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Chapter 9: POLYFLOW

9.1. Introduction
ANSYS POLYFLOW 14.0 is the third version of ANSYS POLYFLOW to be integrated into ANSYS Workbench.
Starting in version 12.1, ANSYS POLYFLOW users were able to create interlinked systems with geometry,
meshing, solution setup, solver and postprocessing inside ANSYS Workbench, using shared licensing
and HPC. Blow molding and extrusion application-specific versions of ANSYS POLYFLOW were introduced
to allow specific industrial processes to be simulated. With regard to modeling, two new models were
introduced: the volume of fluid (VOF) model for free surface modeling in a fixed domain; and the discrete
ordinates (DO) model for radiation.
In ANSYS POLYFLOW 14.0, the ANSYS Workbench integration, licensing, and modeling capabilities have
been further enhanced to meet the needs of ANSYS POLYFLOW users.

Note
ANSYS POLYFLOW 14.0 is installed under ANSYS Inc\v140\polyflow on Windows and
ansys_inc/v140/polyflow on Linux platforms.
ANSYS POLYFLOW 14.0 is available within ANSYS Workbench for Windows and Linux platforms.

9.2. New Features


The new features in ANSYS POLYFLOW 14.0 are as follows:

ANSYS POLYFLOW can use Named Selections from ANSYS Meshing.

ANSYS POLYFLOW can read meshes created using the Assembly Meshing group in ANSYS Meshing
or the CutCell mesher in TGrid.

You can create user-defined templates via the UPDT button to parameterize the values for
the absissa and/or ordinate of:

multi-ramp functions of time or S (for evolution problems), when the multi-ramp functions are
applied on a parameter of a model (e.g., fac, vn, cp)

multi-ramp functions of X, Y, or Z coordinates when defining the average temperature, the average concentration, the initial fluid fraction for volume of fluid (VOF) problems, or the initial
thickness distribution of films or the parison for shell models.

ANSYS POLYFLOW allows you to define force-driven mold motion for shell surface parisons,
with limitations on the maximum displacement.

A new heuristic technique has been implemented for defining the order of elimination of the
equations in the AMF linear solver (which is the default solver in ANSYS POLYFLOW 14.0). This
technique can lead to significant reductions in CPU time and memory requirements under
certain circumstances. Improvements should be observed for fixed and deforming domain
simulations when the mini-element interpolation is used. The new heuristic technique does
not make any difference when pressure stabilization is enabled (linear interpolation of velocities).
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Chapter 9: POLYFLOW

ANSYS POLYFLOW provides further options for decoupling the calculation of various fields:

For internal radiation, you can decouple the calculation of the velocities, irradiance, and/or
temperatures.

For transport of species, you can decouple the calculation of the velocities and species.

ANSYS POLYFLOW allows you to export temperature and thickness data to results files that
can be used for further simulations in ANSYS Mechanical.

ANSYS POLYFLOW allows you to simulate contact release (i.e., the detachment of a free surface
that has come into contact with a wall) for a 3D or shell model, as part of a blow molding or
thermoforming simulation.

ANSYS POLYFLOW allows you to convert .poly files written by ANSYS Meshing to the
POLYFLOW format.

ANSYS POLYFLOW can read and recognize 1D and 2D PMeshes exported from ANSYS ICEM
CFD and ANSYS Meshing.

POLYFLOW allows you to convert a mesh into a sliceable mesh in POLYDATA, so that you can
employ certain remeshing techniques that are otherwise incompatible with the mesh or easily
modify aspects of an existing sliceable mesh.

A POLYFLOW system can be connected to an ANSYS Mechanical system in Workbench, so that


you can transfer thickness and temperature data.

A series of templates are available. These templates are in the form of Workbench projects,
and each contains a complete simulation from geometry to postprocessing, including design
parameters. You are thus able to connect your own geometry, adapt the design parameters
in ANSYS DesignXplorer, and simply update the project. A predefined report is then automatically created in ANSYS CFD-Post. These templates currently cover the main applications of
POLYFLOW: extrusion, blow molding, and thermoforming.

POLYFLOW documentation is available via the Help pull-down menu in the various POLYFLOW
applications, as well as the Help chart button in ANSYS POLYMAT and ANSYS POLYCURVE.

For a boundary that experiences both incoming and outgoing flows (e.g., an outlet with
backflow) as part of a nonisothermal simulation, ANSYS POLYFLOW allows you to impose a
temperature on the flow that enters the domain via the Incoming fluid temperature thermal
boundary condition.

The view in the ANSYS POLYFUSE Graphics Display window can be manipulated via a
graphics toolbar (which replaces the View Options panel), as well as shortcut keys.

A more user-friendly graphical user interface has been introduced for ANSYS POLYMAT and
ANSYS POLYSTAT. The updated GUI provides a higher quality display of the results and allows
an interactive manipulation of graphical objects.

POLYFLOW provides access to POLYFLOW project templates, which are Workbench project
files that you can modify in order to quickly and easily set up your own problem. These templates include blow molding, extrusion, and thermoforming problems.

