Unit 1: Quick Cool Flow Warp

Analysis
Introduction: Quick CFW Analysis

Aim

The aim of this exercise is to complete a Cool, Flow, Warp analysis, from importing an STL file,
to creating a report.

Why do it

Performing this quick analysis will show the overall procedure for running a flow analysis in MPI.
Every project is different, but the basic steps in this unit are typical for an analysis project. The
different sections of the analysis process will not be described in detail, however, other units in
this training course will show the analysis process in more detail.

Overview

In the process of completing this project, you will do the following:

 Open a project
 Import an STL file
 Mesh the STL file
 Diagnose the mesh quality
 Fix the mesh
 Model a runner and cooling system
 Prepare the Cool, Flow, and Warp analysis sequence
 Select a material
 Run the analysis sequence
 Review results
 Create a report

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Figure 1. Snap Cover model

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 Practice: Quick Cool Flow Warp Analysis

Open project

A project is the highest level of organization within Synergy’s project management system. All
information contained within a project is stored in a single directory. You can import and analyze
as many models as you wish within a single project.
In this exercise, you will open a project that has already been created for you.

 To open a project

1. Click (File Open Project), and navigate to the folder where the Moldflow Training
projects are stored, open the folder quickcfw and double click the project file quickcfw.mpi.

Preparing the Mesh

Import STL

When you import a Stereo-lithography (STL) file, it can be created in either ASCII or binary
format. The STL file should be complete and incorrupt.

 To import the STL file

1. Right-click in the Project View pane and select Import.
2. Click on the file snap_cover.stl, and click Open.
3. Accept Fusion as the mesh type to work with, accept the default units (mm), and click OK.
4. Right-click on the Study in the Project View pane, and rename it Snap Cover.
5. Use the model manipulation tools to investigate the STL model.

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 Figure 2. STL representation of the Snap Cover model

Note: The STL model shown in Figure 2 is shown with the display set to Net. Depending on the
settings in the preferences, it could also be shown as transparent, solid, or in combination
with Net. Use the command FilePreferences on the Default Display tab to see what the
setting is and change it.

Mesh STL file

If your STL model has triangles with very high aspect ratio, the mesh will be distorted, and the
analysis results will be less accurate.
For a mesh triangle, the aspect ratio is the ratio of the length of the longest side, to the height
perpendicular to that side. As a general rule, this ratio should be less than 6:1.
On the Generate Mesh dialog, the following Advanced options can be set:
 Edge Length
 Mesh Control
Edge length is the main option that is controlled to adjust the mesh density. Further discussion on
mesh options will occur in the translation unit.

 To mesh the STL file

1. Click (Mesh Generate Mesh), or double-click the Mesh icon in the Study Tasks
pane.
2. Click the Advanced … button in the Generate Mesh dialog.
3. Enter 3.8 (mm) into the Global edge length field.
4. Click Generate Mesh to begin the meshing procedure.
It will only take a few moments to create the meshed model.
5. In the Layers pane, ensure that only the New Triangles layer is selected.

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Note: If the Layers pane is not visible, use the menu command View  Layers or click Ctrl+L to
display the layers dialog.

Figure 3. Meshed model

Check Mesh

Once the STL model file has been meshed, you can quickly check the quality of the mesh, using a
mesh statistics report. The Mesh Statistics report is broken into six main sections:
 Entity counts
 Edge details
 Orientation details
 Intersection details
 Surface triangle aspect ratio
 Match ratio

Generally, the Surface triangle aspect ratio and Match ratio sections are the two most critical
aspects of the mesh, and the most likely to cause problems. In a Fusion mesh, a match ratio of
85% or better is critical for good flow analysis results, and 90% for accurate warpage results. The
match ratio checks if one pair of elements is matched in both directions. For example, elements
on the top and bottom surfaces of a Fusion mesh are checked to ensure that they are matched
spatially.

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 Figure 4. Mesh Statistics Report

 To check the mesh for errors

1. Click (Mesh Mesh Statistics).

2. Scan the Mesh Statistics report for any quality issues, as shown in Figure 4 above.
The report indicates that the mesh is reasonably clean and problem free, although it does
show that the model contains a maximum aspect ratio of 10.7, which may affect the result
accuracy. The mesh match ratio is also important. In this case, it is fine as the ratio is above
90%.
You will now display the aspect ratio plot to conform this result, and then in the next step, get
the maximum aspect ratio down to 6:1.
3. First, click Close to remove the Mesh Statistics display from screen.

4. Click (Mesh Aspect Ratio) and close the tip dialog that opens.
5. Enter 6 into the Minimum field.
6. Ensure that Display is selected in the drop-down list, select the Place results in diagnostic
layer checkbox, and click Show.

