New in. Version 7.0. Simcon kunststofftechnische Software GmbH, 2013 Page 1

Transcription

1 New in Version 7.0 Simcon kunststofftechnische Software GmbH, 2013 Page 1

2 TABLE OF CONTENTS 1 NEW FEATURES NEW CADMOULD 3D STRUCTURAL FEM MODULE BASIS OF CALCULATION IMPORTING STEP AND IGES FILES EXPORTING THE COOLING SYSTEM AS A CLOSED SURFACE IN STEP FILES COOLING CHANNELS DEFINABLE AS HEATING ELEMENTS CALCULATING THE PRESSURE LOSS WITHOUT SIMULATION AUTOMATIC TESTING OF THE COOLING CHANNELS ANIMATING CUTAWAYS CAE IMPORT: 3D FINITE ELEMENT MESHES IN ABAQUS, ANSYS, MARC AND NASTRAN FORMATS STORING SHEAR RATE IN LAYERS LINEAR PROFILE FOR INJECTION VOLUME RATE AND PACKING PRESSURE FEASIBILITY ANALYSIS NEW WALL TEMPERATURE MODE: NODE-BASED WALL TEMPERATURES SUPPORT FOR RUNNER GEOMETRY GENERATION SIMPLIFICATION OF THE WORK AND TIME- SAVING IMPROVEMENTS DISTINGUISHING COOLING CHANNELS AND MOULD COMPONENTS USING COLOURS IMPROVED DISPLAY OF THE VOLUME FLOW RESULTS INTRODUCING OBJECT INFO STARTING CADMOULD WITH A PRE-DEFINED WINDOW HEIGHT AND WIDTH IMPROVEMENT OF THE DEPICTION IN THE RESULTS DIALOG (LONG SIMULATION NAMES) UPDATING THE AVAILABLE RESULTS WITH THE PUSH OF A BUTTON SETTING VIEW-DEPENDENT LIMITS IMPROVEMENT OF FINITE ELEMENT MESH PREPARATION SIMPLE COMPARISON OF VARIOUS SIMULATION AND THEIR RESULTS CONSTRAINTS IN COURSE OF ACTION FOR GATE LOCATION OPTIMISATION AND STORAGE OF ID ELIMINATED DEFAULT SETTINGS FOR ENTERING VOLUME FLOW IN THE PROCESS PARAMETERS SIMPLIFIED DISCOVERY OF ERRONEOUS MEASUREMENT POINTS DURING IMPORTATION CADMOULD CAR COMPRESSOR FOR SIMPLIFIED COLLECTION AND COMPRESSION OF RESULTS MATERIAL DATABASE IMPROVEMENT: ACCESS TO ADDITIONAL INFORMATION AND LINKS TO MANUFACTURERS ZOOMING WITH THE MOUSE WHEEL SIMPLIFIED ERROR ASSESSMENT UNIFORM STORAGE LOCATION FOR THE ERROR FILE EXPANDED MESH STATISTICS IMPROVEMENTS TO VARIMOS STARTING CQC FROM CADMOULD IMPROVED BATCH OPERATIONS TASK SCHEDULER WITH SINGLE LICENSE BATCH OPERATION IN DOMAINS ERROR CORRECTIONS RESOLUTION OF THE TOO MANY PRESSURE ITERATIONS ERROR DELETING ISOLATED NODES PROBLEMS WITH USE OF PRIOR FILLING RESULTS CORRECTED MESH ERROR AFTER ROTATION INCORRECT SUGGESTIONS FOR INJECTION TIME OF THE SECOND COMPONENT OF A 2- COMPONENT SIMULATION ALL TEXT DELETED WHEN ENTERING AN A LABEL ERRORS IMPROVED DRAGGING OF RUNNER AND COOLING SEGMENTS IMPROVED MESH PREPARATION (FOLDS) ACCELERATED CANCELLATION OF SIMULATION JOBS Simcon kunststofftechnische Software GmbH, 2013 Page ii

