below:

Original/Warpage mesh with material properties of molded parts:

*_MSCNASTRAN_Part_Ori.bdf/* MSCNASTRAN_Part_Wap.bdf.


*_MSCNASTRAN_ Part_MAPMESH.bdf.

After importing these files in MSCNASTRAN, users can further conduct other

analyses.

User’s Manual 9

http://www.mscsoftware.com/

http://www.ansys.com/

Chapter 12

12.2.5 Interface to NE/Nastran

Noran Engineering, Inc. is established in 1991, created with the idea of bringing a

true Nastran analysis tool from the mainframe to the desktop. NE/Nastran is a

comprehensive finite element analysis (FEA) tool based on NASA's popular

NASTRAN finite element analysis software. NE/Nastran offers structural analysis

software solutions including: linear static, buckling, pre-stress, modal dynamics,

nonlinear, steady state, and transient heat transfer. (More information please refer to

http://www.nenastran.com)

There are various file types that can be exported from Moldex3D/Shell-I2

NENASTRAN, which are further described below:

Original/ Warpage mesh with material properties of molded parts:

* _NENASTRAN_Part_Ori.nas/* _NENASTRAN_Part_Wap.nas.


*_NENASTRAN_ Part_MAPMESH.bdf.

After importing these files in NE/NASTRAN, users can further conduct other

analyses.

12.2.6 Interface to LS-DYAN

LS-DYNA, which is developed by the Livermore Software Technology Corporation

(LSTC), is being used by Automobile, Aerospace, Military, Manufacturing, and

Bioengineering companies. LS-DYNA has the capabilities from simple linear static

mechanical analysis up to advanced thermal and flow solving methods.(For more

information, please link to http://www2.lstc.com/)

There are various file types that can be exported from Moldex3D/Shell-I2 LS-DYNA,


Original/ Warpage mesh with material properties of molded parts:

*_LSDYNA_Part_Ori.dyn/*_LSDYNA_Part_Wap.dyn


*_LYDYNA_Part_MAPMESH.dyn.

After importing these files in LS-DYNA, users can further conduct other analyses.

12.2.7 Interface to MSC.Marc


10 User’s Manual

http://en.wikipedia.org/wiki/Bioengineering

http://en.wikipedia.org/wiki/Manufacturing

http://en.wikipedia.org/wiki/Military

http://en.wikipedia.org/wiki/Aerospace

http://en.wikipedia.org/wiki/Automobile

http://www.nenastran.com/

Chapter 12

research facilities in many fields. The MSC.Marc product family is a nonlinear FEA

program that enables you to assess the structural integrity and performance of parts

undergoing large permanent deformations as a result of thermal or structural load.

(More information please refer to http://www.mscsoftware.com)

There are various file type that can be exported from Moldex3D/Shell-I2

MSCMARC, which are further described below:


* _MARC_Part_Wap.dat

User-specified mesh with material properties of molded part:

*_MARC_ Part_MAPMESH.bdf.

After importing these files in MSCMARC, users can further conduct other analyses.

12.2.8 Interface to NX Nastran

NX Nastran is a premium computer-aided engineering (CAE) tool that major

manufacturers worldwide rely on to produce safe, reliable and optimized designs

within increasingly shorter design cycle times. (More information please refer to

http://www.designviz.com)

There are various file types that can be exported from Moldex3D/Shell- I2

NXNASTRAN, which are further described below:


*_NXNASTRAN_Part_Ori.dat/* NXNASTRAN_Part_Wap.dat.


*_NXNASTRAN_ Part_MAPMESH.dat.

After importing these files in NXNASTRAN, users can further conduct other analyses.

12.3 Solid Analysis Output

12.3.1 Basic Procedures for Moldex3D/Solid-I2 Module

The basic procedures of Moldex3D/Solid-I2 Module analysis are described as

follows.

Step 1: Create a new project

Step 2: Import a new mesh

User’s Manual 11


Chapter 12

Step 3: Select/import a new material

Step 4: Generate a new process condition

Step 5: Set the Computation parameter

Step 6: Check the requirement Run data

Step 7: Perform Flow/Pack/Cool/Warp analyses first

Step 8: Perform Interfacing function to output these interface files

Step 9: Load these interface files on other CAE platform and perform advanced

analyses

As pointed in item 8, users have to assign the requirement in Interfacing Function

Option dialog as shown in Fig. 12-4.