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Figure 5. High aspect ratio elements

In Figure 5 above, the high aspect ratio elements are in a different layer and the layer color was
changed to yellow so the problem elements are shown better. In addition, there is a colored line
pointing normal to the element. The red lines indicate a higher aspect ratio and the blue is a lower
aspect ratio, but still above 6:1.

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 Fix Mesh Aspect Ratio

As a general rule, the ratio of the longest side to the height (aspect ratio) should be less than 6:1.
Aspect ratios greater than 6:1 should not be used because high aspect ratios can cause the program
to run poorly and affect result accuracy. Long thin elements should be avoided when the pressure,
temperature and velocity of the flow might vary rapidly.
To reduce the aspect ratio of the elements above 6:1, they were placed on a Diagnostic layer. In
the Layers pane, the expand command is used at the default level of 1, which will show the
elements directly surrounding the problem elements. Once the problem elements are identified,
the Mesh Tools can be used to fix the problem and repair the mesh.
Refer to the index term Mesh in the online Help for more information on checking and correcting
mesh problems.

 To expand the mesh around high aspect ratio elements

1. Click (View Layers) to open the Layers dialog if not already open.
2. De-select every layer except the Diagnostic results layer. (This layer was created when you
displayed the aspect ratio plot in the previous step).
3. Highlight the Diagnostic results layer.
4. Click Expand in the Layers pane.
5. Accept the default of 1 level, and click OK.
Every element that was originally on the diagnostics layer (high aspect ratio elements) will
have the elements around them added to the diagnostics layer also.

 To fix the first problem

1. Click (Mesh Mesh Tools).

2. Rotate the model around to look at the problem areas.
3. Find the element with the red line sticking out normal to the element.
4. Center and zoom up on the area.
5. Rotate the model around to help understand the problem.

Tip: An easy way to zoom up on an area and make it easy to work on is to use the Center
command, . Then use the Dynamic zoom command . This will quickly magnify the
required area. The Center command will ensure that when an area is magnified, and the part
is rotated, it will not rotate off the screen.

To make it easy to use the Center and Dynamic zoom commands, program the mouse to use
those commands.

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6. If necessary, turn on the New Triangles layer to see the entire part.

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 Figure 6. Problem element

Note: In Figure 6, the high aspect ratio element is yellow and the expanded elements are in a darker
blue green color. The nodes on the diagnostics layer are red. This was done by putting the
high aspect ratio elements on a diagnostics layer, expanding the layer, then running the
display aspect ratios command again to put them on a second layer. By doing this different
colors can be used. This is done here for clarity only.

Several techniques can be used to fix the problem including;

 Node 1 can be merged into node 2
 Node 1 can be aligned by using nodes 2 and 4
 The high aspect ratio element can be swapped with element 5

To fix this particular problem the Align Nodes command will be used.

7. Click on the Align Nodes tool in the function list on the left of the Mesh Tools dialog.
8. Click on the nodes at the locations marked in Figure 6 as 2 and 4. This will update the fields
Alignment nodes 1 and 2.
9. Click on the node to be moved which is marked in Figure 6 as node 1.
10. Click Apply.

Tip: The right-mouse button can be clicked and Apply in the context menu can be used also.

Note: A yellow dialog field in Synergy indicates it is the active field. Many dialogs have automatic
field switching. For instance, when using the Align Nodes command, it will move between
the 1st to 2nd then to the 3rd field automatically.

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 To fix another problem area

Figure 7. Fix by Merging

The problem shown in Figure 7 will be fixed by node merging. This area is on one of the snap
fingers.
1. Click on the Merge Nodes tool.
2. The first node picked is the node that is kept. Click on the node marked 1.
3. Click on the node marked 2
4. Click Apply.

 To fix the remaining problem areas

 Zoom in and out as necessary to navigate to the other problem areas
 Turn on and off layers as necessary to understand the problem and find problem areas
 When the legend disappears from the right side of the screen, the aspect ratios are all below
6:1

 To recheck the model

1. Click (Mesh Mesh Statistics) to check the mesh statistics again.

2. Verify there are no problems. Be sure to check orientation details. Often in the process of
fixing a mesh the orientation becomes inconsistent.
3. Fix the orientation if necessary by the menu command Mesh Orient All.

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 To move nodes and elements back to the original locations
1. De-select the Nodes and Triangles layers.
2. Ensure the Diagnostic results layer is ON.
3. Ensure the Mesh Tools dialog is closed.
4. Use the menu command Edit Select By Properties , or Ctrl + B.
5. Note the Entity type Node is highlighted.
6. Click OK.
All of the nodes on the Diagnostic results layer are selected.
7. In the Layers pane, click on to highlight the Nodes layer.
8. Click the Assign button.
9. Click on the Triangles layer to highlight it.
10. Click the Make Active button.
The triangles layer will now be displayed in bold text.
11. Click on the Diagnostic results layer to highlight it.
12. Click the Delete button.
13. Click Yes if you are asked if the entities should be moved to the active layer.