3 1 New features 1.1 New Cadmould 3D Structural FEM module The mechanical analysis in Cadmould involves a simple tool for calculating static mechanical problems. The calculations are linear (geometricly as well as in the material model). It is appropriate for small distortions. Results are deformation of the initial geometry by the load, von Mises stresses and strains. 1.2 Basis of calculation Geometries In Cadmould 3D Structural FEM individual components, can be calculated, which have been read into Cadmould 3D-F and have been selected for mechanical analysis Element types For the elements, the choice lies between 4-node and 10- node tetrahedral elements. 4-node tetrahedrons result in faster calculations. In contrast, simulation using 10-node tetrahedrons is more precise. So-called shear locking may occur in particular with the deflection of the part, if there are not enough tetrahedrons across the wall thickness. In this case, selecting 10-node tetrahedrons is recommended Materials The Cadmould 3D Structural FEM module is primarily intended for designers of plastic articles, who want to check if their design will suffice for the demands. In this, fibrereinforced materials can also be calculated when the orientation of the fibres has previously been determined by an injection and holding pressure analysis using Cadmould 3D-F. This anisotropic material behaviour caused by the fibres will automatically be taken into consideration in this case. Furthermore, other materials such as metals can be calculated. Besides of plastics the Cadmould material database contains various types of metals and may be expanded with user-defined materials as usual. Calculations are made linear-elastically and are suitable as a basis for decisions about whether component design and materials will meet the demands or not. Strains and stresses that arise from loads or deformations will be used for this. For simulating elasto-plastic material or failure behaviour structural solvers like ABAQUS, ANSYS, NASTRAN, RADIOSS and so forth can be used. Using Cadmould Converse in this case would take fibres into consideration. materials: the Young s modulus and Poisson s ratio. Fibrereinforced materials involve transversal isotropic materials, meaning that the data for a 100%-oriented material will be required as the starting point by the program. A transversal isotropic material has five independent components: E1, E2, D12, ν12 and ν23. Whereby E1 is Young s modulus in direction of the fibres, E2 is the Young s modulus perpendicular to fibre orientation, D12 is the shear modulus between fibre direction and perpendicular to the fibres, ν12 is Poisson s ratio between fibre direction and perpendicular to the fibres and ν23 is Poisson s ratio between the two perpendicular directions. This data is often not known. They can be approximated using Cadmould Converse based on the mechanical values for the matrix and the fibre through micro-mechanical modelling Fibre orientation If a load case is simulated using a fibre-reinforced material, the fibre orientation will automatically be taken into consideration. If a file containing the fibre orientation data for this project is not available, because (for example) a filling and packing analysis has not been performed, Cadmould 3D Structural FEM will notify the user that an injection and packing pressure analysis must first be performed. Without the fibre orientation file, structural simulation cannot be calculated in consideration of the fibres. In this case, an isotropic calculation using reduction factors is recommended Boundary conditions Boundary conditions (clamping and support) are differentiated from loads applied on the component. Furthermore displacements, thus mounting conditions for example, can also be defined and taken into consideration in Cadmould 3D Structural FEM Fixation A fixation means that the component is no longer free to move at defined points in all spatial directions. In this case, a differentiation is made between translational and rotary fixation conditions. Combinations of translational and rotary fixation may also be defined Translational Three spatial directions: the nodes for the selected object group are fixed in all spatial directions. Two spatial directions: The nodes for the selected object group may move along one axis. For example, this would correspond to the case of a sliding bearing Material data In principle, a differentiation can be made between the data for isotropic and fibre-reinforced materials. There are only two independent material parameters for isotropic Simcon kunststofftechnische Software GmbH, 2013 Page 3

4 Fig. 1 Example of a translationally free axis One spatial direction (plane): The nodes for the selected object group may move along two axes. For example, this would correspond to the case of sliding along a surface, meaning that one plane is defined for this, along which the object group may move Rotary Rotation around one point: The nodes for the selected object group may rotate around a centre point. Rotation around one axis: The surface may rotate around one axis. The rotational axis and one axial point would be specified in this case. The nodes for the selected object group have a free axis of rotation perpendicular to the rotational axis and to the connection line to the rotational axis. those forces, meaning that the direction of force is constant. With pressure, the direction of force is perpendicular to the surface. To specify torques, an axis of rotation must be defined in addition to the object group to which the torque is applied Results Deformations as well as stresses and strains are specified as results Deformation Deformations can be considered and treated like the results from the calculations of shrinkage and warpage with the same names. These deformations are: X deformation Y deformation Z deformation Overall deformation (length of the displacement vector) Stresses and strains Strains result from the derivations of the deformations in all spatial directions and form a symmetrical 3x3 tensor as well as the stress tensor. As usual, comparative values independent of the coordinate system will be calculated from these tensors. They are: the von Mises yield criterion Fig. 2 Example of a free rotational axis Combination Rotational and translational axes may also be combined. the absolute amount of the largest Eigen value of the strain tensor strain energy density Strain is often used as a criterion for the mechanical layout of plastic articles. Examples specified in the literature refer exclusively to strains that occur under tension along a single axis. The following table is specified in the literature as a guideline for the critical strain for static loads, which will automatically appear using software during assessment. A pdf reader is required. Fig. 3 Example of a combination of rotationally and translationally free axes Loads Loads are forces, pressures or torqes that affect the part. A distinction can be made between external loads that are applied at the outside of the component and internal loads that affect the volume. Gravity and centrifugal forces can be specified as internal loads. External loads can be specified as punctual or distributed forces, pressures and torques. With distributed forces, a force vector is specified that is distributed evenly over the object group defined for Simcon kunststofftechnische Software GmbH, 2013 Page 4

5 Materials group Amorphous, unfilled thermoplastic (except for PS) Strain < 0.8% Determining the material properties Polystyrene (PS) < 0.2% Partially crystalline thermoplastic (above the glass transition temperature) Filled thermoplastics, glass mat reinforced UP resins < 2.0% < 0.5% Impact-resistant modified blends < 0.8% Table 1 Critical strain for different group of materials A reduction factor dependant on the filling material content is recommended for filled thermoplastics (with A as the weight portion of the glass fibres). ε krit,gf = ε krit (1 1,5 A) The table value of the critical strain is thereby reduced respectively. The Finite Element Method involves an approximated solution that must be taken into consideration when assessing stresses and strains. The stresses may depend locally on the local details of discretisation. Locally limited stress peaks may occur in particular with non-convex areas that do not have a smooth edge (e.g.. notch effect). The discretisation there must be sufficiently fine so that the numeric solution will reflect this. The load bearing capacity will also be heavily reduced by repeated loading under some circumstances Operating Cadmould 3D-F Structural FEM Fig. 5 Entering the component properties for mechanical analysis In the menu Mechanical Analysis -> Part the desired properties can be defined. If the project contains multiple components, the component to be calculated can be selected from here. If the fibre direction has been previously calculated with a filling and packing analysis, they will automatically be included and the material will be taken as anisotropic. If however the calculation should be isotropic, the material data can be modified manually Determining the kinematic boundary conditions An injection and packing pressure simulation is initially performed for anisotropic materials so that the orientation is available as a result. Fig. 6 Mechanical analysis: entering the kinematic limitation Fig. 4 Fibre orientation degree as a result The material and the boundary conditions can be determined subsequently. The elements are initially to be placed into an object group, to which the boundary condition should be applied. The selection list for the kinematic limitation will open thereafter by clicking 2. Click here to select the Limitation. Simcon kunststofftechnische Software GmbH, 2013 Page 5