12.3.2 Interface to ABAQUS

ABAQUS was founded in 1978 by David Hibbitt, Bengt Karlsson, and Paul Sorensen.

The ABAQUS suite of software for finite element modeling and solution is able to

solve many kinds of challenging simulations. ABAQUS provides a powerful and

12 User’s Manual

Chapter 12

unified system for engineering analysis and digital prototyping in support of design

and manufacturing. (More information please refer to http://www.hks.com)

There are various file types that can be exported from Moldex3D/Solid-I2 ABAQUS, which

are further described below:

(1) Original/Warpage mesh files with material properties of molded parts:

ABAQUS_ Part_Ori_*.inp/ ABAQUS_ Part_Wap_*.inp.

(2) Original/Warpage residual stress files:

Thermal Residual Stress:

ABAQUS_ Part_Ori_*_ThermalStress.sts/ ABAQUS_ Part_Wap_*_ThermalStress.sts.

Flow Residual Stress:

ABAQUS_ Part_Ori_*_FlowStress.sts/ ABAQUS_ Part_Wap_*_FlowStress.sts.

(3) User-specified mesh with material properties of molded parts:

ABAQUS_ Part_MAPMESH_*.inp/ ABAQUS_ Part_MAPMESH_*.sts.

(4) Pressure outputs of multi-component models at various times:

ABAQUS_ PartInsert_Pressure_Ori_*_00x(step time).inp/

ABAQUS _ PartInsert_Pressure_Ori_*_EOF.inp/

ABAQUS_ PartInsert_Pressure_Ori_*_EOP.inp,

Where x presents the number of time steps, which ranges from 1 to the total amount of time

steps.

(5) Pressure outputs of moldbase at various times:

ABAQUS_ Moldbase_Pressure_*_00x(step time).inp/

ABAQUS_ Moldbase_Pressure_*_EOF.inp/

ABAQUS_ Moldbase_Pressure_*_EOP.inp,

ABAQUS_Moldbase_AllPressure_*.inp

Where x presents the number of time steps, which ranges from 1 to the total amount

of time steps.

After importing these files in ABAQUS, users can further conduct other analyses.

12.3.3 Interface to ANSYS

User’s Manual 13

http://www.hks.com/

Chapter 12

ANSYS is committed to developing simulation solutions — from mechanical to

computational fluid dynamics (CFD) — that illustrate realistic and accurate modeling

and simulation of components, subsystems, and systems. Replacing hardware

prototyping and testing, ANSYS solutions drive product designs from concept to

reality, providing an engineering simulation system for a fast, efficient and cost-

conscious information-based development process. (More information please refer to

http://www.ansys.com)

There are various file types that can be exported from Moldex3D/Solid-I2 ANSYS,


(1) Original/Warpage mesh files with material properties of molded parts:

ANSYS_ Part_Ori_*.ans/ ANSYS_ Part_Wap_*.ans.

(2) Original/Warpage residual stress files:

Thermal Residual Stress:

ANSYS_ Part_Ori_*_ThermalStress.ist/ ANSYS_ Part_Wap_*_ThermalStress.ist.

Flow Residual Stress:

ANSYS_ Part_Ori_*_FlowStress.ist/ ANSYS_ Part_Wap_*_FlowStress.ist.

(3) User-specified mesh with material properties of molded parts:

ANSYS_ Part_MAPMESH_*.ans/ ANSYS_ Part_MAPMESH_*.ist.


ANSYS_ PartInsert_Pressure_Ori_*_00x.cdb/

ANSYS _ PartInsert_Pressure_Ori_*_EOF.cdb/

ANSYS_ PartInsert_Pressure_Ori_*_EOP.cdb

Where x right presents the number of time steps, which ranges from 1 to the total amount of time steps.


ANSYS_ Moldbase_Pressure_*_00x.cdb/

ANSYS_ Moldbase_Pressure _*_EOF.cdb/

ANSYS_ Moldbase_Pressure _*_EOP.cdb/

Where x right presents the number of time steps, which ranges from 1 to the total

14 User’s Manual

http://www.ansys.com/

Chapter 12

amount of time steps.

(6) Iinitial Strain Output:

ANSYS_Part_InitialStrain_Ori_*.cdb

After importing these files in ANSYS, users can further conduct other analyses.