The Diagnostics layer no longer exists, the nodes are back on the nodes layer and the triangles are
back on the triangles layer.

Create the Runner and Cooling Systems

Create Runners

The next task requires you to create a runner system for a single-cavity tool. In order to do this,
you will set an injection location on the model, and then use the Runner System Wizard to create
the runner, with a diameter of 4mm and a gate orifice of 1.5mm. The injection location should be
set in the position indicated by the yellow cone in Figure 8.

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 Figure 8. Injection location

 To create the runner

1. Click and rotate the part into a position suitable for setting the injection location, as
indicated in Figure 8.

2. Click and set the injection location.

3. Click (Modeling Runner System Wizard…).

4. Enter 81.69 into the Sprue Position X: field.
5. Enter –25 into the Sprue Position Y: field.
6. Enter 6.48 into the Parting Plane Z[1]: field. This is the Z value for the bottom edge of the
part.
7. Click Next to specify the dimensions of the sprue and runners.
8. Enter 5.56 into the Sprue Orifice diameter field.
This is a standard sprue orifice.
9. Enter 2.38 into the Included Angle field.
This is a taper for a standard sprue.
10. Enter 60 into the Length field.
11. Enter 4.0 into the Runner Diameter field.
12. Click Next to specify the gate properties.
13. Enter 1.5 into the Side gates Orifice diameter field.
14. Enter 15 into the Included Angle field.
15. Click the Angle option under the Included angle field, and enter 45.
16. Click Finish to create the runner.

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 Create Cooling System

After creating the runner system, you should create a cooling system to effectively remove heat
from the mold-cavity during the molding cycle. In this task, you will create 2 cooling lines with a
10mm channel diameter, sitting 25 mm away from the part.
Refer to the Preparing your model Modeling in MPI, and Troubleshooting and design
advice Cooling system related design advice books in the online Help Contents tab for more
on modeling in MPI.

 To create the cooling system

1. Click (Modeling Cooling Circuit Wizard…).

2. Ensure that 10 (mm) is selected in the Channel diameter to use drop-down list.
3. Enter 25 (mm) into the How far above and below part field.
4. Select X-axis aligned and click Next.
5. Enter 2 into the Number of channels field.
6. Enter 30 (mm) into the Distance between channel centers field.
7. Enter 75 (mm) into the Distance to extend beyond part field.
8. Select the Connect channels with hoses checkbox.
9. Click Finish to create the cooling circuit.
The runner and cooling circuit should be modeled as indicated in Figure 9.

Figure 9. Modeled runner and cooling lines

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 Running the Analysis

Analysis Sequence

In this task, you will set the analysis sequence to be performed on the model. In this exercise, you
will run a cool / flow / warp analysis sequence. You can do this by either accessing the Analysis
menu, or by double-clicking on the Analysis Sequence icon in the Study Tasks pane.

 To set the analysis sequence

1. Double-click (Analysis Sequence) in the Study Tasks pane.

2. Select the Cool + Flow + Warp analysis sequence.
Tip: If you click More…, you can select more analysis sequences to be added to the default list.
3. Click OK.
The newly selected sequence is updated in the Study Tasks pane, and the corresponding icons
are updated in the Project View pane.

Select Material

The next pre-processing task is to select a material for analysis. For this design, you will select the
polymer named Cycolac GPT5500: GE Plastics (USA). As with the analysis sequence in the
previous step, you can do this by either accessing the Analysis menu, or by double-clicking on the
Select Material icon in the Study Tasks pane. Refer to the on-line Help for more on material
selection and properties.

 To select a material

1. Double-click (Select Material) in the Study Tasks pane.

2. Click the Manufacturer drop-down list and select GE Plastics (USA).
3. Click the Trade name drop-down list and select Cycolac GPT5500.

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 Process Settings

In this task, you will assign the process settings for analysis. If you look at the Process Settings
icon in the Study Tasks pane, you can see by the green tick that a set of default inputs have been
entered, based on the material that you selected. You will use the default mold surface and melt
temperatures, mold-open time, and specify an injection time and injection + packing + cooling
time.

 To assign process settings

1. Double-click (Process Settings) in the Study Tasks pane.

2. Ensure Specified is selected in the Injection + packing + cooling time drop-down list, and
enter 15 into the field to the right.
3. Click Next.
4. In the Filling Control drop-down list, select injection time and enter 2 into the field that
appears to the right.
5. Click Next.
6. Select the Isolate cause of warpage checkbox, and click Finish.