9.3. Defect Fixes


The defect fixes in ANSYS POLYFLOW 14.0 are as follows:

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It is now possible to get the ideal (pointwise) thickness distribution when optimizing parison in
blow molding/thermoforming simulations.

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Defect Fixes

Error messages about inconsistencies between mesh and data files has been corrected in ANSYS
POLYDATA.

A fix was introduced to avoid the solver crashes when solving a pressing simulation with the secant
method.

It is now possible to display fields on PMeshes in CFD-Post.

Force fields on boundaries now have units in CFD-Post.

Error messages about problems during mesh conversion have been corrected.

A fix was introduced to avoid a crash of ANSYS POLYDATA when switching from the sliding mesh
setup to steady state.

A fix was introduced for shell blow molding / thermoforming problems that use the non-isothermal
KBKZ model, to ensure that the temperature dependence is applied to the additional viscosity.

A fix was introduced to avoid POLYDATA crashes as a result of double-clicking in the tree view.

The Set units for CFD-Post or Ansys Mapper menu item has been removed from the Outputs
menu for mixing tasks.

The unsupported Mini-element for velocities, linear pressure interpolation for viscoelastic flows
is no longer accessible in the Interpolation menu of POLYDATA.

The formulation and interpolation of the Lagrange multiplier for slipping and fluid-structure interaction has been corrected.

A fix was introduced to avoid POLYDATA crashes as a result of converting a viscoelastic VOF subtask into a Newtonian VOF sub-task.

For shell blow molding problems in which evolution is applied on the inflation pressure, the EVOL
summary menu (opened via the LSEV button) has been corrected so that it no longer reports an
inflation pressure of zero.

A fix was introduced to avoid POLYDATA crashes as a result of reading a material data file for a
contact case.

The POLYFLOW listing file has been improved for cases when the solver stops due to insufficient
memory.

A fix was introduced to ensure that the POLYFLOW listing file reports the correct number of processors when running in parallel.

A fix was introduced to ensure that the mathematical library does not use more processors than
the number you specified.

A fix was introduced to ensure that the ordering of input parameters in DesignXplorer is not inconsistent when template parameters are modified in POLYDATA.

The direction of the rotation axis of a moving part (that employs the mesh superposition technique)
no longer affects its velocity.

Contact detection has been improved for shell molds.

A fix was introduced to avoid POLYDATA crashes when you modify the direction of generation
during the creation of a 3D mesh from a shell result.

Running POLYFLOW in standalone mode under ANSYS licensing is now easier, as you no longer
have to set the environment variable.

DOS windows no longer pop up repeatedly when updating a series of Design Points for POLYFLOW
systems in Workbench.

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Chapter 9: POLYFLOW

The axis and speed of rotation of a moving part (that employs the mesh superposition technique)
can now be flagged as a parameter of a user-defined template.

A fix was introduced to avoid POLYDATA crashes when you modify the type of a mold during a
contact problem.

A fix was introduced to avoid POLYDATA crashes when a change of units is rejected.

It is now possible to define all components of the force applied on a mold as template parameters.

It is now possible to define independent time histories for the transient shear rate and the transient
elongational rate when fitting material parameters to your data in POLYMAT.

9.4. Known Limitations


The known limitations for ANSYS POLYFLOW 14.0 are as follows:

The Interrupt action in ANSYS Workbench has no effect on an ANSYS POLYFLOW solver run.

You cannot perform any actions that modify an ANSYS POLYFLOW system (e.g., saving or closing
a project, duplicating an ANSYS POLYFLOW system) while an ANSYS POLYFLOW tool is open. In
some cases, ANSYS Workbench will allow such an action, but an error is generated.

CutCell meshes are not compatible with mixing or volume of fluid (VOF) tasks, viscoelastic
flow sub-tasks, contact detection, internal radiation, the Narayanaswamy model, flow-induced
crystallization, or the adaptive meshing technique. Moreover, the interpolation for the velocity
field is limited: for a pure CutCell mesh, it must be the linear element; for a portion of a CutCell
mesh that has been converted into a sliceable mesh, it can be either the linear element or the
mini-element.

Due to some modifications of the contact algorithm to accommodate the needs of the automatic contact release feature, you may need to make small revisions to the contact parameters
of a blow molding or thermoforming problem that was originally set up using version 13.0,
in order to run it using version 14.0.

IGES files exported by POLYFLOW always use millimeters for the unit of length. When planning
to export an IGES file from POLYFLOW, it is highly recommended that you use millimeters in
your original CAD model or when creating the geometry in ANSYS DesignModeler. You should
then use the mm/g/s unit system in POLYFLOW. If another unit systems is used, you may have
difficulties importing the IGES file of the deformed geometry back into ANSYS DesignModeler
or any other CAD tool.

If you are using Windows XP, POLYDATA may crash when importing a material data file. This
can be avoided if you change the default TEMP directory to a directory that is not deeply
nested in other directories (e.g., change it to D:\temp).

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Release 14.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates.