C-MOLD 99.1 Release Notes

The 99.1 release of C-MOLD is a general release to all customers with current Support & Update agreements. These notes describe what is new since the 98.7 general release in May 1998.

Contents


Highlights in this Release

 

Mesh Express:
from Solid Model to Shrinkage & Warpage in Record Time

We are entering a new phase in technology for midplane, finite-element mesh (FEM) model creation, and its best example is Mesh Express. As the name implies, itís one of the fastest ways to create a mesh available on the market today. There is now a quick connection between solid modeling, 3D QuickFill, and Advanced Solutions. The knowledge and information you can attain from every project is boundless.

Completely Automatic
In minutes, Mesh Express can automatically transform a solid model in stereolithography (STL) format, into a complete, accurate, midplane FEM that can be used in all C-MOLD simulations from Filling through Shrinkage & Warpage.

Very Fast
Previously, due to the complexity of transforming a solid model into a midplane FEM, it was not feasible to run simulations on many part or mold design projects. Now, with modeling times cut from days to minutes, how can you afford not to run simulations on every project?

Supplies Connectivity with Solid Modeling and 3D QuickFill
3D QuickFill is an invaluable addition to the C-MOLD family. Itís perfect for intelligent gate placement, material selection, process optimization, and many more production-related issues. With the addition of Mesh Express, it is now possible to use the same STL model for 3D QuickFill and to continue your evaluation into part performance.

Evaluation Version Available
Visit us on the Web (www.cmold.com) for some positive user comments on Mesh Express. But, decide on your own. An evaluation version of Pre-Release Mesh Express is available on this 99.1 Release CD. For activation of the evaluation version and further instructions, please contact your C-MOLD Account Manager and mention Mesh Express.

To take advantage of the attractive introductory offer, you should act now.

Figure 1. (Click to zoom in.) Mesh Express provides the fastest connection between solid modeling, 3D QuickFill, and C-MOLD Advanced Solutions. The solid model of this fascia was created in SolidWorks®98, exported as STL format to Mesh Express, which automatically converted it into a midplane FEM that was used to complete a Shrinkage & Warpage simulation.

 

C-MOLD Introduces New Gas-Assisted Injection Molding
Productivity and Performance Solutions

C-MOLD again sets the pace in new technology development for the global plastics industry by introducing unprecedented simulation capabilities for gas-assisted injection molding. New in C-MOLD 99.1 are the Gas-Assisted Injection Molding Productivity Solution and Performance Solution.

The Gas-Assisted Injection Molding Productivity Solution gives users the ability to simulate the influence of cooling on cavity filling and gas penetration. This is vital to accurately predicting gas penetration, as well as to detecting potential problems such as gas blowout due to "hot spots" in the mold where shear heating of the polymer melt or insufficient cooling may occur.

The Gas-Assisted Injection Molding Performance Solution simulates mold filling and post-filling, including gas penetration, mold cooling, residual stress, and predicts part shrinkage and warpage. The simulation can also incorporate the influence of fibers in fiber-filled resins and external service loads to predict how well the part performs in use. Not only can you optimize the manufacturability of gas-assist products, but you can now address quality issues relating to the part size, shape, and function.

Figure 2. (Click to zoom in.) This washing machine agitator auger has thick sections at the base of the spiral fin, which cause non-uniform shrinkage leading to part warpage for the injection-molded case (shown at left). Using gas-assist molding (shown at right), the thick sections are cored out by gas, which reduces the shrinkage and drastically improves final part shape.

C-MOLD 99.1 Gas-Assisted Injection Molding Performance Solution now allows for an "apples-to-apples" comparison of final part shape between injection-molded parts and gas-assist molded parts. Other important parameters to compare include cycle time, volumetric shrinkage, part weight, and linear shrinkage.

 

Next Generation Visualizer is Breaking New Ground

As we build up the functionality of our Next Generation Interactives, we will continue to distribute them to all C-MOLD Customers in General and Incremental Releases. The current advancements to our Next Generation Visualizer are available with this release for UNIX and PC platforms. The original Interactive GUIs are still the default on all platforms, but you can access the NG Visualizer by following the instructions below. Please refer to Important Details about Future C-MOLD OS and Platform Support for details about future GUI support on UNIX platforms.

We hope that you will use the NG Visualizer and provide us your comments and suggestions. We are looking for your feedback to help improve the product and make it the best C-MOLD Visualizer to date. All questions and feedback can be directed to your C-MOLD Support Engineer. Here are just a few of the enhancements offered in this release:

Native PC (only for PC)
Since C-MOLD became available on PC platforms, there has been a reliance on some form of emulator to display UNIX-based graphics in a PC-type environment. The emulator most commonly used by C-MOLD is Hummingbird's eXceed. With the NG Visualizer in this 99.1 release, we have broken new ground. This Visualizer is native PC, meaning that it does not require an X-emulator.