Analyze

You have now performed all of the pre-processing tasks for this model. In this task, you will
perform the analysis, and view the screen output file as the analysis proceeds. This file allows you
to check the inputs that were specified, the state of the analysis indicated by any warning or error
messages, and also some text-based results.

 To run the analysis

1. Double-click (Analyze Now) in the Study Tasks pane.

2. Click OK in the Select Analysis Type prompt.
3. Look at the screen output file to track the analysis progress.
The analysis should only take a couple of minutes to complete.

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 Review the Results and Writing the Report

Review Results

In this task, you will use the post-processing features of MPI to view the following results:
 Temperature (top), part result
 Fill Time (animate) result
 Bulk Temperature result
 Pressure (animate) result
 Volumetric Shrinkage (at ejection) result
 Shear Stress at Wall result
 Warp all effects and variants results
Tip: Refer to the online Help for more information on interpreting results. Click on the result
display, and then click F1 get help instantly on that result.

 To display and review the results

1. First, de-select the Channel layers in the Layers pane so that you can see the part clearly.
2. Select the Temperature (top), part cooling analysis result in the Study Tasks pane.

3. Click (Vertical Split) to split the window into two.

4. Display the Temperature (top), part result in the second window and view both sides of the
part.

5. Click (Vertical Split) again to remove the split window display.

6. Select the Fill Time result, click to animate it and check the filling pattern.
7. Select the Bulk Temperature (end of filling) result and investigate the temperatures.
8. Select the Pressure result and animate it to view the pressure history.
9. Select the Volumetric Shrinkage (at ejection) result to view the part shrinkage.

10. Click (Vertical Split) and then (Horizontal Split) to create a four-window display.
11. Display the following results from the top-left window in a clock-wise direction, as indicated
in Figure 10:
 Deflection, all effects: Z Component,
 Deflection, differential cooling: Z component,
 Deflection, orientation effects: Y component,

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  Deflection, differential shrinkage: Z component.

Figure 10. Warp deflection results in split window display

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 Create Report

Once you are satisfied with the analysis results, you may need to let other people know about your
findings. In this task, you will create a report based on some of the results that you have just
displayed. The report is created in HTML, which allows for easy dissemination and viewing
within an internet browser.

 To create a report
1. Click File New Report.
2. If it is not already selected, click on the study in the Available Studies area and click Add to
add it to the report. This means that the report will be based on only the one selected study.
3. Click Next.
4. Click on the following results separately in the Available Data area, and click Add to add
them to the report.
 Bulk temperature
 Fill time
 Pressure
 Volumetric shrinkage (at ejection)

Tip: You can hold down Shift or CTRL key with the right-mouse button to select multiple results.
5. Click Next.
6. Click the Cover Page checkbox, click Properties, and complete the first two fields.
Complete the rest of the dialog if you want to, and click OK.
7. Click on a result in the Included data items list.
You will notice that the Item details area to the right becomes activated. This allows you to
edit screenshot and animation properties, and to add text to accompany a result.
8. Click the Descriptive text checkbox, click Edit, and then enter a one or two sentence
description of the result. Do the same for the other results.
9. Click on the Fill time result, and then click the Move Up button to move it to the top of the
list.
10. Click Generate to create the HTML report.
The HTML report will open automatically into MPI.
11. View the report.

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Competency Check - Quick Cool Flow Warp Analysis

When should the mesh be checked for problems and why?

What analysis type (Cool, Flow, Warp) creates each of the following results?
1) Average Temperature Part
2) Frozen Layer Fraction
3) Bulk Temperature
4) Temperature (top), Part
5) Deflection, all effects: Deflection
6) Volumetric shrinkage
7) Maximum temperature, part
8) Time to Freeze
9) Temperature profile, part
10) Deflection, differential shrinkage: Z Component

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Evaluation Sheet - Quick Cool Flow Warp Analysis

When should the mesh be checked for problems and why?

Answer: It should always be checked after meshing the part.

It could also be checked after the mesh has been fixed to make sure all errors
have been addressed and no new errors are present. The mesh needs to be
checked for problems because a bad mesh can affect analysis results.

What analysis type (Cool, Flow, Warp) creates each of the following results?
1) Average Temperature Part Cool
2) Frozen Layer Fraction Flow
3) Bulk Temperature Flow
4) Temperature (top), Part Cool
5) Deflection, all effects: Deflection Warp
6) Volumetric shrinkage Flow
7) Maximum temperature, part Cool
8) Time to Freeze Flow
9) Temperature profile, part Cool
10) Deflection, differential shrinkage: Z Component Warp

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