Users 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.

CONTENTS

12. INTRODUCTION TO MOLDEX3D-I2 MODULES.....................1 12.1 FUNCTION OVERVIEW.......................................................................1

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 PROCESSINDUCED 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.....................1 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..........................................................................................1 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........................................................................................................1 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..................................................1

12.1.1 Thermal Residual Stress..............................................................................1 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.......................................................................2 12.1.2 Cooling Temperature Distribution..............................................................2 USER CAN USE END-OFCOOLING 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.......................................................................2 12.1.3 The Strength in Weld-Line Region ..............................................................2 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 COEFFICIENTSYET THIS FUNCTION IS NOT AVAILABLE IN MOLDEX3D/SHELL-I2 MODULE.............2 12.1.4 Density Distribution....................................................................................2 USER CAN USE THE DENSITY DISTRIBUTION TO DO MODAL ANALYSIS.YET THIS FUNCTION IS NOT AVAILABLE IN MOLDEX3D/SHELL-I2 MODULE.. .2 12.1.5 Anisotropic Material....................................................................................2 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 CONSTANTS AS SHOWN BELOW:.........................2

MOLDEX3D-I2 PART INSERT MOLDEX3D-I2 PART INSERT .................................3 3 12.1.6 Material Count Reduction...........................................................................4 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 AND 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...................................................................................................4 THE CONTROL PARAMETERS WITHIN THIS FILE IS DESCRIBED AS FOLLOWS:.........................................................................................................4 ISDOMATERIALREDUCTION: 0 OR 1 (ON: 1, OFF: 0)...................................4 PARAMETER (SEGMENT OF ANGLE): 1~35 (INTEGER, MIN=1, MAX=35, DEFAULT=3)......................................................................................................4 SEGMENT NUMBER OF ANGLE. THE ANGLE IS 0~900. THIS PARAMETER IS LIMITED FROM 1~35, AND MUST BE AN INTEGER. THE DEFAULT PARAMETER IS 3............................................................................4 PARAMETER (SEGMENT OFANGLE): 1~35 (INTEGER, MIN=1, MAX=35, DEFAULT=3)......................................................................................................4 SEGMENT NUMBER OF ANGLE. THE ANGLE IS 0~900. THIS PARAMETER IS LIMITED FROM 1~35, AND MUST BE AN INTEGER. THE DEFAULT PARAMETER IS 3............................................................................4 PARAMETER (SEGMENT OF ORIENTATION STRENGTH): 1~10(INTEGRAL, MIN=1, MAX=10, DEFAULT=5)............................................4 THIS PARAMETER IS LIMITED FROM 1~35, AND MUST BE AN INTEGER. THE DEFAULT PARAMETER IS 5....................................................................4

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...........................................................................5 12.1.7 Map Function..............................................................................................5 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 INJECTIONMOLDING ANALYSES IS DIFFERENT FROM THAT FOR STRUCTURE ANALYSES DUE TO DIFFERENT DOMAINS. STRUCTURE ANALYSES FOCUS ON THE AREA OF STRESS CONCENTRATION WHILE INJECTIONMOLDING 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. .....................................5 IN ORDER TO SOLVE THIS AWKWARD SITUATION, A FUNCTION TO MAP ELEMENT PROPERTIES BETWEEN MOLDEX3D MESH AND USERSPECIFIED 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........................5 CURRENTLY, MOLDEX3D/SHELL-I2 SUPPORTS THREE KINDS OF FILE FORMATS FOR USER-SPECIFIED MESH........................................................5 MOLDEX3D SHELL MESH FILE (*.MSH).........................................................5 ABAQUS MESH FILE (*.INP)............................................................................5 NASTRAN MESH FILE (*.BDF;*.DAT;*.NAS)..................................................5 FOR SOLID ELEMENT, MOLDEX3D/SOLID-I2 SUPPORTS VARIOUS FILE FORMATS FOR USER-SPECIFIED MESH........................................................6 MOLDEX3D SOLID MESH FILE (*.MFE)..........................................................6 ABAQUS MESH FILE (*.INP)............................................................................6 ANSYS MESH FILE (*.ANS).............................................................................6 NASTRAN MESH FILE (*.BDF;*.DAT;*.NAS)..................................................6 MARC MESH FILE CREATED BY MENTAT (*.DAT).......................................6

