ANSYS POLYFLOW 14.0: Product Update · PDF file•ANSYS POLYFLOW 14.0 delivers significant...

© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

ANSYS POLYFLOW

14.0: Product

Update

© 2010 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary

Consolidated tools

for CAD, Geometry,

Meshing,

Post-processing

Integration in ANSYS Workbench

• Flexible workflows

• Connect to mechanical, other simulation tools

• Parameter management, system-wide updates

ANSYS Fluid Dynamics 14.0

CFX-Pre CFX-Solver

FLUENT

Setup/Solve/Post

DesignModeler

ANSYS

Meshing

Platform

CFD-Post

ANSYS Workbench

ANSYS

CAD

Plug-in

CAD

System

Geometry Meshing Post-

Processing

Setup SolveCAD

PolyDataPOLYFLOW

Solver


ANSYS POLYFLOW 14.0

• ANSYS POLYFLOW at Release 14.0 delivers critical features and functionalities to enable large gains in user productivity.

– Direct Workbench Link to ANSYS Mechanical and ANSYS Explicit

– “CutCell” mesh support for extrusion

– Contact release for blow molding and thermoforming

– Solver Improvements for speed, memory and efficiency

– Usability enhancements in the ANSYS Workbench

– Materials database and standard templates

– …and many more!

Contact release in thermoforming of a

medical blister


Direct Connection with ANSYS

Mechanical and Explicit

• Thickness data from ANSYS POLYFLOW can be sent to ANSYS Mechanical and ANSYS Explicit via an automatic connection.

• Complete Virtual Prototyping and Testing capability in ANSYS Workbench for packaging manufacturing:

– Simulate blow molding or thermforming process to get final thickness distribution.

– Perform stress and deformation analysis with the variable thickness map. (top load, crush test etc.)

• Benefit: Design Exploration and Optimization of manufacturing process parameters on actual product performance.


CutCell Meshing for Complex

Extrusion Dies

• ANSYS POLYFLOW 14.0 can import and run Cutcell meshes for complex extrusion dies.

• CutCell Meshing: New mesh generation method in TGrid and ANSYS WB.

– Fast and efficient algorithm for rapid hex dominant mesh generation on highly complex geometry, e.g. extrusion dies.

• Benefit: rapid analysis of flow imbalance in complex extrusion dies.

– Sliceable meshes can be created for deforming free jet region.


Sliceable Mesh in Free Jet Region

from CutCell Meshes

• A “Sliceable” mesh can be created for the free jet sub-domain from a CutCell mesh, to allow computation of final extrudate shape.

• Creates conformal prismatic mesh in the free jet subdomainwith CutCell mesh in the die.

– Controls for free jet length and mesh size distribution.

• Take full advantage of rapid hex dominant CutCell meshing for complex die geometries.

Initial CutCell mesh

Sliceable free jet mesh

Final extrudate shape


Mold Motion with Force for Shell

Parisons

• A force can be specified for mold motion with shell meshes for parisons in blow molding and thermoforming.

• Specify maximum displacement of the mold to set a bounding criterion for the motion.


Parametrization of Multi-Ramp

Functions

• It is now possible to parametrize multi-ramp functions with User Parameter Defined Templates (UPDT).

• Choose abscissa and/or ordinate of the multi-ramp function for one or more points.

• Benefit: Internal optimization and design exploration for:

– Initial Thickness distribution on shells and parisons.

– Transient profiles for boundary conditions

– Variables with evolution parameters

– Initial variation of volume fraction, temperature and other variables.


Automatic Contact Release

• A new contact release method has been implemented for blow molding and thermoforming:

– Parison “peeling” from mold for blow molding

– Plug release in thermoforming

• Contact release is compatible with both specified force and specified velocity for the mold.

Thermoforming of a medical blister:

Contact release of plug from sheet

showing velocity, area stretch and

thickness changes


Solver Enhancements: Modified

Pressure Delay Strategy

• A modified pressure delay strategy has been introduced to the standard AMF (Algebraic Multi-Frontal) solver.