12.3.4 Interface to MSC.Nastran


research facilities in many fields. The MSC.Nastran product family is modular,

enabling you to analyze products ranging from simple components to complex

structures and systems. (More information please refer to

http://www.mscsoftware.com)

There are various file type that can be exported from Moldex3D/Solid-I2 MSCNASTRAN,


(1) Original/Warpage mesh with material properties of molded parts:

MSCNASTRAN_Part_Ori_*.bdf/

MSCNASTRAN_Part_Wap_*.bdf.

(2) User-specified mesh with material properties of molded part:

MSCNASTRAN_ Part_MAPMESH_*.bdf.


MSCNASTRAN_PartInsert_Pressure_Ori_*_00x.bdf

MSCNASTRAN_PartInsert_Pressure_Ori_*_EOF.bdf

MSCNASTRAN_PartInsert_Pressure_Ori_*_EOP.bdf

Where x right presents the number of time steps, which ranges from 1 to the total amount of

time steps.


MSCNASTRAN_Moldbase_Pressure_*_00x.bdf

MSCNASTRAN_Moldbase_Pressure_*_EOF.bdf

MSCNASTRAN_Moldbase_Pressure_*_EOP.bdf


time steps.

User’s Manual 15


Chapter 12

After importing these files in MSCNASTRAN, users can further conduct other analyses.

Note:

MSC.Nastran doesn’t support pyramid elements. If pyramid elements exist, they will be removed.

12.3.5 Interface to NE/Nastran

Noran Engineering, Inc. is established in 1991, created with the idea of bringing a

true Nastran analysis tool from the mainframe to the desktop. NE/Nastran is a

comprehensive finite element analysis (FEA) tool based on NASA's popular

NASTRAN finite element analysis software. NE/Nastran offers structural analysis

software solutions including: linear static, buckling, pre-stress, modal dynamics,

nonlinear, steady state, and transient heat transfer. (More information please refer to

http://www.nenastran.com)

There are various file types that can be exported from Moldex3D/Solid-I2 NENASTRAN,


(1) Original/ Warpage mesh with material properties of molded parts:

NENASTRAN_Part_Ori_*.nas/ NENASTRAN_Part_Wap_*.nas.

(2) User-specified mesh with material properties of molded part. The file is

*_NENASTRAN_ Part_MAPMESH_*.bdf.

After importing these files in NE/NASTRAN, users can further conduct other analyses.

Note:

NE/Nastran doesn’t support pyramid elements. If pyramid elements exist, they will be removed.

12.3.6 Interface to LS-DYNA

LS-DYNA, which is developed by the Livermore Software Technology Corporation

(LSTC), is being used by Automobile, Aerospace, Military, Manufacturing, and

Bioengineering companies. LS-DYNA has the capabilities from simple linear static

mechanical analysis up to advanced thermal and flow solving methods.(For more

information, please link to http://www2.lstc.com/)

There are various file types that can be exported from Moldex3D/Solid-I2 LS-DYNA, which



16 User’s Manual

http://en.wikipedia.org/wiki/Bioengineering

http://en.wikipedia.org/wiki/Manufacturing

http://en.wikipedia.org/wiki/Military

http://en.wikipedia.org/wiki/Aerospace

http://en.wikipedia.org/wiki/Automobile

http://www.nenastran.com/

Chapter 12

LSDYNA_Part_Ori_*.dyn

LSDYNA_Part_Wap_*.dyn


LSDYNA_ Part_MAPMESH_*.bdf.


LSDYNA_PartInsert_Pressure_Ori_*_EOF.dyn

LSDYNA_PartInsert_Pressure_Ori_*_EOP.dyn

LSDYNA_PartInsert_Pressure_Ori_*_00x.dyn

where x right presents the number of time steps, which ranges from 1 to the total amount of

time steps.


LSDYNA_Moldbase_Pressure_*_EOF.bdf

LSDYNA _Moldbase_Pressure_*_EOP.bdf

After importing these files in LS-DYNA, users can further conduct other analyses.

12.3.7 Interface to MSC.Marc


research facilities in many fields. The MSC.Marc product family is a nonlinear FEA

program that enables you to assess the structural integrity and performance of parts

undergoing large permanent deformations as a result of thermal or structural load.

(More information please refer to http://www.mscsoftware.com)

There are various file type that can be exported from Moldex3D/Solid-I2 MSCMARC, which



MARC_Part_Ori_*.dat

MARC_Part_Wap_*.dat


MARC_ Part_MAPMESH_*.bdf.


