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FEA Interface

Suresh WSIN
Technical Support Manager

Contents
> Introduction
Why Moldex3D FEA Interface

> Moldex3D FEA Interface Features and Benefits


What FEA Interface can do

> Moldex3D FEA Interface Function Description


> How Moldex3D FEA Interface Combines with FEA Software
ANSYS
ABAQUS

> Conclusion

Introduction

Why Moldex3D FEA Interface

Moldex3D

- Flow-induced stress
- Thermal-induced stress
- Molding defects
* Welding line
* Air trap
- Fiber orientation
- Fiber breakage
- Volume fraction
* Fiber concentration
* Powder concentration
- Void (MuCell)
- Moldbase temperature
- Moldbase pressure
4

FEA Interface

Finite Element
Analysis

- Integration and
mapping results in
molding stage to
the mesh for
structure Analysis

- Consider the state of


parts in molding
process to sequence
simulations after
ejection

- Material properties
reduction

Accuracy
Prediction
- For evaluation of
design improvement
and better processing
conditions

Technology Link of FEA Interface

Molding Simulation

FEA Interface

Finite Element
Analysis Software

Flow
Linear statics
Pack
Buckle
Cool
Warp
Fiber

Nonlinear Statics and


Dynamic

Hot Runner

Heat Conduction

Mold preheat

Coupling Analysis

Curing
RTM
5

Dynamic Response

Multiphysics

Moldex3D FEA Interface R14.0

Structure FEA
Software

ANSYS

Workbench

ABAQUS

MARC

LS-DYNA

MSC
NASTRAN

NX
NASTRAN

NE
NASTRAN

RADIOSS

Material
Reduction

Residual Stress

Initial Strain

EOP
Temperature

Melt Flow
Pressure

Moldbase
Output

Features and Benefits

What FEA Interface can Do (1/3)


> Fiber Orientation Output
How fiber orientation affects workability of fiber reinforced
plastics

> Material Reduction


Reduce the quantity of material properties by topological
grouping method for time-consuming and large number of
elements cases

> Density Output


Export the density distribution of molding part when dynamic
response is considered

> Mesh Mapping


Support results mapping, such as fiber orientation, volume
fraction, and etc., for different application fields between varied
kinds of meshes

What FEA Interface can Do (2/3)


> Residual Stress Output
Flow induced stress of polymer in injection process
Thermal stress owing to non-uniform temperature by cooling
channel

> Temperature Output


Temperature distributions of molding part at end of Packing
and Cooling

> Initial Strains Output


Effective temperature causing warpage and shrinkage

> Weld Line Output


Weaker strength in the weld line area is included

What FEA Interface can Do (3/3)


> Multiple time step melt flow pressure output
Consider deformation of part inserts by flow pressure in MCM
and core shift modules

> Moldbase related data output


Two factors causing moldbase deformation are included:
The flow pressure on the contact surface of the moldbase
and part
The moldbase temperature after Cooling

10

Moldex3D FEA Interface


Function Description

User Interface
Step 2: Select output
mesh type

Step 1: Select structure


FEA software

Step 3: Select output data

Step 4: Export input file

12

Output Mesh Option


> Original
Mapping the selected data on original
mesh without warpage results for further
finite element analysis
Supported mesh type:

Solid mesh

> Deformed
Mapping the selected data on deformed
mesh that includes warpage results
Supported mesh type:

Solid mesh

> Mapped
Mapping the selected data on different
meshes that are generated by other
software
Supported mesh type:
Solid mesh
eDesign mesh
13

Fiber Orientation Output


> Fiber orientation effects
Usually higher strength and stiffness along fiber oriented direction;
lower strength and stiffness perpendicular fiber oriented direction

> Moldex3D FEA Interface can transfer fiber orientation with


isotropic/anisotropic effects to Structural FEA Software

Isotropic material

Anisotropic material

14

Material Reduction
> For fiber reinforced plastic (FRP), each element has different
material properties due to flow-induced non-uniform fiber
orientation distribution
> Moldex3D FEA Interface can reduce the quantity of material by
topological grouping method
> Fiber orientation results can use material reduction for less
material count in Stress analysis software, and have more timesaving analysis

