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Tutorial Guide
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Tutorial Guide
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Tutorial Guide
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Tutorial Guide
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of ANSYS, Inc. and its subsidiaries and affiliates. vii
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Using This Manual
1. The Contents of This Manual
The Polyflow Tutorial Guide contains a number of example problems with complete detailed instructions,
commentary, and postprocessing of results.
The Polyflow User's Guide explains how to use ANSYS Polydata and ANSYS Polyflow to set up and solve
a problem.
The Polyflow Tutorial Guide contains a number of example problems with complete detailed instructions,
commentary, and postprocessing of results.
Tutorials for release 18.0 are available on the ANSYS Customer Portal. To access tutorials and
their input files on the ANSYS Customer Portal, go to http://support.ansys.com/training.
The Polyflow in Workbench User's Guide explains how to use the ANSYS Polyflow application within
ANSYS Workbench.
The Polymat User's Guide explains how to use the ANSYS Polymat module for material property evalu-
ation.
The Polystat User's Guide explains how to set up a MIXING task in ANSYS Polydata and how to
use the ANSYS Polystat module for statistical postprocessing of results.
The Polyflow Examples Manual provides overviews of solutions to a variety of problem types and is
available on the ANSYS Customer Portal. To access documentation files on the ANSYS Customer Portal,
go to http://support.ansys.com/documentation.
The GAMBIT manuals teach you how to use the GAMBIT preprocessor for geometry creation and mesh
generation.
The CFD-Post User's Guide explains how to use CFD-Post to examine your results.
For details on how to access the ANSYS Polyflow manuals, see the ANSYS Polyflow documentation
section of the separate Polyflow User's Guide.
If your support is provided by ANSYS, Inc. directly, Technical Support can be accessed quickly and effi-
ciently from the ANSYS Customer Portal, which is available from the ANSYS Website (www.ansys.com)
under Support > Customer Portal. The direct URL is: support.ansys.com.
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Using This Manual
One of the many useful features of the Customer Portal is the Knowledge Resources Search, which can
be found on the Home page of the Customer Portal. To use this feature, enter relevant text (error
message, etc.) in the Knowledge Resources Search box and click the magnifying glass icon. These
Knowledge Resources provide solutions and guidance on how to resolve installation and licensing issues
quickly.
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Using This Manual
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Part I: Introduction to using Polyflow in Workbench
The following Workbench tutorial is available:
Create a computational mesh for the geometry using the ANSYS Meshing application.
Import a data file, and modify it using ANSYS Polydata to include a user-defined template for the die inlet
flow rate.
View the initial results and create an output parameter for the maximum velocity of the extrudate in CFD-
Post.
Generate results for multiple design points using the Parameter and Design Points view, and chart how
the outflow velocity varies with the inlet flow rate.
1.2. Prerequisites
This tutorial assumes that you have little to no experience with ANSYS DesignModeler, ANSYS Meshing,
ANSYS Polyflow, CFD-Post, or the Parameter and Design Points view of ANSYS Workbench, and so
each step will be explicitly described.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
The melt enters the die as shown in Figure 1.1: Problem Description (p. 4) at an initial flow rate of
cm3/s (this flow rate is a quarter of that for the complete physical system) and the extrudate is
obtained at the exit. It is assumed that the extrudate is fully deformed at the end of the computational
domain, and that it will not deform any further (that is, subdomain 2 is long enough to account for all
the deformation of the extrudate).
The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two subdomains (as shown in Figure 1.1: Problem Description (p. 4))
so that a remeshing algorithm can be applied only to the portion of the mesh that will be deformed.
Subdomain 1 represents the die where the fluid is confined. Subdomain 2 corresponds to the extrudate
that is in contact with the air and can deform freely. The calculation will determine the location of the
free surface (the skin of the extrudate), as well as the velocity of the extrudate at the exit.
The boundary set for the problem is shown in Figure 1.2: The Boundary Set for the Problem (p. 5), and
the conditions at the boundaries of the domains are:
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Setup and Solution
1.4.1. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
4. Narrow the results by using the filter on the left side of the page.
6. Click the ext3d-workbench_R180.zip link to download the input and solution files.
7. Unzip the ext3d-workbench_R180.zip file you have downloaded to your working folder.
The extracted files include the geometry file ext3d.x_t , the data file polyflow.dat , and a
solution folder that contains the solution files created during the preparation of the tutorial.
Note
This tutorial is prepared using ANSYS Polyflow on a Windows system. The screen shots
and graphic images that follow may be slightly different than the appearance on your
system, depending on the operating system or graphics card.
The ANSYS Workbench application window will open, containing the Toolbox on the left and the
Project Schematic on the right. The Toolbox lists the various supported analyses and applications,
and the Project Schematic provides a space to display the components of the analysis systems you
select.
Note
When you first start ANSYS Workbench, the Getting Started message window is dis-
played, offering assistance through the online help for using the application. You can
keep the window open, or close it by clicking the red X icon in the upper right corner.
If you need to access the online help at any time, use the Help menu, or press the F1
key.
2. Create a new fluid flow analysis system by double-clicking the Fluid Flow (Polyflow) option under Ana-
lysis Systems in the Toolbox.
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Setup and Solution
Figure 1.3: Selecting the Fluid Flow (Polyflow) Analysis System in ANSYS Workbench
Extra
You can also create a new fluid flow analysis system by dragging-and-dropping the
analysis system into the Project Schematic: a green dotted outline will indicate a potential
location in the Project Schematic for the new system, which will turn into a red box
when you attempt to drop it.
A new ANSYS Polyflow-based fluid flow analysis system will be displayed in the Project Schematic.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
Figure 1.4: ANSYS Workbench with a New ANSYS Polyflow-Based Fluid Flow Analysis System
Note
The ANSYS Polyflow-based fluid flow analysis system is composed of various cells
(Geometry, Mesh, and so on) that represent the work flow for performing the analysis.
ANSYS Workbench is composed of multiple data-integrated (for example, ANSYS Polyflow)
and native applications into a single, seamless project flow, where individual cells can
obtain data from and provide data to other cells. ANSYS Workbench provides visual in-
dications of a cells state at any given time via icons on the right side of each cell. Because
of the constant flow of data, a cells state can quickly change. Brief descriptions of the
various states are provided below. For more information about cell states, see the ANSYS
Workbench online help.
Unfulfilled ( ) indicates that required upstream data does not exist. For example, when you first
create a new Fluid Flow (Polyflow) analysis system, all cells downstream of the Geometry cell appear
as Unfulfilled because you have not yet specified a geometry for the system.
Refresh Required ( ) indicates that upstream data has changed since the last refresh or update. For
example, after you assign a geometry to the Geometry cell in your new Fluid Flow (Polyflow) analysis
system, the Mesh cell appears as Refresh Required since the geometry data has not yet been passed
from the Geometry cell to the Mesh cell.
Attention Required ( ) indicates that the current upstream data has been passed to the cell, however,
you must take some action to proceed. For example, after you launch ANSYS Polydata from the Setup
cell in a Fluid Flow (Polyflow) analysis system that has a valid mesh, the Setup cell appears as Attention
Required because additional data must be entered in ANSYS Polydata before you can calculate a
solution.
Update Required ( ) indicates that local data has changed and the output of the cell must be regen-
erated. For example, after you launch ANSYS Meshing from the Mesh cell in a Fluid Flow (Polyflow)
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Setup and Solution
analysis system that has a valid geometry, the Mesh cell appears as Update Required because the
Mesh cell has all the data it requires to generate an ANSYS Polyflow mesh file, but the ANSYS Poly-
flow mesh file has not yet been generated.
Up-to-Date ( ) indicates that an update has been performed on the cell and no failures have occurred
(or an interactive calculation has been completed successfully). For example, after ANSYS Polyflow finishes
performing the number of necessary solver iterations, the Solution cell appears as Up-to-Date.
Interrupted ( ) indicates that you have interrupted an update (or stopped an interactive calculation
that is in progress). For example, if you select the stop button ( ) in the Progress Monitor of ANSYS
Workbench at a point where ANSYS Polyflow has generated results but has not yet completed the cal-
culation (such as during a transient simulation), then verify the action in the dialog box that opens,
ANSYS Polyflow is immediately stopped and the Solution cell appears as Interrupted.
Input Changes Pending ( ) indicates that the cell is locally up-to-date, but may change when next
updated as a result of changes made to upstream cells. For example, if you change the Mesh in an Up-
to-Date Fluid Flow (Polyflow) analysis system, the Setup cell appears as Refresh Required, and the
Solution and Results cells appear as Input Changes Pending.
Pending ( ) indicates that a batch or asynchronous solution is in progress. This icon will only appear
when the Solution cell is in background mode.
Refresh Failed, Refresh Required ( ) indicates that the last attempt to refresh cell input data failed,
and so the cell must be refreshed.
Update Failed, Update Required ( ) indicates that the last attempt to update the cell and calculate
output data failed, and so the cell must be updated. For example, if you update the Solution cell and
the solver diverges during the calculation, the Solution cell appears as Update Failed, Update Required.
Update Failed, Attention Required ( ) indicates that the last attempt to update the cell and calculate
output data failed, and so the cell requires attention.
a. Double-click the Fluid Flow (Polyflow) label underneath the analysis system.
a. Select the Save option under the File menu in ANSYS Workbench.
File Save
The Save As dialog will open, where you can browse to a specific directory and enter a specific
name for the ANSYS Workbench project.
b. In your working directory, enter ext3d-wb as the project File name and click the Save button to
save the project. ANSYS Workbench saves the project with a .wbpj extension, as well as supporting
files for the project.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
5. View the files generated by ANSYS Workbench, by enabling the Files option under the View menu.
View Files
Figure 1.5: Displaying the Files View after Adding an ANSYS Polyflow-Based Fluid Flow
Analysis System
ANSYS Workbench allows you to easily view the files associated with your project using the Files view.
You can see the name and type of file, the ID of the cell the file is associated with, the size of the file,
the location of the file, and other information. For more information about the Files view, see the
separate Polyflow in Workbench User's Guide and the ANSYS Workbench online help. To access docu-
mentation files on the ANSYS Customer Portal, go to http://support.ansys.com/documentation.
Note
ANSYS DesignModeler is licensed separately from ANSYS Polyflow. If you do not have access
to ANSYS DesignModeler, you can instead import a geometry file that does not need to be
modified, as noted in step 1.c.
a. Right-click the Geometry cell in the ext3d fluid flow analysis system (cell A2 in the ANSYS Workbench
Project Schematic).
b. Move your pointer over Import Geometry in the context menu that opens, and click Browse....
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Setup and Solution
c. Use the Open dialog box to browse to the folder you unzipped in a previous step, select ext3d.x_t,
and click Open.
Note
If you do not have access to ANSYS DesignModeler, select PFL.agdb in the Open
dialog box instead, then skip to Meshing the Geometry in the ANSYS Meshing Ap-
plication (p. 12).
The state of the Geometry cell becomes Up-to-Date, indicating that there is a geometry now associated
with the fluid flow analysis system.
Right-click the Geometry cell in the ext3d fluid flow analysis system, and select Edit Geometry
in DesignModeler..., to launch the ANSYS DesignModeler application.
3. Finish importing the geometry file by clicking Generate in the ANSYS DesignModeler toolbar. The geometry
will be displayed in the Graphics window.
Note that the scale at the bottom of the Graphics window can be used to confirm that the overall
length of the domain is 0.6 m.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
4. Modify the geometry so that the separate domains ("bodies") are treated as a single entity (a "part"), by
performing the following actions in the Tree Outline.
By uniting the multiple bodies of the geometry into a single part, you will create a conformal mesh
between the separate domains of the bodies.
d. Right-click the highlighted objects and click Form New Part in the menu that opens.
You can simply close the ANSYS DesignModeler application. ANSYS Workbench automatically saves
the geometry and updates the Project Schematic accordingly.
6. View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Note the addition of the geometry file (PFL.agdb, where PFL indicates a Polyflow-based fluid flow
system) to the list of files.
Double-click the Mesh cell in the ext3d fluid flow analysis system (cell A3) to launch the ANSYS
Meshing application with the extrusion geometry already loaded.
Extra
You can also right-click the Mesh cell to display the context menu where you can select
the Edit... option.
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Setup and Solution
Figure 1.7: The ANSYS Meshing Application with the Extrusion Geometry Loaded
2. Group the faces and create named selections to match the boundary set shown in Figure 1.2: The
Boundary Set for the Problem (p. 5).
a. Rotate the view to get your display similar to that shown in Figure 1.8: Rotated View (p. 14), by
holding the center mouse button and moving your pointer in the geometry window. (You can also
manipulate the view by clicking in the ANSYS Meshing toolbar and dragging the model).
Tip
Look at the orientation of the axis triad, , to assist when rotating the
view.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
Information will be displayed about the mesh in the Details view below the Outline tree view.
Note
Note that since the ANSYS Meshing application automatically detects that you are
going to perform a CFD fluid flow analysis, CFD is selected from the Physics Pref-
erence drop-down list.
c. Select the face that will represent the inlet, as shown highlighted in green in Figure 1.9: Selecting
the Inlet Face (p. 15).
d. Right-click and select the Create Named Selection option (from the menu that opens) to open the
Selection Name dialog box.
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Setup and Solution
e. Enter inlet for the name in the Selection Name dialog box, and click OK.
f. Hold down the Ctrl key, select the 2 faces that will represent the zero velocity boundary (as highlighted
in green in Figure 1.10: The Zero Velocity Faces Selected (p. 16)), then create a selection named die
wall in a manner similar to the previous steps.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
g. Hold down the Ctrl key, select the 2 faces that will represent the free surface boundary (as highlighted
in green in Figure 1.11: The Free Surface Faces Selected (p. 17)), and create a selection named free
surface in a manner similar to the previous steps.
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Setup and Solution
h. Rotate the view to get your display to be similar to that shown in Figure 1.12: Rotated View (p. 17),
by holding the center mouse button and moving your pointer in the geometry window.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
i. Hold down the Ctrl key, select the 2 faces that will represent one of the symmetry boundaries (as
highlighted in green in Figure 1.13: The First Pair of Symmetry Faces Selected (p. 18)), and create a
selection named symmetry 1 in a manner similar to the previous steps.
j. Hold down the Ctrl key, select the 2 faces that will represent the other of the symmetry boundaries
(as highlighted in green in Figure 1.14: The Second Pair of Symmetry Faces Selected (p. 19)), and
create a selection named symmetry 2 in a manner similar to the previous steps.
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Setup and Solution
k. Select the face that will represent the flow exit boundary (as highlighted in green in Figure 1.15: The
Flow Exit Face Selected (p. 20)), and create a selection named outlet in a manner similar to the
previous steps.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
3. Set the appropriate meshing parameters for the ANSYS Meshing application in the Details view.
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Setup and Solution
a. Confirm that Polyflow is selected from the Solver Preference drop-down list under Defaults.
a. Right-click Mesh in the Outline tree view, and select Update in the context menu.
Note
Using the Generate Mesh option from the Mesh context menu creates the mesh,
but does not actually create the relevant mesh files for the project and is optional
if you already know that the mesh is acceptable. Using the Update option automat-
ically generates the mesh and creates the relevant mesh files for your project and
updates the ANSYS Workbench cell that references this mesh.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
ii. Right-click Mesh in the Outline tree view, and select Update in the context menu.
Extra
After the mesh is generated, you can view the mesh statistics by expanding the Statistics
node in the Details view to reveal information about the number of nodes, the number
of elements, and other details.
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Setup and Solution
When you close the ANSYS Meshing application, ANSYS Workbench automatically saves the mesh
and updates the Project Schematic accordingly (the state of the Mesh cell changes from Refresh
Required to Up-to-Date, indicating that there is a mesh now associated with the fluid flow analysis
system).
6. View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Note the addition of the mesh files (PFL.1.poly and PFL.mshdb) to the list of files. The
PFL.1.poly file was created when you updated the mesh, and the PFL.mshdb file was generated
when you closed the ANSYS Meshing application.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
The data file you will import has already been set up for a 3D extrusion simulation with a single inlet
flow rate. For details on how to set up a similar data file in ANSYS Polydata, see 3D Extrusion (p. 143).
a. Right-click the Setup cell in the ext3d fluid flow analysis system, and click Import Polyflow Dat ...
in the context menu that opens.
b. Use the Open dialog box to browse to the folder you unzipped in a previous step, select poly-
flow.dat, and click Open.
The state of the Setup cell remains Refresh Required, indicating that even though there is a
data file now associated with the fluid flow analysis system, you still must perform an update for
the cell.
c. Right-click the Setup cell and click Update in the context menu that opens.
After ANSYS Polydata checks for coherence between the mesh and data files, the state for the
Setup cell becomes Up-to-Date. At this point it would be possible to run the ANSYS Polyflow solver
for your simulation; however, for this tutorial you will first modify the data file.
2. View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Note the addition of the data file (polyflow.dat) to the list of files.
Double-click the Setup cell in the ext3d fluid flow analysis system.
Extra
You can also launch ANSYS Polydata by right-clicking the Setup cell and clicking Edit...
in the context menu that opens.
Note
The mesh is automatically loaded and displayed in the Graphics Display window by
default.
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Setup and Solution
4. View the mesh information, in order to verify the unit that should be used for length when defining
your inputs for the simulation.
It is a good practice to always perform this step with new meshes. Polydata and Polyflow do not consider
units when calculating a solution, so it is your responsibility to ensure that you enter values for the ve-
locity, material data, and other settings that are consistent with each other and with the mesh.
b. Click the Info button to open a panel that displays the mesh information.
c. Verify that the Length Unit used to create the mesh was meters and that the dimensions of the
Bounding Box (which surrounds the mesh) are 0.1 x 0.1 x 0.6.
It is therefore recommended that you use meters for the length unit when specifying the inputs for
the simulation. Note that if you decided that you would rather work with a different length unit,
you could scale the mesh using Polyfuse, as described in the Polyflow User's Guide.
d. Close the panel and click the Menus tab at the bottom of the Polydata window.
5. Modify the data file so that the inlet flow rate is flagged as modifiable in a user-defined template (UDT).
Note
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F.E.M. Task 1
3D die swell
3D die swell is the name that was given to the sub-task for the flow problem when the data file
was created.
d. Select Inflow along INLET in the Flow boundary conditions menu and click Modify.
e. Click the UPDT button at the top of the ANSYS Polydata application window, to enable template
inputs.
g. Retain the selections of Automatic and Volumetric flow rate in the Inflow calculation on
INLET menu, and note that the flow rate is already set to 1 x 10-5 (which, since you are using
meters for your length unit, is equal to 10 cm3/sthat is, the initial flow rate proposed in
Problem Description (p. 3)). Then click Upper level menu.
h. Click Create a new template entry in the Create template entry menu.
i. Click the UPDT button again at the top of the ANSYS Polydata application window, to disable template
inputs.
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Setup and Solution
j. Click Upper level menu four times to return to the main Polydata menu.
6. Verify the system of units that will be passed to CFD-Post for postprocessing.
It is a good practice to always perform this step before running a new simulation, to ensure consistency
with the mesh and the units you used when defining the velocity, material data, and other settings.
Outputs
a. Note that the Current output(s) in the Outputs menu indicate that CFD-Post is currently selected
as the intended postprocessor.
c. Note that meter, kilogram, and second are currently selected for Length, Mass, and Time, respect-
ively (which is consistent with the values used in setting up the data file).
d. Click Upper level menu twice to return to the main Polydata menu.
A Parameters cell will be added to the ext3d fluid flow analysis system in the ANSYS Workbench
Project Schematic (cell A7). Also, a Parameter Set bar will be added below the system with an inbound
arrow, indicating that an input parameter has been created.
8. View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
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Note the addition of the template file (templates.upd) to the list of files.
1.4.6. Solution
1. Start ANSYS Polyflow.
In the ANSYS Workbench Project Schematic, right-click the Solution cell in the ext3d fluid flow
analysis system (cell A5), and click Update in the context menu that opens.
The ANSYS Polyflow solver will begin running. When the calculation is complete, the state for the
Solution cell becomes Up-to-Date.
2. View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Note the addition of the listing file (polyflow.lst), the ANSYS Polyflow results file (res), the output
mesh file (res.msh), the CFD-Post file (cfx.res), and the automatically generated probe files (.prb)
to the list of files. For more information about ANSYS Polyflow (and the files associated with it), see files
written and read by ANSYSPolydata in the Polyflow User's Guide. To access documentation files on the
ANSYS Customer Portal, go to http://support.ansys.com/documentation.
1.4.7. Postprocessing
In the following steps you will use ANSYS CFD-Post to view the results of your initial simulation, create
an expression that can be used as an output parameter for ANSYS Workbench, then review the list of
files generated by ANSYS Workbench.
In the ANSYS Workbench Project Schematic, double-click the Results cell in the ext3d fluid flow
analysis system (cell A6).
Extra
You can also start ANSYS CFD-Post by right-clicking the Results cell and selecting the
Edit... option in the context menu that opens.
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Setup and Solution
The ANSYS CFD-Post application will launch with the extrusion geometry already loaded (displayed in
outline mode). Note that ANSYS Polyflow results are also automatically loaded into ANSYS CFD-Post.
2. Obtain the view shown in Figure 1.19: Rotating the View (p. 29).
a. Rotate the view, by holding the center mouse button and moving your pointer in the viewer area.
b. Reduce the magnification of the view by clicking the Zoom icon at the top of the viewer area ( ),
holding the left mouse button, and moving your pointer in the viewer area.
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3. Display contours of velocity magnitude on the boundaries (Figure 1.20: Contours of Velocity Mag-
nitude (p. 32)).
Insert Contour
b. Retain the default entry of Contour 1 for Name and click OK to close the dialog box.
Information about Contour 1 will be displayed in the Details view below the Tree view in ANSYS
CFD-Post. The Details view contains all of the settings for a contour object.
c. Open the Location Selector dialog box by clicking the location editor button ( ) next to the
Locations drop-down list in the Geometry tab.
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Setup and Solution
i. Select all of the boundaries listed under ext3d by clicking the first one in the list
(PART_1_1_SOL_DIE_WALL), holding the Shift key, and clicking the last one in the list
(PART_1_2_SOL_SYMMETRY_2).
e. Click Apply.
The velocity is 0 along the die wall (as expected) and there is a fully developed profile at the inlet of the
die. At the die outlet, the velocity profile changes to become constant throughout the extrudate cross-
section. The transition between these two states can be seen in the first third of the extrudate.
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4. Display contours of velocity in cross-sections (Figure 1.21: Velocity Profiles at cross-sections (p. 37)).
a. Disable Contour 1 under User Locations and Plots in the Outline tab of the Tree view.
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Setup and Solution
i. Select Plane from the Location drop-down menu, located in the toolbar.
ii. Retain the default entry of Plane 1 for Name in the Insert Plane dialog box that opens, and
click OK.
