Anda di halaman 1dari 34

Chapter 1: 3D Thermoforming of a Blister

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. ?). Some steps in the setup procedure
will not be shown explicitly.

1.2. Problem Description


This tutorial simulates a typical thermoforming situation for a blister. Figure 1.1: Thermoforming of a
Blister, Sheet (blue) and Mold (red) (p. 1) shows a view of the process in the initial configuration.

Figure 1.1: Thermoforming of a Blister, Sheet (blue) and Mold (red)

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 1
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. 1).
From a geometric point of view, the initial (1/4) film has the following dimensions:

Length = 15 mm

Width = 5 mm

Initial thickness = 0.35 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.

The finite element mesh and the boundary conditions are displayed in Figure 1.2: Finite Element Mesh,
Subdomains and Boundary Sets (p. 3). 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.

The film has the following material properties:

Viscosity = 105

Density = 10-3 g/mm3

Initial thickness = 0.35 mm

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
2 of ANSYS, Inc. and its subsidiaries and affiliates.
Problem Description

Figure 1.2: Finite Element Mesh, Subdomains and Boundary Sets

As seen in Figure 1.2: Finite Element Mesh, Subdomains and Boundary Sets (p. 3), the topology involves
two subdomains:

Subdomain 1 = film

Subdomain 2 = mold

and four boundary sets:

Boundary 1: will be fixed (clamped boundary)

Boundary 2: will be fixed (clamped boundary)

Boundary 3: symmetry boundary condition with respect to the x-axis

Boundary 4: symmetry boundary condition with respect to the y-axis

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.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 3
3D Thermoforming of a Blister

Often, both types of contact are encountered in a given application.

1.3. Preparation
To prepare for running this tutorial:

1. Prepare a working folder for your simulation.

2. Go to the ANSYS Customer Portal, https://support.ansys.com/training.

Note

If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.

3. Enter the name of this tutorial into the search bar.

4. Narrow the results by using the filter on the left side of the page.

a. Click ANSYS Polyflow under Product.

b. Click 15.0 under Version.

5. Select this tutorial from the list.

6. Click Files to download the input and solution files.

7. Unzip the 3D-Thermo-Blister_R150.zip file you have downloaded to your working folder.

The mesh file blister.msh can be found in the unzipped folder.

8. Start Workbench from Start All Programs ANSYS 15.0 Workbench 15.0.

1.4. Step 1: Project and Mesh


1. Create a Fluid Flow - Blow Molding (Polyflow) analysis system by drag and drop in Workbench.

2. Save the ANSYS Workbench project using File Save, entering blister as the name of the project.

3. Import the mesh file (blister.msh).

4. Double-click the Setup cell to start Polydata.

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.

1.5. Step 2: Models


In this step, define the task representing the mold.

1. Create a task for the model.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
4 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 2: Models

Create a new task

a. Select the following options:

F.E.M. task

Time-dependent problem(s)

2D shell geometry

b. Click Accept the current setup.

2. Define the molds.

Define molds

a. Create the new mold.

Create a new mold

Click Adiabatic mold.

A panel opens, asking for the title of the mold.

b. Click OK to accept the default name, Mold 1.

The Domain of the mold menu item is highlighted.

3. Define the domain where the mold applies.

Domain of the mold

a. Select Subdomain 1 and click Remove.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 5
3D Thermoforming of a Blister

b. Click Upper level menu at the top of the Domain of the mold menu.

4. Define the contact boundary conditions.

Contact conditions

a. Select No contact along Subdomain 2 and click Modify.

b. Select Contact and click Upper level menu twice.

5. Define the motion of the mold.

Mold motion

a. Click Mold motion type : fixed mold

A small panel opens, asking you to specify the type of mold motion.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
6 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 2: Models

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.

c. Set the mold translation velocity.

Modify translation velocity

Polydata prompts for velocity-x.

i. Specify the x-velocity.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 7
3D Thermoforming of a Blister

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.

ii. Specify the y-velocity.

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.

iii. Specify the z-velocity.

Enter 10 mm/s for the New value of velocity-z and click OK.

iv. Specify the time dependence of the z-velocity.

Select f(t) = Ramp function.

v. Define the coordinate pairs (a,b) and (c,d) for the points that define the ramp function.

Click Modify the value of a.

Enter 0.097 as the New value and click OK.

vi. In a similar manner, set the values for b, c, and d to 1.0, 0.103, and 0, respectively.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
8 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 3: Definition of a Sub-task

Figure 1.3: Ramp Function for Mold Velocity

Figure 1.3: Ramp Function for Mold Velocity (p. 9) shows the ramp function you just defined.

Click Upper level menu to return to 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.

The Create a sub-task menu item is highlighted.

1.6. Step 3: Definition of a Sub-task


In this step, define the nature of the flow problem, identify the domain of definition, set the relevant material
properties for the fluid, and define boundary conditions along its boundaries.

1. Create a sub-task for the fluid.

Create a sub-task

a. Select Shell model : Gen. Newtonian isothermal.

A small panel opens, asking for the title of the problem.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 9
3D Thermoforming of a Blister

b. Enter Blister as the New value and click OK.

The Domain of the sub-task menu item is highlighted.

2. Define the domain where the sub-task applies.

Domain of the sub-task

a. Select Subdomain 2 and click Remove.

b. Click Upper level menu button at the top of the Domain of the sub-task menu.

The Flow boundary conditions menu item is highlighted.

3. Specify the flow boundary conditions.

Flow boundary conditions

a. Retain the default settings for Boundary 1 and Boundary 2.

b. Select Zero wall velocity (vn=vs=0) along Boundary 3 and click Modify.

i. Click Plane of symmetry ( fs=0, vn=0 ).

ii. Select normal direction along X axis.

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.

i. Click Plane of symmetry ( fs=0, vn=0 ).

ii. Select normal direction along Y axis.

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.

e. Click Constant for the inflation pressure.

A panel opens, asking for the new value of the constant.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
10 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 3: Definition of a Sub-task

Enter 100000 as the New value and click OK.

f. Click the EVOL button at the top of the Polydata menu to enable evolution inputs.

g. Click Upper level menu.

Polydata directs you to the Time dependence of inflation pressure menu.

i. Select f(t) = Ramp function.

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

Figure 1.4: Ramp Function for Pressure (p. 11) shows the ramp function you just defined.

h. Click Upper level menu.

Click the EVOL button at the top of the Polydata menu to disable evolution inputs.

i. Click Upper level menu to return to the Blister menu.

4. Define the contacts of the blister.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 11
3D Thermoforming of a Blister

Define contacts

a. Click Create a new contact problem.

The Modification of a contact problem menu will open with the Select a contact wall menu
item highlighted.

b. Define the contact wall.

i. Click Select a contact wall.

ii. Select Mold 1 : Contact along Subdomain 2 and click Select.

c. Specify the coefficients and accuracy.

i. Click Modify the slipping coefficient.

Enter 1e+10 as the New value and click OK.

ii. Click Modify the penalty coefficient.

Enter 1e+10 as the New value and click OK.

iii. Click Modify the penetration accuracy.

Enter 0.05 as the New value and click OK.

d. Define the orientation of the mold.

i. Magnify the view of the mold to ensure that you can see the darts that will be displayed.

Alternatively, you can increase the size of the darts:

Graphical window Sizing Darts Size up.

ii. Click Specify mold side / cavity side.

Darts will be displayed in the Graphics Display window, as shown in the following figure.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
12 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 3: Definition of a Sub-task

iii. Click No in the panel 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 panel, rotate the view and/or
change the magnification, click Specify mold side / cavity side again, and then answer
the question appropriately.

e. Click Upper level menu twice.

A warning panel opens, saying that velocity prediction must be disabled, and that the modification
has automatically been done.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 13
3D Thermoforming of a Blister

Click OK.

The Define layers menu item is highlighted.

5. Define the layers of the blister.

Define layers

a. Click Create a new layer.

In the panel that opens, enter blister as the New value.

The blister menu will open with the Material data menu item highlighted.

b. Specify the material data for the blister.

Material Data

i. Click Shear-rate dependence of viscosity.

ii. Click Constant viscosity.

iii. Click Modify fac.

Enter 100000 as the New value and click OK.

iv. Click Upper level menu twice to continue with material data specification.

v. Click Density.

vi. Click Modification of density.

Enter 0.001 as the New value and click OK.

vii. Click Upper level menu to continue with the material data specification.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
14 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 4: Create Sub-tasks for Postprocessing

viii. Click Inertia terms.

Select Inertia will be taken into account and click Upper level menu to continue with
material data specification.

ix. Click Layer permeability.

x. Click Modify coef. of permeability.

Enter 5e-12 g-mm/s/mm2 as the New value and click OK.

xi. Click Upper level menu twice to return to the blister menu.

c. Specify the initial thickness.

Initial thickness

i. Click Constant.

Enter 0.35 as the New value and click OK.

ii. Click Upper level menu four times to return to the F.E.M. Task 1 menu.

1.7. Step 4: Create Sub-tasks for Postprocessing


In this step you will create a number of sub-tasks that will report various statistics about the blown product.
The results for derived quantities that produce a single value are displayed in the listing file. Sub-tasks that
produce a field of values are exported to CFD-Post.

1. Set a task to report the mass of the blown product.

Create a sub-task

Click No in the panel 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 panel that asks for the title of the sub-
task and click OK.

b. Click Mass of blown product.

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.

d. Click Add a new plane.

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)

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 15
3D Thermoforming of a Blister

Polydata asks for the values of Coefficients A, B, C, and D sequentially.

e. Enter 0 for A, 0 for B, -1 for C, and 25.9 for D.

f. Click Upper level menu.

g. Click Upper level menu to ignore contact with Subdomain 2.

2. Set a task to report the permeability of the blown product.

Create a sub-task

Click No in the panel 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 panel that asks for the title
of the sub-task and click OK.

b. Click Permeability of blown product.

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.

d. Click Add a new plane.

Polydata asks for the values of Coefficients A, B, C, and D sequentially.

See Equation 1.1 (p. 15) for more information on the coefficients.

e. Enter 0 for A, 0 for B, -1 for C, and 25.9 for D.

f. Click Upper level menu.

g. Click Upper level menu to ignore contact with Subdomain 2.

3. Set a task to report the volume of the blown product.

Create a sub-task

Click No in the panel 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 panel that asks for the title of the sub-
task and click OK.

b. Click Capacity of blown product.

Click OK in the dialog box that opens saying that the calculation will be performed on Subdo-
main 1.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
16 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 6: Outputs

c. Click Add a new plane.

Polydata asks for the values of Coefficients A, B, C, and D sequentially.

See Equation 1.1 (p. 15) for more information on the coefficients.

d. Enter 0 for A, 0 for B, -1 for C, and 25.9 for D.

e. Click Upper level menu.

f. Click Upper level menu to ignore contact with Subdomain 2 and return to F.E.M. Task 1.

1.8. Step 5: Specify the Numerical Parameters

Numerical parameters

1. Click Modify the transient iterative parameters.

2. Click Modify the initial time value.

Click OK to retain the default value of 0.0 s as the New value.

3. Click Modify the upper time limit.

Enter 0.6 s as the New value and click OK.

4. Click Modify the initial value of the time-step.

Enter 0.001 s as the New value and click OK.

5. Click Modify the min value of the time-step.

Enter 0.0001 s as the New value and click OK.

6. Click Modify the max value of the time-step.

Enter 0.01 s as the New value and click OK.

7. Click Modify the tolerance.

Click OK to retain the default of 0.01 as the New value.

8. Click Modify the max number of successful steps.

Click OK to retain the default of 200 as the New value.

9. Click Upper level menu three times to return to the top-level Polydata menu.

1.9. Step 6: Outputs

Outputs

1. Set the system of units to output to CFD-Post.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 17
3D Thermoforming of a Blister

Set units for CFD-Post, Ansys Mapper or Iges

a. Modify the current system of units.

Modify system of Units

b. Specify the new system of units.

Set to metric_mm/g/s/mA+Celsius

2. Click Upper level menu two times to return to the Outputs menu.

a. Set the output triggering.

Output Triggering

b. Specify the type of output triggering.

Output after N valid steps

The Enter the number of steps menu item is highlighted.

c. Specify the number of steps.

Enter the number of steps

Click OK to retain the default of 1 for the New value.

3. Click Upper level menu twice to return to the top-level Polydata menu.

1.10. Step 7: Save the Data and Exit Polydata

Save and exit

After defining your model in Polydata, save the data file. In the next step, you will have to read this data file
into Polyflow and calculate a 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 the Polyflow format results file (res).

1.11. Step 8: 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.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
18 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 8: Solution

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).

2. Check for convergence in the listing file.

a. Right-click the Solution cell and select Listing Viewer....

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. Scroll up to view the results of the postprocessing sub-tasks.

Scroll up in the listing file to view the results of the Postprocessors.

Here you can see the results of the postprocessor sub-tasks you created in Polydata. For additional in-
formation on postprocessing sub-tasks, see Step 4: Create Sub-tasks for Postprocessing (p. 15) and
Overview of Derived Quantities in the Polyflow User's Guide.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 19
3D Thermoforming of a Blister

1.12. Step 9: Postprocessing


Use CFD-Post to view the results of the Polyflow simulation.

1. Double-click the Results cell in the Workbench analysis system.

CFD-Post reads the solution fields that were saved to the results file.

2. Align the view as shown in the following figure.

3. Display contours of thickness in the fluid region (Subdomain1).

a. Insert 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 of Contour 1 below the Outline tree.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
20 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 9: Postprocessing

c. Specify the following settings in the Geometry tab:

i. Select Subdomain_1_surf from the Locations drop-down list.

ii. Select THICKNESS from the Variable drop-down list, or click the ellipsis button ( ) on the
right and select THICKNESS.

iii. Select User Specified from the Range drop-down list.

iv. Enter 0.1 mm for Min and 0.35 mm for Max.

v. Click Apply.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 21
3D Thermoforming of a Blister

Figure 1.5: Contours of Thickness 1/4 Geometry

4. Show the contours of thickness on the full mold.

a. Double-click Default Transform in the Outline tree tab, under User Locations and Plots (or right-
click Default Transform and select Edit).

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
22 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 9: Postprocessing

b. Disable Instancing Info From Domain under the Definition tab in the details of Default Transform.

c. Enter 2 for the Number of Graphical Instances.

d. Select Value from the Determine Angle From drop-down list in the Instance Definition group
box.

e. Enter 180 for Angle.

f. Enable Apply Reflection, and select ZX Plane from the Method drop-down list.

g. Retain the default value of 0.0 m for Y.

h. Click Apply and revise the magnification of the view to show the whole mold.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 23
3D Thermoforming of a Blister

Figure 1.6: Contours of Thickness on the Whole Mold

5. Display contours of thickness at various time steps.

Polydata exported a total of 73 time steps to CFD-Post.

a. Click the Timestep Selector icon ( ).

b. Scroll up in the Timestep Selector dialog box and select Step 1.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
24 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 9: Postprocessing

c. Click Apply.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 25
3D Thermoforming of a Blister

Figure 1.7: Thickness of the Film at Time=0.001 s

d. Repeat steps a.c. for timesteps 30, 50, and 73.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
26 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 9: Postprocessing

Figure 1.8: Contours of Thickness at Time = 0.2338 s

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 27
3D Thermoforming of a Blister

Figure 1.9: Contours of Thickness at Time = 0.4239 s

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
28 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 9: Postprocessing

Figure 1.10: Contours of Thickness at Time = 0.6000 s

6. Create an animation for the contour plot.

a. Click the animation icon ( ).

b. Ensure Quick Animation is selected in the Animation dialog box.

c. Select Timesteps.

d. To save the animation, expand the dialog box by clicking the button at the lower-right.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 29
3D Thermoforming of a Blister

i. Enable Save Movie.

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.

wmv and mpg are the recommended formats.

iii. Disable to save only one cycle of animations.

iv. Click the play button, to play the animation and save it as a file.

1.13. 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-

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
30 of ANSYS, Inc. and its subsidiaries and affiliates.
Further Improvements

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.

1.14. Further Improvements


In many practical cases, the use of adaptive meshing based on contact, remeshing, or both may be
useful to selectively and automatically refine the mesh during the solution. To illustrate the effects of
such refinement, this tutorial has been run with contact adaptive meshing enabled and made available
as blister-adapt.wbpj in the 3D-Thermo-Blister_R150\solution_files folder you un-
zipped in Preparation (p. 4). The following settings were specified:

F.E.M. Task 1

Numerical parameters

Adaptive meshing

Activate adaptive meshing for contacts

Enable all the local criteria

Switch to calculated from angle and curvature

Modify size_min = .1

Modify tolerance = .01

Modify size_max = 1

Modify dist_crit = .5

Modify Nstep = 4

Modify Maxdiv = 1, 2, and 3 (in separate analysis systems)

For additional information on adaptive meshing, see Adaptive Meshing.

The results are shown in Figure 1.11: Effect of Adaption on Final Mesh and Thickness Variation (p. 32).
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.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 31
3D Thermoforming of a Blister

Figure 1.11: Effect of Adaption on Final Mesh and Thickness Variation

1.15. Appendix
The appendix contains the following topics:
1.15.1. Contact Boundary Conditions
1.15.2. Remark on the Penalty Coefficient
1.15.3. Remeshing

1.15.1. Contact Boundary Conditions


As seen, the subdomain that describes the fluid will eventually come in contact with the mold. Besides
its usual material parameters, it also receives some process parameters: inflation pressure and the contact

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
32 of ANSYS, Inc. and its subsidiaries and affiliates.
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.

1.15.2. Remark on the Penalty Coefficient


The large value of the penalty coefficient can never guarantee an exactly vanishing normal velocity at
the contact. Instead, a residual normal velocity will remain even after mold contact. The amplitude of
this residual velocity will depend on the penalty coefficient. In most cases, the residual velocity is as
low as 10-310-6.

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:

1.15.3. 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.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 33
Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
34 of ANSYS, Inc. and its subsidiaries and affiliates.

Anda mungkin juga menyukai