Animation (Unix and PC)
The power of animation to visualize results is unmatched. It is now possible to animate almost any result with just the touch of a button. You have full control of forward and backward animation, as well as step-by-step action.

Direct-Printing Capability (only for PC)
There are now extensive print preview and print setup options which allow direct printing from the NG Visualizer. The option to print to a file is still available.

...many more features
If you have not had a chance to try the latest Visualizer, you should be pleasantly surprised with how intuitive it is to use. There are several other features beyond those showcased here which should make your results interpretation much easier. Check it out for yourself.

How to Start the Program

On UNIX Machines

After you have completed the C-MOLD 99.1 installation, follow these steps to start the NG Visualizer on UNIX machines:

  1. Start the C-MOLD 99.1 License Manager.
  2. In a UNIX window, set all the environment variables that you normally set to start C-MOLD.
  3. In that same UNIX Window, change to the cmold991/bin directory (default: /usr/local/cmold991/bin).
  4. Type: cviz97 <enter>

On Windows NT 4.0 and Windows 95 Machines

After you have completed the C-MOLD 99.1 Installation, follow these steps to start the NG Visualizer on Windows machines:

  1. Start the C-MOLD 99.1 License Manager.
  2. From the START Bar, choose C-MOLD Environment from the C-MOLD99.1 icon group.
  3. In the DOS window which opens, change to the cmold991\bin directory (default: c:\Program Files\cmold991\bin).
  4. Type: cviz97win <enter>

Figure 3. (Click to zoom in.) The Next Generation Visualizer can easily animate results to give you more information than ever before for making intelligent decisions.

 

C-MOLD Resin Database Continues Steady Growth...
Now Approaching 5,000 Materials Tested

The C-MOLD Resin Database continues to provide unsurpassed material data in regard to the quality of the data, as well as the quantity of materials available. Fast-cooling pvT testing for semi-crystalline materials was introduced near the time of the C-MOLD 98.7 general release, and the market response since then has been extremely impressive. The C-MOLD Polymer Laboratory has been diligently performing fast-cooling pvT testing for resin suppliers and general customers alike. To date, there have been over 100 resins tested using the new fast-cooling methods, and over 40 are now available in the C-MOLD 99.1 Database, which helps bring the grand total to 4,947 resins available in this release.

Now, starting with the C-MOLD 99.1 General Release, tested fast-cooling pvT data for non-confidential resins is available in the Process Estimator. The resins tested for fast-cooling pvT are designated with (fc_pvt) after the Commercial Name (for example, DELRIN 107 BK601 CLA (fc pvT)). With each subsequent C-MOLD release, data for additional non-confidential materials will be added. Never before has data of this potential level of accuracy been readily available to those who perform plastics CAE simulations.

To see the list of data added to the C-MOLD Resin Database since C-MOLD 98.7, refer to the appendix.


Enhancements & Corrections by Module

Modeler

Enhancements

Corrections

Control Panel

Enhancements

Process Estimator

Corrections

License Manager

Enhancements

Corrections

Filling & Post-filling

Enhancements

Cooling

Enhancements

Corrections

Gas-Assisted Injection Molding

Enhancements

Fiber Orientation

Corrections

Residual Stress

Corrections

Shrinkage & Warpage

Corrections


Administrative Information

Keyfiles

As long as your Support & Update agreement is current and you are updating from a 96.7 or higher version, your existing keyfile will enable this release. If you are updating directly to the 99.1 release from a version of C-MOLD earlier than 96.7, you will need a new keyfile. If using your existing keyfile with the 99.1 release results in an Inconsistent encryption code error, contact your local C-MOLD office to obtain your new keyfile.

You can check your C-MOLD license key for the recorded Support & Update expiration date. Find the line with the key for C-MOLD that looks like this:

2eac 4f4a 8ah6 8d74 23d6 28gf d373 6k93 cmold NO EXPIRY 12/01/96 15users

The date in mm/dd/yy format is your Support & Update expiration date. To run version 99.1, this date must be after 09/30/98. If you have a question about your Support & Update agreement, please call your C-MOLD Account Manager.

Supported Platforms

The current release supports the hardware platform and operating system configurations given in the table below. We routinely review this list as part of our semi-annual software update schedule and will periodically make adjustments to reflect available and popular platforms.

Hardware Platform Minimum C-MOLD OS Level
DEC Alpha AXP Digital UNIX 4.0
DEC Alpha AXP NT Windows NT 4.0
HP 9000 HP-UX 10.20
IBM AIX 4.2
Intel-based PC 486, Pentium or Pentium Pro Windows 95
Intel-based PC Pentium or Pentium Pro Windows NT 4.0
SGI (MIPS I) IRIX 5.3
SGI (MIPS IV) IRIX 6.2
Sun SPARC Solaris 2.5 (SunOS 5.5)

Note that since the 98.11 incremental release, C-MOLD for IBM computers is built with compilers and libraries included with the AIX 4.1.5 release. Previously, C-MOLD was built with AIX 3.2.5 compilers and libraries. If you are running an earlier version of AIX, you will need to upgrade your operating system level. Our stated operating system requirement for C-MOLD remains at AIX 4.2.