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iii. Retain the default selection of XY Plane for Method in the Geometry tab of the Details view
for Plane 1.
v. Click Apply
c. In a similar manner, create cross-section planes at =0.08 m, 0.15 m, and 0.45 m named Plane 2,
Plane 3, and Plane 4 respectively. Note that you will retain the default selection of XY Plane for
Method and enter appropriate values for Z in the Details view.
d. Disable Plane 1, Plane 2, Plane 3, and Plane 4 under User Locations and Plots in the Outline tab
of the Tree view, so that the planes are no longer colored gray in the viewer area.
Insert Contour
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Setup and Solution
f. Retain the default entry of Contour 2 for Name and click OK to close the dialog box.
Information about Contour 2 will be displayed in the Details view below the Tree view.
g. Open the Location Selector dialog box by clicking the location editor button ( ) next to the
Locations drop-down list in the Geometry tab.
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i. Select all of the planes listed under User Locations and Plots by clicking Plane 1, holding the
Shift key, and clicking Plane 4.
i. Click Apply.
Velocity profiles at the flow inlet, the flow outlet, and planes just before and just after the die exit are
displayed. Compare the velocity profile within the die to the velocity profile just after the die exit at the
end of the computational domain. In the die the flow is fully developed. The velocity profile is flat (that
is, all the particles in the cross-section are at the same velocity) in the extrudate, far away from the die
exit. In the transitional zone just beyond the die exit, the velocity profile is reorganized. The velocity
profile on the plane =0.15 m is no longer fully developed, but it is not yet flat either. The velocity re-
arrangement is the source of the deformation of the extrudate.
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Setup and Solution
5. Create an expression for the maximum velocity at the flow exit, which can be used as an output parameter
in ANSYS Workbench.
b. Right-click anywhere in the Expressions tab and click New in the menu that opens to create a new
expression.
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c. Right-click in the Definition tab of the Details view, move your pointer over Functions, move your
pointer over CFD-Post, and click maxVal, to specify that the function in the expression obtains the
maximum value.
d. Make sure that the cursor is between the parentheses of maxVal()@, right-click in the Details view
again, move your pointer over Variables, and click VELOCITIES, to specify that the variables obtained
in the expression are velocities.
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Setup and Solution
e. Move the cursor so that it is after the @ symbol of maxVal (VELOCITIES)@, right-click in the Details
view again, move your pointer over Locations, and click PART_1_2_SOL_OUTLET, to specify that
the variables are obtained for the expression at the flow exit.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
f. Click Apply.
The expression in the Definition tab of the Details view will be defined as maxVal (VELOCITIES)@
PART_1_2_SOL_OUTLET with a Value of approximately 7.8 x 10-4m/s, and maxvelocity will
be added to the list in the Expressions tab of the Tree view, as shown in Figure 1.22: Creating an
Expression for an Output Parameter (p. 41).
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Setup and Solution
g. Right-click maxvelocity in the Expressions tab of the Tree view and select Use as Workbench
Output Parameter in the context menu that opens.
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An outbound arrow will be added from the Parameters cell to the Parameter Set bar in the
Project Schematic , indicating that an output parameter has been created.
Note
Note that the ANSYS CFD-Post state files are automatically saved when you exit ANSYS
CFD-Post and return to ANSYS Workbench.
File Save
8. View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
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Setup and Solution
Figure 1.23: Displaying the Files View after Viewing Results in ANSYS CFD-Post
Note the addition of the ANSYS CFD-Post state file (ext3d.cst) to the list of files. For more information
about ANSYS CFD-Post (and the files associated with it), see the ANSYS CFD-Post documentation.
Note
ANSYS DesignXplorer is licensed separately from ANSYS Polyflow. If you do not have access
to ANSYS DesignXplorer, you will not be able to perform some of the steps that follow, such
as computing multiple design points or plotting results in a chart.
1. Open the Parameters Set tab, which contains the Parameters and Design Points view (Figure 1.24: The
Parameters and Design Points View (p. 44)).
In the ANSYS Workbench Project Schematic, double-click the Parameter Set bar below the ext3d
fluid flow analysis system.
Extra
You can also open the Parameters and Design Points view by right-clicking the Para-
meter Set bar and selecting the Edit... option in the context menu that opens.
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If you do not see the panes shown in the previous figure, make them visible by enabling Outline,
Properties, Table, and Chart from the View menu.
2. Run the calculation again with a new inlet flow rate for the current design point.
a. Enter 8E-6 under P1 - flow rate for the DP0 (Current) design point (cell B3) in the Table of
Design Points.
An Update Required icon will be added to the cell under P2- maxvelocity for the DP0
(Current) design point (cell C3 ).
b. Right-click the cell under P2 - maxvelocity for the DP0 (Current) design point and select Update
Selected Design Points in the context menu that opens, to generate the maximum velocity at the
flow exit with the revised inlet flow rate.
Extra
You can also update the design point by clicking Update All Design Points in the
ANSYS Workbench toolbar.
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Setup and Solution
A dialog box may open to inform you that some open editors may close during this process. Click
OK to proceed.
ANSYS Polydata will update the data file based on the revised inlet flow rate and ANSYS Polyflow will
run again. When the calculation is complete, the Table of Design Points will display a new value of
approximately 6.2 x 10-4 m/s under P2 - maxvelocity for the DP0 (Current) design point.
a. Click P1 under Input Parameters (cell A4) in the Outline of All Parameters.
The ANSYS Workbench Toolbox will display options for Parameter Charts.
b. Double-click Parameters Chart P1 vs ? in the Toolbox to open the Properties of Outline A11:0
window at the bottom of the Parameters Set tab.
The Properties of Outline A11:0 window will display an initial setup for Parameter Chart 0 ,
in which P1 - flow rate is selected from the X-Axis (Bottom) drop-down list.
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ANSYS Polyflow in ANSYS Workbench Tutorial: 3D Extrusion
c. Select P2 - maxvelocity from the Y-Axis (Left) drop-down list in the Properties of Outline A11:0
window.
The current design point will be plotted in Parameter Chart 0 (Figure 1.25: The Chart of the Current
Design Point (p. 46)).
a. Enter 1E-5 for P1 - flow rate in the row beneath the DP0 (Current) design point (cell B*) in
the Table of Design Points, so that a new row is added (4) with DP 1 as the Name.
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Setup and Solution
b. In a similar manner, create additional design points DP 2 and DP 3 with a P1 - flow rate of
1.1E-5 and 1.2E-5, respectively.
Extra
By default, Workbench only saves the calculated data for the design point in the
row labeled Current. You can specify that the data generated for any other design
points is saved within the project by enabling the Retain option in column D. After
the design points are updated, you can then right-click a design point in the Table
of Design Points and select Set as Current to access the data.
5. Generate the values for the maximum velocity at the flow exit for all of the new design points.
ANSYS Polydata will update and ANSYS Polyflow will run repeatedly to solve for each of the design
points. As each calculation completes, the Table of Design Points (Figure 1.26: Displaying Values for
All of the Design Points (p. 47)) and Parameter Chart 0 (Figure 1.27: The Chart of All of the Design
Points (p. 48)) will be updated.
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File Save
7. Return to the Project Schematic view by clicking the Project tab above the ANSYS Workbench toolbar.
8. View the files generated by ANSYS Workbench, as displayed in the Project Schematic.
Note that the list of files shows that the design point file (designPoint.wbdp) was updated. For
more information about the files associated with ANSYS Workbench, see the ANSYS Workbench docu-
mentation.
1.5. Summary
In this tutorial, portions of ANSYS Workbench were used to simulate a 3D extrusion and to compare
the flow exit velocities associated with a range of inlet flow rates.
ANSYS DesignModeler was used to prepare the geometry, ANSYS Meshing was used to create a compu-
tational mesh, ANSYS Polydata was used to set up the simulation, ANSYS Polyflow was used to calculate
the fluid flow throughout the geometry using the computational mesh, and CFD-Post was used to
analyze the results. In addition, the Parameters and Design Points view of ANSYS Workbench was
used to add additional design points and compare their associated flow exit velocities on a chart.
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Part II: Extrusion
The following extrusion tutorials are available:
1.1. Introduction
This tutorial illustrates the setup and solution of a 2.5D axisymmetric extrusion problem. The problem
corresponds to a simplified 2D simulation of a swirling flow that occurs around the head of an extrusion
screw. The fluid is forced through the die and exits the extruder after a short die land. The model involves
a free surface, the position of which is unknown.
Create a sub-task.
Set material properties and boundary conditions for a 2.5D axisymmetric extrusion problem.
1.2. Prerequisites
This tutorial assumes that you have little experience with Polyflow and its associated modules.
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Since the problem involves a free surface, the domain is divided into two subdomains: one for the region
near the free surface and the other for the rest of the domain, as shown in Figure 1.2: Subdomains and
Boundary Sets for the Problem (p. 53)
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Problem Description
The boundary sets for the problem are also shown in Figure 1.2: Subdomains and Boundary Sets for the
Problem (p. 53), and the conditions at the boundaries of the domains are:
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2.5D Axisymmetric Extrusion
1.4. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the 25Axi-Extrusion_R180.zip link to download the input and solution files.
7. Unzip the 25-Axi-Extrusion_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
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Setup and Solution
Note
If you create the mesh in GAMBIT or a third-party CAD package, you need to convert it before
you read it into Polydata. In this tutorial, the mesh file has already been converted. So you
can read the mesh file directly into Polydata.
1. Create a Fluid Flow (Polyflow) analysis system by drag and drop in ANSYS Workbench.
a. Rename the project name to Tutorial 1 by double-clicking and editing the text Fluid Flow (Poly-
flow).
Right-click the Mesh cell, hover over Import Mesh File and click Browse....
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2.5D Axisymmetric Extrusion
a. Select ext2d.msh.
b. Click Open.
3. Double-click the Setup cell to start Polydata and read in the mesh. When Polydata starts, the Create a new
task menu item appears in bold text, and the geometry for the problem is displayed in the Graphics Display
window.
Note
At this point (when Create a new task appears in bold text) if you realize that you have
read the wrong mesh file, click STOP at the top of the Polydata menu and repeat the
process to access the correct mesh file.
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Setup and Solution
F.E.M. task
Steady-state problem(s)
The Current setup (above the selected options) will be updated to reflect the selection. In any
problem solved using Polyflow, first an F.E.M. task is defined to calculate the flow field. If inform-
ation regarding the trajectories is necessary, specify a MIXING task after solving the problem
with the F.E.M. task specification and obtaining the results file. Then solve the problem once
again. 3D velocity components (u,v,w) are prescribed in a 2D cylindrical reference frame (r,z), so
2D 1/2 axisymmetric geometry has been chosen. A steady-state condition is assumed for this
problem.
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Note
At this point (when Create a sub-task appears in bold text) if you realize that you
have made a mistake in the creation of the task and you need to return to that menu,
do the following:
ii. Select Redefine global parameters of a task and make the necessary changes.
iii. Click Accept the current setup when you are satisfied with the corrected settings.
Create a sub-task
A small dialog box appears asking for the title of the problem.
Note
At this point (when Domain of the sub-task appears in bold text) if you realize that
you have made a mistake in the creation of the sub-task and you need to return to
that menu, do the following:
ii. Select Redefine global parameters of a sub-task and make the necessary changes.
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Setup and Solution
Since this flow involves a free surface, the domain is divided into two subdomains: one for the region
near the free surface and the other for the rest of the domain. Here, the sub-task applies to both
subdomains (the default condition).
Accept the default selection of both subdomains by clicking Upper level menu.
Material data
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2.5D Axisymmetric Extrusion
(1.1)
where:
= shear rate
3. Specify the value , referred to as fac in the graphical user interface (compare the equation at the top
of the Cross law menu to Equation 1.1 (p. 60)).
Modify fac
Enter 85000 [units: poise] as the New value and click OK.
4. Specify the value for , referred to as tnat in the graphical user interface.
Modify tnat
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Setup and Solution
5. Specify the value for , referred to as expom in the graphical user interface.
Modify expom
6. Check whether the values of the constants are correct, and repeat the previous steps if you need to
modify the constants again.
7. Click Upper level menu three times to leave the Material Data specification.
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2.5D Axisymmetric Extrusion
a. Select Zero wall velocity (vn=vs=0) along BS_1 and click Modify.
b. Click Inflow.
When the Automatic option is selected, Polydata chooses the most appropriate method to compute
the inflow. In this case, Polydata will use a 1D finite-element technique to compute a 1D fully-developed
velocity profile, based on the specified material properties and flow rate. Moreover, the inflow
boundary condition requires that the computational domain be built in such a way that the basic
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Setup and Solution
assumptions of fully-developed flow are satisfied. In axisymmetric geometries, the inflow section must
be perpendicular to the axial direction.
The fluid is assumed to stick to the wall, since at a solid-liquid interface the velocity of the liquid is that
of the solid surface. This is commonly known as the no-slip assumption because the liquid is assumed
to adhere to the wall, and therefore has no velocity relative to the wall.
Retain the default condition Zero wall velocity (vn=vs=0) along BS_2.
In a steady-state problem, the velocity field must be tangential to a free surface, since no fluid
particles go out of the domain through the free surface. This constraint is called the kinematic
condition, = 0. This equation requires an initial condition at the starting point of the free surface,
which in this case is located at the intersection of BS_2 and BS_3.
a. Select Zero wall velocity (vn=vs=0) along BS_3 and click Modify.
Note
Do not select the Outlet option. It is only applicable for die design problems.
As mentioned above, the starting point of the free surface is at the intersection of BS_2 and BS_3.
h. Retain the default settings for the Normal force and Direction of motion.
j. Click Upper level menu to return to the Flow boundary conditions menu.
It is reasonable to consider that a uniform velocity profile is obtained at the exit. In most cases, a bulk
flow is obtained and thus no force is acting, so the selection of zero normal and tangential forces is ap-
propriate. In situations involving pulling velocity or force or gravity, the corresponding boundary condition
should be selected.
a. Select Zero wall velocity (vn=vs=0) along BS_4 and click Modify.
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c. Accept the default value of 0 for the normal force by clicking Upper level menu.
d. Accept the default value of 0 for the tangential force by clicking Upper level menu.
5. Retain the default condition at the symmetry axis (Axis of symmetry along BS_5).
For axisymmetric models, the axis of symmetry is always the y axis. Polydata determines the axis of
symmetry from the mesh file, and automatically imposes the symmetry condition along the line r=0
(x=0).
Since the screw is rotating with angular velocity = 2 = 6.2832 rad/s, the rotational velocity along
this boundary is prescribed to increase linearly with ( = 6.2832 ). In the equation for , X denotes
the direction and Y denotes the direction. Since the fluid sticks to the wall, = 0 = .
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Setup and Solution
a. Select Zero wall velocity (vn=vs=0) along BS_6 and click Modify.
c. Accept the default value of 0 for the normal velocity ( ) and tangential velocity ( ) by selecting Upper
level menu twice.
e. Click Velocity w imposed and select 'w' velocity = linear function of coordinates.
f. Accept the default value of 0 [units: cm/s] for the constant A by clicking OK.
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g. Enter 6.2832 [units: rad/s] as the New value for the constant B and click OK.
h. Accept the default value of 0 [units: rad/s] for the constant C by clicking OK.
j. Click Upper level menu at the top of the Flow boundary conditions menu.
1.5.5. Remeshing
This model involves a free surface for which the position is unknown. A portion of the mesh is affected by
this unknown boundary. Hence a remeshing technique is applied on this part of the mesh. The free surface
is entirely contained within subdomain 2, and hence only subdomain 2 will be affected by the relocation of
the free surface.
Global remeshing
In some cases, when the mesh is geometrically complex, it may be necessary to split it into additional
subdomains in order to define a specific remeshing method on each of them. For this purpose, Polydata
allows you to create several local remeshings. For the current problem, a single local remeshing is sufficient.
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Setup and Solution
SD_1 is moved from the top list to the bottom list, indicating that only SD_2 will be remeshed.
If you accidentally remove the wrong subdomain, select it and click Add to restore it. Then, follow
the instructions to remove the correct subdomain.
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The purpose of the remeshing technique is to relocate internal nodes according to the displacement of
boundary nodes due to the motion of the free surface. Mesh nodes are organized along lines of
remeshing (spines), which are collections of nodes logically arranged in a one-dimensional manner. This
technique is most suited for 2D extrusion problems. Polydata requires the specification of the first and
last spines that the fluid encounters (inlet of spines and outlet of spines, respectively).
In this case, the inlet of spines is the intersection of subdomain 2 with subdomain 1, and the outlet of
spines is the intersection of subdomain 2 with the flow exit (boundary 4).
Method of Spines
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Setup and Solution
At this point, if you realize that you have made a mistake in global remeshing, click die swell at the
bottom of the menu and perform this Step again.
1. Select Condition on the stream function for field 1. Click No in the window that pops up.
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If you have made a mistake in assigning the stream function, click F.E.M. Task 1 to get into that menu
and then repeat this Step.
1.5.7. Outputs
After Polyflow calculates a solution, it can save the results in several different formats. Choose the format
that is appropriate for your postprocessor. In this case, save the outputs in the default format for ANSYS
CFD-Post.
Outputs
2. Accept the default output option for CFD-Post by clicking Upper level menu.
When exiting the menu, Polydata asks you to confirm the current system units and fields that are to be
saved to the results file for postprocessing.
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Setup and Solution
If you do not enter the menu Outputs, Polydata will ask you to confirm the current system units at
the end of the session, if it is a new session.
If this was not yet done before (see above), Polydata asks you to confirm the current system units. It will
also ask to confirm fields that are to be saved to the results file for postprocessing.
1. Click Accept.
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2. Click Continue.
This accepts the default names for graphical output files ( cfx.res ) that are to be saved for postpro-
cessing, and for the Polyflow format results file ( res ).
1.5.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update from the shortcut
menu.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
ANSYS Workbench opens the View listing file dialog box, which displays the listing file.
b. In the View listing file dialog box, disable the Show only last 200 lines option and click the Manual
refresh button. Then find the SOLVER section that relates to F.E.M. Task 1; at the end of this
section, a message Convergence assumed is displayed. This indicates that the solution has con-
verged. See the Polyflow User's Guide for more information on convergence.
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Setup and Solution
1.5.10. Postprocessing
ANSYS CFD-Post has similar interfaces for UNIX and Windows, the postprocessing steps are illustrated for
Windows.
1. Double-click the Results cell in the ANSYS Workbench analysis and read the results files saved by Polyflow.
ANSYS CFD-Post reads the solution fields that were saved to the results file.
a. Right-click a blank area anywhere in the graphical window, hover over Predefined Camera in the
context menu, and select View From +Z.
The central mouse button allows you to zoom in and zoom out. The left mouse button allows rotating
the image. The right mouse button allows you zoom to an area.
b. Also, right-click a blank area anywhere in the graphical window and deselect Ruler, if needed.
a. Click the Insert menu and select Contour or click the Contour button ( ).
b. Click OK to accept the default name (Contour 1) and open the details view below the Outline tab.
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c. In the details view for Contour 1, specify the following settings under Geometry:
i. Next to Locations, click the ellipsis button ( ) on the right and select SD_1_surf and SD_2_surf
(use Ctrl to select multiple items).
ii. Select PRESSURE from the Variable drop-down list, or click the ellipsis button ( ) on the right
and select PRESSURE.
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The details view of Default Transform will open below the Outline tab.
ii. In the details view of Default Transform, disable Instancing Info From Domain.
iv. Select Y from the Axis drop-down list in the Axis Definition group box.
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Setup and Solution
i. Click the Insert menu and select Text or click the button.
ii. Click OK to accept the default name (Text 1) and open the details view below the Outline tab.
iii. Enter Polyflow Results for Text String in the Definition tab of the details view.
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a. Deselect Contour 1.
b. Click the Insert menu and select Vector or click the Vector button ( ).
c. Click OK to accept the default name (Vector 1) and open the details view below the Outline tab.
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Setup and Solution
i. In the Geometry tab, click the ellipsis button ( ) next to Locations, select SD_1_surf and
SD_2_surf (use Ctrl to select multiple items), and click OK.
ii. Select VELOCITIES from the Variable drop-down list, or click the ellipsis button ( ) on the right
and select VELOCITIES.
iv. Define the attributes of vectors: in the Symbol tab, set Symbol to Arrow3D and Symbol Size to
3.
v. Click Apply.
i. Deselect Text 1 in the Outline tab, under User locations and plots.
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i. Rotate to the isometric view by clicking the cyan-blue dot in the axis triad (bottom right of the
graphics window).
This allows you to better visualize the magnitude of the velocity vectors.
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Setup and Solution
ii. Enable Normalize Symbols in the Symbol tab of the details view for Vector 1.
This allows you to better visualize the direction of the velocity vectors.
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The velocity vectors take all components of the velocity into account. Along the screw tip, the
rotational component is important, leading to long vectors that are not in the xy plane. After the
die exit, a rearrangement of the velocity field takes place. The flow slows down along the axis of
symmetry and accelerates on the outside. This makes the particles go toward the free surface,
creating the swelling.
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Setup and Solution
ii. Under Render tab, deselect Show Faces and select Show Mesh Lines.
iii. Under Color tab, click the ellipsis ( ), select the color white and click OK.
i. Double-click Vector 1 under User Locations and Plots in the Outline tab.
i. Right-click a blank area in the graphics window, hover over Predefined Camera in the context menu,
and select View from +Z.
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i. Move the mouse to the left-hand border of the graphic window until the cursor suggests a rotation
along a vertical line.
ii. Click and move the mouse slowly to the right-hand side.
1.6. Summary
This tutorial demonstrated how to set up and solve a 2.5D axisymmetric extrusion problem. It showed
how to set up a free surface problem and the associated remeshing, and demonstrated the use of CFD-
Post to examine the flow behavior associated with the problem.
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Chapter 2: Fluid Flow and Conjugate Heat Transfer
This tutorial is divided into the following sections:
2.1. Introduction
2.2. Prerequisites
2.3. Problem Description
2.4. Setup and Solution
2.5. Summary
2.1. Introduction
This tutorial illustrates the setup and solution of a problem involving heat transfer between a Newtonian
fluid and a cooled circular die. Along with a good die design, rheological and thermo physical properties
of the melt and the thermal settings in the die are very important in obtaining a geometrically well-
defined polymer product. The heat transfer calculation is important when temperature-sensitive polymers
are shaped and when product surface qualities are of critical importance. The temperature field at the
die exit influences the swelling and drawing behavior of the product.
In this tutorial, you will solve the non-isothermal flow problem for the fluid and the heat conduction
in the die, making some assumptions regarding the rheological and thermo physical properties of the
melt.
Set material properties and boundary conditions for a fluid-solid heat conduction and flow problem.
2.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the set up procedure
will not be shown explicitly.
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= 180C and =0.6e06 m3/s, respectively. The problem involves flow, heat transfer by conduction
and convection, and heat generation by viscous dissipation. Energy, momentum, and incompressibility
equations are solved in the fluid domain. The energy equation for heat conduction is solved in the
solid domain.
