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Presentation for ANSYS Seminar:
Moldex3D FEA Interface for Workbench
Presenter: Jeff Kloberdanz
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Outline
> Company introduction
> Why use Moldex3D
> Fiber orientation and anisotropy: Isotropic
and Anisotropic
> FEA Integration Analysis with Workbench
> A case study: Tensile Bar
> Step-by-Step Example
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Company introduction
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CoreTech System and Moldex3D
The worlds largest injection molding CAE company
200 employees, 80% experienced engineering professionals
80 + Research and Development
80 + front-line technical sales and support engineers
9 global offices
Local support at Northville, Michigan
1,500+ global customers, 6,000+ users
10,000+ industrial projects validation

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> Adopted by many renowned companies and industries to
prove its capabilities of bringing quality solutions:
Moldex3D Reference Customers
Automobile High Tech/Electronics Material/Equipment
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Reference Customers in Automotive Industry
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Reference Customers in IC Industry
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Our commitment Your Benefits
2003: 1
st
complete 3D CAE for plastic molding(Solid)
2005: 1
st
Parallelized 3D CAE for plastic molding
2007: propriety automatic 3D meshing (eDesign)
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Fiber orientation and anisotropy

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Why Predict Fiber Orientation?
Processing
Properties
Structure
Flow induces fiber orientation

Poor orientation causes warpage
Orientation Modeling
Micromechanical Modeling
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Flow-Induced Fiber Alignment
> Shear flows align fibers in the direction of flow
> Stretching align fibers in the direction of stretch

shear flow
fiber aligned along flow direction
shear-free flow
Fiber aligned perpendicular to flow direction
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Shell-Core Structures of Fiber Orientation
> The shell-core structure of fiber orientation in injection
molded parts
velocity Shear rate
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Orientation Verification with Experiments
> Industrial connector with fiber-reinforced polymer
> Cross-section fiber orientation
Moldex3D R7 simulation Experiment (SEM)
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Case : Throttle Valve
(DSM Engineering Plastics Korea)
Material = PET 35%GF
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Filling and Cooling Results
Melt Front Cooling Temperature
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Orientation and Melt Front
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Anisotropic Mechanical Properties
Major Modulus
Fiber Orientation
Color!
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Fiber-Induced Warpage
Total Deformation Orientation Effect
Color!
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Warpage Comparison
x20
x20
W/ Fiber Warpage W/O Fiber Warpage
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Concept Design
Production
CAE
Structure Analysis
CAE
Injection molding
Ideal case by
assuming uniform
material properties
Since it is fabricated
with injection molding,
process induced
material properties
must be addressed!

Concept Design
CAE
Structure Analysis
Concept Design
CAE
Structure Analysis
Concept Design
CAE
Structure Analysis
Concept Design Concept Design
PLM and Injection Molding Process
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Moldex3D-Workbench Integration-
Flow Chart
eDesign
Setup Runner and
Cooling in Designer
Structural mesh
Create user defined options
Static Structural
Use the structural mesh
as mapping target
Part Geometry
Workbench
Injection Molding
Analysis
FEA Interface
Structural
Analysis
Export the results as
Workbench format
Moldex3D
Extension
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Moldex3D-Workbench Integration
The Moldex3D extension toolbar and
Moldex3D button are now part of the
ANSYS Mechanical user interface.

The Moldex3D function is available from a
drop-down menu to set analysis properties.

When solution done, user can open the post
to view the result.

Moldex3D Output
Moldex3D
ANSYS
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How to Activate the Interfacing function
Open desired Moldex3D project