LS-DYNA MESH FILE(*.DYN)...........................................................................6 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. ..............................6 12.1.8 High Order Element....................................................................................6 SOMETIMES USER WOULD LIKE TO USE HIGH ORDER ELEMENT (QUADRATIC ELEMENT) FOR MORE ACCURATE SIMULATION. THEREFORE, MOLDEX3D-I2 FURTHER SUPPORTS THE AUTOTRANSLATION OF 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. 6 WHILE OUTPUT AS HIGH ORDER ELEMENT IS SELECTED, MOLDEX3D-I2 WILL TRANSLATE THE ELEMENT TYPE AUTOMATICALLY. 7 12.2 SHELL ANALYSIS OUTPUT........................................................................................7 12.2.1 Basic Procedures for Moldex3D/Shell-I2 Module......................................7 THE BASIC PROCEDURES OF MOLDEX3D/SHELL-I2 MODULE ANALYSIS ARE DESCRIBED AS FOLLOWS......................................................................7 AS POINTED IN ITEM 8, USERS HAVE TO ASSIGN THE REQUIREMENT IN INTERFACING FUNCTION OPTION DIALOG AS SHOWN IN FIG. 12-3.........8 12.2.2 Interface to ABAQUS...................................................................................8 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)..................................................................................8 THERE ARE VARIOUS FILE TYPES THAT CAN BE EXPORTED FROM MOLDEX3D/SHELL-I2 ABAQUS, WHICH ARE FURTHER DESCRIBED BELOW: .............................................................................................................8 ORIGINAL/WARPAGE MESH FILES WITH MATERIAL PROPERTIES OF MOLDED PARTS:..............................................................................................8

* _ABAQUS_PART_ORI.INP/ *_ABAQUS_PART_WAP.INP. .......................8 USER-SPECIFIED MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS:...............................................................................................................9 *_ABAQUS_ PART_MAPMESH.INP...............................................................9 AFTER IMPORTING THESE FILES IN ABAQUS, USERS CAN FURTHER CONDUCT OTHER ANALYSES........................................................................9 12.2.3 Interface to ANSYS......................................................................................9 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) .............................................................................9 THERE ARE VARIOUS FILE TYPES THAT CAN BE EXPORTED FROM MOLDEX3D/SHELL-I2 ANSYS, WHICH ARE FURTHER DESCRIBED BELOW: .............................................................................................................9 ORIGINAL/WARPAGE MESH FILES WITH MATERIAL PROPERTIES OF MOLDED PARTS: .............................................................................................9 *_ANSYS_PART_ORI.ANS/ *_ANSYS_PART_WAP.ANS. .............................9 USER-SPECIFIED MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS:...............................................................................................................9 *_ANSYS_ PART_MAPMESH.ANS. ................................................................9 AFTER IMPORTING THESE FILES IN ANSYS, USERS CAN FURTHER CONDUCT OTHER ANALYSES........................................................................9 12.2.4 Interface to MSC.Nastran............................................................................9 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)...........................9 THERE ARE VARIOUS FILE TYPES THAT CAN BE EXPORTED FROM MOLDEX3D/SHELL- I2 MSCNASTRAN, WHICH ARE FURTHER DESCRIBED BELOW: .......................................................................................9

ORIGINAL/WARPAGE MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS:...............................................................................................................9 *_MSCNASTRAN_PART_ORI.BDF/* MSCNASTRAN_PART_WAP.BDF......9 USER-SPECIFIED MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS:...............................................................................................................9 *_MSCNASTRAN_ PART_MAPMESH.BDF. ..................................................9 AFTER IMPORTING THESE FILES IN MSCNASTRAN, USERS CAN FURTHER CONDUCT OTHER ANALYSES....................................................10 12.2.5 Interface to NE/Nastran.............................................................................10 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)..................................................................10 THERE ARE VARIOUS FILE TYPES THAT CAN BE EXPORTED FROM MOLDEX3D/SHELL-I2 NENASTRAN, WHICH ARE FURTHER DESCRIBED BELOW: ...........................................................................................................10 ORIGINAL/ WARPAGE MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS: ............................................................................................................10 * _NENASTRAN_PART_ORI.NAS/* _NENASTRAN_PART_WAP.NAS.......10 USER-SPECIFIED MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS: ............................................................................................................10 *_NENASTRAN_ PART_MAPMESH.BDF. ....................................................10 AFTER IMPORTING THESE FILES IN NE/NASTRAN, USERS CAN FURTHER CONDUCT OTHER ANALYSES....................................................10 12.2.6 Interface to LS-DYAN................................................................................10 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/)............................................................................10

