Plastics Lesson 1: SOLIDWORKS and the 3DEXPERIENCE Plastic Injection App

After teaching 1000’s of students and writing about SOLIDWORKS for over 25 years, David Planchard, emeritus WPI, is exploring SOLIDWORKS desktop and the integrated 3DEXPERIENCE Platform.  Through the 3DEXPERIENCE Works Lesson series, David helps educators understand the 3DEXPERIENCE Engineer, Plastics Injection App with simple examples and industry practices. The Platform offers are available thru your Education Partner (VAR). 

SIMULIA apps provide a full spectrum of solutions that enable you to simulate the behavior of your designs in a Multi-physics modeling environment. These apps span a scalable portfolio of finite element analysis solutions that include simulating structural, thermal, and fluid dynamics problems.

In this lesson, simulate the injection molding of a part made from a single material using the Plastic Injection App on the 3DEXPERIENCE platform.

Open the part in SOLIDWORKS. Save the part in your Collaborative space using an existing Bookmark. Return to your SOLIDWORKS desktop. Lock the part. Apply the Plastic Injection App. Create the FE Model or FEM.

Assign the appropriate domains to the geometries that contribute to the molding simulation. Note: A domain must be assigned to all geometries that contribute to the simulation.

Apply Polycarbonate material. The material you select must have the Injection molding behavior specified in their simulation domains.

Define the process settings. Modify the Fill Rate Profile and Pack Switch point.

Define the injection point on the back of the model. Mesh the Switch Plate.

Run the Simulation study. Use the Physics Results Explorer App. Note: The Simulation should take approximately 6 – 7 minutes using 4 CPU cores.

View the created simulations: Fill, Pack + Cool and Warp. Analyze various simulation contour plots. Create an animation of the Warp Simulation – Total Displacement contour plot. Save the study. Close the study.

Before we start, there are a few items that you need to know.

In this lesson, use your default Collaborative space. A 3DEXPERIENCE ID is required.

The Simulation lesson provides a foundation to users who are new to using simulation to solve real-world engineering and design problems. Before you use the Plastic Injection App, you must define all required parts. For example, you must have a model of the part cavity defined as a single solid part. If you plan to simulate the temperature distribution in the mold, you must also define any mold cooling lines as solid parts. You can use the Functional Plastic or Mold Tooling Design Apps to create these parts.

The Switch Plate part has been updated from the SOLIDWORKS Plastics tutorials to use with the 3DEXPERIENCE platform.

Launch the Platform and SOLIDWORKS

3DEXPERIENCE Launcher needs to be installed. 3DEXPERIENCE Works Lesson 1: Getting Started with SOLIDWORKS.

The 3DEXPERIENCE platform is browser driven. Your existing cookies and cache determine what you will see on your computer desktop or during a SOLIDWORKS login. A full installation of SOLIDWORKS 2019 SP0 or later is required.

Start a SOLIDWORKS session from your desktop.

Double-click the SOLIDWORKS icon.

View the illustration below. Depending on your system setup, cookies, and cache, it will be different. Read the provided information.

Input the requested data.

Click Accept All.

The Welcome – SOLIDWORKS dialog box is displayed.

You are logged into the 3DEXPERIENCE platform.

Close the Welcome dialog box.

Click the 3DEXPERIENCE icon in the Task Pane. The MySession panel is displayed. This displays the two-way communication between SOLIDWORKS running on your desktop and the 3DEXPERIENCE platform running in the cloud.

In this lesson, I’m using a Collaborative space named Quick Start xDesign.

Note: If you do not see the 3DEXPERIENCE icon, click the Options drop-down arrow, click Add-Ins, check the 3DEXPERIENCE box, click OK, from the SOLIDWORKS Main menu.

Click Accept All if needed.

Download SOLIDWORKS Switch Plate part and Save to Cloud

Switch Plate

Open the Switch Plate part that has not been previously uploaded or saved to the 3DEXPERIENCE platform. Do not run Feature recognition. The Switch Plate is displayed in a back view. View the position of the Injection point.