Click the shortcut Icon found in the Run toolbar

Or

Go through the main Toolbars.
Post->Interfacing function
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Interfacing Function Interface
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Selecting Solver - WorkBench
Click dropdown menu and select desired solver WorkBench.
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Extensions Manager
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Moldex3D Interface in WorkBench
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Example: Tensile Bar
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Tensile Bar Filling Animation
Weld Line Location
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Tensile Bar Fiber Orientation
Weld Line Location
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Tensile Bar Major Modulus
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Tensile Bar Minor Modulus
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Tensile Bar Stress
30MPa Load Applied
Yield at 80 Mpa
Yield at 80 Mpa
79 MPa
47 MPa
30 MPa Load
30 MPa Load
0-80 MPa Range displayed
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Tensile Bar Stress
40MPa Load Applied
Yield at 80 Mpa
Yield at 80 Mpa
63 MPa
105 MPa
40 MPa Load
40 MPa Load
0-105 MPa Range displayed
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Tensile Bar Stress
50MPa Load Applied
Yield at 80 Mpa
Yield at 80 Mpa
79 MPa
132 MPa
50 MPa Load
50 MPa Load
0-132 MPa Range displayed
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Tensile Bar Stress
Yield stress comparison
0-80 MPa Range displayed
Yield at 80 Mpa
Yield at 80 Mpa
79 MPa
79 MPa
50 MPa Load
30 MPa Load
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Tensile Bar Conclusions
> The isotropic model assumes uniform mechanical
properties and can lead to inaccurate predictions and in
this case leads to an over prediction in part strength.

> The isotropic model shows the onset of yield at a load of
50 Mpa while the anisotropic model shows the yielding
will start at a load of 30 Mpa.

> Distributions of the peak stresses differ greatly when
considering the molding conditions for the weld line.

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Step-by-Step Example
> Step1:
> Injection Molding Analysis with eDesign
> Generate structural mesh on workbench
> Export the Workbench mesh to FEA interface

> Step2: Export the eDesign Data for Workbench
> Use commands(APDL)
> Use the ACT extension for a Project

> Step3:
> Prepare a Workbench Project
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Step1: Injection Molding Analysis with eDesign
> Open the geometry in Moldex3D Designer, build up the
runners and cooling system, generate a 3D mesh.
> Open the mesh in Moldex3D Project, setup the process
conditions, then launch the injection molding analysis.

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Step1-2 : Generate structural mesh on workbench

Generate mesh
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Step1-3 :Export the Workbench mesh to FEA interface

1.Choose Static Structural
2.Tools Write Inputs File
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Step1-4: Export the eDesign Data for Workbench
> Run Moldex3D FEA Interface to generate ACT extension
and output data

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Step2: Export the eDesign Data for Workbench (cont)
> You can integrate in ANSYS Workbench by two ways
1) Use commands(APDL)

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Step2: Export the eDesign Data for Workbench (cont)
2) Use the ACT extension for a Project
Move the output data to current working directory.
By default, the Extension Manager contains the extensions
located in the installation repository of ANSYS:


You can place the Moldex3DtoANSYS extension folders and
files in the extensions folder of a users Applications Data
folder, C:\Documents and Settings\<USER>\Application
Data\Ansys\v140\ AdvancedAddinPackage. When
extensions are installed in a users Applications Data folder,
only the owner of that folder has access to the extensions.

%ANSYS140_DIR%\..\Addins\AdvancedAddinPackage\extensions
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Step3: Prepare a Workbench Project
1. Copy the installer zip file to WB 14
installation area (%AWP_ROOT140%)
e.g.: C:\Program Files\ANSYS
Inc\v140
2. Close all WB 14 sessions
3. Extract the zip file in the same path
If prompted about replacing any files,
click Yes
4. Start a new WB 14 session
5. Activate the Beta options in the
Project page.
6. Activate the Debug Mode for ACT
1
2
3
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Step3: Prepare a Workbench Project
> Generate the mesh and load your Moldex3D extension
Extension Manager to
Load / Unload
available extensions
ANSYS mesh for mapping the
Moldex3D results
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Step3: Prepare a Workbench Project (cont)
> Set your BC conditions
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Step3: Prepare a Workbench Project (cont)
> The context of the Moldex3D
extension and button has
been set to Mechanical.
Consequently, this extension
was loaded with the
Mechanical application.

> Click Moldex3D icon
The Moldex3D function is
available from a drop-down
menu to set the analysis
properties.


Information provided by
Moldex3D FEA Interface
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Step3: Prepare a Workbench Project (cont)
If you choose many items to output in Moldex3D FEA Interface, you will see more items
appearing in the Definition list.
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Step4: Run the Structural Analysis
Including Initial strain (warpage)
Without Initial strain