Total material number from 76,150 to 1,866


15

Total material number from 3,392 to 668

Density Output
> Moldex3D FEA Interface can export the density distribution
at the end of packing to Structural FEA software
1
2
3
4
5
6

16

Natural frequency
Constant
EOP
13.65
13.561
72.355
71.498
82.114
81.757
143.36
141.63
441.45
435.72
580.31
570.76

Mesh Mapping
> Due to different application fields, mesh requirements are varied.
Users need to map the injection molding results to find the suitable
mesh for further structural analysis
> Moldex3D FEA Interface can map material properties and analysis
result between different meshes and element types

17

Moldex3D tetra mesh

Structure analysis 2nd order hexa mesh

Original mesh

High order element mesh (2nd order)

Residual Stress Output


> Moldex3D FEA Interface can transfer residual stress results
to structural FEA software

LS-DYNA

18

Supported File for ABAQUS Analysis


> Moldex3D FEA Interface ABAQUS
Residual stress data output
Notes: Before running
ABAQUS, make sure the
workspace includes the two
file types
*.inp
*.sts

Von-Mises stress

19

Supported File for ANSYS Analysis


> Moldex3D FEA Interface ANSYS
Residual stress data output
Only SOLID186 supports
both pyramid element &
initial stress

Before running ANSYS, make


sure the workspace includes
the two file types, *.cdb & *.ist
Max. material reference number = 100,000
Von-Mises stress

20

Supported Temperature Output


> Packing Phase Temperature Output
Show the distribution inside the part

> End of Cooling Temperature Output


Show the distribution on the surface of the part

21

Supported Initial Strain Output


> Initial strain output results for Solid and Shell Analysis
Solid

Shell

Moldex3D
ABAQUS

FEA Software
22

ANSYS

LS-DYNA

ABAQUS

Supported Weld Line Output


> Weld Line Effect Validation
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 area

Simple Tensile

Transfer part geometry and


weld-lines strength into ANSYS
23

Including weld line effect


UYMX=505.09

Normal
UYMX=341.18

Supported Multiple Time Step Melt Flow Pressure Output

> Through this function, users can observe the deformation of


part insert at different time step during mold filling stage

U Magnitude: 0 ~ 3.607e-1 mm

U U1: -2.258e-2 ~ 2.254e-2 mm


24

U U2: -2.535e-2 ~ 1.678e-4 mm

U U3: -3.598e-1 ~ 9.068e-5 mm

Supported Mold Base Related Data Output


> Mesh Output
> Moldbase Pressure Output
Can be utilized for monitoring the core shift behaviour of
moldbase, which has significant influence on the product
accuracy

> Moldbase Temperature Output


Show the distribution inside the cavity

25

How Moldex3D FEA Interface


Combines with FEA Software
-

ANSYS
ABAQUS

Moldex3D Integration with ANSYS


Workbench

ACT Tool
> The Application Customization Toolkit is a full-featured
scripting interface to customize applications in Workbench
Replace command snippets with interactive objects
Do much more than what the standard features in
Mechanical offer

Access node/element information, material, solution, results


data
Even replace the APDL solver with your customer solver

> ACT provides an option to migrate APDL users to


Mechanical
Allow reusing legacy APDL developments in user-friendly way
Get the best of the two worlds

28

Note:
More user friendly with no additional ACT license needed in Moldex3D R14

Moldex3D-Workbench Integration in ANSYS


> Integrated with ANSYS with a seamless workflow for efficient
analysis validation
Moldex3D function is
available from the drop-down
menu to set analysis
properties
When solution done, users
can open the post to view the
result
ANSYS

Moldex3D Output

Moldex3D
29

Moldex3D-Workbench Integration in ANSYS


> Cover the process-induced variation during the processes
Map material properties between different meshes
Thermal / Flow residual stress output
EOP / EOC temperature output
Initial strain output