Expand the Task Pane bar. The MySession panel displays the Components Name, Status (Displays an icon that represents the status of a given revision, save or not saved to the platform), Locked status (Locked or Unlocked), Rev (Revision #), Is Last Revision (Yes/No), Maturity State (Lifecycle state of the family, for example: Private, In Work, Frozen, Released, Obsolete), Description, File Name (Displays the PLM external ID of the object for reference objects and the PLM external ID of the connection for instances) and Type (Physical Product or Drawing).

The orange save Status icon for the Switch Plate part informs you that the local file on your computer have not been saved to the platform. Save the part to the 3DEXPERIENCE platform.

Click Save Active Window from the Lifecycle tab in the Action bar. Note: You can also right-click Switch Plate in MySession, and click Save with Options.

The file is temporarily being saved to a local cache area. The platform is checking for out-of-date components, modified components from the last save to the platform, different revisions, missing components, etc.

The Save to 3DEXPERIENCE dialog box is displayed. Product lifecycle management (PLM) attributes are displayed. The PLM attributes include: Bookmark locations, Selected Collaborative space, Owner, Title, Saved Status (3DEXPERIENCE), Revision, Maturity Lifecycle State and Collaborative Space name.

Save the part. Use your existing Collaborative space. Use an existing Bookmark. Note: If needed review 3DEXPERIENCE Works Lesson 3: SOLIDWORKS Bookmarks, Share and Delete. Use Bookmarks (links) to delete entire groups of data or just a single file. For assemblies within the Bookmark folder, there is an option to delete the entire structure of the assembly and all reference components.

Click the Select Bookmark down arrow.

Click Select Bookmark. The Select a Bookmark dialog box is displayed.

In the below example, I selected Design Project 104 as my bookmark.

Click Apply from the Select a Bookmark dialog box.

Click Save from the Save to 3DEXPERIENCE dialog box.

The part is directly loaded into your Collaborative space and Bookmarked on the 3DEXPERIENCE platform. You are returned back into your SOLIDWORKS desktop session.

View the Status column in the updated MySession panel. The Status icon displays a green check mark. This means that the current file on your SOLIDWORKS desktop is updated and saved to the platform. The default Revision is A. The Maturity State is “In Work”. This is the default Lifecycle state after you saved the model to the 3DEXPERIENCE platform.

Lock the part in the MySession panel. This prevents anyone in making a change to the part.

Right-click the part name.

Click Lock. The part is locked.

 

Select the Switch Plate from the MySession panel.

Click the center of the Compass. Use the Plastic Injection App. Think of this App as the SOLIDWORKS Flow Simulation Add-in inside of SOLIDWORKS. Most of the 3DEXPERIENCE Apps run in your web browser. 3DEXPERIENCE Simulation Apps perform a small installation on your windows machine. Both types of Apps are linked to your PLM data on the platform.

Launch the Plastics Injection App

Drag the slider downward to view the Plastic Injection App.

Launch the Plastic Injection App. If this is your first time using a 3DEXPERIENCE Simulation App, or an update is available, download the needed App information on your computer. It is recommend to restart your SOLIDWORKS session.

This can take 10 – 15 seconds.

The 3DEXPERIENCE | SIMULIA Plastic Injection App is displayed.

Display the Simulation study tree.

Right-click in the Graphics area. View the Pop-up menu.

Click Display. View the drop-down menu.

Click Tree Display from the drop-down menu as illustrated.

View the default Simulation study tree.

The Simulation study tree displays the simulation process: Model, Scenario, and Result.

Save the Simulation study.

Click the Share icon as illustrated.

Click Save.

Display the Assistant and Define Parts

The Assistant is a useful tool if you are a beginner or experienced in simulation. The Assistant helps the user understand what conditions are required for the study. Note: The Assistant is available in most SIMULIA native Apps. It is similar to other panels in native Apps; you can move, resize, and dock.