THERE ARE VARIOUS FILE TYPES THAT CAN BE EXPORTED FROM MOLDEX3D/SHELL-I2 LS-DYNA, WHICH ARE FURTHER DESCRIBED BELOW: ...........................................................................................................10 *_LSDYNA_PART_ORI.DYN/*_LSDYNA_PART_WAP.DYN.........................10 *_LYDYNA_PART_MAPMESH.DYN. .............................................................10 AFTER IMPORTING THESE FILES IN LS-DYNA, USERS CAN FURTHER CONDUCT OTHER ANALYSES......................................................................10 12.2.7 Interface to MSC.Marc..............................................................................11 MSC.SOFTWARE PROVIDES SIMULATION TECHNOLOGY AND SERVICES TO MANUFACTURERS AND 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)............................................................11 THERE ARE VARIOUS FILE TYPE THAT CAN BE EXPORTED FROM MOLDEX3D/SHELL-I2 MSCMARC, WHICH ARE FURTHER DESCRIBED BELOW: ...........................................................................................................11 ORIGINAL/WARPAGE MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS:.............................................................................................................11 * _MARC_PART_WAP.DAT...........................................................................11 USER-SPECIFIED MESH WITH MATERIAL PROPERTIES OF MOLDED PART:...............................................................................................................11 *_MARC_ PART_MAPMESH.BDF. ...............................................................11 AFTER IMPORTING THESE FILES IN MSCMARC, USERS CAN FURTHER CONDUCT OTHER ANALYSES......................................................................11 12.2.8 Interface to NX Nastran.............................................................................11 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)..................................11 THERE ARE VARIOUS FILE TYPES THAT CAN BE EXPORTED FROM MOLDEX3D/SHELL- I2 NXNASTRAN, WHICH ARE FURTHER DESCRIBED BELOW: ...........................................................................................................11 ORIGINAL/WARPAGE MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS:.............................................................................................................11

*_NXNASTRAN_PART_ORI.DAT/* NXNASTRAN_PART_WAP.DAT..........11 USER-SPECIFIED MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS:.............................................................................................................11 *_NXNASTRAN_ PART_MAPMESH.DAT. ...................................................11 AFTER IMPORTING THESE FILES IN NXNASTRAN, USERS CAN FURTHER CONDUCT OTHER ANALYSES....................................................11 12.3 SOLID ANALYSIS OUTPUT......................................................................................11 12.3.1 Basic Procedures for Moldex3D/Solid-I2 Module....................................11 THE BASIC PROCEDURES OF MOLDEX3D/SOLID-I2 MODULE ANALYSIS ARE DESCRIBED AS FOLLOWS....................................................................11 AS POINTED IN ITEM 8, USERS HAVE TO ASSIGN THE REQUIREMENT IN INTERFACING FUNCTION OPTION DIALOG AS SHOWN IN FIG. 12-4.......12 12.3.2 Interface to ABAQUS.................................................................................12 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)................................................................................12 THERE ARE VARIOUS FILE TYPES THAT CAN BE EXPORTED FROM MOLDEX3D/SOLID-I2 ABAQUS, WHICH ARE FURTHER DESCRIBED BELOW: ...........................................................................................................13 WHERE X PRESENTS THE NUMBER OF TIME STEPS, WHICH RANGES FROM 1 TO THE TOTAL AMOUNT OF TIME STEPS.....................................13 12.3.3 Interface to ANSYS....................................................................................14 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) ...........................................................................14 THERE ARE VARIOUS FILE TYPES THAT CAN BE EXPORTED FROM MOLDEX3D/SOLID-I2 ANSYS, WHICH ARE FURTHER DESCRIBED BELOW: ...........................................................................................................14