MARC_PartInsert_Pressure_Ori_*_EOF.dat

User’s Manual 17


Chapter 12

MARC_PartInsert_Pressure_Ori_*_EOP.dat

MARC_PartInsert_Pressure_Ori_*_00x.dat


time steps.


MARC _Moldbase_Pressure_*_EOF.bdf

MARC _Moldbase_Pressure_*_EOP.bdf

After importing these files in MSCMARC, users can further conduct other analyses.

18 User’s Manual

Chapter 12

12.3.8 Interface to NX Nastran

NX Nastran is a premium computer-aided engineering (CAE) tool that major manufacturers

worldwide rely on to produce safe, reliable and optimized designs within increasingly shorter

design cycle times. (More information please refer to http://www.designviz.com)

There are various file type that can be exported from Moldex3D/Solid-I2 NXNASTRAN, which



NXNASTRAN_Part_Ori_*.dat/

NXNASTRAN_Part_Wap_*.dat.


NXNASTRAN_ Part_MAPMESH_*.dat.


NXNASTRAN_PartInsert_Pressure_Ori_*_00x.dat

NXNASTRAN_PartInsert_Pressure_Ori_*_EOF.dat

NXNASTRAN_PartInsert_Pressure_Ori_*_EOP.dat


time steps.


NXNASTRAN_Moldbase_Pressure_*_00x.dat

NXNASTRAN_Moldbase_Pressure_*_EOF.dat

NXNASTRAN_Moldbase_Pressure_*_EOP.dat


time steps.

After importing these files in NXNASTRAN, users can further conduct other analyses.

12.3.9 Interface to Radioss

Radioss is one of leading computer-aided engineering (CAE) tool that is applied widely in

analyzing product structure under high-speed impact. Its simulation can be used to

understand and predict product behavior in complex environments and further make sure the

reliability and optimization of product designs. (More information please refer to

http://www.radioss.com)

User’s Manual 19

Chapter 12

There are various file type that can be exported from Moldex3D/Solid-I2 Radioss, which are

further described below:


Radioss_Part_Ori_*.fem

Radioss _Part_Wap_*. fem


Radioss _ Part_MAPMESH_*. fem

(3) Packing phase temperature output

Radioss _Part_PackTemperature_ Ori_*.fem

Radioss _Part_PackTemperature_ MAPMESH_*.fem

(4) Initial strain output

Radioss _Part_InitialStrain_ Ori_*.fem

Radioss _Part_InitialStrain_ MAPMESH_*.fem


Radioss _PartInsert_Pressure_Ori_*_00x. fem

Radioss _PartInsert_Pressure_Ori_*_EOF. fem

Radioss _PartInsert_Pressure_Ori_*_EOP. fem


Radioss _Moldbase_Pressure_*_00x. fem

Radioss _Moldbase_Pressure_*_EOF. fem

Radioss _Moldbase_Pressure_*_EOP. fem


time steps.

12.4 Application Tips

Moldex3D-I2 Interface modules provide a bridge between injection molding CAE and

other professional CAE. Users only need to import these interface files as initial

condition on other CAE platform and perform advanced simulations. These

simulations could be linear static, buckling, pre-stress, modal dynamics, nonlinear,

steady state, transient heat transfer … etc. This integration tool will be provided a

20 User’s Manual

Chapter 12

cost-effective total solution for related part/mold designers.

12.5 Moldex3D to Digimat Interfaces

1. Moldex3D to Digimat interfaces

Moldex3D to Digimat interface enables users to take material data resulted from

injection molding process, especially fiber orientation, into Digimat to gain readable

material parameters for further analyzing in structure softwares, such as ABAQUS

and ANSYS:

Moldex3D – DIGIMAT – ABAQUS

Moldex3D – DIGIMAT – ANSYS

1.1 Moldex3D – DIGIMAT – FE Software

Following is the detailed steps performing Moldex3D – DIGIMAT – FE software

analysis.

1.1.1 Moldex3D

Run Moldex3D analysis to obtain an orientation file (.o2d).

It is suggested to enter 1 in the box of Solver Accuracy/Performance Options to get

accurate orientation tensors. Other value for performance parameter may lead to

imprecise analysis in the following CAE calculation.

User’s Manual 21

Chapter 12

.o2d analysis example: the orientation file is presented as below.