Right-click in the Graphics area. View the Pop-up menu.

Click Assistant.

The Assistant dialog box is displayed. View the options.

Assign the appropriate domains to the geometries that contribute to the simulation.

A domain characterized the type of component (Physical Product) of an injection molding machine that is included in a simulation. A domain must be assigned to all geometries that contribute to the simulation. The domains include:

• Plastic, which represents a mold cavity
• Part (Physical Product) insert
• Hot runner
• Cold runner.
• Coolant.
• Model insert

Click Parts from the Assistant dialog box.

Click Contributing Parts from the Commands box. Note: You can also click Contributing Parts from the Setup tab in the Action bar.

The Contributing Parts dialog box is displayed.

Assign the Plastic domain to the Switch Plate.

Right-click Switch Plate A as illustrated. View your options.

Click Plastic from the drop-down menu. The plastic part represents the mold cavity to be filled with plastic.

Click OK from the Contributing Parts dialog box.

View the study tree.

Apply Materials

Add material to the Switch Plate. Apply Polycarbonate. The material you select must have the Injection molding behavior specified in their simulation domains.

Click Materials from the Assistant dialog box.

Click Material Palette from the Commands box. Note: You can also select Material Palette from the Setup tab in the Action bar.

Enter PC in the Filter search box. Expand the Plastics (PC) folder.

Select Generic material / Generic PC | A.1. View the Simulation material properties.

Click the Simulation tab.

Return to the Core Material box.

Drag and drop Generic material / Generic PC | A.1 on the Switch Plate as illustrated.

Click the Application on Switch Plate Part icon from the Pop-up menu.

Click Close from the Pop-up menu.

Close the Material Palette dialog box.

Material is apply to the Switch Plate. View the study tree,

Save the Simulation study.

Click the Share icon as illustrated.

Click Save.

Define the Process Settings

The process setting dialog box provides the ability to control settings of the plastic injection analysis.

Simulate the main plastic injection molding steps: Filling the mold cavity with a plastic material, packing a plastic material inside the cavity, and cooling the mold.

Click Process Settings from the Assistant dialog box.

Click Process Settings from the Commands box. Note: You can also select Process Settings from the Setup tab in the Action bar.

The Process Settings dialog box is displayed. View the default Shared settings and options. Accept the default Shared settings.

Expand the Plastic flow simulations column as illustrated.

View the options.

Address the injection fill rate. Fill rate profiles define the filling rate as a function of time or as a percentage of filled cavity volume.

Click the Edit profile icon. The Fill Rate Profile dialog box is displayed.

Enter 1 in the second row under Time.

Click OK from the Fill Rate Profile dialog box.

Define the percentage of filled cavity volume at which the packing stage begins. To avoid abrupt pressure increases, it is common to begin packing just before the cavity becomes 100% full.

Enter 94% in the Pack switch point box.

Expand the Summary column as illustrated. View the provided information.

Click OK from the Process Settings dialog box.

Injection Location

Define the injection point on the back of the model.

The injection unit of an injection molding machine injects molten polymer under high pressure into a mold’s cavity.

Display a back view of the Switch Plate.

Click the center of the injection circle. The Pop-up menu is displayed.

Click the Injection Location icon. The Injection Location dialog box is displayed.

Accept the default values. Note: Support Type face specifies an entire surface as the injection. Point on face specifies the center of a circular area as the injection location. Point on face is selected by default.

Click OK from the Injection Location dialog box.

A cone-shaped glyph indicates the injection location.

Define Mesh

View the default Local Mesh size. The Local Mesh Size dialog box enables you to customize the mesh density for critical regions of the mesh and to project locations in the mesh where you need to add extra nodes or lines of nodes.

Click Local Mesh Size from the Mesh tab in the Action bar.

The Local Mesh Size dialog box provides the ability to choose the faces for which you want to specify a local mesh density.