6 Fig. 7 Selection list for the kinematic limitation The limitation will be selected with a click on the corresponding symbol. In the element list the additional entries that define the final description of the boundary conditions will then become visible. Fig. 9 Mechanical analysis: entering the boundary condition for the limitation Displacement, rotational or scaling adjustments can be entered. If multiple fixations have been defined for a component area, the last one added is always the point of reference Definition of loads The load cases will be defined from the Mechanical Analysis -> External Load dialog. Fig. 10 Mechanical Analysis: entering the external load Fig. 8 Mechanical analysis: entering the boundary condition for the limitation For example, the normal of the plane on which the selected elements may move, must be determined. Which elements the load should affect are initially determined from here. An additional dialog will then appear to the right, where the load case can be defined. Additionally, the Displacement ---> button can be clicked. This will open a menu for defining a displacement. Simcon kunststofftechnische Software GmbH, 2013 Page 6

7 Changing the type of element The type of tetrahedron can be selected from the Mechanical Analysis -> Options dialog. 10-node tetrahedrons are selected by default. By removing the check from the box, 4-node elements will be activated. Fig. 11 Mechanical analysis: entering the load case Whether a given load involves a force, torque or pressure is initially determined in the upper area of the dialog. The value for the force can be entered afterwards. The corresponding load becomes active, and is entered in a table, by clicking the Add button. Fig. 14 Option dialog for mechanical analysis Starting the simulation The calculation is started from Mechanical Analysis -> Simulation Results The results of the mechanical analysis will be shown under the result selection. Deformations as well as stresses and strains are specified as results Deformation Like described in Chapter deformation results can be considered and treated like the results from the calculations of shrinkage and warpage with the same names. Fig. 12 Mechanical analysis: load overview Various load cases can be superimposed with the help of this table. The entries are accepted by clicking Ok Entering volume forces The boundary condition can be set from Mechanical Analysis -> Body Forces dialog in order to include the effects of gravity or centrifugal force. Fig. 13 Mechanical analysis: entering volume forces Realistic loads can be taken into consideration, in particular, for components with large volumes or assembly situations with rotary loads. Simcon kunststofftechnische Software GmbH, 2013 Page 7

8 Fig. 15 X deformation of the component under load Fig. 17 von Mises yield criterion for the component under load Fig. 16 Overall deformation of the component under load Stresses and strains Like described in Chapter strains result from the derivations of the deformations in all spatial directions and form a symmetrical 3x3 tensor as well as the stress tensor. As usual, comparable values will be calculated from these tensors independent of the coordinate system. They are: the von Mises yield criterion the largest value of the strain tensor Fig. 18 Component strains under load Table 1 (refer to Chapter ) gives a guideline for evaluation of allowable strains depending on the material used in the part. 1.3 Importing STEP and IGES files CAD files in the STEP and IGES formats can now be comfortably imported directly into Cadmould 3D-F. With it, the step of creating an STL file externally disappears. Designers simply export a STEP or IGES file from their CAD systems and import it into Cadmould 3D-F with the click of a mouse. The finite element mesh is then generated automatically in Cadmould 3D-F. For designers, this means a significant simplification in contrast to previous approaches. The new import feature has been available since version of Cadmould 3D-F from the Cadmould 3D-F Rapid module. Simcon kunststofftechnische Software GmbH, 2013 Page 8

9 Fig. 19 Design of a technical component in TopSolid. A technical component in the TopSolid CAD system can be seen in Fig. 19. The STEP file imported into Cadmould 3D-F can be seen in Fig. 20 after automatic finite element mesh generation. Fig. 20 The component from Fig. 19 after import into Cadmould 3D-F Procedure for importing STEP and IGES files Click on the menu options File -> Import -> IGES or File - > Import -> STEP as shown in Fig. 21. Fig. 21 Menu option for importing a STEP file The IGES or STEP file to be imported is to be selected from the dialog that appears thereafter and will be automatically converted into the usual STL format (Fig. 22). Simcon kunststofftechnische Software GmbH, 2013 Page 9

10 Fig. 24 Dialog for configuring the chord deviations Fig. 22 File selection dialog for importing an IGES file An STL file will be created by doing so in the project directory for the imported file and simultaneously stored there, so that it will be permanently available afterwards. If the user does not have write permission for the import directory (for example, when opening the file from a CD), the STL will be created temporarily in a user directory with write permission and then deleted after import Setting the precision CAD application users are accustomed to having the ability to set the precision for converting files. The import procedure for IGES and STEP files also has this capability. The Configuration button exists in Cadmould 3D-F for this purpose during import procedure (Fig. 23). After the CAD file has been imported and automatically converted into the STL format, work can continue in Cadmould 3D-F as usual, i. e. runner, material, process parameters and so forth can be defined. A finite element mesh optimised for calculations is then generated for simulation and the thickness of the component is measured. In this, it does not matter whether the data has been opened directly as an STL file or imported and converted as an IGES or STEP file, as described above. 1.4 Exporting the cooling system as a closed surface in STEP files When a cooling system has been created in Cadmould 3D-F, the geometry of the cooling system can also be saved as a STEP file. This is useful, when the geometries should be used as 3D entities in CAD applications in order to subtract from the tool. Additionally these files are needed, when the cooling system should be importet into Cadmould 3D-F Thermal Analysis. The dialog can be found under File -> Save -> Heating / Cooling System. Fig. 23 Button for opening the precision configuration dialog The maximum value of chord deviation relative to the spatial diagonals of the part can be specified from there. The default value for this is 0.1 %. The value may be changed as desired in order to generate more or less precise STL data (Fig. 24). Doing so avoids unnecessarily long preparation times at first. A more precise resolution can be selected for parts with detailed structures. Simcon kunststofftechnische Software GmbH, 2013 Page 10

11 Fig. 26 The Heating Channel dialog with option buttons for heating elements Clicking the button with the water or electricity symbol (Fig. 26) switches the channel properties. A profile for heating over time can be specified (Fig. 27) after switching to electrical heating. Fig. 25 Above: The cooling system in Cadmould. Below: The system saved as a STEP file imported into Solid Works The exported STEP file for the cooling system is converted into individual components by the integrated CAD kernel. Connected cooling loops that can be used further in the CAD systems are created by doing this. 1.5 Cooling channels definable as heating elements Until now, a heating/cooling agent was assigned to a heating/cooling channel, through which it flowed. Now, a channel can be defined as a heating element, meaning that this channel is a heat source (such as through induction) and providing energy to the tool. This finds application, for example, when highly polished surfaces should be generated through very precise moulding of the cavity surface structure. This technique may also be applied for heating moulds for rubber injection moulding. Fig. 27 The Heating Elements dialog 1.6 Calculating the pressure loss without simulation In order to be able to estimate the pressure loss before the real simulation and thereby assessing the pressure loss of sequentially connected cooling channels or the effect of increasing the volume flow rate, the pressure loss can be calculated in advance. For this, the Pressure Loss button on the cooling channel dialog must be clicked. Simcon kunststofftechnische Software GmbH, 2013 Page 11

12 Fig. 28 Calculation button for displaying the pressure loss A quick calculation is started thereafter. Subsequently, the result is displayed in the table. 1.7 Automatic testing of the cooling channels Very short cooling channel segments may arise when, for example, the system has been imported as an IGES line and short lines are present. These segments could lead to discontinuation of the calculation, whereby only manual repairs were possible until now. The examination is now automatically performed at the beginning of the cooling calculation process to make this work easier. If elements are too short, they are deleted and a message is displayed. Fig. 29 Message about segments that are too short After confirmation using the Ok button, the system is automatically repaired and elements that are too short are deleted. The gaps arising thereby are filled with neighbouring segments. Calculation of the temperatures is then started using this repaired cooling system. In order to ensure that the cooling system is intact and these changes correspond to the demands, it is recommended to display the cooling circuits in the corresponding dialog. Fig. 30 Sequence of images of various sections similar to computer tomography 1.9 CAE import: 3D finite element meshes in ABAQUS, ANSYS, MARC and NASTRAN formats An extension of the finite element interface now permits importing 3D finite element meshes from Abaqus, Ansys, Marc or Nastran directly. In doing this, either the 3D mesh may be retained or a 3D mesh may be generated automatically for the imported geometry. If there are hexahedrons or wedges, these are converted automatically into tetrahedrons during import. Through the import of the entire 3D meshes, 3D structures created in external programs can be used in a selective manner, making the calculated results directly comparable Storing shear rate in layers Shear rates in layers is a new optional result. Using this result, the position in the component and time in the process, where and when the material will be heavily sheared and potentially damaged, can be assessed. These damages can lead to surface defects in the component, for example. To generate this result, the check must be set in the Shear Rate checkbox on the Optional Results tab page of the Simulation Options dialog. 1.8 Animating Cutaways To make assessment of the thickness ratios easier in nonvisible component areas as well as to make an overview of the sectional results (such as internal temperature) in the overall component easier, sections can now be roamed similar to the procedure of computer tomography (Fig. 30). The sequence of images can be saved as a video clip and played using either Cadmould 3D-F or an external player. Fig. 31 Entering the option for storing the shear rate in layers The shear rate is saved after the checkbox has been activated at the same times when other snap shots are saved. Simcon kunststofftechnische Software GmbH, 2013 Page 12

13 Fig. 32 The internal shear rate result When the Cross-Sectional Profiles display option has been activated, this result can also be depicted over the flow channel as a chart. Fig. 34 Checkbox for entering linear or beam profiles Fig. 33 Shear rate result as a chart over the cross-section 1.11 Linear profile for injection volume rate and packing pressure Entry of linear profiles for volume rates and pressure has been implemented for the depiction of real machine behaviour for injection and packing pressure profiles. Aside from this, it is possible to switch between the entry of bars and the entry of support points. The resulting profile will be displayed as a chart. In order to be able to use this option, it must be activated from the process parameters options. To do this, the options are opened once in the process parameters and the check next to the Interactive Bar Chart checkbox removed on the Miscellaneous tab page. This setting is stored specificly to the user and remains so for subsequent projects. Linear profiles are entered in the Profile Entry dialog through a table, in which the supporting points are entered. A linear profile will then be created between these points. Fig. 35 Table for entering the volume flow and pressure profile Simcon kunststofftechnische Software GmbH, 2013 Page 13