(1) ORIGINAL/WARPAGE MESH FILES WITH MATERIAL PROPERTIES OF MOLDED PARTS:............................................................................................14 ANSYS_ PART_ORI_*.ANS/ ANSYS_ PART_WAP_*.ANS...........................14 (2) ORIGINAL/WARPAGE RESIDUAL STRESS FILES:................................14 THERMAL RESIDUAL STRESS:....................................................................14 ANSYS_ PART_ORI_*_THERMALSTRESS.IST/ ANSYS_ PART_WAP_*_THERMALSTRESS.IST..........................................................14 FLOW RESIDUAL STRESS:...........................................................................14 ANSYS_ PART_ORI_*_FLOWSTRESS.IST/ ANSYS_ PART_WAP_*_FLOWSTRESS.IST.................................................................14 (3) USER-SPECIFIED MESH WITH MATERIAL PROPERTIES OF MOLDED PARTS:.............................................................................................................14 ANSYS_ PART_MAPMESH_*.ANS/ ANSYS_ PART_MAPMESH_*.IST. .....14 (4) PRESSURE OUTPUTS OF MULTI-COMPONENT MODELS AT VARIOUS TIMES:..............................................................................................................14 ANSYS_ PARTINSERT_PRESSURE_ORI_*_00X.CDB/ ...............................14 ANSYS _ PARTINSERT_PRESSURE_ORI_*_EOF.CDB/..............................14 ANSYS_ PARTINSERT_PRESSURE_ORI_*_EOP.CDB...............................14 (5) PRESSURE OUTPUTS OF MOLDBASE AT VARIOUS TIMES:...............14 ANSYS_ MOLDBASE_PRESSURE_*_00X.CDB/..........................................14 ANSYS_ MOLDBASE_PRESSURE _*_EOF.CDB/........................................14 ANSYS_ MOLDBASE_PRESSURE _*_EOP.CDB/........................................14 WHERE X RIGHT PRESENTS THE NUMBER OF TIME STEPS, WHICH RANGES FROM 1 TO THE TOTAL AMOUNT OF TIME STEPS.....................15 ANSYS_PART_INITIALSTRAIN_ORI_*.CDB.................................................15 AFTER IMPORTING THESE FILES IN ANSYS, USERS CAN FURTHER CONDUCT OTHER ANALYSES......................................................................15 12.3.4 Interface to MSC.Nastran..........................................................................15 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).........................15 12.3.5 Interface to NE/Nastran.............................................................................16 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)..................................................................16 12.3.6 Interface to LS-DYNA................................................................................16 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/)............................................................................16 THERE ARE VARIOUS FILE TYPES THAT CAN BE EXPORTED FROM MOLDEX3D/SOLID-I2 LS-DYNA, WHICH ARE FURTHER DESCRIBED BELOW: ...........................................................................................................16 12.3.7 Interface to MSC.Marc..............................................................................17 MSC.SOFTWARE PROVIDES SIMULATION TECHNOLOGY AND SERVICES TO MANUFACTURERS AND 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)............................................................17 THERE ARE VARIOUS FILE TYPE THAT CAN BE EXPORTED FROM MOLDEX3D/SOLID-I2 MSCMARC, WHICH ARE FURTHER DESCRIBED BELOW: ...........................................................................................................17 12.3.8 Interface to NX Nastran.............................................................................19 12.3.9 Interface to Radioss...................................................................................19 12.4 APPLICATION TIPS 20 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 COST-EFFECTIVE TOTAL SOLUTION FOR RELATED PART/MOLD DESIGNERS.............................................................20 12.5 MOLDEX3D TO DIGIMAT INTERFACES....................................................................21 1. MOLDEX3D TO DIGIMAT INTERFACES..................................................21 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:..........................................21 MOLDEX3D DIGIMAT ABAQUS...............................................................21 MOLDEX3D DIGIMAT ANSYS..................................................................21 1.1 MOLDEX3D DIGIMAT FE SOFTWARE.............................................21 FOLLOWING IS THE DETAILED STEPS PERFORMING MOLDEX3D DIGIMAT FE SOFTWARE ANALYSIS..........................................................21 1.1.1 MOLDEX3D...........................................................................................21 RUN MOLDEX3D ANALYSIS TO OBTAIN AN ORIENTATION FILE (.O2D).21 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........................................................................................21 .O2D ANALYSIS EXAMPLE: THE ORIENTATION FILE IS PRESENTED AS BELOW.............................................................................................................22 IN THE FIRST PART, IT SHOWS RELATED INFO, SUCH AS MESH FILE, MATERIAL FILE, AND PROCESS CONDITION FILE. ...................................22 22 SECOND, IT PRESENTS DIFFERENT PARAMETERS AS ELEMENT ID, THE NUMBER OF THE INTEGRATION POINT (INTEGRATIONID), AND THE ORIENTATION TENSORS. .............................................................................22 22 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. .............................................................................23 23 1.1.2 DIGIMAT TO CAE..................................................................................23 STEP 1: LOAD THIS MATERIAL FILE...........................................................23 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. ..............................................................................................................23 INCLUSIONS' ORIENTATIONS GIVEN IN: THE AXES SYSTEM USED TO STORE THE ORIENTATION TENSORS IN THE ORIENTATION FILE...........23 INCLUSIONS' ORIENTATIONS USED IN: THE AXES SYSTEM THAT DIGIMAT WILL USE TO PERFORM THE HOMOGENIZATION......................23 DEFINE THE INCLUSIONS ORIENTATION: PHASE NAME, ORIENTATION FILE FORMAT AND FILE NAME.....................................................................23 STEP 2: RUN DIGIMAT TO CAE JOB ..........................................................23 THE JOB COMPLETED SUCCESSFULLY IS SHOWN IN DIGIMAT LOG MESSAGE SPACE. BESIDES, RELATED FILES HAVE BEEN CREATED IN THE WORKING DIRECTORY:.........................................................................23 .MAT : WITH THE MATERIAL PROPERTIES................................................23 .LOG : WITH THE ERROR AND WARNING MESSAGES..............................23 WHEN ABAQUS IS SELECTED AS FE SOFTWARE, THE FILE TYPE CREATED IN THE WORKING DIRECTORY IS...............................................23 .ABA ...............................................................................................................23 WHEN ANSYS IS SELECTED AS FE SOFTWARE, THE FILE TYPE CREATED IN THE WORKING DIRECTORY IS...............................................23 .ANS.................................................................................................................24 WHEN LS-DYNA IS SELECTED AS FE SOFTWARE, THE FILE TYPE CREATED IN THE WORKING DIRECTORY IS ..............................................24 .DYN.................................................................................................................24 FOR FURTHER INFO, PLEASE REFER TO DIGIMAT TO ABAQUS, ANSYS AND LS-DYNA DOCUMENTATION.................................................................24