Boundary layers are thin mesh cells created at the inner and outer surfaces of the part. For high accuracy, specify two or more boundary layers.

Accept the default settings.

Click Cancel from the Local Mesh Size dialog box. Note: There are always tradeoffs in creating a mesh (capability, time, and accuracy). Currently, the Educational version has a maximum allowable node count of 1million nodes with up to 4 physical cores are supported.

Display a Front view of the Switch Plate in the Graphics area.

Click front from the View tab in the Action bar.

Mesh the Switch Plate.

Click Create Mesh from the Mesh tab in the Action bar.

The Switch Plate is meshed.

View the Plastic Mesh Part Manager.

Click Mesh Part Manager from the Mesh tab in the Action bar.

The Plastic Mesh Part Manager dialog box is displayed. View the default Size.

View the number of Elements and Nodes. There are always tradeoffs in creating a mesh (capability, time, and accuracy). Currently, the Educational version has a maximum allowable node count of 1million nodes with up to 4 physical cores are supported.

View the Quality Analysis of the Surface Triangle Mesh.1.

Right-click Surface Triangle Mesh.1.

Click Quality Analysis from the drop-down menu.

The Quality Report dialog box is displayed.

Explore the Quality, Connectivity, and Failed Criteria tabs.

Return back to the Plastic Mesh Part Manager dialog box.

Close the Quality Report dialog box.

 Close the Plastic Mesh Part Manager dialog box.

Simulate Fill, Pack + Cool and Warp

Run the simulation.

Click Simulate from the Assistant dialog box.

Click Simulate from the Commands box. Note: You can also select Simulate from the Results tab in the Action bar.

The Simulate dialog box is displayed.

Run the Simulation using Local interactive. Local interactive is set by default using an embedded license. The Simulation is excuted on your computer and the user interface is locked while the Simulation is in process.

With an Educational license, up to 4 physical cores are supported. Select All is the default option. Note: The Simulation should take approximately 6 – 7 minutes using 4 CPU cores.

Click OK from the Simulate dialog box.

The Simulation Status dialog is display.

When finished, click Close.

View the created simulations: Fill, Pack + Cool and Warp.

Close the second Simulation Status box.

View Results

View the results in the Graphics area. The default contour plot is Fill time. The Fill time plot displays the time when the plastic flow front reaches each point in the model. The portion of the Switch Plate that is filled with plastic last is the furthest from the injection location.

View the Result folder.

Generate contour plots for the Pack Simulation.

Review the pressure at the end of the Pack analysis case.

Select Pack + Cool Simulation from the Step drop-down menu as illustrated.

Select Pressure at end of Pack from the Plot drop-down menu.

View the results. During the pack stage, the injection molding machine applies additional pressure to the molten plastic to add more polymer material into the filled cavity. The additional pressure compensates for part shrinkage and reduces the occurrence of external sink marks.

Review the temperature at the end of Pack analysis case.

Select Temperature at end of Pack from the Plot drop-down menu.

Click a point on the model as illustrated. The mouse cursor automatically acts as a probe. View the temperature at that point. A Pop-up menu is displayed.

Click the Show Min/Max Values icon from the Pop-up menu. View the results.

View the Global Max temperature at end of Plot (injection point).

Click the Hide Max or Min values and close icon from the Pop-up menu.

Generate a contour plot for the Warp Simulation.

Select Warp Simulation from the Step drop-down menu.

Select Displacement, total from the Plot drop-down menu.

The largest displacement due to warp occurs at the corners of the plate. Warp occurs because of the stresses that develop during the Fill and Pack stages of the injection molding process, as well as the stresses that develop as the material contracts during cooling.

Edit the deformation scale of the displacement plot to view the deformed shape of the Switch Plate in true scale.

Click a point on the Switch Plate. A Pop-up menu is displayed.

Click the Plot options icon from the Pop-up menu.

The Contour Plot dialog box is displayed.

Enter 1 for Scale factor.