14 Fig. 36 Depiction of the volume flow profile in a chart There are other options for filling out the table additionally to manual entry. The respective commands can be selected with the help of the icons under the table. The icon functions are as follows (from left to right). Delete Table Default Values: Only the first row of the table will be filled respectively by clicking this button. The result is depicted in Fig. 37 for filling and in Fig. 38 for pressure. Fill: 1. Column: Flow Rate [cm3/s]" = volume of the cavity / injection time 2. Column: The Pressure [bar] column is empty 3. Column: Time [s] = injection time 4. Column: Level [%] = Column: Residual Volume [cm3] = Holding pressure: 1. Column: Pressure [bar] = default pressure 2. Column: Pressure Ratio [%] is empty 3. Column: Packing Time [s] = default pressure time 4. Column: Cycle Time [s] = Injection time + default packing time Fig. 38 Default entries for holding pressure Import Table from File: The associated file selection dialog provides access to: Project files (*.rm1) Design files (*.des) Symmetry files (*.sym) Pre-set flow rate and pressure files exported from other projects Calculated Flow rate and pressure files exported from the other project Chart files (*_104_???????.car) Text files (*.txt) Save Table to File: A text file is saved by clicking this button. The Cadmould support will gladly help you with questions about this format. Insert Row above Selected Row Delete Selected Row Flow rate or time dependent switching: If this button is pressed, the third column, Time [s], can be edited and the fourth column, Injection Status [%] can only be read, and vice versa. The values in the greyed column are calculated from those of the entry column by the program. The existing entries are kept when switching. Bar Chart: switches between the bar diagram entry dialog and curves. The existing entries are kept when switching. Create Chart from Table Content displays a chart of the entries previously made. The display is updated with each change to the table. Fig. 37 Default entries for injection Options: Clamping force and injection pressure limitation, constant starting with filling time/percentage can be activated from here. Simcon kunststofftechnische Software GmbH, 2013 Page 14

15 Test and Apply Table Content, Dismiss Dialog: corresponds to the OK button. This button will not be visible during simulation Feasibility analysis The basic threshold data for the project can be determined before the simulation using this new feature. The feasibility analysis can be started in the View menu with a license of Cadmould 3D-F Fill. clamping force or undercuts. Aside from this, the occurrence of undercuts and the projected area can be determined and assessed given a pre-defined direction of closure Production data An estimation of whether or not the component can be produced is provided using the calculated production data. The maximum flow path length, as well as the foreseeable packing pressure and cooling times are specified. The entries affect each other mutually such that contradictions are detected and automatically prevented. In this manner, an initial estimation of the component and the production cycle can be made quickly without having to perform a full blown simulation. The result that is displayed in colours on the part can be selected in the bottom selection dialog. The results available for display are: Draft Angle [ ] Undercuts [-] Flow Length [mm] Flow Length / Wall Thickness [-] Mass Accumulation [-] Cooling Time [s] Options In the options the limits for the Zero-Draft Angle [ ] and the Prediction of Undercut Detection can be set New wall temperature mode: node-based wall temperatures The node-based wall temperature for fixed times mode may be selected in the process parameters dialog. This mode has been especially developed for depicting the results of the new Cadmould 3D Thermal Analysis module. Fig. 39 The Feasibility Analysis dialog Recommended closing direction This new feature can determine automatically the direction of mould closing that will minimise the projected area for Simcon kunststofftechnische Software GmbH, 2013 Page 15

16 Fig. 41 Runner without division into transverse distributors Fig. 40 The Process Parameters dialog with the Node-Based Wall Temperature for Fixed Times feature 1.14 Support for runner geometry generation To support the user in the generation of runners, division into transverse distributors will be done automatically when testing the system. In this manner, interactive work of the user to design or repair transverse distributors can be saved, because the cutting points will be found automatically and do not have to be created by the users themselves. Fig. 42 Automatic division into transverse distributors for calculation 2 Simplification of the work and time-saving improvements 2.1 Distinguishing cooling channels and mould components using colours So that the individual loops and components will be easier to distinguish in complex cooling systems or entire moulds after importing the STL file, Cadmould 3D-F automatically assigns a colour to each cooling channel or mould component (Fig. 43). If a colour assignment has already been created by the user, that assignment will be used. If the user selects Edit -> Default Settings before importation, the automatic colour assignments will be used. Simcon kunststofftechnische Software GmbH, 2013 Page 16