EXAMPLE :......................................................................................................24 .MAT SHOWS THE DATA IN WHICH THE LINK BETWEEN MOLDEX3D AND DIGIMAT IS DONE...................................................................................24 24 .LOG................................................................................................................24 25 .ABA WITH THE DEFINITION OF THE USER MATERIAL CARD.................25 25 AND THE MEANING OF EVERY SDV IN WHICH THE RESULTS OF DIGIMAT CALCULATION IS STORED CAN BE DISPLAYED IN ABAQUS POSTPROCESSOR..........................................................................................25 25 .ANS WITH THE DEFINITION OF THE USER MATERIAL CARD.................25 25 25 AND THE MEANING OF EVERY SVAR IN WHICH THE RESULTS OF DIGIMAT CALCULATION IS STORED CAN BE DISPLAYED IN ABAQUS POSTPROCESSOR..........................................................................................25 .DYN WITH THE DEFINITION OF THE USER MATERIAL CARD.................25 26 26 AND THE MEANING OF EVERY HISTORY VARIABLE IN WHICH THE RESULTS OF DIGIMAT CALCULATION IS STORED CAN BE DISPLAYED IN ABAQUS POSTPROCESSOR.........................................................................26 1.1.3 USE DIGIMAT MATERIAL FILE IN FE SOFTWARE.........................26 BELOW SHOWS HOW TO USE DIGIMAT MATERIAL FILE IN FE SOFTWARE, SUCH AS ABAQUS, ANSYS OR LS-DYNA..............................26 ABAQUS..........................................................................................................26 1. OPEN MODEL FILE....................................................................................26 - LAUNCH ABAQUS 26

- IMPORT MODEL (*.INP)27 2. OPEN PLUG-INS.........................................................................................27 - CLICK PLUG-INS 27 - SELECT DIGIMAT 27 - SELECT 1. ADD DIGIMAT MATERIAL......................................................................27 A PANEL SHOWS FOR USERS TO LOAD A DIGIMAT MATERIAL. CLICK SELECT, SELECT THE DESIRED MODEL, AND THEN CLICK ADD. BACK TO ABAQUS................................................27 ENTER PROPERTY. CLICK EDIT JOB TO CHANGE MATERIAL AS DIGIMAT MATERIAL. .........27 3. RUN JOBS 27 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.

28 ADD THE OUTPUT OF SDV (STATE VARIABLES TO HAVE PER-PHASE OUTPUTS)...................28 *OUTPUT, FIELD 28 *ELEMENT OUTPUT, DIRECTIONS=YES.........................................................................28 E, S, SDV 28 SUBMIT THE JOB AND USE THE SUB-ROUTINE PRECISELY...................................................28 *ABAQUS JOB=JOBNAME USER=C:\DIGIMAT\DIGIMAT2CAE\3.0.1\EXEC\DIGI2ABA\. .28 *DIGI2ABASTD.OBJ 28 *WITH ABAQUS CAE SUBMIT OPTIONS.........................................................................28 ANSYS 28 DEFINE A "USER MATERIAL" IN YOUR ANSYS MODEL...................................................28 USER MATERIAL OPTIONS ARE AVAILABLE IN THE MATERIAL CATEGORY: "PREPROCESSOR MATERIAL PROPERTIES". THE INPUT FILE DATA CAN BE READ FROM DIGIMAT (.ANS) THERE. 28 TWO ITEMS, STATE VARIABLES AND USER CONSTANTS, HAVE BEEN CREATED UNDER THE MATERIAL MODELS. 29 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.29 OTHER RUNNING PROCEDURES ARE THE SAME AS THE ONES FOR RUNNING A GENERAL ANSYS JOB. 29 LS-DYNA 29 DEFINE A USER MATERIAL CARD AND A SPECIFIC JOBNAME FOR THE LS-DYNA FE MODEL. 29 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. 29 AN EXAMPLE OF PLATE ANALYSIS IS LISTED BELOW:........................................................29 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...............................................................30 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. 30