To solve the coupled problem, two sub-tasks are defined: one for the fluid (sub-task 1) and the other
for the solid (sub-task 2). Each sub-task will contain a particular model, domain of definition, material
properties, and boundary conditions, including interface conditions with the other sub-task. The sub-
tasks are coupled, because the global solution of the problem depends on the values of the solution
variables at the intersection of the fluid and solid domains.
Figure 2.1: A Schematic Diagram of the Fluid and the Circular Die
Viscous heating is taken into account. For the solid region, the thermal conductivity is 35 W/m-C.
The boundary sets for the problem are shown in Figure 2.2: Boundaries and Sub-domains (p. 87), and
the conditions at the boundaries of the domains are as follows:
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Setup and Solution
boundary 2: insulated
boundary 3: = 100C
boundary 4: insulated
2.4.1. Preparation
To prepare for running this tutorial:
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Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the Fluid-Solid_R180.zip link to download the input and solution files.
7. Unzip the Fluid-Solid_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering fluid-solid as the name of the project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
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Setup and Solution
Steady-state problem(s)
2D axisymmetric geometry
Since the problem involves an axisymmetric steel die, the computational domain for the problem is
chosen to be a 2D cylindrical reference frame (r,z) with r=0 as the axis of symmetry, and involves two
velocity components (u,v); hence 2D axisymmetric geometry has been chosen. A Steady-state condition
is assumed for the problem.
Create a sub-task
Note
To solve the coupled problem, the computational domain is divided into two sub-domains with a
common intersection. A sub-task with its own model, material properties, and boundary conditions
is defined on each of the non-overlapping subdomains. Sub-task 1 is defined for SUBDOMAIN_1,
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since SUBDOMAIN_1 represents the fluid (as shown in Figure 2.2: Boundaries and Sub-do-
mains (p. 87)).
SUBDOMAIN_2 is moved from the top list to the bottom list, indicating that subtask 1 is defined
on SUBDOMAIN_1.
Polydata indicates which material properties are relevant for your sub-task by graying out the irrelevant
properties. In this sub-task, Polyflow solves energy, incompressibility and momentum equations, so you
have to define viscosity, density, thermal conductivity, heat capacity per unit mass, and viscous heating.
For a non-isothermal flow problem, the viscosity can depend on both shear rate and temperature. In
this case, the viscosity is constant, so it depends on neither of them.
Material Data
Since the fluid flow is Newtonian, specify a constant value for the viscosity.
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Setup and Solution
ii. Specify the value for , referred to as fac in the graphical user interface.
Modify fac
iii. Enter 2500 [units: Pas] as the New value and click OK.
iv. Click Upper level menu two times to continue the Material Data specification.
Polydata displays the following message, confirming that there is no temperature dependence
for the viscosity.
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iii. Click Upper level menu to continue the Material Data specification.
c. Click Density.
Modification of density
i. Enter 950 [units: kg/m3] as the New value and click OK.
ii. Click Upper level menu to continue the Material Data specification.
As shown at the top of the menu, the thermal conductivity is defined as a nonlinear function of
the temperature:
(2.1)
In this problem, the thermal conductivity is assumed to be a constant for the fluid so only the
constant coefficient is modified.
Modify a
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Setup and Solution
i. Enter 0.5 [units: W/m-C] as the New value and click OK.
ii. Click Upper level menu to continue with the Material Data specification.
As shown at the top of the menu, the heat capacity per unit mass is defined as a nonlinear function
of temperature:
(2.2)
The temperature variation of differs with the nature of the polymer melts. In this problem, is
assumed to be constant, so only the constant coefficient is modified.
Modify a
i. Enter 2300 [units: J/kg-C] as the New value and click OK.
ii. Click Upper level menu to continue with the Material Data specification.
When shearing occurs in a flow, the friction of the different fluid layers generates heat. When the
fluid is highly viscous and/or the shear rate is high, the heating of the fluid caused due to this
phenomenon must be taken into account.
ii. Click Upper level menu to return to the Material Data specification.
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The intersection acts as a wall for the fluid, and since the fluid is assumed to stick to the wall, zero
normal and tangential velocities is imposed along this boundary.
i. Retain the default condition Zero wall velocity (vn=vs=0) along SUBDOMAIN_2.
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
iii. Retain the default settings, Automatic and Volumetric flow rate.
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Setup and Solution
v. Enter 0.6e-06 [units: m3/s] as the New value in the dialog box that appears, and click OK.
The flow rate of the melt is very low due to the highly viscous nature of the melt.
When the Automatic option is selected, Polydata automatically chooses the most appropriate
method to compute the inflow condition.
It is assumed that a fully developed velocity profile is reached at the exit, so the outflow condition
is appropriate. This condition imposes a zero normal force, (which includes a pressure term),
and zero tangential velocity, .
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY_5 and click Modify.
For axisymmetric models, Polydata recognizes the axis of symmetry from the mesh file, and auto-
matically imposes the symmetry condition along the line r=0. This condition imposes a zero normal
velocity and zero tangential force along this boundary.
e. Click Upper level menu at the top of the Flow boundary conditions menu to return to the fluid
menu.
For non-isothermal problems, specify either the temperature or the heat flux on each boundary segment.
The temperature along a given boundary can be a constant or a prescribed function of coordinates.
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An interface condition is set at the intersection of subdomain 1 and subdomain 2. This condition
ensures continuity of the temperature field and of the heat flux along the interface. Since you are
solving a coupled problem, this condition of continuity is essential for the global solution of the
temperature and heat flux variables.
iii. Click Upper level menu to accept the default setting (continuous heat flux along the interface).
In the case of an interface condition, both the heat flux and temperature are usually continuous
along the interface. It is possible to specify a nonzero value for the heat flux jump ( ), but
this is mainly used in problems where internal radiation is simulated. Here, accept the default
value for the definition of heat flux discontinuity, = 0.
Polydata prompts you for the new value of the constant temperature.
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Setup and Solution
iv. Enter 180 [units: C] as the New value and click OK.
v. Click Upper level menu to return to the Thermal boundary conditions menu.
e. Click Upper level menu twice to return to the F.E.M. Task 1 menu.
Create a sub-task
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b. Click No, since this sub-task has different parameters associated with it.
A small dialog box appears asking for the title of the problem.
Material Data
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Setup and Solution
In this problem, thermal conductivity is assumed to be a constant, so only the constant coefficient
is modified.
i. Select Modify a.
ii. Enter 35 [units: W/m-C] as the New value and click OK.
b. Click Upper level menu two times to return to the solid menu.
In this step, set the conditions at each of the boundaries of the domain. When a boundary set is
selected, it is highlighted in red in the graphics window.
iii. Click Upper level menu to accept the default option for continuity of temperature and heat
flux.
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Polydata prompts you for the new value of the constant temperature.
iv. Enter 100 [units: C] as the New value and click OK.
v. Click Upper level menu to return to the Thermal boundary conditions menu.
e. Click Upper level menu three times to return to the top-level Polydata menu.
Polydata asks you to confirm the current system units and fields that are to be saved to the results file
for postprocessing.
4. Click No.
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In this instance, the convergence strategy will not assist Polyflow in reaching a solution as the problem
is quasi-linear.
5. Click Accept.
6. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and for the Polyflow format results file (res).
2.4.7. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Workbench opens the View listing file dialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
2.4.8. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1. Double-click the Results cell in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
Right-click the Graphics window and select View from +Z under Predefined Camera.
(Or you can click +Z on the axis triad in the graphic window.)
a. Click the Insert menu and select Contour or click the Contour button ( ).
b. Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
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c. In the details view for Contour 1, specify the following settings under Geometry:
i. Next to Locations, click the ellipsis button ( ) on the right and select SUBDOMAIN_1_surf
and SUBDOMAIN_2_surf (use Ctrl to select multiple items).
ii. Select PRESSURE from the Variable drop-down list, or click the ellipsis button ( ) on the
right and select PRESSURE.
Most of the pressure drop occurs in the upper part of the die where the cross-section is smallest (Fig-
ure 2.3: Pressure Contours (p. 103)). The pressure is linear except in the contraction zone. The isobars are
perpendicular to the flow direction, as expected for the fully developed flow that occurs in the second
part of the die.
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a. In the details of Contour 1, select VELOCITIES from the Variable drop-down list.
b. Click Apply.
The velocity is higher in the second part of the die where the cross-section is smaller (Figure 2.4: Velocity
Distribution (p. 104)). It reaches a maximum value in the center of the thin tube.
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a. In the Outline tab, under User Locations and Plots, deselect Contour 1.
i. Click the Insert menu and select Vector or click the button.
iii. In the Geometry tab of the details view of Vector 1, click the button next to Locations.
iv. Select the location SUBDOMAIN_1 and click OK to close the Location Selector dialog box.
v. In the Symbol tab, select Arrow 3D and increase the Symbol Size to 3.
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Setup and Solution
The flow is fully developed in the downstream part of the die (Figure 2.5: Velocity Vectors (p. 105)). Observe
the classical parabolic velocity profile. The Poiseuille flow is rapidly reached after the contraction because
inertia is not taken into account here.
6. Display of the temperature distribution in the solid and the fluid regions.
a. Deselect Vector 1 in the Outline tab under User Locations and plots.
b. Double-click Contour 1 (in the Outline tab under User Locations and plots.
c. In the details view for Contour 1, specify the following settings under Geometry:
i. Ensure SUBDOMAIN_1_surf and SUBDOMAIN_2_surf are selected for Locations, (click the
ii. Select Temperature from the Variable drop-down list, or click the ellipsis button ( ) on the
right and select Temperature.
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Setup and Solution
As expected, the temperature gradients are larger in the fluid than in the die, (the isolines are closer
together in the fluid than in the diesee Figure 2.6: Temperature Distribution (Celsius) (p. 106)). This is
because the conductivity of the fluid is much lower than the conductivity of the solid. The temperature
isolines are perpendicular to the boundaries where the (normal) flux becomes zero. The heating of the
fluid due to viscous dissipation can be clearly seen. In order to visualize contours in Kelvin, select the
Edit/Options... menu item, click Units under Common, select K from the Temperature drop-down
menu, and click OK.
ii. Click OK to accept the default name (Line 1) and display the details view below the Outline
tab.
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iv. Enter 0, 0.006, and 0 for Point 1 and enter 0.008, 0.006, and 0 for Point 2.
Note
You will need to ensure that your unit of length is set to meter in CFD-Post.
v. Click Apply.
b. Create a plot.
i. Click the Insert menu and select Chart or click the Chart button ( ).
ii. Click OK to accept the default name (Chart 1) and display the details view below the Outline
tab tree.
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Setup and Solution
iii. In the General tab, ensure XY is selected for the Chart Type and enter Temperature Profile
for the Title.
iv. In the Data Series tab, select Line 1 from the Location drop-down list.
vi. In the Y Axis tab, select Temperature from the Variable drop-down list.
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The thermal boundary layer located along the die wall is clearly visible. This boundary layer is the result
of the low thermal conductivity and high heat capacity of the fluid. The temperature of the fluid at the
center is not affected by the low temperature of the solid. The heat does not diffuse quickly enough
through the fluid layer to reach the axis of symmetry, before the fluid exits the die.
2.5. Summary
This tutorial introduced the coupling of sub-tasks of different types: a non-isothermal flow problem and
a heat conduction problem in a solid. Coupled calculations like this are very useful in polymer processing
applications where thermal effects are critical (for example: extrusion, coating, fiber spinning). Coupling
can also be applied through fields other than temperature (for example: electrical potential and pressure
in porous media).
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Chapter 3: Non-Isothermal Flow Through a Cooled Die
This tutorial is divided into the following sections:
3.1. Introduction
3.2. Prerequisites
3.3. Problem Description
3.4. Setup and Solution
3.5. Summary
3.6. Appendix: Nonlinearity and Evolution
3.1. Introduction
This tutorial examines the flow of a polymer melt through a die. The temperature of the melt increases
due to viscous dissipation caused by the shearing taking place in the die. The temperature of the fluid
is critical for the process. The viscosity of the fluid changes with temperature, which leads to the
modification of the shape of the extrudate. The polymer might degrade if the temperature is too high,
so a numerical simulation is of great interest to optimize the operating conditions.
Set material properties and boundary conditions for the contraction flow problem.
3.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the set up procedure
will not be shown explicitly.
In solving for the free surface location, the position variables are also coupled to the temperature, velocity,
and pressure fields. To solve the coupled problem, you will define two sub-tasks: one each for the fluid
(sub-task 1) and the solid (sub-task 2). Each sub-task contains a particular model, domain of definition,
material properties, and boundary conditions, including interface conditions with the other sub-task.
The sub-tasks are coupled because the global solution of the problem depends on the values of the
solution variables at the intersection of the fluid and solid domains.
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The high flow rate introduces strong nonlinearity in the problem, which can lead to a loss of convergence
in the iterative scheme. In Polyflow an evolution scheme is available to solve such highly nonlinear
problems. In this problem, the evolution scheme is applied to the flow rate, which is increased from a
low value to the desired value. This leads to a simultaneous increase of viscous dissipation and inertia
effects.
Viscous heating is taken into account and the shear-rate dependence of viscosity obeys the Bird-Carreau
law. For the solid region, the thermal conductivity ( ) is 30 W/m-C.
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Problem Description
The boundary sets for the problem are shown in Figure 3.2: Boundaries and Subdomains (p. 113), and
the flow and thermal conditions for the fluid and the die at the boundaries of the domains are:
boundary 4: free surface with convective heat transfer to surroundings ( = 20 W/m2-C, = 20C)
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3.4.1. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the Non-Iso-Flow_R180.zip link to download the input and solution files.
7. Unzip the Non-Iso-Flow_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering non-iso-flow as the name of the
project.
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Setup and Solution
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
Evolution problem(s)
2D axisymmetric geometry
The Current setup (above the selected options) is updated to reflect your selections. Since the
problem involves an axisymmetric die, Polyflow uses a 2D cylindrical reference frame (r,z) with r=0
as the axis of symmetry. The use of evolution inputs allows the flow rate to be slowly ramped up to
ensure that the solution converges.
Create a sub-task
Note
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To solve the coupled problem, the computational domain is divided into three subdomains. There are
two sub-tasks in this problem. Define a sub-task with its own model, material properties, and boundary
conditions for the fluid region. Since this problem involves a free surface, the domain for sub-task 1 is
divided into two subdomains: one for the region near the free surface (SUBDOMAIN_2) and the other
for the rest of the fluid domain (SUBDOMAIN_1). In this problem, sub-task 1 applies to SUBDOMAIN_1
and SUBDOMAIN_2.
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Setup and Solution
SUBDOMAIN_3 is moved from the top list to the bottom list, indicating that subtask 1 is defined
on SUBDOMAIN_1 and SUBDOMAIN_2.
b. Click Upper level menu at the top of the Domain of the sub-task menu.
Polydata indicates the material properties that are relevant for your sub-task by graying out the irrelevant
properties. In this sub-task, Polyflow solves energy, incompressibility, and momentum equations. Hence,
define viscosity, density, thermal conductivity, and heat capacity per unit mass. For a non-isothermal
generalized Newtonian fluid, the viscosity depends on the shear rate and the temperature. Hence, define
the shear-rate dependence of viscosity and the temperature dependence of viscosity.
Material data
where is the viscosity at zero shear rate, is the shear rate, is the Bird-Carreau law
index, and is the natural time.
ii. Specify the value , referred to as fac in the graphical user interface (compare the equation
at the top of the Bird-Carreau law menu to Equation 3.1 (p. 117)).
Modify fac
Enter 5000 [units: Pas] as the New value and click OK.
iii. Specify the value , referred to as tnat in the graphical user interface.
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Modify tnat
iv. Specify the value for , referred to as expo in the graphical user interface.
Modify expo
When you click Upper level menu , Polydata displays the following warning message:
For this tutorial, you will use an evolution function for the flow rate (the third recommended
method).
vii. Click Upper level menu again to continue with the Material Data specification.
For this problem, assume that the dependence of viscosity on temperature follows the Arrhenius
law.
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Setup and Solution
(3.2)
where is the ratio of the activation energy to the thermodynamic constant and is a ref-
erence temperature for which = 1. The parameter denotes the absolute 0 temperature
in your selected temperature scale. It is set to 0, when and are absolute temperatures.
In this example, specify the temperatures in Celsius, so enter a value of -273 for .
ii. Specify the value for , referred to as alfa in the graphical user interface (compare the equation
at the top of the Temperature dependence of viscosity menu to Equation 3.2 (p. 119)).
Modify alfa
Enter 2300 [units: 1/C] as the New Value and click OK.
iii. Specify the value for , referred to as talfa by the graphical user interface.
Modify talfa
iv. Specify the value for , referred to as t0 by the graphical user interface.
Modify t0
v. Click Upper level menu two times to continue with the Material Data specification.
c. Click Density.
Modification of density
i. Enter 950 [units: kg/m3] as the New value and click OK.
ii. Click Upper level menu to continue with the Material Data specification.
For this problem, the thermal conductivity of the fluid is assumed to be a constant. So only the
constant coefficient is modified.
Modify a
i. Enter 0.5 [units: W/m-C] as the New Value and click OK.
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ii. Click Upper level menu to continue with the Material Data specification.
The heat capacity per unit mass is defined as a nonlinear function of temperature:
(3.4)
The temperature variation of depends on the nature of the polymer melt. For this problem,
is assumed to be constant, so only the constant coefficient is modified.
Modify a
i. Enter 2300 [units: J/kg-C] as the New value and click OK.
ii. Click Upper level menu to continue with the Material Data specification.
When shearing occurs in a flow, the friction of the different fluid layers generates heat. When the
fluid is highly viscous and/or the shear rate is high, the heating of the fluid caused by this phe-
nomenon must be taken into account.
ii. Click Upper level menu to return to the Material Data specification.
a. Retain the default condition Zero wall velocity (vn=vs=0) along SUBDOMAIN_3 at the intersection
of SUBDOMAIN_1 and SUBDOMAIN_3.
The liquid is assumed to stick to the wall, since at a solid-liquid interface the velocity of the liquid
is that of the solid surface. This is known as the no-slip assumption because the liquid is assumed
to adhere to the wall, and hence, has no velocity relative to the wall.
By default, Polydata imposes = = 0 along all boundaries. No action is required to accept the
default condition.
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
ii. Click EVOL at the top of the Polydata menu to enable the evolution inputs for the flow rate.
For information on nonlinearity and evolution, see Appendix: Nonlinearity and Evolution (p. 142).
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Setup and Solution
Polydata prompts for the new value of the volumetric /mass flow rate.
Enter 5e-06 [units: m3/s] as the New Value and click OK.
When the Automatic option is selected, Polydata automatically chooses the most appropriate
method to compute the inflow condition.
vii. Click Upper level menu. Polydata prompts for the evolution function .
The Current choice (at the top of the menu) is updated to reflect your selection.
ix. Click EVOL at the top of the Polydata menu to disable the evolution inputs.
x. Click Upper level menu to return to the Flow boundary conditions menu.
For axisymmetric models, Polydata recognizes the axis of symmetry from the mesh file, and auto-
matically imposes the symmetry condition along the line = 0. This condition imposes a zero
surface normal velocity ( ) and zero tangential force ( ) along this boundary.
It is assumed that a uniform velocity profile is reached at the exit. The melt is not subjected to any
externally applied stress at the exit, so the condition of zero normal and tangential forces is selected.
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY_3 and click Modify.
iii. Click Upper level menu to accept the default value of 0 [units: Pa] for .
iv. Click Upper level menu to accept the default value of 0 [units: Pa] for .
In a steady-state problem, the velocity field must be tangential to a free surface, since no fluid
particles leave the domain through the free surface. This constraint is called the kinematic condition,
= 0. This equation requires an initial condition, which is the starting line of the free surface. In
this problem, the starting line of the free surface is the intersection of BOUNDARY_4 and SUBDO-
MAIN_3 (see Figure 3.2: Boundaries and Subdomains (p. 113) ).
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY_4 and click Modify.
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vii. Click Upper level menu to return to the Kinematic condition menu.
Polydata prompts for the new value of the Y-component of the direction-of-displacement
vector.
xiv. Click Upper level menu to return to the Kinematic condition menu.
xv. Click Upper level menu to return to the Flow boundary condition menu.
For non-isothermal problems, specify either the temperature or the heat flux on each boundary set.
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Setup and Solution
Set an interface condition at the intersection of SUBDOMAIN_1 and SUBDOMAIN_3. This condition
ensures the continuity of the temperature field and the heat flux along the interface. Since the
problem is coupled, the condition of continuity is essential for the global solution of the temperature
and heat flux variables.
iii. Click Upper level menu to accept the default setting (continuous heat flux along the interface).
For an interface condition, both the heat flux and temperature are usually continuous along
the interface. It is possible to specify a nonzero value for the heat flux jump ( ), but this is
mainly used in problems where internal radiation is simulated. Accept the default value for
the definition of heat flux discontinuity ( =0).
iv. Enter 200 [units: C] as the New Value and click OK.
v. Click Upper level menu to return to the Thermal boundary conditions menu.
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If the heat transfer from radiation is neglected, the heat flux can be written as
(3.5)
where is the heat convection coefficient and is the reference temperature (in this case,
the temperature of the air surrounding the extrudate).
Modify alpha
Modify Talpha
v. Click Upper level menu to return to the Thermal boundary conditions menu.
This model involves a free surface for which the position is unknown. A portion of the mesh is affected
by the relocation of this boundary. Hence, a remeshing technique is applied on this part of the mesh.
The free surface is entirely contained within SUBDOMAIN_2 and hence, only SUBDOMAIN_2 is affected
by the relocation of the free surface.
Global remeshing
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Setup and Solution
SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that only SUBDOMAIN_2
will be remeshed.
The purpose of the remeshing technique is to relocate internal nodes according to the displacement
of boundary nodes due to the motion of the free surface. Mesh nodes are organized along lines of
remeshing (spines), which are collections of nodes logically arranged in a one-dimensional manner.
Polydata requires the specification of the first and last spines (inlet and outlet) that the fluid en-
counters. In this case, the inlet of spines is the intersection of SUBDOMAIN_2 with SUBDOMAIN_1,
and the outlet of spines is the intersection of SUBDOMAIN_2 with the flow exit (BOUNDARY_3).
Method of Spines
i. Specify the inlet for the system of spines by selecting SUBDOMAIN_1 and clicking Modify.
ii. Specify the outlet for the system of spines by selecting BOUNDARY_3 and clicking Modify.
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iii. Click Accept the current setup in the Element distortion check menu.
The finite-element mesh can undergo great deformations. The Element distortion check
menu deals with the detection of all possible distortions of the elements.
For this problem, accept the default options and proceed to the next step.
Interpolation
You can expect important temperature gradients in the calculation. Therefore, you can retain the
quadratic interpolation (9 unknowns per element) for velocity and the linear interpolation (4 unknowns
per element) for pressure, but it is recommended that you select the 4x4 interpolation for temperature.