– ~ 2-3 x faster and ½ the memory than the standard AMF solver.

– Available via a keyword in the .p3rc file.

• Benefit: faster computation with lower memory on large meshes.

Mesh Size

Rati

o o

f C

PU

tim

eSolver Memory Memory Ratio

Modified AMF11.403 0.64

Standard AMF17.84 1.00

GMF34 1.91

Memory Usage for largest case (1.03 M)


Solver Enhancements: Numerical

Decoupling of Species and VOF

• ANSYS POLYFLOW will now allow numerical decoupling of species and VOF volume/fill fractions from the flow calculation.

– Reduce memory requirements and improve solution speed by segregating the volume fraction field.

• This is very useful for applications like multi-fluid coextrusion and glass forming.

Fill fraction of the primary fluid in multi-fluid

coextrusion: Flow through a complex die

modeled with VOF method


New Boundary Condition: “Incoming

Fluid Temperature” for Non-isothermal

Backflow

• New “incoming fluid temperature” thermal boundary condition allows realistic computation of thermal fluxes with reverse flow at inlets and outlets.

• Benefit: Accurate and robust computation of non-isothermal backflow in twin screw extrusion with adverse counter-pressure.

Temperature imposed Incoming fluid temperature

Barrel Temperature, Counterpressure = 3.0 bars


ANSYS Workbench Enhancements:

Named Boundaries and Subdomains

• Polydata will support named boundaries and

subdomains, using Named Selections in

ANSYS Workbench.


ANSYS Workbench Enhancements:

“pmesh” Support

• ANSYS POLYFLOW will support 1-D and 2-D pmeshes generated in ANSYS Meshing and ANSYS ICEM CFD.

• Named Selections can be created on edges or faces to create pmeshes in ANSYS Meshing.

– 1-D pmeshes for 2-D meshes

– 1-D and 2-D pmeshes for 3-D

• Polydata will automatically read the pmeshes.

• Assign special boundary conditions for radiation, porous media and electric boosting.


Usability Enhancements:

Standardized Materials Library

• POLYFLOW includes a standardized materials data library.

– Material_Data folder in the POLYFLOW 14.0 installation.

• Predefined rheological models for commonly used polymer materials (HDPE, LDPE, PVC etc.) at particular temperatures for specific applications.

• Simply read in the material file in POLYDATA and convert the units to those used for the problem.


Usability Enhancements: Standard

Workbench Templates for Common

Applications

• Database of ANSYS Workbench ProjectsTemplates for ANSYS POLYFLOW use for common applications.

– Templates folder in the POLYFLOW 14.0 installation.

• Each project contains a complete calculation (Geometry to Post-processing) with parameters and a final report.

– Blow-molding, extrusion, thermoforming examples in ANSYS WB archived (.wbpz) format.

• The template projects can be used for learning purposes or as starting points for individual projects.


Usability Enhancements: GUI

Improvements for ANSYS POLYFLOW

Utilities

• The ANSYS POLYFLOW utilities have new

graphics options for geometry manipulation,

plotting and data entry.


Other Enhancements

• POLYFLOW documentation migration to the ANSYS Help System.

• It is now possible to get the ideal (point wise) thickness distribution when optimizing shell parisons in blowmolding/thermoforming.

• CFD-Post will now show fields on pmeshes.

• Force fields on boundaries now have units in CFD-Post.

• Mesh conversion issues and error messages in ANSYS WB have been fixed.


Summary and Conclusion

• ANSYS POLYFLOW 14.0 delivers significant functionalities in critical areas:

– CutCell meshing for rapid analysis of complex extrusion dies

– Automatic Contact release and other enhancements for Blow Molding and Thermoforming

– Direct connection with ANSYS Mechanical and Explicit for transferring thickness data

– Faster and efficient solver computation for large cases, including species and VOF

– Named Selections and pmesh support in ANSYS Workbench

– Standard materials library

– Enhanced usability


Thank you!

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