*DATABASE_EXTENT_BINARY. LOOK AT THE LS-DYNA KEYWORD FILE FOR A 30 *DATABASE_EXTENT_BINARY......................................................................30 $$FORCE SHELL HISTORY VARIABLE OUTPUT AT ALL 20 IN-PLANE INTEGRATION POINT30 **DATABASE_EXTENT_BINARY....................................................................30 $ NEIPH NEIPS MAXINT STRFLG SIGFLG EPSFLG RLTFLG ENGFLG................30 130 $# CMPFLG IEVERP BEAMIP DCOMP SHGE STSSZ N3THDT IALEMAT............30 0 0 0 0 0 0 0 0..........................................30 OTHER RUNNING PROCEDURES ARE THE SAME AS THE ONES FOR RUNNING A GENERAL LSDYNA JOB. 31 12.6 MOLDEX3D-I2 FUNCTIONS TABLE........................................................................31
COMPLETE DESCRIPTION.

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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/LSDYNA/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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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 User can use End-ofcooling 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 The 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 coefficientsYet this function is not available in Moldex3D/Shell-I2 module. 12.1.4 Density Distribution User can use the density distribution to do Modal analysis.Yet this function is not available in Moldex3D/ShellI2 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 6 6 stressstrain relationship matrix constants as shown below:

[D]

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

Symmetric

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Di , j

D11 D 21 D = 31 D41 D51 D61

D22 D32 D42 D52 D62

D33 D43 D53 D63 D44 D54 D64 D55 D65

D66

Moldex3D-I2 Part Insert Moldex3D-I2 Part Insert

Fig 1.1 Part Insert run ID

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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 fibercontained 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 and 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 easily. function Moldex3D toolbar helps user find cmi files more

The control parameters within this file is described as follows: IsDoMaterialReduction: 0 or 1 (ON: 1, OFF: 0) Parameter (Segment of angle): 1~35 (Integer, Min=1, Max=35, Default=3) Segment number of angle. The angle is 0~900. This parameter is limited from 1~35, and must be an integer. The default parameter is 3. Parameter (Segment ofangle): 1~35 (Integer, Min=1, Max=35, Default=3) Segment number of angle. The 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.

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Fig 1.2 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)

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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
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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 1.3 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

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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. 12-3.

Fig 1.4 Interfacing Function Dialog

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.

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User-specified mesh with material properties of molded parts: *_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 costconscious 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, which are further described below: Original/Warpage mesh files with material properties of molded parts: *_ANSYS_Part_Ori.ans/ *_ANSYS_Part_Wap.ans. User-specified mesh with material properties of molded parts: *_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. User-specified mesh with material properties of molded parts: *_MSCNASTRAN_ Part_MAPMESH.bdf.

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After importing these files in MSCNASTRAN, users can further conduct other analyses. 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. User-specified mesh with material properties of molded parts: *_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, which are further described below:
Original/ Warpage mesh with material properties of molded parts:

*_LSDYNA_Part_Ori.dyn/*_LSDYNA_Part_Wap.dyn
User-specified mesh with material properties of molded parts:

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

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12.2.7 Interface to MSC.Marc MSC.Software provides simulation technology and services to manufacturers and 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: Original/Warpage mesh with material properties of molded parts: * _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: Original/Warpage mesh with material properties of molded parts: *_NXNASTRAN_Part_Ori.dat/* NXNASTRAN_Part_Wap.dat. User-specified mesh with material properties of molded parts: *_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
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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 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.

Fig 1.5 Interfacing Function Dialog

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

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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/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.

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12.3.3 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 costconscious 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, which are further described below: (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. (4) Pressure outputs of multi-component models at various times: 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.

(5) Pressure outputs of moldbase at various times: ANSYS_ Moldbase_Pressure_*_00x.cdb/ ANSYS_ Moldbase_Pressure _*_EOF.cdb/ ANSYS_ Moldbase_Pressure _*_EOP.cdb/
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Where x right presents the number of time steps, which ranges from 1 to the total 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 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 type that can be exported from Moldex3D/Solid-I2 MSCNASTRAN, which are further described below:

(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. (3) Pressure outputs of multi-component models at various times: 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. (4) Pressure outputs of moldbase at various times: MSCNASTRAN_Moldbase_Pressure_*_00x.bdf MSCNASTRAN_Moldbase_Pressure_*_EOF.bdf MSCNASTRAN_Moldbase_Pressure_*_EOP.bdf Where x right presents the number of time steps, which ranges from 1 to the total amount of
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time steps. After importing these files in MSCNASTRAN, users can further conduct other analyses.