In the 4x4 discretization scheme, each finite element is divided into 16 sub-elements, with the temper-
ature being linearly interpolated over each sub-element. This leads to 25 temperature unknowns per
element.
a. Scroll down to select 4x4 element for temperature in the Interpolation menu.
The Current setup (at the top of the menu) is updated to reflect your selection.
b. Click Upper level menu two times to return to the F.E.M. Task 1 menu.
Create a sub-task
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Setup and Solution
b. Click No, since this sub-task has different parameters associated with it.
c. Click Upper level menu at the top of the Domain of the sub-task menu.
For this problem, specify a constant value for the thermal conductivity .
Material data
For this problem, thermal conductivity is assumed to be a constant, so only the constant coefficient
is modified.
b. Select Modify a.
d. Click Upper level menu two times to return to the solid menu.
Set the conditions at each of the boundaries of the domain. The selected boundary set will be highlighted
(in red) in the graphics window as you select them..
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iii. Click Upper level menu to accept the default option for continuity of temperature and heat
flux.
Take only the heat convection into account: see Equation 3.5 (p. 124) .
Modifiy alpha
Modifiy Talpha
v. Click Upper level menu to return to the Thermal boundary conditions menu.
Modify alpha
Modifiy Talpha
v. Click Upper level menu to return to the Thermal boundary conditions menu.
5. Click Upper level menu twice to return to the F.E.M. Task 1 menu.
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Setup and Solution
Numerical parameters
b. Define the starting solution for the iterative scheme in the calculation of the inflow condition.
2. Click Upper level menu three times to return to the top-level Polydata menu.
3.4.7. Outputs
Outputs
Set to metric_MKSA+Celsius
2. Click Upper level menu three times to return to the top-level Polydata menu.
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Click No, as you have already defined an evolution strategy on the flow rate.
1. Click Accept.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and for the Polyflow format results file (res).
3.4.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Ten CFD-Post files are created, corresponding to the ten evolution steps in the problem.
Workbench opens the View listing file panel, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
3.4.10. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1. Double-click the Results cell in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
In the graphical window, right-click, and select the option Predefined Camera.
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Setup and Solution
a. Right-click in the graphical window and select View from +Z under Predefined Camera.
b. To remove the ruler right-click in the graphical window, select Viewer Options, and disable Ruler
Visibility.
a. Click the Insert menu and select Contour or click the button.
b. In the panel that opens, click OK to accept the default name (Contour 1) display the details view
below the Outline tab.
c. Perform the following steps In the Geometry tab of the details view for Contour 1:
i. Next to Locations, click the ellipsis button ( ) on the right and select SUBDOMAIN_1_surf
and SUBDOMAIN_2_surf (use Ctrl to select multiple items).
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ii. Select PRESSURE from the Variable drop-down list, or click the ellipsis button ( ) on the
right and select PRESSURE.
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Setup and Solution
a. In the details view of Contour 1, select VELOCITIES from the Variable drop-down list.
b. Click Apply.
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Non-Isothermal Flow Through a Cooled Die
The fluid experiences high velocity gradients in the narrow section of the die. This leads to important
viscous dissipation effects that cause the temperature of the melt to increase.
a. In the Outline tab under User Locations and Plots, disable Contour 1.
b. Click the Insert menu and select Vector or click the button.
c. Click OK to accept the default name (Vector 1) and open the details view below the Outline tab.
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Setup and Solution
i. In the Geometry tab, click the button next to Locations to open the Location Selector
dialog box.
ii. Select SUBDOMAIN_1_surf and SUBDOMAIN_2_surf (use Ctrl to select multiple items).
iii. In the Symbol tab, select Arrow3D and retain the default Symbol Size of 1.0.
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Non-Isothermal Flow Through a Cooled Die
The velocity vectors in the wide section of the die are very small compared to those in the narrow section
of the die (Figure 3.5: Velocity Vectors (p. 136)). Also, the important velocity re-arrangement takes place
at the die exit. This leads to the swelling of the extrudate.
6. Display the temperature distribution in the solid and the fluid regions.
a. In the Outline tab, under User Locations and Plots, disable Vector 1, and enable and double-click
Contour 1.
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Setup and Solution
i. Next to Locations, click the ellipsis button ( ) on the right and select SUBDOMAIN_1_surf,
SUBDOMAIN_2_surf and SUBDOMAIN_3_surf (use Ctrl to select multiple items).
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Setup and Solution
Figure 3.7: Temperature Profile Near the Die Exit (p. 139) shows a magnified view of the temperature
contours near the die exit. The high velocity gradients near the die exit lead to an important viscous
dissipation effect. The temperature of the polymer melt increases from the converging zone to the die
lip. This increase in temperature must be monitored to avoid melt degradation. The simulation helps
optimize the geometry of the die, the flow section for the cooling fluid, and other conditions in order
to maximize the flow rate and the extrudate speed.
a. Verify that you have millimeters selected as your units for length in CFD-Post.
b. Define the line for the plot with the points (0, 1, 0) and (15, 1, 0).
ii. Click OK to accept the default name (Line 1) and display the details view below the Outline
tab.
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Non-Isothermal Flow Through a Cooled Die
v. Click Apply.
c. Create a plot.
ii. Click OK to accept the default name (Chart 1) and display the details view below the Outline
tab.
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Setup and Solution
iii. In the General tab of the details view, ensure XY is selected for the chart Type and disable
Display Title.
iv. In the Data Series tab, select Line 1 from the Locations drop-down list for Series 1.
vi. In the Y Axis tab, select TEMPERATURE from the Variable drop-down list.
vii. With Series 1 (Line 1) enabled under the Line Display tab, select Rectangle from the Symbols
drop-down list. Retain the default Symbol Color (green).
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3.5. Summary
In this tutorial, you solved the non-isothermal flow of a polymer melt through a cooled die. You set the
material properties for the melt and supplied suitable boundary conditions. A specific interpolation
scheme was used for the temperature in order to cope with the important gradients. You applied an
evolution scheme to solve the convergence problems caused by the viscous dissipation coupled with
the temperature-dependent viscosity law.
In Polyflow, this procedure is fully automated. The increments are automatically adapted according to
the results of previous calculations. Polyflow uses an evolution variable ( ) that is incremented during
the evolution scheme. starts at an initial value of and is increased up to a final value of . Each
parameter that you evolve is defined as .
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Chapter 4: 3D Extrusion
This tutorial is divided into the following sections:
4.1. Introduction
4.2. Prerequisites
4.3. Problem Description
4.4. Preparation
4.5. Setup and Solution
4.6. Summary
4.1. Introduction
This tutorial illustrates the simulation of a 3D extrusion process. Due to the velocity rearrangement that
occurs at the die exit, the shape of the extrudate is usually different from the die lip cross-section.
Polyflow is capable of handling 3D free surfaces, so it can predict the extrudate shape that corresponds
to a given die geometry under prescribed operating conditions.
4.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the setup procedure
will not be shown explicitly.
The melt enters the die as shown in Figure 4.1: Problem Description (p. 144) at a flow rate of = 10
3
cm /s (a quarter of the actual flow rate) and the extrudate is obtained at the exit. At the end of the
computational domain, it is assumed that the extrudate is fully deformed and that it will not deform
any further. It is assumed that subdomain 2 is long enough to account for all the deformation of the
extrudate.
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3D Extrusion
The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two subdomains (as shown in Figure 4.1: Problem Description (p. 144))
so that the remeshing algorithm can be applied only to the portion of the mesh that will be deformed.
The subdomain 1 represents the die where the fluid is confined. The subdomain 2 corresponds to the
extrudate that is in contact with the air and can deform freely. The main aim of the calculation is to
find the location of the free surface (the skin of the extrudate).
The boundary sets for the problem are shown in Figure 4.2: Boundary Sets for the Problem (p. 145), and
the conditions at the boundaries of the domains are as follows.
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Preparation
4.4. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the 3D-Extrusion_R180.zip link to download the input and solution files.
7. Unzip the 3D-Extrusion_R180.zip file you have downloaded to your working folder.
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3D Extrusion
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering 3D-extrusion as the name of the
project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
Steady-state problem(s)
This problem is a 3D simulation of the extrusion process, that is, a three-dimensional geometry is
assumed for the die. A Cartesian (x,y,z) reference frame is used for the 3D calculations. A steady-
state condition is assumed for the problem.
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Setup and Solution
Create a sub-task
Since this problem involves a free surface, the domain is divided into two subdomains; one for the region
near the free surface (subdomain 2) and the other for the rest of the domain (subdomain 1). In this
problem, the sub-task applies to both subdomains, which is the default condition.
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Accept the default selection of both subdomains (SUBDOMAIN_1 and SUBDOMAIN_2) by clicking
Upper level menu.
Material Data
The Cross law exhibits shear-thinning (the decrease in viscosity as the shear rate increases) that is a
characteristic of many polymers. The viscosity in this tutorial is given by the Cross law:
(4.1)
where:
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Setup and Solution
= shear rate
3. Specify the value , referred to as fac in the graphical user interface (compare the equation at the top
of the Cross law menu to Equation 4.1 (p. 148)).
Modify fac
Enter 85000 [units: poise] as the New value and click OK.
4. Specify the value for , referred to as tnat in the graphical user interface.
Modify tnat
5. Specify the value for , referred to as expom in the graphical user interface.
Modify expom
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6. Select Upper level menu three times to return to the 3D die swell menu.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
b. Click Inflow.
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Setup and Solution
When the Automatic option is selected, Polydata automatically chooses the most appropriate
method to compute the inflow condition.
2. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY_2 at the wall of SUBDO-
MAIN_1 (BOUNDARY_2).
At a solid-liquid interface, the velocity of the liquid is that of the solid surface. Hence the fluid is assumed
to stick to the wall. This is known as the no-slip condition because the liquid is assumed to adhere to
the wall, and hence, has no velocity relative to the wall.
By default, Polydata imposes = = 0 along all boundaries. No action is required to accept the default
condition.
In 2D axisymmetric problems, Polydata automatically identifies the axis of symmetry, but for 3D flows,
you must manually identify a plane of symmetry.
The normal velocity ( ) and the tangential force ( ) are set to zero on a symmetry plane. A particle
cannot cross the plane ( = 0) due to the symmetry, so the particles flow at the same velocity on both
sides of the symmetry plane, leading to a zero tangential force.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_3 and click Modify.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_4 and click Modify.
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In a steady-state problem, the velocity field must be tangential to a free surface, since no fluid particles
go out of the domain through the free surface. This constraint is called the kinematic condition, .
This equation requires an initial condition, that is, the starting line of the free surface. In the current
problem, the starting line of the free surface is the intersection of boundary 2 and boundary 5 (see Fig-
ure 4.2: Boundary Sets for the Problem (p. 145)).
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_5 and click Modify.
h. Click Upper level menu to return to the Flow boundary conditions panel.
It is assumed that a uniform velocity profile is reached at the exit. The melt is not subjected to any ex-
ternally applied stress at the exit, so the condition of zero normal and tangential forces is selected.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_6 and click Modify.
c. Accept the default value of 0 for the normal force, , by clicking Upper level menu.
d. Accept the default value of 0 for the tangential force, , by clicking Upper level menu.
e. Click Upper level menu at the top of the Flow boundary conditions panel.
4.5.5. Remeshing
This model involves a free surface, whose shape is unknown a priori, which will be calculated together with
the flow equations. A portion of the mesh is affected by the relocation of this boundary, so a remeshing
technique is applied on this part of the mesh. The free surface is entirely contained within subdomain 2,
therefore only subdomain 2 is affected by the relocation of the free surface.
Global remeshing
In general, only one local remeshing is required for direct extrusion simulations. It becomes necessary
to define multiple local remeshings for inverse extrusion simulations. A single local remeshing is sufficient
for this case.
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Setup and Solution
SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that only SUBDOMAIN_2
will be remeshed.
The purpose of the remeshing technique is to relocate internal nodes according to the displacement of
boundary nodes due to the motion of the free surface, since a part of the mesh is deformed. For 3D
extrusion problems where large deformations of the extrudate are expected, the optimesh remeshing
technique is recommended
The optimesh remeshing technique requires the direction of extrusion to be parallel to the , , or
axis, and all slices into which the remeshing domain is cut must be perpendicular to the extrusion axis.
The domain to be remeshed is cut into a series of 2D slices (planes) in a direction perpendicular to the
direction of extrusion, and each plane is remeshed independently. For this process, Polyflow requires
the selection of the initial plane and the final plane. In this problem, the initial plane is the intersection
of subdomain 2 with subdomain 1, and the final plane is the intersection of subdomain 2 with the flow
exit (boundary 6).
a. Specify the initial plane for the optimesh remeshing technique, by selecting SUBDOMAIN_1
and clicking Modify.
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b. Specify the final plane for the optimesh remeshing technique, by selecting BOUNDARY_6 and
clicking Modify.
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Setup and Solution
Polydata asks if you want to change from the surface kinematic condition to the line kinematic
condition.
The line kinematic condition is recommended for extrusion problems, and should be used in com-
bination with the optimesh remeshing technique.
Polydata asks you to confirm the current system units and fields that are to be saved to the results file for
postprocessing.
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2. Click Accept.
3. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and for the Polyflow format results file (res).
4.5.7. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Workbench opens the View listing file dialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
4.5.8. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1. Double-click the Results cell in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
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Setup and Solution
a. Click the Insert menu and select Contour or click the button.
b. Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
c. In the Outline tree tab, under User Locations and Plots, deselect Wireframe.
ii. Select all topological entities under PFL in the Location Selector dialog box (use Shift) and
click OK.
iii. Select VELOCITIES from the Variable drop-down list (or by clicking ).
v. Click Apply.
In Figure 4.3: Contours of Velocity Magnitude (p. 158), the velocity is zero along the die wall (as expected)
and there is a fully developed profile at the inlet of the die. At the die outlet, the velocity profile changes
to become constant throughout the extrudate cross-section. The transition between these two states
can be seen in the beginning section of the extrudate.
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a. Deselect Contour 1 in the Outline tree tab under User Locations and Plots.
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Setup and Solution
ii. Click OK to accept the default name (Plane 1) and display the details view below the Outline
tab.
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iii. In the Geometry tab of the details view of Plane 1, ensure XY Plane is selected from the
Method drop-down list.
v. Click Apply.
vi. Repeat steps 3.b.i.v. for the other planes, at Z = 0.08, 0.15, and 0.45 m.
vii. In the Outline tree tab, under User Locations and Plots, deselect Plane 1, Plane 2, Plane 3,
and Plane 4.
c. Click the Insert menu and select Contour or click the button.
d. Click OK to accept the default name (Contour 2) and display the details view below the Outline tab.
e. In the Outline tree tab under User Locations and Plots, select Wireframe.
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Setup and Solution
ii. Select all planes under User Locations and Plots (use Shift for multiple selection).
iv. Select VELOCITIES from the Variable drop-down list (or click ).
Velocity profiles at the flow inlet, the flow outlet, and planes just before and just after the die exit are
displayed (Figure 4.4: Velocity Profiles at Cross-Sections (p. 162)). Compare the velocity profile within the
die to the velocity profile just after the die exit at the end of the computational domain. In the die the
flow is fully developed. The velocity profile is flat in the extrudate, far away from the die exit; all the
particles in the cross-section plane are at the same velocity. Just beyond the die exit, in the transitional
zone, the velocity profile is reorganized. The velocity profile on the plane = 15 is no longer fully de-
veloped, but it is not yet flat either. The velocity rearrangement is the source of the deformation of the
extrudate.
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In the Outline tree tab, under User Locations and Plots, deselect Contour 2 and Wireframe.
ii. Click OK to accept the default name (Polyline 1) and display the details view below the Outline
tab.
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Setup and Solution
iii. In the Geometry tab of the details view, select Boundary Intersection from the Method drop-
down list.
vi. Under the Color tab, click next to Color and select dark blue.
ii. Click OK to accept the default name (Polyline 2) and display the details view below the Outline
tab.
iii. In the Geometry tab of the details view, select Boundary Intersection from the Method drop-
down list.
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d. On the axis triad in the graphics window click +Z to view from Z-direction.
This allows you to compare the size and shape of the flow inlet with that of the flow outlet without
distortion due to perspective.
Since the model involves a generalized Newtonian fluid, there are no viscoelastic effects. The swelling
(Figure 4.5: Swelling of the Extrudate (p. 164)) is only due to reorganization of the velocity profile at the
die exit. Fluid from the high-speed region moves to the low-speed region and pushes the free surface
to the exterior.
a. Define the line of the plot with the points (0.0, 0.1, 0.1) and (0.1, 0.0, 0.1).
ii. Click OK to accept the default name (Line 1) and display the details view below the Outline
tab.
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Setup and Solution
iii. Enter 0, 0.1, 0.1 for Point 1 and 0.1, 0, 0.1 for Point 2.
b. Create a plot.
ii. Click OK to accept the default name (Chart 1) and display the details view below the Outline
tab.
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iii. In the General tab of the details view, ensure XY is selected for Type, and enter 3D Extrusion
for Title.
iv. In the Data Series tab, for Series 1, select Line 1 from the Locations drop-down list (or by
vi. In the Y Axis tab, select VELOCITIES from the Variable drop-down list.
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Setup and Solution
The shear-thinning introduced by the Cross law is not clearly visible in Figure 4.6: Velocity Magnitude
Along a Diagonal of Die Exit Section (p. 167) due to the large finite elements along the die wall. The
mesh should be refined in that zone.
a. Define the line of the plot with the points (0.08, 0.02, 0.00) and (0.08, 0.02, 0.50).
ii. Click OK to accept the default name (Line 2) and display the details view below the Outline
tab.
iii. Enter 0.08, 0.02, 0 for Point 1 and 0.08, 0.02, 0.5 for Point 2.
b. Create a plot.
ii. Click OK to accept the default name (Chart 2) and display the details view below the Outline
tab.
iii. In the General tab of the details view, ensure XY is selected for Type, and disable Display Title.
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iv. In the Data Series tab, select Line 2 from the Locations drop-down list for Series 1.
vi. In the Y Axis tab, select VELOCITIES X from the Variable drop-down list.
Figure 4.7: X-Velocities Along a Line Close to the Center of the Die
a. In the Y Axis tab of the details of Chart 2, select VELOCITIES Y from the Variable drop-down list.
b. Click Apply.
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Setup and Solution
Figure 4.8: Y-Velocities Along a Line Close to the Center of the Die
a. In the Y Axis tab of the details view of Chart 2, select VELOCITIES Z from the Variable drop-down
list.
b. Click Apply.
Figure 4.9: Velocities Along a Line Close to the Center of the Die (p. 170) shows that the flow
slows down ( decreases) after the die exit. Meanwhile, particles travel from the center of
the extrudate toward the edge, creating the swelling of the extrudate. Figure 4.7: X-Velocities
Along a Line Close to the Center of the Die (p. 168) and Figure 4.8: Y-Velocities Along a Line
Close to the Center of the Die (p. 169) show that the peak values of and are located at
the very beginning of the extrudate, and vanish at the end of the free jet.
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Figure 4.9: Velocities Along a Line Close to the Center of the Die
4.6. Summary
This tutorial introduced the concept of a 3D extrusion problem. You solved the problem using a specific
3D geometry for the die and made suitable assumptions about the physics of the problem. You analyzed
the factors affecting the extrudate shape. In Polydata you learned how to use the optimesh remeshing
method, which is recommended for 3D extrusion problems.
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Chapter 5: Direct Extrusion
This tutorial is divided into the following sections:
5.1. Introduction
5.2. Prerequisites
5.3. Problem Description
5.4. Setup and Solution
5.5. Summary
5.6. Appendix
5.1. Introduction
This tutorial is similar to the 3D extrusion problem solved in 3D Extrusion (p. 143), where the shape of
the extrudate was computed from the die geometry. In this tutorial, a complex geometry (free surface)
is associated with the exit section of the die and undergoes large deformations during the extrusion
process. Consequently, the problem becomes highly nonlinear and special convergence techniques are
required to obtain a solution. This tutorial introduces the evolution procedure in Polyflow that is used
to handle nonlinear problems.
Set material properties and boundary conditions for a direct extrusion problem.
5.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the set up procedure
will not be shown explicitly.
The melt enters the die as shown in Figure 5.1: Problem Description (p. 172) at a flow rate = 10 cm3/s
(a quarter of the actual flow rate) and the extrudate is obtained at the exit. It is assumed that subdomain
2 is long enough to account for all the deformation of the extrudate.
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The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two subdomains (as shown in Figure 5.1: Problem Description (p. 172))
so that the remeshing algorithm can be applied only to the portion of the mesh that is deformed.
Subdomain 1 represents the fluid as it enters and is confined by the die. Subdomain 2 corresponds to
the extrudate that is in contact with the air (and can deform freely). The main aim of the calculation is
to find the location of the free surface (the skin of the extrudate).
The boundary set for the problem are shown in Figure 5.2: Boundary Set for the Problem (p. 173), and
the conditions at the boundaries of the domains are:
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Setup and Solution
5.4.1. Preparation
To prepare for running this tutorial:
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Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the Direct-Extrusion_R180.zip link to download the input and solution files.
7. Unzip the Direct-Extrusion_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering direct-extrusion as the name of
the project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
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Setup and Solution
Evolution problem(s)
The complex geometry associated with the free surface of the extrudate introduces nonlinear
terms into the kinematic condition equation used to find its location. An evolution scheme is
used to handle the nonlinear problem.
Create a sub-task
Since this problem involves a free surface, the domain is divided into two subdomains; one for the
region near the free surface (SUBDOMAIN_2) and the other for the rest of the domain (SUBDO-
MAIN_1). In this problem, the sub-task applies to both subdomains, which is the default condition.
Accept the default selection of both subdomains by clicking Upper level menu.
Material Data
The viscosity in this tutorial is given by the power law. For information on power law, see Appendix (p. 192)
.
3. Specify the value for , referred to as fac in the graphical user interface (compare the equation at the
top of the Power law menu to the equation shown in the Appendix (p. 192)).
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Modify fac
Enter 3e+05 [units: poise] as the New value and click OK.
4. Retain the default value for , referred to as tnat in the graphical user interface.
Modify tnat
5. Specify the value for , referred to as expo in the graphical user interface.
Modify expo
6. Click Upper level menu three times to return to the Direct extrusion menu.
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Setup and Solution
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
b. Click Inflow.
c. Ensure Volumetric flow rate is selected and click Modify volumetric flow rate.
When the Automatic option is selected, Polydata chooses the most appropriate method to compute
the inflow condition.
In 2D axisymmetric problems, the axis of symmetry is automatically identified by Polydata, but for 3D
flows, you must manually identify a plane of symmetry. The normal velocity ( ) and the tangential
force ( ) are set to zero on a symmetry plane. A particle cannot cross the plane ( = 0) due to the
symmetry, so the particles flow at the same velocity on both sides of the symmetry plane, leading to a
zero tangential force.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_2 and click Modify.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_3 and click Modify.
4. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY_4 at the wall of SUBDO-
MAIN_1 (BOUNDARY_4).