In the first part, it shows related info, such as mesh file, material file, and process

condition file.

Second, it presents different parameters as Element Id, the number of the integration

point (IntegrationId), and the orientation tensors.

22 User’s Manual

Chapter 12

As for the last part of the file, the data in the first column presents the element

number after integration, the second column presents the number of the integration

point, and the rest columns are the value of the orientation tensors.

Note:

Moldex3D defines injection file (.o2d) for solid mesh only.

1.1.2 DIGIMAT to CAE

Step 1: Load this material file.

CAE interface: generate interface file. Select the desired software. Software with

Global axes orientation function, like Abaqus/Explicit, is included in the selection list

as well.

Inclusions' orientations given in: the axes system used to store the orientation

tensors in the orientation file.

Inclusions' orientations used in: the axes system that Digimat will use to perform the

homogenization.

Define the inclusions’ orientation: phase name, Orientation file format and File name.

Step 2: Run DIGIMAT to CAE job .

The job completed successfully is shown in Digimat log message space. Besides,

related files have been created in the Working directory:

.mat : with the material properties

.log : with the error and warning messages

When ABAQUS is selected as FE software, the file type created in the Working

directory is

.aba

When ANSYS is selected as FE software, the file type created in the Working

User’s Manual 23

Chapter 12

directory is

.ans

When LS-DYNA is selected as FE software, the file type created in the Working

directory is

.dyn

For further info, please refer to DIGIMAT to Abaqus, Ansys and Ls-Dyna

documentation.

Example :

.mat shows the data in which the link between Moldex3D and Digimat is done.

.log

24 User’s Manual

Chapter 12

.aba with the definition of the USER material card

and the meaning of every SDV in which the results of DIGIMAT calculation is stored

can be displayed in ABAQUS Postprocessor.

.ans with the definition of the USER material card

and the meaning of every SVAR in which the results of DIGIMAT calculation is stored

can be displayed in ABAQUS Postprocessor.

.dyn with the definition of the USER material card

User’s Manual 25

Chapter 12

And the meaning of every history variable in which the results of DIGIMAT calculation

is stored can be displayed in ABAQUS Postprocessor.

1.1.3 Use Digimat material file in FE – Software

Below shows how to use Digimat material file in FE software, such as ABAQUS,

ANSYS or LS-DYNA.

ABAQUS

1. Open model file

- Launch Abaqus

26 User’s Manual

Chapter 12

- Import Model (*.inp)

2. Open Plug-Ins

- Click Plug-Ins

- Select DIGIMAT

- Select 1. Add DIGIMAT material

A panel shows for users to load a DIGIMAT Material. Click Select, select the desired model,

and then click Add. Back to Abaqus.

Enter Property. Click Edit Job to change material as digimat material.

3. Run Jobs

User’s Manual 27

Chapter 12

Two words, assembly and part, are not allowed to use for the file name. These two words may

disorder the orientation tensor relationship between the original element and its corresponding

one in model renumbering phase at the beginning of running.

Add the output of SDV (state variables to have per-phase outputs)

*Output, field

*Element Output, directions=YES

E, S, SDV

Submit the job and use the sub-routine precisely.

*abaqus job=JobName user=C:\DIGIMAT\Digimat2CAE\3.0.1\exec\digi2aba\

*digi2abaStd.obj

*with Abaqus CAE submit options

ANSYS

Define a "user material" in your ANSYS model.

User material options are available in the material category: "Preprocessor – Material

Properties". The input file data can be read from DIGIMAT (.ans) there.

28 User’s Manual

Chapter 12

Two items, State variables and user constants, have been created under the material models.

Before starting the calculation, the name of the .mat file generated by DIGIMAT must be

modified to follow the generic name “DigimatMaterialID.mat”. ID has to be replaced by the

material ID in your ANSYS calculation. By default, it is 1. The name is therefore

“DigimatMaterial1.mat”.

Other running procedures are the same as the ones for running a general ANSYS job.

LS-DYNA

Define a user material card and a specific jobname for the LS-DYNA FE model.

A job name in LS-DYNA should be named following the rule: *KEYWORD_ID. All LS-DYNA

input files using DIGIMAT as a material model need to define this keyword and the name to

refer to the DIGIMAT mat file name.

