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.
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.
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.
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 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.
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.
After you have completed the C-MOLD 99.1 installation, follow these steps to start the NG Visualizer on UNIX machines:
After you have completed the C-MOLD 99.1 Installation, follow these steps to start the NG Visualizer on Windows machines:
|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.|
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.
The ANSYS to C-MOLD mesh translator executable image name changed from ansys to ans2cm in the 98.12 incremental release. This removes a possible conflict that could arise from having the same executable name used by both ANSYS and C-MOLD. If you access the mesh translator from the graphical user interface in C-MOLD Control Panel or C-MOLD Modeler, you will see no difference. Only if you run the translator from the command line or from some custom-built scripts will you need to take into account the new name.
The I-DEAS translator (executable image name tabg70) has been updated. It will now translate the mesh information from I-DEAS 6.x or Master Series Universal file format (UNV) or Input file format (INP) to C-MOLD FEM format.
Protection for a situation involved with creating tangent lines that resulted in a divide-by-zero error on DEC Alpha NT computers has been added. This fix was implemented in the 98.10 incremental release.
For the gas-assisted injection molding process, TCODEs have been added to the material and process templates for specifying coolant, mold materials, and additional processing parameters associated with the capability to run Productivity and Performance Solution simulations.
For the regular thermoplastic injection molding and gas-assisted injection molding processes, the following obsolete TCODEs have been removed from the parameter file templates:
|300||Pressure convergence criterion|
|301||Flow-rate convergence criterion|
|400||Max # of pressure iterations|
|401||Max # of flow-rate iterations|
|522||Age of mold (COOL)|
For the thermoplastic injection molding process, the Productivity Solution Integrated Filling and Cooling selection performs a Filling & Post-Filling simulation and then performs a Cooling simulation. The heat load from the Filling & Post-Filling simulation is used as a boundary condition for the Cooling simulation. Previously, only a Filling simulation was performed, and this output was interfaced to the Cooling simulation. Since the post-filling time is longer than the filling time, the effect of the heat load on the mold is greater under the new configuration, which improves the accuracy of the resulting integrated solution.
These enhancements were implemented in the 98.12 incremental release.
A problem that occurred when adding multiple materials to the thermoplastic resin database via .fit files was corrected in the 98.11 incremental release. Previously, only the most recently customer-entered flow data would be accessible. All data provided in the standard C-MOLD Database was unaffected.
C-MOLD License Manager now checks license dependencies when a C-MOLD module is launched. For example, the C-MOLD Gas-Assisted Injection Molding module requires C-MOLD Filling & Post-Filling, and the C-MOLD Microchip Encapsulation module requires C-MOLD Reactive Molding and C-MOLD Shrinkage & Warpage. The License Manager now checks that each prerequisite license is available. This enhancement was implemented in the 98.12 incremental release. Refer to the C-MOLD product descriptions on our Web site (www.cmold.com/cm_info/solutions.html) for information about product prerequisites, or contact your C-MOLD Account Manager.
A problem that prevented C-MOLD applications from connecting to the License Manager on SGI MIPS IV computers was corrected in the 98.11 incremental release. Previously, the workaround was to run the IRIX 5.2 version of C-MOLD. Note that with this problem correction, 64-bit IRIX 6.2 or higher is required to run C-MOLD on SGI MIPS IV computers.
C-MOLD's weld-line prediction has been improved to better capture weld (meld, knit) lines that occur due to melt-front hesitation during filling. This enhancement was introduced in the 98.9 incremental release.
The interface file from C-MOLD Filling & Post-Filling to C-MOLD Cooling, formerly filename.PFC, is replaced by filename.PPC. The new interface file enables C-MOLD Cooling to be integrated with C-MOLD Gas-Assisted Injection Molding to implement the new Productivity Solution and Performance Solution capabilities for the gas-assisted injection molding process. This enhancement was implemented in the 98.12 incremental release.
C-MOLD Cooling simulation now is integrated with C-MOLD Gas-Assisted Injection Molding to provide Productivity Solution and Performance Solution capabilities. Note that for a successful C-MOLD Cooling simulation of a gas-assist part, connectors cannot be used when modeling the gas channels. C-MOLD Cooling does not handle connector elements between 1D (part runner) elements and triangular elements in the part mesh.
Significant changes to C-MOLD Cooling simulation were introduced in the C-MOLD 98.7 general release. These changes were introduced to remove the limitation of cooling-channel overlap at bends and to reduce the computation time required. Although both objectives were achieved, a problem occurred that caused discrepancies in results for some cases, compared to results from previous versions of the software. The program could exit from the iterations prematurely, before the solution was converged. It was observed in some cases that the resulting mold-wall temperature was unreasonably uniform and the temperature difference was too small, both of which are due to insufficient iterations of the solution. The cause of this premature exit was identified and fixed in the C-MOLD 98.12 incremental release.
A problem that caused a core dump on Hewlett Packard computers when running the simulation with very large models has been fixed. This fix was implemented in the 98.10 incremental release.
C-MOLD Gas-Assisted Injection Molding is now able to output thermal data (filename.ppc) for use in C-MOLD Cooling, as well as read mold wall temperature data (filename.c2p) from Cooling calculations. C-MOLD Gas-Assisted Injection Molding can also calculate residual stress for use in the layer-based Shrinkage & Warpage simulation. These changes allow cooling design to be examined, as well as part shrinkage and part shape to be predicted for gas-assist parts. This allows an "apples-to-apples" comparison of gas-assist parts to injection molded parts for such important parameters as cycle time, volumetric shrinkage, part weight, linear shrinkage, and part warpage.
C-MOLD Fiber Orientation generated many non-convergence warning messages. These have been consolidated to a single warning message which indicates the labels of the non-converged elements. This fix was implemented in the 98.11 incremental release.
A problem that caused non-convergence of the fiber-orientation calculation on Hewlett Packard computers has been fixed. This fix was implemented in the 98.10 incremental release.
A problem that resulted in unreasonably large residual stress values when the temperature difference between consecutive time steps was very small has been fixed. This fix was implemented in the 98.10 incremental release.
A problem in C-MOLD Shrinkage & Warpage 98.7 that could produce inconsistent results when the temperature difference between consecutive time steps is very small was corrected in the C-MOLD 98.10 incremental release.
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.
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|
|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.
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.
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.|
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|
For all but HP computers, type ./install, and follow the on-screen instructions.
HP: type ./INSTALL.\;1
Follow these instructions to install C-MOLD on the following hardware platforms:
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)
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:
|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|
On Windows and using Exceed 5.1.1, the Control Panel analysis launching sequence can sometimes stack windows in the incorrect order, putting the informational message under a file selection dialog. If you have not saved your design prior to entering the Design Diagnostics dialog, when you try to leave the dialog you will be prompted to first save your design. However, the Design Diagnostics dialog will remain on top of the Save Design selection dialog. In order to save the design, you need to dismiss the Design Diagnostics dialog. Even though you dismiss the Design Diagnostics dialog, your selection, either Run Now, Run as Batch, or Cancel will be processed. The workaround is to save your design before entering the Design Diagnostics dialog.
For Shrinkage & Warpage results, when displaying Displacement Data, the warped outline of the part should display correctly. However, when the Use Displaced Mesh option is activated to display Data Shaded results, the direction of the displaced mesh will appear to be reversed. The Use Displaced Mesh option under Plot; Displacement Options should not be used until it has been corrected.
Copyright 1998 Advanced CAE Technology, Inc. All Rights Reserved.