At a solid-liquid interface, the velocity of the liquid is that of the solid surface. Hence the velocity the
fluid is assumed to stick to the wall. This is known as the no-slip assumption because the liquid is assumed
to adhere to the wall, and hence, has no velocity relative to the wall.
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By default, Polydata imposes = = 0 along all boundaries. No action is required to accept the default
condition.
In a steady-state problem, the velocity field must be tangential to a free surface, since no fluid particles
go out of the domain through the free surface. This constraint is called the kinematic condition, =
0. This equation requires an initial condition, that is, the starting line of the free surface. In this problem,
the starting line of the free surface is the intersection of boundary 4 and boundary 5 (see Figure 5.2: Bound-
ary Set for the Problem (p. 173)).
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_5 and click Modify.
d. Select No condition along BOUNDARY_4 (the boundary where the free surface starts) and click
Modify.
f. Click Upper level menu to return to the Boundary conditions on the moving surface menu.
g. Click Upper level menu two times to return to the Flow boundary conditions menu.
It is assumed that a uniform velocity profile is reached at the exit. The melt is not subjected to any ex-
ternally applied stress at the exit, so the condition of zero normal and tangential forces is selected.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_6 and click Modify.
c. Accept the default value of 0 for the normal force, , by clicking Upper level menu.
d. Accept the default value of 0 for the tangential force, , by clicking Upper level menu.
5.4.6. Remeshing
This model involves a free surface, whose shape is unknown a priori, which will be calculated together with
the flow equations. A portion of the mesh is affected by the relocation of this boundary, so a remeshing
technique is applied on this part of the mesh. The free surface is entirely contained within subdomain 2,
therefore only subdomain 2 is affected by the relocation of the free surface.
Global remeshing
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Setup and Solution
In general, only one local remeshing is required for direct extrusion simulations. It becomes necessary
to define multiple local remeshings for inverse extrusion simulations. A single local remeshing is sufficient
for this case.
SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that only SUBDOMAIN_2
will be remeshed.
The purpose of the remeshing technique is to relocate internal nodes according to the displacement of
boundary nodes due to the motion of the free surface, since a part of the mesh is deformed. For 3D
extrusion problems where large deformations of the extrudate are expected, the optimesh remeshing
technique is recommended. For information on optimesh remeshing technique, refer to the Ap-
pendix (p. 192).
a. Specify the initial plane for the optimesh remeshing technique, by selecting SUBDOMAIN_1 and
clicking Modify.
b. Specify the final plane for remeshing technique, by selecting BOUNDARY_6 and clicking Modify.
Polydata asks if you want to change from the surface kinematic condition to the line kinematic
condition.
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The line kinematic condition is recommended for extrusion problems, and must be used in combin-
ation with the optimesh remeshing technique.
d. Click Accept the current setup in the Element distortion check menu.
In complex extrusion simulations, the finite element mesh can undergo great deformations. The
Element distortion check menu deals with the detection of all possible distortions of the elements.
Numerical parameters
a. Define the starting solution for the iterative scheme in the calculation of the free surface location.
The first calculation is performed at . Increase the value of the initial increment of ( ) to reduce
the number of evolution steps and to speed up the calculation.
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Setup and Solution
3. Click Upper level menu two times to return to the top-level Polydata menu.
5.4.8. Outputs
After Polyflow calculates a solution, it can save the results in several different formats. Choose the one that
is appropriate for your postprocessor. In this case, save the outputs in IGES format, as well as the default
format for CFD-Post.
Outputs
1. Retain the default output (CFD-Post) and click Enable Iges file output.
The default CFD-Post output is used for postprocessing with CFD-Post. The IGES output contains the
modified geometry of the extrudate (after remeshing) calculated at every step of the evolution procedure.
For information on IGES output, see Appendix (p. 192).
Polydata asks you to confirm the current system units and fields that are to be saved to the results file
for postprocessing.
Polydata asks you to confirm fields that are to be saved to the results file for postprocessing.
1. Click Accept.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and for the Polyflow format results file (res).
5.4.10. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
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Workbench opens the View listing file dialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
5.4.11. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1. Double-click the Results tab in the Polyflow analysis system. This will start CFD-Post and read the results
files saved by Polyflow. CFD-Post reads the mesh information and the solution fields that were saved to
the results file.
Deselect Wireframe in the Outline tree tab, under User Locations and Plots.
a. Click the Insert menu and select Contour or click the button.
b. Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
c. Perform the following steps in the Geometry tab of the details view of Contour 1:
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Setup and Solution
ii. Select all topological entities under Fluid Flow Extrusion Polyflow in the Location Selector
dialog box (use Shift for multiple selection) and click OK.
iii. Select VELOCITIES from the Variable drop-down list (or by clicking ).
d. Rotate the image so that you can see the fluid at the inlet of the die, as shown in Figure 5.3: Contours
of Velocity Magnitude (p. 183).
Observe that the velocity is zero along the die wall, as expected, and there is a fully developed profile
at the inlet of the die. At the die outlet, the velocity profile changes to become constant throughout the
extrudate cross-section. The transition between these two states can be seen in the first third of the ex-
trudate.
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In the Outline tree tab, under User Locations and Plots, deselect Contour 1.
ii. Click OK to accept the default name (Plane 1) and display the details view below the Outline
tab.
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iii. In the Geometry tab of the details view, ensure XY Plane is selected from the Method drop-
down list.
v. Click Apply.
vi. Repeat steps 3.b.i.v. for the other planes, at Z = 0.03, 0.07, and 0.1999 m.
vii. In the Outline tree tab, under User Locations and Plots, deselect Plane 1, Plane 2, Plane 3,
and Plane 4.
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i. Click the Insert menu and select Contour or click the button.
ii. Click OK to accept the default name (Contour 2) and display the details view below the Outline
tab.
iii. In the Outline tree tab under User Locations and Plots, select Wireframe.
iv. In the Geometry tab of the details view of Contour 2, click the button next to Locations.
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v. Select all planes under User Locations and Plots (use Shift for multiple selection).
vii. Select VELOCITIES from the Variable drop-down list (or click ).
Figure 5.4: Velocity Profiles at Cross-Sections (p. 188) shows the velocity profiles at the flow inlet, the flow
outlet, and at the planes just before and just after the die exit.
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Compare the velocity profile within the die to the velocity profile just after the die exit at the end of the
computational domain. In the die the flow is fully developed. In the extrudate, far away from the die
exit, the velocity profile is flat. That is, all the particles in a cross-sectional plane are at the same speed.
Just after the die exit, there is a transitional zone where the velocity profile is reorganized. The velocity
profile on the plane Z = 7 cm is no longer fully developed, but it is not yet flat either. The velocity re-
arrangement is the source of the deformation of the extrudate.
In the Outline tree tab, under User Locations and Plots, deselect Contour 2 and Wireframe.
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ii. Click OK to accept the default name (Polyline 1) and display the details view below the Outline
tab.
iii. In Geometry tab of the details view, select Boundary Intersection from the Method drop-down
list.
iv. Click next to Boundary List and select SUBDOMAIN_1_BOUNDARY_4. Click OK to close
the Location Selector dialog box.
vi. In the Color tab, click next to Color and select dark blue.
ii. Click OK to accept the default name (Polyline 2) and display the details view below the Outline
tab.
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iii. In Geometry tab of the details view, select Boundary Intersection from the Method drop-down
list.
d. Right-click in the graphic window and select View From +Z under Predefined Camera.
This allows you to compare the size and shape of the flow inlet with that of the flow outlet without
distortion due to perspective.
a. Click the Insert menu and select Instance Transform, or click the button.
b. Click OK to accept the default name (Instance Transform 1) and display the details view below the
Outline tab.
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iv. Ensure Method is set to Principal Axis and Z is selected from the Axis drop-down list.
d. In the Outline tree tab, under User Locations and Plots, right-click Polyline 1 and click Edit (or
double-click Polyline 1).
e. In the View tab, scroll down and enable Apply Instancing Transform.
g. Click Apply.
h. In the Outline tree tab, under User Locations and Plots, right-click Polyline 2 and click Edit (or
double-click Polyline 2).
You can use the central-mouse button to zoom in and out. This allows you to compare the size and
shape of the flow inlet with that of the flow outlet without distortion due to perspective.
You can also click the fit view button ( ) to properly center the image.
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The deformations come from the rearrangement of the velocity profile. Particles coming from high-
speed regions in the die must slow down, while particles coming from low-speed regions must
accelerate. Observe that the central part of the cross, where the fluid easily flows in the die, is en-
larged in the extrudate, while the extremities of the branches are smaller in the extrudate. Since
the combined effect of cross-sectional expansions and reductions is very difficult to guess, a nu-
merical simulation is necessary for a moderate to high complexity die.
5.5. Summary
This tutorial introduced the concept of a direct extrusion problem. You solved the problem using a
specific 3D geometry for the die, made suitable assumptions about the physics of the problem, and
analyzed the factors affecting the extrudate shape. The nonlinear problem was solved using an evolution
technique to reach the convergence.
5.6. Appendix
The appendix contains the following sections:
5.6.1. Power Law
5.6.2. Optimesh Remeshing Technique
5.6.3. Evolution Scheme
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Appendix
where:
= consistency factor
= power-law index
= natural time
The domain to be remeshed is cut into a series of 2D slices (planes) in a direction perpendicular to the
direction of extrusion, and each plane will be remeshed independently. For this process, Polyflow requires
the selection of the initial plane and the final plane. In this problem, the initial plane is the intersection
of SUBDOMAIN_2 with SUBDOMAIN_1, and the final plane is the intersection of SUBDOMAIN_2 with
the flow exit (boundary 6).
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Chapter 6: Inverse Extrusion
This tutorial is divided into the following sections:
6.1. Introduction
6.2. Prerequisites
6.3. Problem Description
6.4. Setup and Solution
6.5. Summary
6.6. Appendix
6.1. Introduction
Inverse extrusion deals with the computation of the shape of a die that produces an extrudate of the
desired shape. This tutorial illustrates how to handle a complex inverse extrusion problem. In this tutorial,
slip conditions along the die walls are considered and evolution on the slip coefficient is enabled to
aid convergence.
Set material properties and boundary conditions for a inverse extrusion problem.
6.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the set up procedure
will not be shown explicitly.
The melt enters the die as shown in Figure 6.1: Problem Description (p. 196) at a flow rate = 10 cm3/s
(a quarter of the actual flow rate) and the extrudate is obtained at the exit.
The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two sub-domains (as shown in Figure 6.1: Problem Description (p. 196))
so that specific remeshing algorithms can be applied in each sub-domain to accurately predict the die
profile. Subdomain 1 represents the fluid as it enters and is confined by the die. Subdomain 2 corresponds
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to the extrudate that is in contact with the air (and can deform freely). The main aim of the calculation
is to compute the geometry of the die to obtain the desired extrudate.
The boundary set for the problem are shown in Figure 6.2: Boundary Set for the Problem (p. 196), and
the conditions at the boundaries of the domains are given below
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Setup and Solution
6.4.1. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the Inverse-Extrusion_R180.zip link to download the input and solution files.
7. Unzip the Inverse-Extrusion_R180.zip file you have downloaded to your working folder.
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8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering inverse-extrusion as the name of
the project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
Evolution problem(s)
Apply the evolution scheme on the slip coefficient along the outer wall of the die (boundary 4)
when you define the slip boundary conditions.
Create a sub-task
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Setup and Solution
This problem involves a free surface, so the domain is divided into two sub-domains; one for the region
near the free surface (SUBDOMAIN_2) and the other for the rest of the domain (SUBDOMAIN_1). In this
problem, the sub-task applies to both sub-domains, which is the default condition.
Accept the default selection of both subdomains by clicking Upper level menu.
Material Data
The viscosity in this tutorial is given by the power law. For information on power law, see Power
Law (p. 219) .
3. Specify the value of , referred to as fac in the graphical user interface (compare the equation at the
top of the Power law menu to the equation shown in the Power Law (p. 219)).
Modify fac
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Enter 300000 [units: poise] as the New value and click OK.
4. Retain the default value for , referred to as tnat in the graphical user interface.
Modify tnat
5. Specify the value for , referred to as expo in the graphical user interface.
Modify expo
6. Click Upper level menu three times to return to the Inverse Extrusion menu.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
b. Click Inflow.
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Setup and Solution
When the Automatic option is selected, Polydata chooses the most appropriate method to compute
the inflow condition.
In 2D axisymmetric problems, the axis of symmetry is automatically identified by Polydata, but for 3D
flows, you must manually identify a plane of symmetry.
The normal velocity ( ) and the tangential force ( ) are set to zero on a symmetry plane. A particle
cannot cross the plane ( = 0) due to the symmetry, so the particles flow at the same velocity on both
sides of the symmetry plane, leading to a zero tangential force.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_2 and click Modify.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_3 and click Modify.
4. Set the conditions along the outer wall of the die (BOUNDARY_4).
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_4 and click Modify.
The evolution scheme is used to aid with convergence by starting with a low value for the slip
coefficient and slowly increasing the value of the coefficient to reach a no-slip condition. With a
low value for the slip coefficient there is no swelling of the extrudate, simplifying the calculation.
As the slip coefficient increases, the extrudate begins to swell because the fluid in contact with the
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wall slows down, which increases the velocity of the fluid in the center of the die. For more inform-
ation on the evolution scheme, see Evolution Scheme (p. 219).
i. Click EVOL at the top of the Polydata menu to enable the evolution inputs for the slip coefficient.
Modify k
You will retain the default values for a and b, and will modify the values for c and d.
xi. Click EVOL at the top of the Polydata menu to disable the evolution inputs.
xiv. Click Upper level menu two times to return to the Flow boundary conditions menu.
In a steady-state problem, the velocity field must be tangential to a free surface, since no fluid particles
go out of the domain through the free surface. This constraint is called the kinematic condition, =
0. This equation requires an initial condition (the starting line of the free surface). In this problem, the
starting line of the free surface is the intersection of boundary 4 and boundary 5 (see Figure 5.2: Boundary
Set for the Problem (p. 173)).
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_5 and click Modify.
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d. Select No condition along BOUNDARY_4 (the boundary where the free surface starts) and click
Modify.
f. Click Upper level menu to return to the Boundary conditions on the moving surface menu.
h. Click Outlet (Inv. prediction) to define the outlet of the moving surface.
In inverse extrusion problems, you have to predict the appropriate die exit cross-section to obtain
a given extrudate cross-section. By defining the outlet of a free surface, inform Polyflow the desired
extrudate shape. Hence, you impose the outlet of the moving surface along the last section of the
free jet as the outlet of the free surface. This section will not be modified during the calculation.
i. Select BOUNDARY_6 as the outlet of the moving surface and click Confirm.
j. Click Upper level menu to return to the Flow boundary conditions menu.
It is assumed that a uniform velocity profile is reached at the exit. The melt is not subjected to any ex-
ternally applied stress at the exit, so the condition of zero normal and tangential forces is selected.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_6 and click Modify.
c. Accept the default value of 0 for the normal force, , by clicking Upper level menu.
d. Accept the default value of 0 for the tangential force, , by clicking Upper level menu.
7. Click Upper level menu at the top of the Flow boundary conditions menu.
6.4.6. Remeshing
The purpose of the remeshing technique is to relocate internal nodes according to the displacement of
boundary nodes due to the motion of the free surface, since a part of the mesh is deformed. For information
on remeshing technique, see Appendix (p. 219).
Global remeshing
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SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that only SUBDOMAIN_2
will be remeshed.
For 3D extrusion problems where large deformations of the extrudate are expected, the optimesh
remeshing technique is recommended. For information on optimesh remeshing technique see
Appendix (p. 219).
a. Specify the initial plane for the optimesh remeshing technique, by selecting SUBDOMAIN_1 and
clicking Modify.
b. Specify the final plane for the remeshing technique, by selecting BOUNDARY_6 and clicking Modify.
c. Polydata asks if you want to change from the surface kinematic condition to the line kinematic condition.
The line kinematic condition is recommended for extrusion problems, and must be used in combin-
ation with the optimesh remeshing technique.
e. Click Accept the current setup in the Element distortion check menu.
In complex extrusion simulations, the finite element mesh can undergo great deformations. The
Element distortion check menu deals with the detection of all possible distortions of the elements.
Accept default options.
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Setup and Solution
The technique of inverse prediction is selected to calculate the profile for the constant section
region of the die.
Numerical parameters
Note
Setting the final value of equal to 20 creates a large enough slip coefficient that
it is equivalent to a no-slip condition at the die wall (BOUNDARY_4, as discussed
in a previous step).
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2. Click Upper level menu three times to return to the top-level Polydata menu.
6.4.8. Outputs
After Polyflow calculates a solution, it can save the results in several different formats. Choose the one that
is appropriate for your postprocessor. In this case, save the outputs in IGES format, as well as the default
format for CFD-Post.
Outputs
1. Retain the default output (CFD-Post) and click Enable Iges file output.
The default CFD-Post output is used for postprocessing with CFD-Post. The IGES output contains the
modified geometry of the extrudate (after remeshing) calculated at every step of the evolution procedure.
For information on IGES output, see Appendix (p. 219).
Polydata asks you to confirm the current system units and fields that are to be saved to the results file
for postprocessing.
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Setup and Solution
1. Click Accept.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and for the Polyflow format results file (res).
6.4.10. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
A cfx.res file (corresponding to the eight evolution steps of the flow case) will be created.
Workbench opens the View listing file dialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
6.4.11. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1. Double-click the Results tab in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
a. Deselect Wireframe in the Outline tree tab, under User Locations and Plots.
b. Click the Insert menu and select Contour or click the button.
c. Click OK to accept the default name (Contour 1) and open the details view below the Outline tab.
d. Perform the following steps In the Geometry tab of the details view.
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ii. Select all topological entities under PFL in the Location Selector dialog box (use Shift for
multiple selection) and click OK.
iii. Select VELOCITIES from the Variable drop-down list (or by clicking ).
You can see in Figure 6.3: Contours of Velocity Magnitude (p. 209) that the velocity is zero along the die
wall, as expected, and there is a fully developed profile at the inlet of the die. At the die outlet, the velocity
profile changes to become constant throughout the extrudate cross-section. The transition between
these two states can be seen at the beginning of extrudate section.
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In the Outline tree tab, under User Locations and Plots deselect Contour 1.
ii. Click OK to accept the default name (Plane 1) and display the details view below the Outline
tab.
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iii. In the Geometry tab of the details view, select XY Plane from the Method drop-down list.
v. Click Apply.
vi. Repeat steps 3.b.i.v. to create the other planes at Z = 0.03, 0.07, and 0.1999 m.
vii. In the Outline tree tab, under User Locations and Plots, deselect Plane 1, Plane 2, Plane 3,
and Plane 4.
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c. Click the Insert menu and select Contour or click the button.
d. Click OK to accept the default name (Contour 2) and open the details view below the Outline tree
tab.
e. In the Outline tree tab under User Locations and Plots, select Wireframe.
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Setup and Solution
ii. Select all planes under User Locations and Plots (use Shift for multiple selection).
iv. Select VELOCITIES from the Variable drop-down list (or click ).
The velocity profiles planes are located at the flow inlet, the flow outlet, and planes just before and after
the die exit as shown in Figure 6.4: Velocity Profile Planes (p. 214).
Compare the velocity profile within the die to the velocity profile just after the die exit at the end of the
computational domain.
The velocity profile is flat in the extrudate, far away from the die exit. All particles in the cross-section plane
are at the same velocity.
Just after the die exit, there is a transitional zone where the velocity profile is reorganized.
The velocity profile on the plane = 7 cm is not fully developed, but it is not flat either.
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In the Outline tree tab, under User Locations and Plots, deselect Contour 2 and Wireframe.
ii. Click OK to accept the default name (Polyline 1) and display the details view below the Outline
tab.
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Setup and Solution
iii. In the Geometry tab of the details view, select Boundary Intersection from the Method drop-
down list.
iv. Click next to Boundary List and select SUBDOMAIN_1_BOUNDARY_4. Click OK to close
the Location Selector dialog box.
vi. In the Color tab, click next to Color and select dark blue.
ii. Click OK to accept the default name (Polyline 2) and display the details view below the Outline
tab.
iii. In the Geometry tab of the details view, select Boundary Intersection from the Method drop-
down list.
d. Right-click in the graphic window and select View From +Z under Predefined Camera.
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a. Click the Insert menu and select Instance Transform, or click the button.
b. Click OK to accept the default name (Instance Transform 1) and display the details view below the
Outline tab.
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Setup and Solution
c. Perform the following steps in the Definition tab of the details view of Instance Transform 1:
iv. Ensure Principal Axis and Z are selected for Method and Axis in the Axis Definition group
box.
d. In the Outline tree tab, under User Locations and Plots, right-click Polyline 1 and click Edit (or
double-click Polyline 1).
e. In the View tab of the details view, scroll down and enable Apply Instancing Transform.
g. Click Apply.
h. In the Outline tree tab, under User Locations and Plots, right-click Polyline 2 and click Edit (or
double-click Polyline 2).
You can use the central-mouse button to zoom in and out. This allows you to compare the size and
shape of the flow inlet with that of the flow outlet without distortion due to perspective.
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You can also click the fit view button ( ) to properly center the image.
The deformation of the extrudate is the result of the rearrangement taking place at the die exit. Particle
coming from high-speed regions in the die must slow down, while particles coming from low-speed re-
gions must accelerate. You can change the speed by enlarging the flowing section. A tube of fluid at
high speed in the die will enlarge its cross-section in the extrudate to decrease its average velocity. A
tube of fluid at low speed in the die will reduce its cross-section in the extrudate in order to increase
average speed. In Figure 6.5: Swelling of the Extrudate (p. 218), you can see that the die design tool
compensated for these effects. The central part of the cross-section where the fluid easily flowed in the
original die has been reduced by the die design tool, while the extremities of the branches were enlarged
because the flow was much slower in the original die. Since the combined effects of the cross-sectional
enlargements and reductions are very difficult to guess, the numerical simulation is necessary to help
the die designer reduce the number of trial-and-error iterations.
6.5. Summary
This tutorial introduced the concept of an inverse extrusion problem. You solved the problem assuming
suitable conditions for the physics of the problem and Polyflow predicted the shape of the die. You
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Appendix
used multiple domain calculations with remeshing methods most suited to 3D inverse extrusion problems.
The nonlinear problem was solved using an evolution technique to aid convergence.
6.6. Appendix
The appendix contains the following sections:
6.6.1. Power Law
6.6.2. Evolution Scheme
6.6.3. Remeshing Technique
6.6.4. Optimesh Remeshing Technique
6.6.5. IGES Output
where:
= consistency factor
= power-law index
= natural time
where:
= material parameters
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= material parameters
This technique modifies the location of the section where the boundary conditions on the kinematic
condition apply (the die-lip region). Apply local remeshing technique to the region between the entry
section and the die-lip area (subdomain 1). In this tutorial, you define a "constant section" on this sub-
domain. This means that the die cross-section is constant from the die entry to the die exit (a parallel
die). Using this two-stage remeshing technique, Polyflow calculates the die profile that produces an
extrudate of the desired shape. More complex deformations of the die are available via the definition
of different local remeshings within the die.