Note:
MSC.Nastran doesnt 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, which are further described below:

(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 doesnt 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
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are further described below: (1) Original/Warpage mesh with material properties of molded parts: LSDYNA_Part_Ori_*.dyn LSDYNA_Part_Wap_*.dyn (2) User-specified mesh with material properties of molded part: LSDYNA_ Part_MAPMESH_*.bdf. (3) Pressure outputs of multi-component models at various times: 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. (4) Pressure outputs of moldbase at various times: 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 MSC.Software provides simulation technology and services to manufacturers and 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 are further described below: (1) Original/Warpage mesh with material properties of molded parts: MARC_Part_Ori_*.dat MARC_Part_Wap_*.dat (2) User-specified mesh with material properties of molded part: MARC_ Part_MAPMESH_*.bdf.

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(3) Pressure outputs of multi-component models at various times: MARC_PartInsert_Pressure_Ori_*_EOF.dat MARC_PartInsert_Pressure_Ori_*_EOP.dat MARC_PartInsert_Pressure_Ori_*_00x.dat Where x right presents the number of time steps, which ranges from 1 to the total amount of time steps. (4) Pressure outputs of moldbase at various times: MARC _Moldbase_Pressure_*_EOF.bdf MARC _Moldbase_Pressure_*_EOP.bdf After importing these files in MSCMARC, users can further conduct other analyses.

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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 are further described below: (1) Original/Warpage mesh with material properties of molded parts: NXNASTRAN_Part_Ori_*.dat/ NXNASTRAN_Part_Wap_*.dat. (2) User-specified mesh with material properties of molded part: NXNASTRAN_ Part_MAPMESH_*.dat. (3) Pressure outputs of multi-component models at various times: NXNASTRAN_PartInsert_Pressure_Ori_*_00x.dat NXNASTRAN_PartInsert_Pressure_Ori_*_EOF.dat NXNASTRAN_PartInsert_Pressure_Ori_*_EOP.dat Where x right presents the number of time steps, which ranges from 1 to the total amount of time steps. (4) Pressure outputs of moldbase at various times: NXNASTRAN_Moldbase_Pressure_*_00x.dat NXNASTRAN_Moldbase_Pressure_*_EOF.dat NXNASTRAN_Moldbase_Pressure_*_EOP.dat Where x right presents the number of time steps, which ranges from 1 to the total amount of 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)

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There are various file type that can be exported from Moldex3D/Solid-I2 Radioss, which are further described below: (1) Original/Warpage mesh with material properties of molded parts: Radioss_Part_Ori_*.fem Radioss _Part_Wap_*. fem (2) User-specified mesh with material properties of molded part: 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 (5) Pressure outputs of multi-component models at various times: Radioss _PartInsert_Pressure_Ori_*_00x. fem Radioss _PartInsert_Pressure_Ori_*_EOF. fem Radioss _PartInsert_Pressure_Ori_*_EOP. fem (6) Pressure outputs of moldbase at various times: Radioss _Moldbase_Pressure_*_00x. fem Radioss _Moldbase_Pressure_*_EOF. fem Radioss _Moldbase_Pressure_*_EOP. fem Where x right presents the number of time steps, which ranges from 1 to the total amount of 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

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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.

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.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.

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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

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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

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.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

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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

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- 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

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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.

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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:

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The full .mat file name is name41.mat. 41 refers to the user material model number inside LSDYNA 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 1 $# cmpflg 0 ieverp 0 0 beamip 0 dcomp 0 0 shge 0 stssz 0 n3thdt ialemat strflg sigflg epsflg rltflg engflg

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

12.6 Moldex3D-I2 Functions Table

Table 5.1 Moldex3D-I2 available functions for ANSYS

Option
Mesh Output Fiber Orientation Material reduction Weld line Output Density Distribution Output Thermal residual stress Output Flow residual stress Output Initial strain OutputAs Temperature Difference Packing phase temperature output End of cooling temperature output Digimat option to export fiber orientation data

ANSYS
Original Mesh Deformed Mesh Mapped Mesh

Part

Part Insert Moldbase

Flow Pressure Output Moldbase Output Moldbase Pressure Output Moldbase Temperature Output Runner Output Output as high order element

eDesign Mesh (*.mde)

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Table 5.2

Moldex3D-I2 available functions for ABAQUS

Option
Mesh Output Fiber Orientation Material reduction Weld line Output Density Distribution Output Thermal residual stress Output Flow residual stress Output Initial strain OutputAs Temperature Difference Packing phase temperature output End of cooling temperature output Digimat option to export fiber orientation data

ABAQUS
Original Mesh Deformed Mesh Mapped Mesh

Part

Part Insert Moldbase

Flow Pressure Output Moldbase Output Moldbase Pressure Output Moldbase Temperature Output Runner Output Output as high order element

eDesign Mesh (*.mde)

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13.