Installation Procedure

This release uses an interactive procedure that guides you through the installation process. Most users will be able to install C-MOLD without system administrator assistance in less than ten minutes. You may need superuser privileges in order to mount the CD or install C-MOLD to a restricted directory. If you run into problems installing the new release, consult your system administrator.

Refer to the C-MOLD System Administrator Guide for setting up special configurations and/or troubleshooting system problems. A hard copy is included with this C-MOLD 99.1 general release, and it is available on-line in HTML format from the documentation screens. Type cmdoc once C-MOLD is installed to access the on-line documentation set.

For UNIX Machines

Follow these instructions to install C-MOLD on the following hardware platforms:

SGI users should install the MIPS IV version only on a machine with an R8000 or higher CPU that is capable of executing MIPS IV instructions in 64-bit mode.

1 Insert the CD-ROM into the computer.
2 For all but SGI computers, type mkdir cdrom_dir, where cdrom_dir is the directory to which you'd like to mount the CD-ROM drive.
3

DEC: type mount -t cdfs -o noversion device cdrom_dir, where device is the device name for your particular hardware configuration.

HP: type /etc/mount -rt cdfs /dev/dsk/#s0 cdrom_dir, where # is a digit reliant on your hardware configuration.

IBM: type mount -v cdrfs -r /dev/cd0 cdrom_dir

SGI: The mount is done automatically by the media daemon to /CDROM or /cdrom. Substitute the appropriate name (/CDROM or /cdrom) for cdrom_dir in the subsequent instructions.

Sun: type mount -F hsfs -r /dev/sr0 cdrom_dir

4 Type cd cdrom_dir
5

For all but HP computers, type ./install, and follow the on-screen instructions.

HP: type ./INSTALL.\;1

For Windows NT 4.0 and Windows 95 Machines

Follow these instructions to install C-MOLD on the following hardware platforms:

1

Intel CPU: locate cd_rom_drive_letter:\cmoldxxx\winintel\ on the distribution CD.

DEC Alpha AXP CPU: locate cd_rom_drive_letter:\cmoldxxx\winalpha\ on the distribution CD.

(where xxx corresponds to the particular release you are installing)

2 Run setup.exe.

Important Details about Future C-MOLD OS and Platform Support

As C-MOLD migrates from developing the software on UNIX platforms towards developing the software on PC platforms, there will be some significant changes that will affect many C-MOLD users currently using UNIX systems. The exact changes are detailed below.

In this C-MOLD 99.1 general release, all previously supported platforms for Interactives and Solvers will be supported. In subsequent incremental releases, any modifications to the new Interactive GUI's (cviz97 and future GUI developments) will be available only for PC platforms until the C-MOLD 99.7 general release. By the release of C-MOLD 99.7, we will phase the new interactive GUI modifications into the supported UNIX platforms: HP, SGI, and SUN. The new interactive GUI's will become the default from C-MOLD 99.7 onward, and the current interactive GUI's will be supported only until October 1999. With the C-MOLD general release in November 1999, one year from now, the current default interactive GUI's of C-MOLD 99.1 will no longer be supported on any platform.

Due to the below-average demand (<10% of C-MOLD users) for IBM and DEC UNIX (Compaq) platforms, we have decided to cease support and development of the Interactive GUI's for these platforms after October 1999. At that time, users of these platforms will be advised to switch to one of the supported platforms for the C-MOLD general release in November 1999.

The solvers will continue to be supported on all platforms.

Starting with the C-MOLD 99.7 general release, the following operating systems and graphics-handling capabilities will be required:

Future C-MOLD OS and Platform Support
Platforms Supported for C-MOLD 99.1 Minimum OS Level Required for C-MOLD 99.7 Interactives Supported for November 1999 Release Solvers Supported for November 1999 Release Graphics Required for Release 99.7
DEC Alpha AXP Digital UNIX 4.0 Not Supported Supported N/A
DEC Alpha AXP NT Windows NT 4.0 Supported Supported N/A
HP 9000 HP-UX 10.20 Supported Supported fX2 Visualize or higher OpenGL Graphics
IBM AIX 4.2 Not Supported Supported N/A
Intel-based PC 486, Pentium or Pentium Pro Windows 95 Supported Supported N/A
Intel-based PC Pentium or Pentium Pro Windows NT 4.0 Supported Supported N/A
SGI (R5000 and higher) IRIX 6.2 Supported Supported N/A
Sun SPARC Solaris 2.6 Supported Supported Ultra Creator 3D Graphics


Known Problems in this Release

Control Panel

Visualizer


Copyright 1998 Advanced CAE Technology, Inc. All Rights Reserved.