The domain to be remeshed is cut into a series of 2D slices (planes) in a direction perpendicular to the
direction of extrusion, and each plane will be remeshed independently. For this process, Polyflow requires
the selection of the initial plane and the final plane. In this problem, the initial plane is the intersection
of subdomain 2 with subdomain 1, and the final plane is the intersection of subdomain 2 with the flow
exit (boundary 6).
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Chapter 7: Flow of Two Immiscible Fluids
This tutorial is divided into the following sections:
7.1. Introduction
7.2. Prerequisites
7.3. Problem Description
7.4. Setup and Solution
7.5. Summary
7.1. Introduction
This tutorial examines the flow of two fluids in a single die. Two polymer melts with distinct physical
properties are fed through different channels into a die. The aim of the calculation is to predict the
location of the interface between the two fluids.
Set material properties and boundary conditions for a moving interface problem.
7.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the set up procedure
will not be shown explicitly.
Incompressibility and momentum equations are solved in the fluid domains. To solve the fully coupled
problem, two sub-tasks are defined one each for fluid 1 (sub-task 1) and fluid 2 (sub-task 2). Each sub-
task will contain a particular model, domain of definition, material properties, and boundary conditions,
including the moving interface along the intersection of the two sub-tasks.
The domain of definition for the problem is divided into four subdomains: sub-task 1 is defined on
subdomain 1 and subdomain 2, and sub-task 2 is defined on subdomain 3 and subdomain 4 (see Fig-
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Flow of Two Immiscible Fluids
ure 7.2: Boundary Sets and Subdomains for the Problem (p. 223)). Each sub-task is defined over two
subdomains to allow for the definition of the remeshing method only where it is necessary, (in the area
near the moving interface).
Fluid 1 has a viscosity of = 10000 poise, and fluid 2 has a viscosity of = 5000 poise.
The boundary sets for the problem are shown in Figure 7.2: Boundary Sets and Subdomains for the
Problem (p. 223).
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Problem Description
An interface is defined at the intersection of subdomain 2 and subdomain 4. In this problem, the interface
is a moving one, since the exact line of separation between the fluids is unknown.
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7.4.1. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the Two-Fluids_R180.zip link to download the input and solution files.
7. Unzip the Two-Fluids_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering two-fluids as the name of the project.
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Setup and Solution
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
Steady-state problem(s)
2D axisymmetric geometry
Create a sub-task
A small dialog box appears asking for the title of the problem.
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Flow of Two Immiscible Fluids
Sub-task 1 is defined for SUBDOMAIN2 (the region of fluid 1 near the moving interface) and SUBDOMAIN1
(the rest of fluid 1), as shown in Figure 7.2: Boundary Sets and Subdomains for the Problem (p. 223).
Material Data
Polydata indicates which material properties are relevant for your sub-task by graying out the irrelevant
properties. In this case, viscosity, density, inertia terms, and gravity are available for specification. For
this model, define only the viscosity of the material.
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Setup and Solution
5. Specify the value for , referred to as fac in the graphical user interface.
Modify fac
Enter 10000 [units: poise] as the New value and click OK.
6. Click Upper level menu three times to return to the fluid 1 menu.
7. Specify the flow boundary conditions for fluid 1 (SUBDOMAIN1 and SUBDOMAIN2).
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The boundary uses the interface condition, which is the standard boundary condition between two
adjacent fluids. This condition establishes the continuity of the velocity field and the contact forces
in the momentum equation.
The position of the line separating the two fluids is unknown at the start of the problem and is
calculated as part of the solution, so the intersection will be defined as a moving interface. In
steady flows and problems involving immiscible fluids, the interface must be a streamline. To sat-
isfy this condition and to obtain the exact location of the line of separation, an additional equation,
the kinematic condition, ( = 0), is added to the system. This guarantees that the material points
do not cross the interface.
Polydata asks you to select the boundary or subdomain on which the position of the moving
surface is to be imposed.
viii. Click Upper level menu twice to return to the Kinematic condition menu.
ix. Select Upwinding in the kinematic equation. Click Upper level menu.
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Setup and Solution
x. Click Accept the current setup to return to the Flow boundary conditions menu.
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY1 and click Modify.
iv. Enter 3 [units: cm3/s] as the New value and click OK.
When this option is selected, Polydata automatically chooses the most appropriate method
to compute the inflow condition.
vi. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY2 at the outer
wall of SUBDOMAIN1 (BOUNDARY2).
At a solid-liquid interface, the velocity of the liquid is that of the solid surface. Hence the fluid
is assumed to stick to the wall. This is known as the no-slip assumption because the liquid is
assumed to adhere to the wall, and therefore has no velocity relative to the wall.
It is assumed that a fully developed velocity profile is reached at the exit, so the outflow condition
is appropriate. This condition essentially imposes a zero normal force ( ) that includes a pressure
term, and zero tangential velocity ( ).
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY5 and click Modify.
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d. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY6 at the outer wall
common to SUBDOMAIN1 and SUBDOMAIN2 (BOUNDARY6).
The fluid is assumed to stick to the wall, since at a solid-liquid interface the velocity of the liquid
is that of the solid surface.
This model involves a free surface, whose shape is unknown a priori, which will be calculated together
with the flow equations. A portion of the mesh is affected by the relocation of this boundary. Hence a
remeshing technique is applied on this part of the mesh. The moving interface is entirely contained
within SUBDOMAIN2, and hence only SUBDOMAIN2 will be affected by the relocation of the moving
interface.
Global remeshing
If you have a complex geometry, it may be necessary to split it into additional subdomains in order
to define a specific remeshing method on each of them.
For this purpose, Polydata allows you to create several local remeshings. For this problem, a single
local remeshing is sufficient.
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Setup and Solution
The purpose of the remeshing technique is to relocate internal nodes according to the displacement
of boundary nodes due to the motion of the interface. Mesh nodes must be organized along lines
of remeshing (spines), which are collections of nodes logically arranged in a one-dimensional
manner. Polydata requires the specification of the first and last spines that the fluid encounters
(inlet of spines and outlet of spines, respectively). In this case, the inlet of spines is the intersection
of SUBDOMAIN2 with SUBDOMAIN1, and the outlet of spines is the intersection of SUBDOMAIN2
with the flow exit (BOUNDARY5).
Method of Spines
i. To specify the inlet for the system of spines, select SUBDOMAIN1 and click Modify.
ii. Specify the outlet for the system of spines, select BOUNDARY5 and click Modify.
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Create a sub-task
a. Polydata asks you if you want to copy data from an existing sub-task.
b. Click No, since this sub-task has different parameters associated with it.
A small dialog box appears asking for the title of the problem.
Material Data
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Setup and Solution
c. Specify the value for , referred to as fac in the graphical user interface.
Modify fac
Enter 5000 [units: poise] as the New value and click OK.
d. Click Upper level menu three times to return to the fluid 2 menu.
4. Specify the flow boundary conditions for fluid 2 (SUBDOMAIN3 and SUBDOMAIN4).
i. Select Zero wall velocity (vn=vs=0) along SUBDOMAIN2 and click Modify.
The interface condition was defined as a moving interface when setting the boundary condi-
tions for fluid 1. So further inputs are not required to define the moving interface for fluid 2.
Surface tension effects are neglected in this problem.
b. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY2 at the outer wall of
SUBDOMAIN3 (BOUNDARY2).
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY3 and click Modify.
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iv. Accept the default value of 1 [units: cm3/s] for the flow rate by clicking OK.
d. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY4 at the outer wall
common to SUBDOMAIN3 and SUBDOMAIN4 (BOUNDARY4).
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY5 and click Modify.
f. Click Upper level menu to return to the Flow boundary conditions menu.
Global remeshing
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Setup and Solution
In this case, the inlet of spines is the intersection of SUBDOMAIN3 with SUBDOMAIN4, and the
outlet of spines is the intersection of SUBDOMAIN4 with the flow exit (BOUNDARY5).
Method of Spines
i. Specify the inlet for the system of spines by selecting SUBDOMAIN3 and click Modify.
ii. Specify the outlet for the system of spines by selecting BOUNDARY5 and click Modify.
Polydata asks you to confirm the current system units and fields that are to be saved to the results file for
postprocessing.
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2. Click Accept.
3. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and for the Polyflow format results file (res).
7.4.7. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Workbench opens the View listing file dialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
7.4.8. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
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Setup and Solution
1. Double-click the Results tab in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
a. In the graphical window, right-click, and select the option Predefined Camera.
a. Click the Insert menu and select Contour or click the button.
b. Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
ii. In the Location Selector dialog box that opens, select SUBDOMAIN1_surf, SUBDOMAIN2_surf,
SUBDOMAIN3_surf, and SUBDOMAIN4_surf (use Ctrl for multiple selection) and then click
OK.
iii. Select VELOCITIES from the Variable drop-down list (or by clicking ).
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The velocity is much larger at the inlet of fluid 1 than at the inlet of fluid 2. There are two reasons for
this:
The flow rate is three times larger for fluid 1 than for fluid 2.
You are modeling an annular die. Hence the flow section is smaller for the interior channel than for the ex-
terior channel.
When the two fluids come into contact with each other, the interface between the two fluids is pushed
towards the exterior of the annular die.
The die is annular, so even identical flow rates cause the interface to move in order to equilibrate the flow
sections.
The viscosity of fluid 1 is higher than the viscosity of fluid 2. In the process of giving more room to the most
viscous fluid, its shearing decreases. This leads to a smaller global dissipation.
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Setup and Solution
In the Outline tree tab, under User Locations and Plots deselect Contour 1.
b. Click the Insert menu and select Vector or click the button.
c. Click OK to accept the default name (Vector 1) and display the details view below the Outline tab.
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Flow of Two Immiscible Fluids
ii. In the Location Selector dialog box that opens, select SUBDOMAIN1_surf, SUBDOMAIN2_surf,
SUBDOMAIN3_surf, and SUBDOMAIN4_surf (use Ctrl for multiple selection) and click OK.
iv. In the Symbol tab, set Symbol to Arrow3D and increase the Symbol Size to 3.
v. Click Apply.
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Setup and Solution
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You can see that the velocity is continuous across the interface. As both the fluids are Newtonian, the
velocity profile is a parabola on both sides of the interface. Since the force must be continuous across
the interface, the shear stress generated within fluid 1 is equal to the shear stress generated within fluid
2 along the interface.
7.5. Summary
This tutorial introduced the concept of fluid layers flowing in the same duct. In Polydata, you learned
how to set up a multiple-domain calculation, including the definition of a moving interface and associated
remeshing methods.
The location of the interface depends largely on the physical properties of the fluids involved, the
geometry of the channels, and the operating conditions (for example: flow rates of the fluids). A CFD
simulation with Polyflow allows you to test different setups (for example: in order to optimize the
feeding of a coextrusion die).
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Chapter 8: Flow of Two Immiscible Fluids by Species Method
This tutorial is divided into the following sections:
8.1. Introduction
8.2. Prerequisites
8.3. Problem Description
8.4. Setup and Solution
8.5. Summary
8.1. Introduction
This tutorial examines the flow of two fluids in a single die. Two polymer melts with distinct physical
properties are fed through different channels into a die. The aim of the calculation is to predict the
location of the interface between the two fluids.
Define a species.
8.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the set up procedure
will not be shown explicitly.
Incompressibility and momentum equations are solved in the fluid domains. To determine the interface,
an extra scalar transport equation is solved and material properties are made functions of this scalar
using PMAT. If the scalar value is greater than 0.5, material properties of first fluid are used and if the
scalar value is less than 0.5, material properties of second species are used. A Scalar value of 0.5 determ-
ines the location of interface.
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Note that the same problem has been solved using the interface tracking method (see Flow of Two
Immiscible Fluids (p. 221)).
The advantage of this method over the interface tracking method is that it can be used for more complex
geometries, and it is less computationally expensive than the interface tracking method (no remeshing
method must be defined). However this comes at a loss of accuracy. The interface tracking method
gives a very accurate position of interface, whereas the species method produces a blurred interface.
The geometry and mesh from Flow of Two Immiscible Fluids (p. 221) is used.
Fluid 1 has a viscosity of = 10000 poise, and fluid 2 has a viscosity of = 5000 poise.
The boundary sets for the problem are shown in Figure 8.2: Boundary Sets and Subdomains for the
Problem (p. 245).
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Problem Description
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Flow of Two Immiscible Fluids by Species Method
Note that when using this method for a sharp interface, you should ensure that the scalar doesn't diffuse
much into the domain. To ensure this, an evolution is applied on scalar diffusivity starting from a large
value and gradually decreasing it to a very small number.
8.4.1. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the Two-Fluids-Species_R180.zip link to download the input and solution files.
7. Unzip the Two-Fluids-Species_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
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Setup and Solution
2. Save the ANSYS Workbench project using File Save, entering two-fluids-species as the name
of the project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
Evolution problem(s)
2D axisymmetric geometry
1. Create a species A.
Define species
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Create a sub-task
b. Click SpeciesA.
Material data
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Setup and Solution
Polydata indicates the material properties that are relevant for the sub-task by graying out the irrelevant
properties. For this model, you will only define the diffusivity of the species. The evolution will be applied
on diffusivity with an initial high value (1) and decreases it to a small value (1e-9).
a. Click Diffusivity.
b. Click EVOL button at the top of Polydata menu to enable evolution inputs.
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Polydata will take you to evolution panel. Here you will make species diffusivity a function of
evolution parameter . Since the diffusivity must be decreased by several orders of magnitude,
is selected.
h. Click the EVOL button at the top of the Polydata menu to disable evolution inputs.
i. Click Upper level menu twice to return to the Transport of SpeciesA menu.
6. Specify the concentration boundary conditions for fluid 1 (SUBDOMAIN1 and SUBDOMAIN2).
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Setup and Solution
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iii. Repeat step (i) and step (ii) for BOUNDARY5 and BOUNDARY6.
Create a sub-task
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Setup and Solution
Material Data
Polydata indicates the material properties that are relevant for the sub-task by graying out the irrelevant
properties. For this model, you will define only the viscosity of the material. The viscosity of material 1
will be used if the species concentration is greater than 0.5, otherwise the viscosity of material 2 will be
used. This can be achieved by the use of PMAT.
d. Specify the value for , referred to as fac in the graphical user interface.
Modify fac
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g. Click f1(...).
Polydata will ask to define pairs of values. A minimum of two pairs must be defined. Here you will
define (0.495, 5000) and (0.505, 10000), where the first index stands for species concentration and
the second index stands for viscosity [units: poise] value.
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Setup and Solution
Enter 0.495 for X1( 1), and 5000 for f(X1)( 1).
n. Select SpeciesA.
p. Click Upper level menu six times to return to the fluid 1 and 2 menu.
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i. Select Zero wall velocity (vn=vs=0) along BOUNDARY1 and click Modify.
Polydata prompts for the new value of the volumetric flow rate.
iv. Enter 3 [units: cm3/s] as the New value and click OK.
When the Automatic option is selected, Polydata automatically chooses the most appropriate
method to compute the inflow condition.
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Setup and Solution
b. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY2.
At a solid-liquid interface, the velocity of the liquid is that of the solid surface. Hence the fluid is
assumed to stick to the wall. This is known as the no-slip assumption because the liquid is assumed
to adhere to the wall, and so has no velocity relative to the wall.
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY3 and click Modify.
Polydata prompts for the new value of the volumetric flow rate.
iv. Click OK to accept the default value of 1 [units: cm3/s] for New Value.
d. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY4.
It is assumed that a fully developed velocity profile is reached at the exit, so the outflow condition
is appropriate. This condition essentially imposes a zero normal force ( ) that includes a pressure
term, and a zero tangential velocity ( ).
i. Select Zero wall velocity (vn=vs=0) along BOUNDARY5 and click Modify.
f. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY6.
The fluid is assumed to stick to the wall, since at a solid-liquid interface the velocity of the liquid
is that of the solid surface.
g. Click Upper level menu three times to return to the top-level Polydata menu.
Polydata asks you to confirm the current system units and fields that are to be saved to the results file for
postprocessing.
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2. Click Accept.
3. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and the Polyflow format results file (res).
8.4.7. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Workbench opens theView listing filedialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
8.4.8. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
1. Double-click the Results tab in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
In the graphical window, right-click, and select View from +Z under Predefined Camera.
a. Click the Insert menu and select Contour or click the Contour button ( ).
b. Click OK to accept the default name (Contour 1) and display the details view below the Outline tab.
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Setup and Solution
ii. In the Location Selector dialog box that opens, select SUBDOMAIN1_surf, SUBDOMAIN2_surf,
SUBDOMAIN3_surf, and SUBDOMAIN4_surf (use Ctrl for multiple selection) and click OK.
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The velocity is much larger at the inlet of fluid 1 than at the inlet of fluid 2. There are two reasons for
this:
The flow rate is three times larger for fluid 1 than for fluid 2.
You are modeling an annular die. Hence the flow section is smaller for the interior channel than for the ex-
terior channel.
When the two fluids come into contact with each other, the interface between the two fluids is pushed
towards the exterior of the annular die.
The die is annular, so even identical flow rates cause the interface to move in order to equilibrate the flow
sections.
The viscosity of fluid 1 is higher than the viscosity of fluid 2. In the process of giving more room to the most
viscous fluid, its shearing decreases. This leads to a smaller global dissipation.
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Setup and Solution
a. In Outline tree tab, under User Locations and Plots, deselect Contour 1.
b. Click the Insert menu and select Vector or click the button.
c. Click OK to accept the default name (Vector 1) and display the details view below the Outline tab.
ii. In the Location Selector dialog box that opens, select the locations SUBDOMAIN1_surf, SUB-
DOMAIN2_surf, SUBDOMAIN3_surf and SUBDOMAIN4_surf (use ctrl for multiple selections)
and click OK.
iii. In the Symbol tab, select Arrow 3D from the Symbol drop-down list.
v. Click Apply.
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Flow of Two Immiscible Fluids by Species Method
You can see that the velocity is continuous across the interface. As both the fluids are Newtonian, the
velocity profile is a parabola on both sides of the interface. Since the force must be continuous across
the interface, the shear stress generated within fluid 1 is equal to the shear stress generated within fluid
2 along the interface.
a. In Outline tree tab, under User Locations and Plots, deselect Vector 1.
b. Click the Insert menu and select Contour or click the Contour button ( ).
c. Click OK to accept the default name (Contour 2) and display the details view below the Outline tab.
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Setup and Solution
ii. In the Location Selector dialog box that opens, select SUBDOMAIN1_surf, SUBDOMAIN2_surf,
SUBDOMAIN3_surf, and SUBDOMAIN4_surf (use Ctrl for multiple selection), and then click
OK.
iv. In the Variable Selector dialog box that opens, select SpeciesA, and then click OK.
a. In Outline tree tab, under User Locations and Plots, deselect Contour 2.
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Flow of Two Immiscible Fluids by Species Method
c. Click OK to accept the default name (Isosurface 1) and display the details view below the Outline
tab.
i. In the Geometry tab, click the button next to Variable and select SpeciesA.
ii. Enter 0.5 for Value in order to locate the interface line.
iii. In the Color tab, select Constant from the Mode drop-down list and select pink by clicking
next to Color.
iv. In the Render tab, select Draw As Lines from the Draw Mode drop-down list.
v. Click Apply.
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Summary
8.5. Summary
This tutorial introduced the concept of fluid layers flowing in the same duct. In Polydata, you learned
how to set up a species transport equation, a PMAT function, and you learned how to define a coextrusion
problem using species transport and PMAT functions. This method avoids the use of the remeshing
method, which is computationally expensive.
The species method, although less accurate, can help in quickly finding a solution when the die has a
complex shape. For more accurate results, the interface tracking method, as demonstrated in Flow of
Two Immiscible Fluids (p. 221), should be used. Generating a mesh for a complex die may be an issue
with the interface tracking method.
The location of the interface depends largely on the physical properties of the fluids involved, the
geometry of the channels, and the operating conditions (for example: flow rates of the fluids). A CFD
simulation with Polyflow allows you to test different setups (for example: in order to optimize the
feeding of a coextrusion die).
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Part III: Blow Molding
The following blow molding tutorials are available:
1.1. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the setup procedure
will not be shown explicitly.
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3D Thermoforming of a Blister
To reduce the computational run time, and utilizing the symmetric nature of the blister, only one quarter
of the blister/mold is modeled, Figure 1.1: Thermoforming of a Blister, Sheet (blue) and Mold (red) (p. 270).
From a geometric point of view, the initial (1/4) film has the following dimensions:
Length = 15 mm
Width = 5 mm
Dimensions are intentionally given in millimeters due to the small size of the object. The simulation will be
built around the system of units consisting of millimeters, grams and seconds.
The thickness compared to the length/width of the blister is rather small. This allows for the use of the
membrane (shell) element, which is suited for the analysis of 3D blow molding and thermoforming
simulations. The use of the membrane element is presently restricted to time-dependent flows and is
combined with Lagrangian representation (each mesh node is a material point). Node displacement
results from the time integration of nodal velocity.
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Problem Description
The finite element mesh and the boundary conditions are displayed in Figure 1.2: Finite Element Mesh,
Subdomains and Boundary Sets (p. 271). A 3D surface mesh has been generated for both the mold and
the film. The most important aspect is the proper description of the inner mold surfaces that will shape
the blister.
Viscosity = 105
As seen in Figure 1.2: Finite Element Mesh, Subdomains and Boundary Sets (p. 271), the topology involves
two subdomains:
Subdomain 1 = film
Subdomain 2 = mold
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3D Thermoforming of a Blister
The inflation pressure will be defined on the subdomain representing the film (Subdomain 1).
An important new concept is introduced in this tutorial: contact with a mold. Typically, two cases may
be encountered:
The moving mold comes in contact with the shell and the shell acquires the mold velocity.
The shell is inflated according to a certain rate and eventually comes into contact with the mold, acquiring
its shape.
1.3.1. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
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Setup and Solution
6. Click the 3D-Thermo-Blister_R180.zip link to download the input and solution files.
7. Unzip the 3D-Thermo-Blister_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering blister as the name of the project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
Time-dependent problem(s)
2D shell geometry
Define molds
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b. Click Upper level menu at the top of the Domain of the mold menu.
Contact conditions
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Setup and Solution
Mold motion
A dialog box opens, asking you to specify the type of mold motion.
Enter 1 as the New value to impose a translation velocity, and click OK.
b. Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
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Click OK to accept the default value of 0 for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x-direction.
Click OK to accept the default value of 0 for the New value of velocity-y, and click Upper
level menu, as there is no velocity in the y-direction.
Enter 10 [units: mm/s] for the New value of velocity-z and click OK.
v. Define the coordinate pairs (a,b) and (c,d) for the points that define the ramp function.