17 Fig. 43 Automatic assignment of various colours to the individual cooling channels 2.2 Improved display of the volume flow results The flow rate for the cooling agent is now displayed in the unit litres per minute. This is the standard unit for specifying cooling agent flow rate, Therefore conversion is no longer necessary. 2.3 Introducing object info With the help of the Object Info toolbox, the properties of various elements in the model can be quickly assessed. The Object Info toolbox can be opened from the View -> Object Data menu option. An object (node, element, edge, part or cooling segment) may then be clicked and the geometric information (such as the node numbers for an element) will be displayed. This information is helpful for reproducibly finding the same element in various geometric variations. Fig. 45 Object Info display for a part Model is another menu option. Information about the actual Finite Element mesh will be provided from there. The number of elements and nodes will be directly visible, like the number of potential mesh defects. Fig. 46 Object info: model Fig. 44 Object Info in Cadmould Furthermore, the toolbox provides information about the component and the finite element mesh. The volume and the surface as well as the dimensions of the bounding box are displayed for parts, for example. Whether this information is displayed for individual parts or the entire model can be chosen. If another object is referred to in this toolbox, such as the element picked from the info box (Fig. 47), then an additional Object Info toolbox opens, that supplies the corresponding information about that clicked object. Clicking on Node 3195, for example, will open an Object Info toolbox with the information about Node 3195 (Fig. 48). Simcon kunststofftechnische Software GmbH, 2013 Page 17

18 The start options are entered in the link (icon) to Cadmould. To do this, right-click on the Cadmould icon and open the properties dialog. On the tab Link the target has been set to Cadmould.exe. The corresponding start options should be placed after this value. It is not necessary to enter all values, also a selection of the options can be chosen. Example: "C:\Program Files (x86)\cadmould\3d-f\7.0.0\cadmould.exe" -lng ger -w h 800 will open Cadmould with a width of 1500 pixels and a height of 800 pixels. The window position will not be determined by these parameters. Parameter Value Effect Fig. 47 Object data: element -x 50 Opens the Cadmould 50 pixels from the right edge. -y 100 Opens Cadmould 100 pixels from the top edge. -w 1500 Opens a Cadmould window with a width of 1500 pixels (important for images of the same size) -h 800 Opens a Cadmould window with a height of 800 pixels (important for images of the same size) -fsc Full screen: starts Cadmould in full screen mode. Note: This parameter takes precedence over the other parameters. The -fsc parameter is more powerful than the -x, -y, -w or -h parameters. Table 2 Start options for manipulating the position and size of the Cadmould window Fig. 48 Object data: node 2.4 Starting Cadmould with a predefined window height and width In order to be able to generate images reproducibly on various computers with different screen resolutions, Cadmould must be opened with the display window set to the same size on those computers. The position of the window on the screen can also be pre-determined, so that Cadmould is always opened at the same position or so that multiple Cadmould windows can be properly positioned. In order to simplify this, start options for the position as well as the height and width of the window have been introduced. 2.5 Improvement of the depiction in the results dialog (long simulation names) Differentiating between longer designations for the various project simulations was not always certain until now, because excess characters would be cut off after a certain number of characters. To avoid this, the selection list now adjusts itself to the length of the simulation name so that longer names are now displayed completely. Simcon kunststofftechnische Software GmbH, 2013 Page 18

19 Fig. 49 Example of the result selection given a long simulation name 2.6 Updating the available results with the push of a button The Simulation button has been added to the Result Selection dialog for the selection of the simulation type. The results available in the list are being updated with the help of this button. This is helpful when multiple calculations are running simultaneously or results should be viewed during the simulation process. Fig. 51 Button for limiting the result display to the visible area 2.8 Improvement of finite element mesh preparation Mesh preparation as individual icon The icon for the preparation of a finite element mesh has been integrated into the default toolbar for editing of the pre-processing in order to makemesh preparation individually accessible, e.g. for directly measuring the wall thickness distribution, which requires a Cadmould finite element mesh. Fig. 52 Default toolbar with the button for mesh preparation Thickness measurement via nodes Fig. 50 The Simulation button for updating the result selection 2.7 Setting view-dependent limits In order to adjust the limits of the results to the visible area and only see the results scale that is relevant, the Viewdependent limits button has been added to the Result Selection dialog. If this button is clicked, the upper and lower limits for the legend will be adjusted to the values relevant to the current view. The values that are outside of the displayed limits will be shown in grey. In this manner, the maximum and minimum for a result can be determined more easily, for example, in a certain partial component area or in a single component in a family mould. There are now three methods for measuring wall thickness in Cadmould. The wall thickness is a definition that plays a role from the calculation of filling up to shrinkage and warpage. In this, there are a variety of approaches in special areas for how the wall thickness can and should be measured.. Hereafter, the available methods will be explained with the uses and notes for when they should best be selected. 1. Sphere method: Default method, usable for all geometries. This method will automatically be selected when the user does not choose anything else. It determines the wall thickness with the help of spheres that roll through the component. 2. Element normal method (E-Normal): Previously known as old thickness preparation. This method determines the element normal and its length. It is particularly applicable for voluminous parts and full cylinders. 3. Node normal method (N-Normal): This method determines the node normal and its length. The direction results from the elements surrounding the node. This method is particularly applicable for small surface structures, such as grooves, in order to calculate the behaviour of the primary geometry. Simcon kunststofftechnische Software GmbH, 2013 Page 19