An example of plate analysis is listed below:

User’s Manual 29

Chapter 12

The full .mat file name is name41.mat. 41 refers to the user material model number inside LS-

DYNA system. No. 41 to 50 are reserved in LS-DYNA for user to define material model. That

means 10 DIGIMAT material can be used in one LS-DYNA DIGIMAT coupled simulation.

In order to record history variables or state variables referring to DIGIMAT in LS-DYNA, the

following keyword in the LS-DYNA input file should be activated.

*DATABASE_EXTENT_BINARY. Look at the LS-DYNA keyword file for a complete

description.

*DATABASE_EXTENT_BINARY

$$FORCE SHELL HISTORY VARIABLE OUTPUT AT ALL 20 in-plane INTEGRATION POINT

**DATABASE_EXTENT_BINARY

$ neiph neips maxint strflg sigflg epsflg rltflg engflg

1

$# cmpflg ieverp beamip dcomp shge stssz n3thdt ialemat

0 0 0 0 0 0 0 0

30 User’s Manual

Chapter 12

Other running procedures are the same as the ones for running a general LS-DYNA job.

12.6 Moldex3D-I2 Functions Table

Table 12-1 Moldex3D-I2 available functions for ANSYS

OptionANSYS

Original Mesh Deformed Mesh Mapped Mesh

Part

Mesh Output ○ ○ ○

Fiber Orientation - Material reduction ○ ○ ○

Weld line Output ○ ○ ○

Density Distribution Output ○ ○ ○

Thermal residual stress Output ○ ╳ ○

Flow residual stress Output ○ ╳ ○Initial strain Output（As

Temperature Difference）○ ╳ ○

Packing phase temperature output ○ ╳ ○

End of cooling temperature output ○ ╳ ○

Digimat option to export fiber orientation data ○ ○ ╳

Part Insert Flow Pressure Output ○ ╳ ○

Moldbase

Moldbase Output ○ ╳ ○Moldbase Pressure Output ○ ╳ ○

Moldbase Temperature Output ○ ╳ ○

　 Runner Output ○ ○ ○

　 Output as high order element ○ ○ ○

eDesign Mesh (*.mde) ╳ ╳ ○

User’s Manual 31

Chapter 12

Table 12-2 Moldex3D-I2 available functions for ABAQUS

OptionABAQUS


Part










Digimat option to export fiber orientation data ○ ○ ╳


Moldbase






32 User’s Manual

Chapter 12

13. Moldex3D-I2 available functions for LS-DYNA

OptionLS-DYNA


Part










Digimat option to export fiber orientation data ╳ ╳ ╳


Moldbase





eDesign Mesh (*.mde) ╳ ╳ ╳

User’s Manual 33

Chapter 12

14. Moldex3D-I2 available functions for MSC.Nastran

OptionMSC-Nastran


Part





Thermal residual stress Output ╳ ╳ ╳

Flow residual stress Output ╳ ╳ ╳Initial strain Output（As






Moldbase






34 User’s Manual

Chapter 12

15. Moldex3D-I2 available functions for NE-Nastran

OptionNE-Nastran


Part












Moldbase






User’s Manual 35

Chapter 12

16. Moldex3D-I2 available functions for MSC.Marc

OptionMSC-Marc


Part












Moldbase






36 User’s Manual

Chapter 12

17. Moldex3D-I2 available functions for NX Nastran

OptionNX Nastran


Part












Moldbase






User’s Manual 37

Chapter 12

18. Moldex3D-I2 available functions for Radioss

OptionRadioss


Part











Part Insert Flow Pressure Output ○ ╳ ○Moldbase Moldbase Output ○ ╳ ○

Moldbase Pressure Output ○ ╳ ○





38 User’s Manual

Chapter 12

19. The software versions of each stress solver supported by Moldex3D-I2:

ANSYS ANSYS 10, ANSYS 11 , and ANSYS 12.1 and

ANSYS13

ABAQUS ABAQUS 6.8, ABAQUS 6.9 and ABAQUS 6.10

LS-DYNA LS-DYNA v9.71 R4.2

MSC.Marc Msc.Marc2010

MSC.Nastran Msc.Nastran2010

NE Nastran NE Nastran V8.3

NX Nastran UGS NX 7.0

User’s Manual 39

R10-UM_Ch12-SP2 (4)

Documents

injection molding analysis

moldex3di2 interface

moldex3d data

different cae analysis

injection molding simulation

molding effects

application of cae analysis

structure analysis software