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Setup and Solution
vi. In a similar manner, set the values for b, c, and d to 1.0, 0.103, and 0, respectively.
Figure 1.3: Ramp Function for Mold Velocity (p. 277) shows the ramp function you just defined.
vii. Click the EVOL button at the top of the menu to disable evolution inputs.
viii. Click Upper level menu three times to return to the F.E.M. Task 1 menu.
Create a sub-task
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b. Click Upper level menu button at the top of the Domain of the sub-task menu.
b. Select Zero wall velocity (vn=vs=0) along Boundary 3 and click Modify.
iii. Click Upper level menu to continue specifying flow boundary conditions.
c. Select Zero wall velocity (vn=vs=0) along Boundary 4 and click Modify.
iii. Click Upper level menu to return to the Flow boundary conditions menu.
d. Click Inflation pressure imposed at the bottom of the Flow boundary conditions menu.
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Setup and Solution
A dialog box opens, asking for the new value of the constant.
Enter 100000 [units: Pa] as the New value and click OK.
f. Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
ii. Click Modify the value of a, and enter 0.1 as the New value.
iii. In a similar manner, set constants b, c, and d to 0, 0.11, and 1.0, respectively.
Figure 1.4: Ramp Function for Pressure (p. 279) shows the ramp function you just defined.
Click the EVOL button at the top of the Polydata menu to disable evolution inputs.
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Define contacts
The Modification of a contact problem menu will open with the Select a contact wall menu
item highlighted.
i. Magnify the view of the mold to ensure that you can see the darts that will be displayed.
Darts will be displayed in the Graphics Display window, as shown in the following figure.
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Setup and Solution
iii. Click No in the dialog box that opens, to specify that the darts are not pointing towards the
mold body.
If the direction of the darts is not clear to you, you can close the dialog box, rotate the view
and/or change the magnification, click Specify mold side / cavity side again, and then
answer the question appropriately.
A warning dialog box opens, saying that velocity prediction must be disabled, and that the modi-
fication has automatically been done.
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Click OK.
Define layers
In the dialog box that opens, enter blister as the New value.
The blister menu will open with the Material data menu item highlighted.
Material Data
iv. Click Upper level menu twice to continue with material data specification.
v. Click Density.
Enter 0.001 [units: g/mm3] as the New value and click OK.
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Setup and Solution
vii. Click Upper level menu to continue with the material data specification.
Select Inertia will be taken into account and click Upper level menu to continue with
material data specification.
Enter 5e-12 [units: g-mm/s/mm2] as the New value and click OK.
xi. Click Upper level menu twice to return to the blister menu.
Initial thickness
i. Click Constant.
Enter 0.35 [units: mm] as the New value and click OK.
ii. Click Upper level menu four times to return to the F.E.M. Task 1 menu.
Create a sub-task
Click No in the dialog box that opens asking if you want to copy the data of an existing sub-task.
a. Click Postprocessor.
Enter Mass of product as the New value in the dialog box that asks for the title of the
sub-task and click OK.
Click OK in the dialog box that opens saying that the calculation will be performed on Subdo-
main 1.
c. Confirm that the Density of layer [blister] is set to 1.00E-03, and click Upper level menu.
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The plane is calculated by the following equation (which is displayed at the top of the Restric-
tion of Layers by cutting planes menu).
(1.1)
Create a sub-task
Click No in the dialog box that opens asking if you want to copy the data of an existing sub-task.
a. Click Postprocessor.
Enter Permeability of product as the New value in the dialog box that asks for the
title of the sub-task and click OK.
Click OK in the dialog box that opens saying that the calculation will be performed on Subdo-
main 1.
c. Confirm that the Permeability of layer [blister] is set to 5.00E-12, and click Upper level menu.
See Equation 1.1 (p. 284) for more information on the coefficients.
Create a sub-task
Click No in the dialog box that opens asking if you want to copy the data of an existing sub-task.
a. Click Postprocessor.
Enter Volume of product as the New value in the dialog box that asks for the title of
the sub-task and click OK.
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Setup and Solution
Click OK in the dialog box that opens saying that the calculation will be performed on Subdo-
main 1.
See Equation 1.1 (p. 284) for more information on the coefficients.
f. Click Upper level menu to ignore contact with Subdomain 2 and return to F.E.M. Task 1.
Numerical parameters
Click OK to retain the default value of 0.0 [units: s] as the New value.
Click OK to retain the default value of 0.0001 [units: s] as the New Value.
9. Click Upper level menu three times to return to the top-level Polydata menu.
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1.3.7. Outputs
Outputs
Set to metric_mm/g/s/mA+Celsius
2. Click Upper level menu two times to return to the Outputs menu.
Output Triggering
3. Click Upper level menu twice to return to the top-level Polydata menu.
1. Click Accept.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and the Polyflow format results file (res).
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Setup and Solution
1.3.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Workbench opens the View listing file dialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
Here you can see the results of the postprocessor sub-tasks you created in Polydata. For additional in-
formation on postprocessing sub-tasks, see Postprocessing Sub-Tasks (p. 283) and derived quantities in
the Polyflow User's Guide. To access documentation files on the ANSYS Customer Portal, go to http://
support.ansys.com/documentation..
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1.3.10. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
CFD-Post reads the solution fields that were saved to the results file.
b. In the dialog box that opens, click OK to accept the default name (Contour 1) and display the details
of Contour 1 below the Outline tree.
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Setup and Solution
v. Click Apply.
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a. Double-click Default Transform in the Outline tree tab, under User Locations and Plots (or right-
click Default Transform and select Edit).
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Setup and Solution
b. Disable Instancing Info From Domain under the Definition tab in the details of Default Transform.
d. Select Value from the Determine Angle From drop-down list in the Instance Definition group box.
f. Enable Apply Reflection, and select ZX Plane from the Method drop-down list.
h. Click Apply and revise the magnification of the view to show the whole mold.
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Setup and Solution
c. Click Apply.
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Setup and Solution
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Setup and Solution
c. To save the animation, expand the dialog box by clicking the button at the lower-right.
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ii. Click the file icon to the right and enter the path where you would like to save the animation.
Enter Thickness.wmv for the name of the file and click Save to close the Save Movie
dialog box.
iv. Click the play button, to play the animation and save it as a file.
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Further Improvements
1.4. Summary
This tutorial introduced the concept of a blow molding problem. The mold moved into contact with
the film, where a constant pressure was applied to the film. This blew the film into the mold where it
assumed the shape of the mold.
You represented the film by a shell geometry under the valid assumption that the thickness of the film
was much smaller than the other two dimensions. Polyflow linearly interpolated the process vari-
ablesthickness, velocity and position. By reporting the individual time steps to CFD-Post you were
able to view the thickness of the product as a function of time.
F.E.M. Task 1
Numerical parameters
Adaptive meshing
Modify size_min = .1
Modify size_max = 1
Modify dist_crit = .5
Modify Nstep = 4
For additional information on adaptive meshing, see adaptive meshing in the Polyflow User's Guide.
To access documentation files on the ANSYS Customer Portal, go to http://support.ansys.com/document-
ation.
The results are shown in Figure 1.11: Effect of Adaption on Final Mesh and Thickness Variation (p. 300).
Note how the mesh changes as the Maxdiv value increases. The results do not change very much as
a result of the adaption, which indicates that the original solution was already mesh independent.
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1.6. Appendix
The appendix contains the following topics:
1.6.1. Contact Boundary Conditions
1.6.2. Remark on the Penalty Coefficient
1.6.3. Remeshing
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Appendix
with the (moving) molds. In all forming applications (blow molding and thermoforming for example),
the definition of the contact is an important aspect, as it will eventually lead to the desired shape. The
contact involves a what and a how. The what describes the geometry of the film/sheet and the
mold surface it may get in contact with (contact problem). The how refers to other process parameters
such as a moving mold. In this case, a velocity (possibly time-dependant) must be specified for the
mold. In some cases, the material may slip along the contact wall, which can also be taken into account.
Next to these operating attributes, some numerical parameters must be specified. A geometrical algorithm
is applied for detecting the occurrence of contact, while a penalty formation is used for the treatment
of contact. A penalty coefficient ensures that a geometrical contact is detected. It should not be too
small. A coefficient is also specified in the tangential direction. If the fluid sticks along the wall, this
tangential coefficient should preferably receive the same value as the penalty coefficient. Two additional
coefficients are also needed; a tolerance on penetration accuracy and an element dilatation.
Presently, the penalty coefficient has been set to 1010, while the same value has been selected for the
coefficient along the tangential direction (slipping coefficient). The tolerance on penetration and element
dilatation equal 0.05 and 0.05 mm, respectively.
In classical thermoforming applications, such residual velocity will not produce any significant numerical
penetration of the fluid film/sheet through the mold in view of the short times involved (physically, the
thermoforming process is very fast). However, some situations may involve longer time scales such as
in the glass industry.
The question that is now raised concerns the best evaluation of the penalty coefficient. The penalty
formulation mainly establishes a balance between a force (for example: the inflation pressure, ) and
a penalty force because of contact. The penalty force is simply the product of the penalty coefficient,
, and the residual velocity of the film/sheet upon contact. The other elements of the momentum
equation can be ignored for the present consideration. Assuming a typical time scale (for example:
the simulation time), and a maximum penetration depth , a good penalty coefficient can be selected
as:
1.6.3. Remeshing
No remeshing must be specified. In the context of the membrane element, a Lagrangian representation
is applied where all mesh nodes are considered material points.
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Chapter 2: 2D Axisymmetric Blow Molding
This tutorial contains the following sections:
2.1. Introduction
2.2. Prerequisites
2.3. Problem Description
2.4. Setup and Solution
2.5. Summary
2.6. Appendix
Files required to work on this tutorial can be downloaded from this website: http://support.ansys.com/
training.
2.1. Introduction
Molding is a process of forcing a preform or a parison (preshaped sleeve) into a mold cavity so that the
preform assumes the shape of the cavity. There are numerous molding methods, including blow
molding, compression and transfer molding, and slush and rotational molding. These methods differ
in the formation of the preform and the filling of the mold cavity. Also, each processing method is
suitable for a specific class of polymers.
Blow molding is an important processing method for molding hollow articles such as bottles. The preform
is usually made by extrusion and forced between the mold halves by pressurization (blowing air). The
polymer solidifies upon contact with the cold mold and the finished product is then ejected. The homo-
geneity and rheological properties of the preform along with the operating conditions (temperature
and pressure variations) are crucial in this step and will affect the design of the processing machinery.
This process reflects all facets of polymer processing the isothermal and transient flow of Newtonian
fluids in complex geometries with simultaneous structuring and solidification.
Set material properties and boundary conditions for a 2D axisymmetric blow molding problem.
2.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the setup procedure
will not be shown explicitly.
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A large pressure is applied to the preform, which enters the mold and eventually takes its shape. The
operating conditions must account for a low pressure drop at the entrance, low material waste, and
slow cooling to avoid premature solidification of the preform.
The cylindrical geometry of the preform (Figure 2.1: Problem Description (p. 304)) has an internal radius
of 2 cm and external radius of 3 cm (the initial thickness of the preform is 1 cm). The height of the
preform is 10 cm.
The domain for the problem is divided into two subdomains: one for the fluid preform (subdomain 1)
and the other for the mold (subdomain 2). Incompressibility and momentum equations are solved in
subdomain 1 (the fluid preform). The problem involves two free surfaces (boundary 2 and boundary 4,
shown in Figure 2). boundary 2 will eventually come into contact with the mold, and its position is
calculated as a part of the solution.
The fluid preform has a density of =1 g/cm3 and a viscosity of = 100000 poise. Inertia terms and
the effects of gravity will be included in the calculation.
The boundary sets for the problem are shown in Figure 2.2: Boundary Set for the Problem (p. 305), and
the conditions at the boundaries of the domain (for the preform) are:
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Setup and Solution
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2D Axisymmetric Blow Molding
2.4.1. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the 2D-Axi-Blow-Molding_R180.zip link to download the input and solution files.
7. Unzip the 2D-Axi-Blow-Molding_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering Final-blow-mold as the name of the
project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
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Setup and Solution
F.E.M. task
Time-dependent problem(s)
2D axisymmetric geometry
The Current setup is updated to reflect the selected options. This example is a simulation of
blow molding for a 2D axisymmetric bottle and the mold is two-dimensional. The problem is as-
sumed to be time-dependent.
Define molds
a. Create a mold.
Adiabatic mold
c. When prompted, click OK to retain the default name for the mold (Mold 1).
SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that the mold is
defined as SUBDOMAIN_2 .
e. Specify the boundary that represents the part of the mold that comes into contact with the fluid.
Polyflow uses this information to determine the penetration distance (into the mold) of every
point of the free surface (BOUNDARY2).
Contact conditions
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The free surface, BOUNDARY2 of the preform comes into contact with the mold wall,
BOUNDARY5 (as shown in Figure 2.2: Boundary Set for the Problem (p. 305)).
f. Click Upper level menu four times to return to the F.E.M. Task 1 menu.
Create a sub-task
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Setup and Solution
The domain is divided into two subdomains, one for the fluid preform (SUBDOMAIN_1) and the other
for the mold (SUBDOMAIN_2). In this problem, the sub-task applies only to the preform.
SUBDOMAIN_2 is moved from the top list to the bottom list, indicating that the sub-task is
defined on SUBDOMAIN_1 .
Material data
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c. Click Modify fac to specify the value of , which is referred to as fac in the graphical user interface.
d. Enter 100000 [units: poise] as the New value and click OK.
e. Click Upper level menu two times to continue with the Material Data specification.
a. Click Density.
d. Click Upper level menu to continue with the Material Data specification.
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Setup and Solution
In this problem inertia plays an important role. When internal pressure is applied, the preform expands,
and the fluid accelerates towards the mold. In order to obtain a realistic blowing time, inertia must be
taken into account.
c. Click Upper level menu to continue with the Material Data specification.
The fluid preform flows in the negative y direction under gravity, so specify the component of gravity
along the y direction ( ).
a. Click Gravity.
Modify gy
Polydata prompts for the new value of the gravity along the y-axis.
c. Enter -981 [units: cm/s2] as the New value and click OK.
d. Click Upper level menu two times to return to the blow molding menu.
No action is required to accept the default value. You can simply proceed to the next step. For 2D
axisymmetric models, Polydata recognizes the axis of symmetry from the mesh file and automatically
imposes the symmetry condition along the line .
The free surface boundary condition in contact detection problems is different from their simulations
in Polyflow. In blow molding problems, a free surface comes into contact with a solid mold. Polyflow
applies a contact detection algorithm at each location of the surface to detect the occurrence of the
contact.
You need to specify the following for the free surface on BOUNDARY2:
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the contact wall (the boundary of the mold along which the contact is detected)
This determines the accuracy of the contact; the smaller its value, the deeper the contact is.
The fluid may slip along the contact wall, so to take this factor into account, a slipping coefficient
must be specified along the tangential direction.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY2 and click Modify.
iii. Specify where the free surface will contact the mold.
Polyflow uses the definition of the contact wall in the determination of the penetration distance
(into the mold) of every point of the free surface (BOUNDARY2).
As shown in Figure 2.2: Boundary Set for the Problem (p. 305), the free surface (BOUNDARY2)
of the preform comes into contact with the mold (BOUNDARY5).
With such a high value of the slipping coefficient, the fluid will stick to the contact wall.
vii. Click Upper level menu two times to return to the Kinematic condition menu.
d. Click Upper level menu to return to the Flow boundary conditions panel.
In contact detection problems, abrupt changes in the velocity field occur at the contact points
between the fluid preform and the mold. Polydata gives the warning message shown below. Since
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the prediction of the velocity field in such cases destroys the prediction scheme, you can continue
by clicking OK.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY3 and click Modify.
c. Click Upper level menu to accept the default value of 0 for the normal velocity, .
d. Click Upper level menu to accept the default value of 0 for the tangential force, .
This boundary of the preform is subjected to pressure by the application of a normal force, so specify
a normal force along this boundary.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY4 and click Modify.
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d. Click Upper level menu to return to the Flow boundary conditions menu.
2.4.6. Remeshing
This model involves free surfaces for which the positions are unknown. A portion of the mesh is affected by
the relocation of these boundaries. Hence a remeshing technique is applied on this part of the mesh. The
free surfaces are entirely contained within SUBDOMAIN_1, and hence only SUBDOMAIN_1 is affected by the
relocation of the free surfaces.
Global remeshing
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a. Click Accept the current setup in the Element distortion check menu.
In blow molding simulations, the finite-element mesh can undergo great deformations. The Element
distortion check menu deals with the detection of all possible distortions of the elements. In this
problem, you can accept the default options and proceed to the next step.
b. Click Upper level menu two times to return to the F.E.M. Task 1 menu.
Numerical parameters
1. Specify the parameters for the iterative scheme in the calculation of the free surface.
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This option specifies the time at which the solution procedure stops.
This option is used to define the initial time step, which is used for the calculation of the next two
time steps. After that, the step size is automatically calculated by Polyflow. This first time step
should be set according to the characteristic time scale of the process considered.
If a calculated value for the time step falls below the minimum for the time step at any point in
the calculation, the iterative scheme stops since this might be a symptom of calculation difficulties.
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In order to guarantee accuracy of the time-marching scheme and to avoid useless calculations
(rejection of inaccurate time steps), you can limit the growth of the time increment.
The tolerance is the admissible error between the predicted solution and the exact solution at a
particular time step. A very small value of the tolerance can result in large computational costs
and a very large value can result in wrong solution.
This option is used to select the maximum number of converged steps. If this value is reached, the
calculation stops, even if the upper time limit has not been reached.
2. Click Upper level menu three times to return to the top-level Polydata menu.
2.4.8. Outputs
You can specify how often Polyflow saves the solution data when it calculates a solution. In this tutorial,
save the results at every 4 time steps.
Outputs
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4. Click Upper level menu twice to return to the top-level Polydata menu.
F.E.M. Task 1
Create a sub-task
b. Click Postprocessor.
c. Enter parison thickness as the New value for the title and click OK.
6. Specify the boundary sets representing the starting and ending borders to be used in the thickness calcu-
lation.
Polyflow evaluates the distance between these borders at a point between them to determine the
thickness at that location.
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7. Click Upper level menu five times to return to the top-level Polydata menu.
Polydata asks you to confirm fields that are to be saved to the results file for postprocessing.
1. Click Accept.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and the Polyflow format results file is (res).
2.4.11. Solution
In the following steps you will run Polyflow to calculate a solution for the model you just defined using
Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Workbench opens the View listing file dialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
2.4.12. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
CFD-Post reads the solution fields that were saved to the results file.
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a. Click the Insert menu and select Contour or click the button.
b. In the box that opens, click OK to accept the default name (Contour 1) and display the details below
the Outline tree.
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Setup and Solution
ii. Select estim. THICKNESS from the Variable drop-down list, or click the ellipsis button ( )
on the right and select estim. THICKNESS.
i. Click the Insert menu and select Text or click the button.
ii. Click OK to accept the default name (Text 1) and display the details view below the Outline
tab.
v. Click Apply.
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a. Double-click Default Transform in the Outline tree tab, under User Locations and Plots (or right-
click Default Transform and select Edit).
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Setup and Solution
b. Disable Instancing Info From Domain under the Definition tab in the details of Default Transform.
c. Enable Apply Reflection, and select YZ Plane from the Method drop-down list.
e. Click Apply.
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Display the results at several time steps to see the shape and thickness of the parison during the blow
molding process.
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Setup and Solution
The thickness decreases as the parison inflates. At the final time step, the thickness is smallest
where the parison has been the most extended, (in the corner of the bottle). It is largest at the top
where the deformation was much less important due to the small diameter here.
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a. Click the Tools menu and select Animation or click the button.
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a. Double-click Contour 1 under the Outline tab to display the details view.
b. Select VELOCITIES from the Variable drop-down list and click Apply.
There is zero velocity at the contact between the parison and the mold, but the velocity magnitude
is still important where the fluid does not yet touch the mold. At the final time of the simulation,
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Summary
the velocity is near zero, which indicates that the contact is completed. The residual value originates
from the penalty formulation used for the contact, as explained in 3D Thermoforming of a
Blister (p. 269).
2.5. Summary
This tutorial introduced a time-dependent problem with a 2D axisymmetric geometry for the mold.
Suitable assumptions were made regarding the nature of the preform and the operating conditions.
You analyzed the factors affecting the process in the postprocessing section. An optimization of the
preform shape could be performed in order to minimize the weight of the bottle while avoiding weak
(too thin) bottle walls.
You used a remeshing method that is most suited for contact detection problems. This problem also
introduced the concept of the calculation of free surfaces for contact detection problems. You used
efficient numerical techniques to more accurately solve a time-dependent problem.
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2.6. Appendix
The appendix covers the following topics:
2.6.1. Remeshing Technique
2.6.2.Time Marching Scheme
Because this application involves contact occurring over time, a Lagrangian representation is used for
the free surface that undergoes the contact; this improves the robustness of the contact algorithm. The
Lagrangian on the border only technique remeshes based on the combination of a Lagrangian rep-
resentation on the border of the fluid domain and a minimum-pseudo-energy representation for the
inner mesh nodes. For additional information on this technique, see Lagrangian method on borders in
the Polyflow User's Guide. To access documentation files on the ANSYS Customer Portal, go to http://
support.ansys.com/documentation.
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Chapter 3: Plug-Assisted Thermoforming of a Blister
This tutorial is divided into the following sections:
3.1. Prerequisites
3.2. Problem Description
3.3. Setup and Solution
3.4. Summary
3.5. Appendix
3.1. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the setup procedure
will not be shown explicitly.
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Figure 3.1: Plug-Assisted Thermoforming of a Blister: Plug (Orange), Sheet (Blue), and Mold (Green)
in the Initial Configuration
To reduce the computational run time, and utilizing the symmetric nature of the blister, only one quarter
of the blister/plug/mold is modeled, Figure 3.1: Plug-Assisted Thermoforming of a Blister: Plug (Orange),
Sheet (Blue), and Mold (Green) in the Initial Configuration (p. 334). From a geometric point of view, the
initial (1/4) film has the following dimensions:
length = 15 mm
width = 5 mm
Dimensions are intentionally given in millimeters due to the small size of the object. The simulation will be
built around the system of units consisting of millimeters, grams and seconds.
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Problem Description
The thickness compared to the length/width of the blister is rather small. This allows the use of the
membrane (shell) element, which is suited for the analysis of 3D blow molding and thermoforming
simulations. The use of the membrane element is presently restricted to time-dependant flows and is
combined with Lagrangian representation. That is, each mesh node is a material point.
The finite element mesh and the boundary conditions are displayed in Figure 3.2: Finite Element Mesh,
Subdomains and Boundary Sets (p. 335). As shown, a full 3D finite element is built for the mold, the plug
and the film. Only a surface mesh is required for the three subdomains, but the most important aspect
remains the proper description of the inner mold surfaces which will shape the blister.
viscosity = 105
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As seen in Figure 3.2: Finite Element Mesh, Subdomains and Boundary Sets (p. 335), the mesh topology
involves three subdomains:
Subdomain 1 = film
Subdomain 2 = mold
Subdomain 3 = plug
The inflation pressure will be defined on the subdomain representing the film (Subdomain 1).