20 The method for measuring wall thickness is selected from the Mesh Prepare dialog. If the user is uncertain which method should be selected, the Sphere Method is the method that is universally used. The other two methods provide advantages in the two special cases described above. Fig. 53 The Mesh Prepare dialog with the selection of the thickness measuring method Creating the volume mesh In order to know before the simulation has been performed whether the display of the 3D flow front is possible, the generation of the 3D volumetric mesh has been integrated into the mesh preparation process under the menu path: Edit -> Geometry -> Parts -> Mesh Prepare. If a volume mesh cannot be generated, an error message is displayed. Fig. 55 Dialog for opening the projects to be compared Bar charts or curves can be compared. In bar charts for example it is possible to compare individual values, such as the pre-determined quality characteristics and dimensions. Fig. 54 Error message for the failure to create the 3D volumetric mesh 2.9 Simple comparison of various simulation and their results Additional comparison features have been introduced in order to be able to compare various simulations with each other more quickly. In this, the simulations may have different names and contain different geometries. Fig. 56 Comparison of the results using a bar chart Curves allow the courses of the results to be compared. The course of all simulations that have been compared will be displayed after the selection of a result. Simcon kunststofftechnische Software GmbH, 2013 Page 20

21 Fig. 57 Selection dialog for the curves to be compared Fig. 59 Bar chart with active input assistance 2.12 Simplified discovery of erroneous measurement points during importation If measurement points are found that do not fit the current geometry when importing Dim files, they will be identified in red. This makes quick discovery, deactivation and repair of these measurement points easily possible. Fig. 58 Display of the compared curves in one chart 2.10 Constraints in course of action for gate location optimisation and storage of ID eliminated So that process parameters, material data and so forth do not need to be re-entered each time for optimisation of the injection point position, these process constraints have been eliminated. Aside from this the ID button is always active, which allows interim states of the preparation process to be saved with their own identifications and names Default settings for entering volume flow in the process parameters The input assistance option is now active by default for entry by bars so that new projects can be better designed with this assistance. For re-simulation of existing processes this setting can be deactivated. Fig. 60 Measurement devices dialog showing disconnected measuring point 1 Simcon kunststofftechnische Software GmbH, 2013 Page 21

22 Fig. 61 Table of the stored dimensions with disconnected Dimension 1 (in red) and connected Dimension 2 (in green) 2.13 Cadmould car compressor for simplified collection and compression of results The Cadmould car Compressor archive tool now exists for making the compression and collection of results easier. One or more projects and their results may be selected. The selected results are then saved in a Zip file. There are defined correlations between the results in this. This means that the selection of certain result types automatically takes other necessary result types into account in order to make reasonable display of the results possible. The zipped file can then be given to customers in order to be observed using the viewer software there or they can be used for archival purposes. Thus, results that should not be transferred to customers can be easily culled. Aside from this, the file size can simply be reduced in order to make transfer in an message possible. The tool can be started from within Cadmould by selecting the Compress Project option from the File menu. The Cadmould Car Compressor is started and automatically opens the current project. The result group, from which the results should be stored, can be selected from the selection list (in blue). The selection of result details that are available are opened in the table upon selection. They can then be moved to the right pane by double-clicking them, using Drag&Drop or with the help of the arrow buttons and thereby made active. An overview of all opened projects as well as the active results can be seen at the bottom of the dialog. Whether each result step or only a part should be retained can be set from there. An estimate of the size of the final Zip file is visible next to the diskette icon. The zip process can be stared using this icon. The storage location can be specified afterwards Material database improvement: access to additional information and links to manufacturers Additional information Additional information can now be stored in the Cadmould material database. This information may be images and/or text describing the components made with a particular material or results achieved for the selected plastic material. The customised user database can be adjusted at any time. Thus, comments about the materials, like experiences during already realised projects, can be recorded. In this manner, the company knowledge from previous projects about various materials can be saved in the user database and made available for the future. This feature is also used within the supplier database for assessment of the material data. The logo as well as the link to the material manufacturer s home page can be stored for known manufacturers so that additional information can be accessed quickly. If materials should be used from additional manufacturers, this information can be stored in the customised database. Fig. 62 Dialog for compression of one or more projects One or more projects can be opened using the + button at the top of the dialog in order to archive them together. The X button deletes all opened projects from memory (Fig. 62). Fig. 63 The expanded Cadmould material database with information and manufacturers links Simcon kunststofftechnische Software GmbH, 2013 Page 22

23 Simplified comparison of different materials For comparison of the properties of various materials, the curves can be opened together in one chart.. As of Version 7, the name of the respective material is displayed in the legend for improved differentiation. The desired chart for the first material is opened first for this. In the options Copy data to clipboard is selected. The chart corresponding to the second material will then be opened and Paste data from clipboard is selected. Fig. 65 Display: mouse options 2.16 Simplified error assessment If problems arise during simulations, Cadmould displays an error code. This error code can be sent to the Simcon support team, who can better categorise the message on that basis. Fig. 64 Cadmould material database: viscosity comparison for two materials Improved material data quality Material data is generally tested by the Simcon Material Data Support team. A standard test plate with defined process parameters is simulated according to ISO Standard for this and the results assessed. Boundary conditions for this can be found in the material database with the information about the respectively tested material. The geometry has also been attached in the software. Some material data tests have been adjusted due to the test results with regard to shrinkage, because the simulated shrinkage values did not correspond to the values given by the manufacturer. The shrinkage results have been clearly improved with this adjustment. These modified material data records can now be found as additional material data with corresponding comments in the database. The users can themselves choose whether the original manufacturer s data or the modified records are to be used Zooming with the mouse wheel Fig. 66 Error information for supporting the Simcon support team 2.17 Uniform storage location for the error file The error file is always saved in the %APPDATA%\Simcon\Cadmould directory in order to be able to find it more easily for the discovery of error messages about the project Expanded mesh statistics The mesh statistics have been expanded with the statistics for the 3D tetrahedron elements. The information about the volume and quality of the tetrahedron elements can now be accessed from the View -> Mesh Statistics -> Tetrahedra menu path. The customer request for the ability to use the mouse wheel exclusively for zooming has been implemented in order to counteract irritation and unwanted scrolling through lists. Users no longer scroll unintentionally through the currently active list, such as with the result selection list. If this default setting is not desired, the original behaviour can be re-activated from the display options by selecting the Mouse Wheel Scrolling option. Simcon kunststofftechnische Software GmbH, 2013 Page 23