30

Moldex3D-Workbench Integration - Flow Chart

Part Geometry

eDesign

Workbench

Setup Runner and


Cooling in Designer

Structural mesh
Use the structural mesh
as mapping target

Injection Molding
Analysis

Create user defined options

Static Structural
Moldex3D
Extension

FEA Interface

31

Export the results as


Workbench format

Structural
Analysis

Efficient ABAQUS Interface Output

File Reading Issues for ABAQUS


> Users sometimes met a trouble if they would like to transfer
a mesh from Moldex3D to ABAQUS for fiber-filled plastic
parts
> They need to wait for several hours only for loading .inp file
in ABAQUS even though the model has only hundred
thousand solid elements

> Moldex3D FEA Interface provides a suitable way to improve


the efficiency of file reading
33

Efficient ABAQUS Interface Output

As shown in figure, the total element number: 776800


Choose *Distribution format and export to improve the efficiency of file reading.

The latest Moldex3D version


Medium-Level Material
reduction (Before R12)
No Material reduction
(Before R12)
34

FEA Interface Output Time

Output File Size

ABAQUS Analysis Time

CPU Time = 467 sec

786MB

Solve 30mins
(2G memory is enough)

CPU Time = 51,599 sec.

393MB

Solve 1 day
(Huge memory needed)

CPU Time = 458 sec.

405MB

Solve 1 day
(Huge memory needed)

ABAQUS/Standard vs. ABAQUS/CAE


ABAQUS/Standard

ABAQUS/CAE

Note:
Only ABAQUS/Standard supports the item output of Distribution format
35

Mapped Mesh Adjustment Tool

Coordinate Adjustment for Mapped Meshes


> Provide the coordinate adjustment tool to map one mesh
onto the other in FEA Interface
Making the position and orientation of CAE simulation mesh
coincide with structural analysis mesh
Provides auto move and 3-points mapping approaches

> Provide inconsistent model mapping happened

37

Mapped Mesh Adjustment Tool


> Click View/Edit model mapping item in FEA Interface
Function Option
> Designer interface will launch automatically
> All leading FEA software are supported

38

Model Mapping Method


> 1. Auto translation:
Translate mapped mesh to match the location of original mesh
automatically

> 2. Original:
Keep the mapped mesh at its original position.

> 3. 3-point mapping:


By define 3-point to adjust mapped mesh position

39

3D Results to Shell Mesh Mapping


> 3D results are able to map onto a shell mesh model for LS-DYNA
structure analysis, the results include:

Temperature at EOP and EOC

Volume shrinkage (as initial strain)

Fiber orientation

> Running shell structure analysis in LS-DYNA becomes much easier


with this function
1

1. Choose LS-DYNA as Stress solver


2. Choose 3D mapping to shell as output
mesh type

40

Multiple Time Step Output of Mold Temperature


> Available output option of mold temperature for multiple
time steps
> Based on the mold temperature variation history, model
deformation behaviour can be caught more accurately in
stress solver

41

More Output Options to ABAQUS Shell Analysis


> Support more output options in Shell FEA Interface for
ABAQUS, including:
Initial strain output
Packing phase temperature output
End of cooling temperature output
ABAQUS

Moldex3D

End of cooling
temperature output

42

Conclusion

Moldex3D FEA Interface (1)


> Integrated with leading FEA software with functions of results
output and mesh mapping for more accurate structure analysis:
Fiber orientation output
Material reduction
Density output

Mesh mapping
Residual stress output
Temperature output
Initial strains output
Weld line effects

Multiple time step melt flow pressure output


Moldbase related data output

> Anisotropic and non-homogeneous mechanical properties


of fiber-reinforced plastic can be output by FEA Interface

44

Moldex3D FEA Interface (2)


> Combine with Digimat to easily capture more accurate
material behaviour for structure analysis
> Provide users complete validation from molding, material
modeling (non-linear, fraction), and finite element simulation
to capture the product effects by external loading
FEA software

FE simulation
Molding

Results output

FEA Interface
- ANSYS
- ABAQUS
- LS-DYNA
- MSC-Nastran
- Marc
- Radioss

45

Micro Mechanics
Interface

Coupling material simulation

Material modeling for Composite


(non-linear, fraction)

Real product
effects
validation

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