An important new concept is introduced in this tutorial: plug-assisted contact with a mold. The film
acquires the mold velocity then the plug guides the film into the mold. Once inside the mold, the film
is inflated according to a certain rate where it eventually comes into contact with the mold, finally ac-
quiring its shape.
3.3.1. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
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Setup and Solution
4. Narrow the results by using the filter on the left side of the page.
6. Click the Plug-Thermo-Blister_R180.zip link to download the input and solution files.
7. Unzip the Plug-Thermo-Blister_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering Blister-plug-assist as the name
of the project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
Time-dependent problem(s)
2D shell geometry
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Define molds
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c. Click Upper level menu at the top of the Domain of the mold menu.
Contact conditions
Mold motion
A dialog box opens, asking you to specify the type of mold motion.
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Enter 1 as the New value, to impose a translation velocity, and click OK.
b. Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
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Setup and Solution
Click OK to accept the default value of 0 [units: mm/s] for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x direction.
Click OK to accept the default value of 0 [units: mm/s] for the New value of velocity-y,
and click Upper level menu, as there is no velocity in the y direction.
Enter 10 [units: mm/s] for the New value of velocity-z and click OK.
v. Define the coordinate pairs (a,b) and (c,d) for the points that define the ramp function.
vi. In a similar manner, set the values for b, c, and d to 1.0, 0.103, and 0, respectively.
Figure 3.3: Ramp Function for Mold Velocity (p. 342) shows the ramp function you just defined.
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vii. Click the EVOL button at the top of the menu to disable evolution inputs.
viii. Click Upper level menu two times to return to the Define molds menu.
A dialog box opens, asking if you want to copy the data of an existing mold.
Click No.
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c. Click Upper level menu at the top of the Domain of the mold menu.
Contact conditions
Mold motion
A dialog box opens, asking you to specify the type of mold motion.
Enter 1 as the New value, to impose a translation velocity, and click OK.
b. Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
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Click OK to accept the default value of 0 [units: mm/s] for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x direction.
Click OK to accept the default value of 0 [units: mm/s] for the New value of velocity-y,
and click Upper level menu, as there is no velocity in the y direction.
Enter -500 [units: mm/s] for the New value of velocity-z and click OK.
Enter 0.11 as the New value for time( 1) and click OK.
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Retain the default, 0 as the New value for f(time)( 1) and click OK.
vi. Click Insert new pair, and in a similar manner, define the following three pairs: (0.12, 1),
(0.13, 1), and (0.14, 0).
Figure 3.4: Multi-Ramp Function for Plug Velocity (p. 345) shows the multi-ramp function you
just defined.
Click Upper level menu three times to return the Mold motion menu.
vii. Click the EVOL button at the top of the menu to disable evolution inputs.
viii. Click Upper level menu three times to return to the F.E.M. Task 1 menu.
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Create a sub-task
c. Click Upper level menu button at the top of the Domain of the sub-task menu.
b. Select Zero wall velocity (vn=vs=0) along Boundary 3 and click Modify.
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Setup and Solution
iii. Click Upper level menu to continue specifying flow boundary conditions.
c. Select Zero wall velocity (vn=vs=0) along Boundary 4 and click Modify.
iii. Click Upper level menu to return to the Flow boundary conditions menu.
d. Click Inflation pressure imposed at the bottom of the Flow boundary conditions menu.
A dialog box opens, asking for the new value of the constant.
Enter 1e05 [units: Pa] as the New value and click OK.
f. Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
ii. Click Modify the value of a, and enter 0.14 as the New value.
iii. In a similar manner, set constants b, c, and d to 0, 0.15, and 1.0 respectively.
Figure 3.5: Ramp Function for Pressure (p. 348) shows the ramp function you just defined.
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Click the EVOL button at the top of the Polydata menu to disable evolution inputs.
Define contacts
The Modification of a contact problem menu will open with the Select a contact wall menu
item highlighted.
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Setup and Solution
i. Increase the size of the darts that will be used to display the orientation, to ensure that they are
visible.
ii. Rotate the view to an oblique angle and zoom in on the mold.
Darts will be displayed in the Graphics Display window, as shown in the following figure.
iv. Click No in the dialog box that opens, to specify that the darts are not pointing towards the
mold body.
If the direction of the darts is not clear to you, you can close the dialog box, rotate the view
and/or change the magnification, click Specify mold side / cavity side again, and then
answer the question appropriately.
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The Modification of a contact problem menu will open with the Select a contact wall menu item
highlighted.
Click Yes in the dialog box that asks if you want to activate contact release.
i. Rotate the view and change the magnification so that you can see the plug.
Darts will be displayed in the Graphics Display window, as shown in the following figure.
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Setup and Solution
iii. Click Yes in the dialog box that opens, to verify that the darts are pointing toward the plug body
(away from contact with the film).
If the direction of the darts is not clear to you, you can close the dialog box, rotate the view
and/or change the magnification, click Specify mold side / cavity side again, and then
answer the question appropriately.
iv. Click Upper level menu to return to the Define contacts menu.
e. Click OK in the warning box that opens, saying that velocity prediction must be disabled.
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Define layers
Enter blister as the New value in the dialog box that opens and click OK.
The blister menu will open with the Material data menu item highlighted.
Material Data
iv. Click Upper level menu twice to continue with material data specification.
v. Click Density.
Enter 0.001 [units: g/mm3] as the New value and click OK.
vii. Click Upper level menu to continue with the material data specification.
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Initial thickness
i. Click Constant.
Enter 0.35 [units: mm] as the New value and click OK.
ii. Click Upper level menu four times to return to the F.E.M. Task 1 menu.
Numerical parameters
The maximum number of steps must be increased due to the case containing two contacts and sharp
changes in the kinematics. This higher number was determined by running the problem with a maximum
of 200 steps and observing that more steps were required to reach the final time.
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It is recommended that you specify a convergence criterion of 0.0001 or lower when contact release is
activated.
12. Click Upper level menu three times to return to the top-level Polydata menu.
3.3.7. Outputs
Outputs
Set to metric_mm/g/s/mA+Celsius
4. Click Upper level menu three times to return to the top-level Polydata menu.
1. Click Accept.
2. Click Continue.
This accepts the default names for the graphical output files (cfx.res) that are to be saved for post-
processing, and the Polyflow format results file (res).
3.3.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
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Setup and Solution
Workbench opens the View listing file dialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
3.3.10. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
CFD-Post reads the solution fields that were saved to the results file.
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a. Click the Insert menu and select Contour or click the button.
b. In the box that opens, click OK to accept the default name (Contour 1) and display the details view
below the Outline tree.
ii. Select THICKNESS from the Variable drop-down list, or click the ellipsis button ( ) on the
right and select THICKNESS.
v. Click Apply.
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a. Double-click Default Transform in the Outline tree tab, under User Locations and Plots (or right-
click Default Transform and select Edit).
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The details view of Default Transform will be displayed below the Outline tab.
b. Perform the following steps in the Definition tab of the details view.
iii. Select Value from the Determine Angle From drop-down list in the Instance Definition group
box.
v. Enable Apply Reflection, and select ZX Plane from the Method drop-down list.
c. Rotate the view and change the magnification, as shown in Figure 3.7: Contours of Thickness on the
Whole Thermoformed Blister (p. 359).
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c. Click Apply.
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c. To save the animation, expand the dialog box by clicking the button at the lower-right.
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Setup and Solution
ii. Click the file icon to the right and enter the path where you would like to save the animation.
Enter Thickness.wmv for the name of the file and click Save to close the Save Movie
dialog box.
iv. Click the play button, to play the animation and save it as a file.
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3.4. Summary
This tutorial introduced the concept of a plug-assisted blow molding problem. The mold moved into
contact with the film, where a plug guided the film into the mold, and a constant pressure was applied
to the film. This blew the film into the mold where it assumed the shape of the mold.
You represented the film by a shell geometry under the valid assumption that the thickness of the film
was much smaller than the other two dimensions. Polyflow linearly interpolated the process vari-
ablesthickness, velocity and position. By reporting the individual time steps to CFD-Post you were
able to view the thickness of the product as a function of time.
3.5. Appendix
The appendix covers the following topics:
3.5.1. Contact Boundary Conditions
3.5.2. Remark on the Penalty Coefficient
3.5.3. Remeshing
Next to these operating attributes, some numerical parameters have to be specified. A geometrical al-
gorithm is applied for detecting the occurrence of contact, while a penalty formation is used for the
treatment of contact. A penalty coefficient makes sure that a geometrical contact is detected. It should
not be too small. A coefficient is also to be specified in the tangential direction. If the fluid sticks along
the wall, this tangential coefficient should preferably receive the same value as the penalty coefficient.
Two additional coefficients are also needed; a tolerance on penetration accuracy and an element
dilatation.
Presently, the penalty coefficient has been set to 109, while the same value has been selected for the
coefficient along the tangential direction (slipping coefficient). The tolerance on penetration and element
dilatation equal 0.05 and 0.05 mm respectively.
In classical thermoforming applications, such residual velocity will not produce any significant numerical
penetration of the fluid film/sheet through the mold in view of the short times involved (physically, the
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Appendix
thermoforming process is very fast). However, some situations may involve longer time scales such as
in the glass industry.
The question that is now raised concerns the best evaluation of the penalty coefficient. The penalty
formulation mainly establishes a balance between a force (for example, the inflation pressure, ) and
a penalty force because of contact. The penalty force is simply the product of the penalty coefficient,
, and the residual velocity of the film/sheet upon contact. The other elements of the momentum
equation can be ignored for the present consideration. Assuming a typical time scale (for example,
the simulation time), and a maximum penetration depth , a good penalty coefficient can be selected
as:
3.5.3. Remeshing
The results of this tutorial could be refined and improved with the use of adaptive meshing.
In the context of the membrane element, a Lagrangian representation is applied where all mesh nodes
are considered material points. Therefore, the only available remeshing technique is Lagrangian and is
the one that should be specified for this case.
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Chapter 4: 3D Blow Molding of a Bottle
This tutorial is divided into the following sections:
4.1. Prerequisites
4.2. Description
4.3. Setup and Solution
4.4. Summary
4.5. Further Improvements
4.6. Appendix
4.1. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. 51). Some steps in the setup procedure
will not be shown explicitly.
4.2. Description
This tutorial simulates a typical blow molding situation for a bottle. In the present case, it is assumed
that a cylindrical parison with uniform thickness distribution has been extruded. The present calculation
involves two major steps; parison pinch-off due to mold closing, and inflation. Figure 4.1: Blow Molding
Initial Configuration (p. 370) shows a sketch of the process in the initial configuration, before the pinch-
off and parison inflation.
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From a geometric point of view, the initial parison has the following dimensions:
height = 0.276 m
radius = 0.0225 m
The thickness of the fluid parison is much smaller than the other two dimensions of the bottle, which
allows for the use of the membrane (shell) element, which is suited for the analysis of 3D blow molding
simulations. It is important to remember when preparing the surface mesh, that the mesh elements on
the mold should not be the same order of magnitude as the expected final local thickness. The use of
the membrane element is presently restricted to time-dependant flows and is combined with Lagrangian
representation. That is, each mesh node is a material point.
The finite element mesh and the boundary conditions are displayed in Figure 4.2: Finite Element Mesh,
Subdomains, and Boundary Sets (p. 371). As shown, a full 3D finite element is built for both the mold
and the parison. Only a surface mesh is needed for both the mold and the parison, but the most im-
portant aspect remains the proper description of the inner mold surfaces that will shape the bottle.
viscosity = 104
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Setup and Solution
As seen in Figure 4.2: Finite Element Mesh, Subdomains, and Boundary Sets (p. 371), the mesh topology
involves three subdomains (MoldLeft, parison, and Moldright) and two boundary sets (TopEdge and
BottomEdge). The fluid parison is covered by the subdomain named parison while MoldLeft and
MoldRight will be defined as molds. Along boundary sets TopEdge and BottomEdge, a symmetry
boundary condition will be imposed. The inflation pressure will be defined on the subdomain repres-
enting the parison.
4.3.1. Preparation
To prepare for running this tutorial:
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Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
6. Click the 3D-Blow-Molding-Bottle_R180.zip link to download the input and solution files.
7. Unzip the 3D-Blow-Molding-Bottle_R180.zip file you have downloaded to your working folder.
8. Start Workbench from Start > All Programs > ANSYS 18.0 > Workbench 18.0.
2. Save the ANSYS Workbench project using File Save, entering instanet-PF-only as the name of
the project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
Time-dependent problem(s)
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Setup and Solution
2D shell geometry
Define molds
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c. Click Upper level menu at the top of the Domain of the mold menu.
Contact conditions
Mold motion
A small dialog box opens, asking you to specify the type of mold motion.
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Enter 1 as the New value, to impose a translation velocity, and click OK.
b. Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
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Click OK to accept the default value of 0 for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x direction.
Click OK to accept the default value of 0 for the New value of velocity-y, and click Upper
level menu, as there is no velocity in the y direction.
Enter 0.736842 [units: m/s] for the New value of velocity-z and click OK.
v. Define the coordinate pairs (a,b) and (c,d) for the points that define the ramp function.
vi. In a similar manner, set the values for b, c, and d to -1.0, 0.1, and 0, respectively.
Figure 4.3: Ramp Function for Right Mold Velocity (p. 377) shows the ramp function you just
defined.
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Setup and Solution
vii. Click the EVOL button at the top of the menu to disable evolution inputs.
viii. Click Upper level menu two times to return to the Define molds menu.
A dialog box opens, asking if you want to copy the data of an existing mold.
Click No.
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c. Click Upper level menu at the top of the Domain of the mold menu.
Contact conditions
Mold motion
A small dialog box opens, asking you to specify the type of mold motion.
Enter 1 as the New value, to impose a translation velocity, and click OK.
b. Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
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Click OK to accept the default value of 0 for the New value of velocity-x.
Polydata asks you to the specify the time dependence of the x-velocity. Click Upper level
menu, as there is no velocity in the x direction.
Click OK to accept the default value of 0 for the New value of velocity-y, and click Upper
level menu, as there is no velocity in the y direction.
Enter 0.736842 [units: m/s] for the New value of velocity-z and click OK.
v. Define the coordinate pairs (a,b) and (c,d) for the points that define the ramp function.
vi. In a similar manner, set the values for b, c, and d to 1.0, 0.1, and 0, respectively.
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Figure 4.4: Ramp Function for Left Mold Velocity (p. 380) shows the ramp function you just
defined.
vii. Click Upper level menu to return the Mold motion menu.
d. Click the EVOL button at the top of the menu to disable evolution inputs.
e. Click Upper level menu three times to return to the F.E.M. Task 1 menu.
Create a sub-task
A small dialog box opens, asking for the title of the problem.
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c. Click Upper level menu button at the top of the Domain of the sub-task menu.
a. Select Zero wall velocity (vn=vs=0) along BOTTOMEDGE and click Modify.
iii. Click Upper level menu to continue specifying flow boundary conditions.
b. Select Zero wall velocity (vn=vs=0) along TOPEDGE and click Modify.
iii. Click Upper level menu to return to the Flow boundary conditions menu.
c. Click Inflation pressure imposed at the bottom of the Flow boundary conditions menu.
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Darts will be displayed in the Graphics Display window, to indicate the orientation of the pressure
on the parison.
As shown in the figure that follows, the darts point into the center of the parison.
A dialog box opens, asking for the new value of the constant.
Enter -1e4 [units: Pa] as the New value and click OK.
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f. Click the EVOL button at the top of the Polydata menu to enable evolution inputs.
h. Define the settings in the Time dependence of inflation pressure menu that opens.
ii. Click Modify the value of a, enter 0.1 as the New value, and click OK.
iii. In a similar manner, set the values for b, c, and d to 0, 0.2, and 1.0, respectively.
Figure 4.5: Ramp Function for Pressure (p. 383) shows the ramp function you just defined.
j. Click the EVOL button at the top of the Polydata menu to disable evolution inputs.
Define contacts
The Modification of a contact problem menu will open with the Select a contact wall menu
item highlighted.
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i. Increase the size of the darts that will be used to display the orientation, to ensure that they are
visible.
Darts will be displayed in the Graphics Display window, as shown in the following figure.
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Setup and Solution
iv. Click No in the dialog box that opens, to specify that the darts are not pointing towards the
mold body.
If the direction of the darts is not clear to you, you can close the dialog box, rotate the view
and/or change the magnification, click Specify mold side / cavity side again, and then
answer the question appropriately.
The Modification of a contact problem menu will open with the Select a contact wall menu item
highlighted.
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i. Rotate the view slightly to display the bottle-shaped cavity from an oblique angle.
Darts will be displayed in the Graphics Display window, as shown in the following figure.
iii. Click No in the dialog box that opens, to specify that the darts are not pointing towards the
mold body.
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If the direction of the darts is not clear to you, you can close the dialog box, rotate the view
and/or change the magnification, click Specify mold side / cavity side again, and then
answer the question appropriately.
iv. Click Upper level menu to return to the Define contacts menu.
e. Click OK in the warning box that opens, to acknowledge that the velocity prediction must be disabled.
Define layers
In the dialog box that opens, enter parison as the New value.
The parison menu will open with the Material data menu item highlighted.
Material Data
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iv. Click Upper level menu twice to continue with material data specification.
v. Click Density.
Enter 900 [units: kg/m3] as the New value and click OK.
vii. Click Upper level menu to continue with the material data specification.
ix. Select Inertia will be taken into account and click Upper level menu twice to return to the
parison menu.
Initial thickness
i. Click Constant.
ii. Click Upper level menu four times to return to the F.E.M. Task 1 menu.
Numerical parameters
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Setup and Solution
9. Click Upper level menu three times to return to the top-level Polydata menu.
4.3.7. Outputs
Outputs
The Current system is shown at the top of the Change system of Units for specific outputs menu.
3. Click Upper level menu twice to return to the top-level Polydata menu.
1. Click Accept.
2. Click Continue.
This accepts the default names for the graphical output files (cfx.res) that are to be saved for post-
processing, and the Polyflow format results file (res).
4.3.9. Solution
Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Workbench opens the View listing file dialog box, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the following
printed at the bottom of the listing file:
The computation succeeded.
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4.3.10. Postprocessing
Use CFD-Post to view the results of the Polyflow simulation.
CFD-Post reads the solution fields that were saved to the results file.
2. Change the view in the Graphics Display window as shown in the figure that follows.
a. Click the Insert menu and select Contour or click the button.
b. In the dialog box that opens, click OK to accept the default name (Contour 1) and display the details
view below the Outline tree.
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Setup and Solution
v. Click Apply.
d. Disable the Wireframe in the Outline tree tab, under User Locations and Plots.
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a. Enable and double-click MOLDLEFT_surf in the Outline tree tab, under Fluid Flow Blow Molding
Polyflow at 2s.
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b. Enter 0.7 for Transparency in the Render tab in the details view of MOLDLEFT_surf.
The contours of thickness on the parison would not be visible without increasing the transparency
of the mold.
c. Click Apply.
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c. Click Apply.
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c. To save the animation, expand the dialog box by clicking the button at the lower-right.
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Setup and Solution
ii. Click the file icon to the right and enter the path where you would like to save the animation.
Enter Thickness.wmv for the name of the file and click Save to close the Save Movie
dialog box.
iv. Click the play button, to play the animation and save it as a file.
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4.4. Summary
This tutorial introduced the concept of a parison blow molding problem. The two halves of the mold
moved into contact with the parison, where it became pinched, and a vacuum was applied to the par-
ison. This blew the parison into the mold where it assumed the shape of the mold, which was a bottle
in this case.
You represented the parison by a shell geometry under the valid assumption that the thickness of the
parison was much smaller than the other two dimensions (diameter and height). Polyflow linearly inter-
polated the process variablesthickness, velocity and position. By reporting the individual time steps
to CFD-Post you were able to view the thickness of the product as a function of time.
F.E.M. Task 1
Numerical parameters
Adaptive meshing
Modify Nstep = 5
Modify Maxdiv = 1
For additional information on adaptive meshing, see adaptive meshing in the Polyflow User's Guide.
To access documentation files on the ANSYS Customer Portal, go to http://support.ansys.com/document-
ation.
The results are shown in Figure 4.11: Effect of Adaption on Final Mesh and Thickness Variation (p. 401).
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Appendix
4.6. Appendix
The appendix contains the following topics:
4.6.1. Contact Boundary Conditions
4.6.2. Remark on the Penalty Coefficient
4.6.3. Remeshing
4.6.4. Evolutions
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contact involves a "what" and a "how". The "what" describes the geometry of the parison and the mold
surface it may come in contact with (contact problem). The "how" refers to other process parameters,
such as a moving mold. In this case, a velocity (that is possibly time dependent) must be specified for
the mold. In some cases, the material may slip along the contact wall, which can also be taken into
account.
Along with these operating attributes, some numerical parameters must be specified. A geometrical
algorithm is applied for detecting the contact, while a penalty formation is used for the treatment of
the contact. A penalty coefficient ensures that a geometrical contact is detected. It should not be too
small. A coefficient is also specified in the tangential direction. If the fluid sticks along the wall, this
tangential coefficient should preferably receive the same value as the penalty coefficient. Two additional
coefficients are also needed; a tolerance on penetration accuracy and an element dilatation.
Presently, the penalty coefficient and the slipping coefficient (tangential direction) are both set to 109.
The tolerance on penetration and element dilatation are equal to 0.001 and 0.002 m respectively.
In classical blow molding applications, such residual velocity will not produce any significant numerical
penetration of the fluid parison through the mold in view of the short times involved (physically, blow
molding process is very fast). However, some situations may involve longer time scales such as in the
glass industry.
The question that is now raised concerns the best evaluation of the penalty coefficient. The penalty
formulation mainly establishes a balance between a force (for example: the inflation pressure, ) and
a penalty force because of contact. The penalty force is simply the product of the penalty coefficient,
, and the residual velocity of the parison upon contact. The other variables of the momentum equation
can be omitted for the present problem. Considering a typical time scale, (for example, the simulation
time), and a maximum penetration depth that can be practically accepted, , a good penalty coefficient
can be selected as:
4.6.3. Remeshing
In the context of the membrane element, a Lagrangian representation is applied where all mesh nodes
are considered material points. Therefore, the only available remeshing technique is Lagrangian and is
the one that should be specified for this case.
4.6.4. Evolutions
The present case involves a mold motion followed by inflation.
For the mold motion, the x and y-components are zeros. The two mold halves move only in the z dir-
ection at the same speed but in opposite directions. The two mold halves move at 0.736842 m/s in the
z direction. To control the duration and the direction of the motion, a simple ramp function is applied
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Appendix
on the mold speed. The ramp function is multiplied by the z-velocity component to give each half of
the mold the proper speed in the appropriate direction.
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