Click OK from the Contour Plot dialog box.

Display an Isometric view of the Switch Plate.

Animate Displacement

Create an animation of the current contour plot (Warp Simulation – Displacement, total).

Click the Play Animation icon from the Results tab in the Action bar.

View the animation.

Click the Stop and Rewind icon.

Save the animation.

Click the Options icon.

The Animation Options dialog box is displayed.

Click the Save video icon.

Click the Open to choose browser location icon.

Select file location and name.

Click Save from the Animation Options dialog box.

Close the Animation Options dialog box.

Close the Player.

Click Exit from the Player tab in the Action bar.

Save and Close

Save the Simulation study (Model, Scenario, and Result).

Click the Share icon as illustrated.

Click Save.

Close the Simulation study.

Click Close on the Physics Simulation tab.

The lesson is finished.

 

Community

Academic Community: After you create a 3DEXPERIENCE ID, Educators, can get more information on xDesign and SOLIDWORKS.  Request to join the 3DEXPERIENCE Academic Community for free at go.3ds.com/academiccommunity.

Student Community: Students, join the student community for free at go.3ds.com/studentcommunity.  Check out great posts on Mechanism Mondays, FEA Fridays,  Solid Saturdays (animations),  Formula Student and Formula SAE exercises.

SIMULIA Community: Students and Educations, join the SIMULIA community to learn the latest in simulation technology with the Abaqus solver, CST Studio Suite for Electro-magnetics, Antenna Magus and more.

SOLIDWORKS Community: Connect with the SOLIDWORKS community with our SOLIDWORKS User Forum, SOLIDWORKS User Groups, news and info,

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Analysis Lesson 5: SOLIDWORKS and 3DEXPERIENCE Simulation Structural Model Creation

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CFD Lesson 2: SOLIDWORKS and 3DEXPERIENCE Fluid Scenario Creation (Part 2)

CFD Lesson 3: SOLIDWORKS and 3DEXPERIENCE Fluid Scenario Creator (Part 3)

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From SOLIDWORKS Desktop to the 3DXPERIENCE Platform

Additional Lessons in this series on 3DEXPERIENCE Works:

3DEXPERIENCE Works Lesson 1: Getting Started with SOLIDWORKS and the Platform

3DEXPERIENCE Works Lesson 2: SOLIDWORKS and Save and Revision

3DEXPERIENCE Works Lesson 3: SOLIDWORKS and Bookmarks, Share and Delete

3DEXPERIENCE Works Lesson 4: SOLIDWORKS and Lifecycle Maturity States

3DEXPERIENCE Works Lesson 5: SOLIDWORKS, Collaborative Space and Bookmarks

3DEXPERIENCE Works Lesson 6: SOLIDWORKS with Search Tools

3DEXPERIENCE Works Lesson 7: SOLIDWORKS with 3DPlay

3DEXPERIENCE Works Lesson 8: SOLIDWORKS with 3DDrive

3DEXPERIENCE Works Lesson 9: SOLIDWORKS and 3DSWYM

3DEXPERIENCEWorks Lesson 10: SOLIDWORKS and 3DEXPERIENCE Simulation

 

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SOLIDWORKS xDesign Lesson #2: Mouse Control and Collaborative Space

SOLIDWORKS xDesign Lesson #3: Sketch Planes

SOLIDWORKS xDesign Lesson #4: Create A Dashboard

SOLIDWORKS xDesign Lesson #5: Views and Orientations

SOLIDWORKS xDesign Lesson #6: Importing Files and Using Bookmarks

SOLIDWORKS xDesign Lesson #7: Assemblies

SOLIDWORKS xDesign Lesson #8: 4Bar Linkage and Kinematics

SOLIDWORKS xDesign Lesson #9: External References and Copy with Mates

SOLIDWORKS xDesign Lesson #10: Sketching, Constraints and Dimensions

SOLIDWORKS xDesign Lesson #11: Sketch Based and Applied Features

Design well.  Marie