Moldex3D-I2 available functions for LS-DYNA

Option
Mesh Output Fiber Orientation Material reduction Weld line Output Density Distribution Output Thermal residual stress Output Flow residual stress Output Initial strain OutputAs Temperature Difference Packing phase temperature output End of cooling temperature output Digimat option to export fiber orientation data

LS-DYNA
Original Mesh Deformed Mesh Mapped Mesh

Part

Part Insert Moldbase

Flow Pressure Output Moldbase Output Moldbase Pressure Output Moldbase Temperature Output Runner Output Output as high order element

eDesign Mesh (*.mde)

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14.

Moldex3D-I2 available functions for MSC.Nastran

Option
Mesh Output Fiber Orientation Material reduction Weld line Output Density Distribution Output Thermal residual stress Output Flow residual stress Output Initial strain OutputAs Temperature Difference Packing phase temperature output End of cooling temperature output Digimat option to export fiber orientation data

MSC-Nastran
Original Mesh Deformed Mesh Mapped Mesh

Part

Part Insert Moldbase

Flow Pressure Output Moldbase Output Moldbase Pressure Output Moldbase Temperature Output Runner Output Output as high order element

eDesign Mesh (*.mde)

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15.

Moldex3D-I2 available functions for NE-Nastran

Option
Mesh Output Fiber Orientation Material reduction Weld line Output Density Distribution Output Thermal residual stress Output Flow residual stress Output Initial strain OutputAs Temperature Difference Packing phase temperature output End of cooling temperature output Digimat option to export fiber orientation data

NE-Nastran
Original Mesh Deformed Mesh Mapped Mesh

Part

Part Insert Moldbase

Flow Pressure Output Moldbase Output Moldbase Pressure Output Moldbase Temperature Output Runner Output Output as high order element

eDesign Mesh (*.mde)

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16.

Moldex3D-I2 available functions for MSC.Marc

Option
Mesh Output Fiber Orientation Material reduction Weld line Output Density Distribution Output Thermal residual stress Output Flow residual stress Output Initial strain OutputAs Temperature Difference Packing phase temperature output End of cooling temperature output Digimat option to export fiber orientation data

MSC-Marc
Original Mesh Deformed Mesh Mapped Mesh

Part

Part Insert Moldbase

Flow Pressure Output Moldbase Output Moldbase Pressure Output Moldbase Temperature Output Runner Output Output as high order element

eDesign Mesh (*.mde)

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17.

Moldex3D-I2 available functions for NX Nastran

Option
Mesh Output Fiber Orientation Material reduction Weld line Output Density Distribution Output Thermal residual stress Output Flow residual stress Output Initial strain OutputAs Temperature Difference Packing phase temperature output End of cooling temperature output Digimat option to export fiber orientation data

NX Nastran
Original Mesh Deformed Mesh Mapped Mesh

Part

Part Insert Moldbase

Flow Pressure Output Moldbase Output Moldbase Pressure Output Moldbase Temperature Output Runner Output Output as high order element

eDesign Mesh (*.mde)

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18.

Moldex3D-I2 available functions for Radioss

Option
Mesh Output Fiber Orientation Material reduction Weld line Output Density Distribution Output Thermal residual stress Output Flow residual stress Output Initial strain OutputAs Temperature Difference Packing phase temperature output End of cooling temperature output Digimat option to export fiber orientation data

Radioss
Original Mesh Deformed Mesh Mapped Mesh

Part

Part Insert Moldbase

Flow Pressure Output Moldbase Output Moldbase Pressure Output Moldbase Temperature Output

Runner Output Output as high order element

eDesign Mesh (*.mde)

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19.
ANSYS ABAQUS L S - D YN A M S C . M a rc M S C . N as t r a n N E N as t r a n N X N as t r a n

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

A N S Y S 10 , A N S Y S 1 1 , an d A N S Y S 1 2 . 1 a n d ANSYS13 ABAQUS 6.8, ABAQUS 6.9 and ABAQUS 6.10 LS-DYNA v9.71 R4.2 M sc . M a r c 2 0 10 M sc . N a s t r a n2 0 1 0 N E Na s t ra n V 8 . 3 U G S NX 7 . 0

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