24 Fig. 70 Task scheduler Fig. 67 Mesh statistic for the tetrahedron elements: tetrahedron volumes 4.2 Batch operation in domains Problems with user rights used to arose in particular domain configurations when using the batch module. Registration in a domain is now possible without incurring problems with user rights. The User Data Task window now informs users about the effects of entering passwords on the capability to perform tasks in a domain. 3 Improvements to Varimos 3.1 Starting CQC from Cadmould In order to simplify working with Varimos, CQC is now licensed through Cadmould and no longer requires its own dongle. The CQC button, which only appears when there is a license for Varimos, has been added to the toolbar in order to be able to start the software using the corresponding license. Fig. 68 Default toolbar with the CQC button CQC can be started using this button without opening a project or a result. Opening an already in Cadmould simulated project in CQC will continue to work using the CQC button in the task scheduler. Fig. 71 Registering in a domain for using batch operation 5 Error corrections Fig. 69 Task scheduler with the CQC button 4 Improved batch operations 4.1 Task scheduler with single license The task scheduler control module for batch mode can now be started separately from Cadmould. For opening the task scheduler no license is needed, that checking the status of a calculation is now possible even with a single license. 5.1 Resolution of the Too Many Pressure Iterations error Cause The pressure resistance as well as the flow profile over the cross-section (temperature, shear and velocity) are calculated iteratively from the boundary conditions of the geometry (flow cross-section), of the materials (viscosity, compression etc.) and of the process (flow rate and mass temperature). The flow resistance, and the distribution of pressure and speed along with it, depend non-linearly on the volume flow due to the structural viscosity. The calculation must be performed iteratively in order to find the solution, meaning the equilibrium, until the solution converges. The compressibility and the pvt characteristics along with it, affect additionally the convergence of the mathematical problem. If the iterations converge therefore depends on the pvt Simcon kunststofftechnische Software GmbH, 2013 Page 24

25 and viscosity data as well as on the boundary conditions (geometry and flow rate). The numberics of iterations are generally very robust and achieves convergence even with inconsistent data in most, but certainly not all, cases. The causes provoking this message often lead also in reality to quality losses in the material or article, to the extent that they are conditioned by the geometry or the process Workarounds Reducing the injection speed Reduction of injection speed Definition of a flow rate profile or refinement of the profile Immediately at the beginning of an injection simulation, it is often sufficient to add a volume flow of 50% for the first 5% of the total injection state. For problems at the intersection of a cold runner into the part at the gate: analogous to the previous issue, reduce the injection speed until the injection of the part has begun. In the final phase of injecting a potentially unbalanced injection: earlier switching to holding pressure or definition of an injection profile. Avoiding fluctuations in flow rate Example: reduction of switching from a low injection pressure (100 bar) to a relatively high holding pressure (750 bar), by adding a short (0.1 sec) holding pressure level at half of the pressure difference (425 bar). Increase flow cross-section Example: Enlarge the gate diameter so that the shear load will be reduced Adjusting the pvt data for the material The transition from the melt to solid state should be continuous and therefore without fluctuations. With the IKV and two-domain Tait approaches, this is not assured due to the mathematical formulae. The Renner approach does not know any fluctuations. As a workaround, check the existing status of the data and correct it or re-fit the material using the Renner approach. The Too Many Pressure Iterations message will then no longer appear. 5.2 Deleting isolated nodes With some geometries, nodes that were disconnected arose in the 3D mesh. Afterwards, the calculation could not be started. These free nodes are now deleted automatically and the calculation is no longer interrupted. 5.3 Problems with use of prior filling results corrected In some cases, the shrinkage and warp results were no longer correct when the filling results were read in from a prior simulation. This error has been corrected. 5.4 Mesh error after rotation Erroneous geometries could arise from rotating runner geometries with sensors. This has been corrected. 5.5 Incorrect suggestions for injection time of the second component of a 2-component simulation Depending on the input sequence, the injection time was not always suggested correctly when entering a 2-component simulation. A reasonable value will now always be suggested. 5.6 All text deleted when entering an A In some cases, entering of an A could delete all of the text entered when describing a simulation or creating an automated report, for example. This will no longer happen. 5.7 Label errors Using certain settings in the Windows display options would display labels incorrectly. This error has been corrected. 5.8 Improved dragging of runner and cooling segments When translating or rotating runner or cooling channel segments, identical segments were sometimes deleted and the translated system would indicate an error. The deletion has now been suppressed and parallel translation is now possible. 5.9 Improved mesh preparation (folds) With some geometries, folds would arise during mesh preparation that prevented the generation of the 3D mesh. This error will no longer occur Accelerated cancellation of simulation jobs If the Cancel button was clicked during a simulation job, performing the cancellation often took some time. This time period has been shortened and the simulation job will now stop more quickly. Simcon kunststofftechnische Software GmbH, 2013 Page 25