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Chapter 7
C-MOLD Shrinkage & Warpage User's Guide
Shrinkage & Warpage Example Log File
Following is an example of a C-MOLD Integrated Shrinkage & Warpage Analysis execution log file. The log would be displayed on the screen, if you select Run Now, or contained in filename.owl, if you select Run as Batch.
- End of preparing the interface data.
- --------------------------------------------------------
- C-MOLD Cooling is successfully completed.
- --------------------------------------------------------
- real 3102.8
- user 2988.0
- sys 20.8
- --------------------------------------------------------
- C-MOLD Filling
- C-MOLD Post-filling
- C-MOLD Fiber Orientation
- C-MOLD Residual Stress
- (c)1987-1995 by Advanced CAE Technology, Inc.
- --------------------------------------------------------
- Date : MAY11-95
- Time : 18:42:26
- --------------------------------------------------------
- Beginning of memory allocation for analysis ....
- End of memory allocation for analysis.
- --------------------------------------------------------
- Beginning of reading the input data ....
- File name : bottom
- Reading parameters ....
- Performing fiber orientation analysis ....
- Reading material data ....
- ** WARNING ** Fiber properties is not specified and fiber orientation analysis is turned off.
- Reading process conditions ....
- Reading finite-element mesh ....
- ** WARNING ** Parting plane is not specified; the default parting plane normal along the z-axis of the global coordinates will be used in the analysis.
- Reading C-MOLD Cooling data ....
- Reading re-start data ....
- ** WARNING ** Analysis is continuing without .RSP file ....
- End of reading the input data.
- --------------------------------------------------------
- Beginning of re-numbering elements and nodes ....
- End of re-numbering elements and nodes.
- --------------------------------------------------------
-
- Beginning of checking input data ....
- ** WARNING ** Polymer mechanical prop., wrong order of magnitude.
- The approximate order of Elongational Modulus (E) is 10^9 Pa and that of Poisson's ratio (MU) for isotropic materials is 0.3 - 0.5.
- End of checking input data.
- --------------------------------------------------------
- Beginning of optimizing memory usage ....
- End of optimizing memory usage.
- --------------------------------------------------------
- Beginning of calculating element orientation ....
- End of calculating element orientation.
- --------------------------------------------------------
- Beginning of initializing variables ....
- End of initializing variables.
- --------------------------------------------------------
- The analysis will be based on :
- (1) Parameters :
- ----------
- # of layers across full-gap (12) = 12
- # design outputs in filling (12) = 12
- # detail outputs in filling (0) = 4
- # design outputs in post-filling (12) = 12
- # detail outputs in post-filling (0) = 4
- Pressure convergence criterion (0.5) = 5.0000E-01 %
- Flow-rate convergence criterion (0.5) = 5.0000E-01 %
- Melt-temp convergence criterion (0.2) = 2.0000E-01 K(d)
- Mold-melt heat transfer coefficient (2.5E+04) = 2.5000E+04 W/m^2-K
- Max # of pressure iterations (8) = 32
- Max # of flow-rate iterations (125) = 125
- Max # of melt-temp iterations (100) = 100
- Pressure work option (0) = 1
- Residual stress analysis (W) (1) = 1
- Option for structural package (W) (0) = 1
- Isolate mechanism for warpage? (W) (1) = 1
- # of modes for stress analysis (W) (3) = 3
- C-MOLD v3.0 format (1) = 1
- --------------------------------------------------------
- (2) Material :
- --------
- Polymer 1 : PC/GE PLASTICS/LEXAN 940
- ---------
- 2-domain mod Tait polymer density
- 1
- RHO = -----------------------
- Vo*(1-C*ln(1+p/B)) + Vt
- where C = 0.0894
- Tt = b5 + b6*p
- Vo = b1 + b2*Tbar
- B = b3 * EXP(-b4*Tbar)
- Vt = 0.0 or b7*EXP(b8*Tbar-b9*p)
- Tbar = T - b5
- b5 = 4.1715E+02 K
- b6 = 4.4800E-07 K/Pa
- Liquid phase Solid phase
- ------------ ------------
- b1 = 8.4746E-04 b1 = 8.4746E-04 m^3/kg
- b2 = 5.6600E-07 b2 = 1.8900E-07 m^3/kg-K
- b3 = 1.6808E+08 b3 = 2.9688E+08 Pa
- b4 = 3.6775E-03 b4 = 1.6527E-03 1/K
- b7 = 0.0000E+00 m^3/kg
- b8 = 0.0000E+00 1/K
- b9 = 0.0000E+00 1/Pa
-
- Constant polymer specific heat
- Cp = 2.2000E+03 J/kg-K
-
- Constant polymer thermal conductivity
- K = 2.4000E-01 W/m-K
-
- Cross-WLF polymer viscosity
- ETAo
- ETA = ---------------------------
- 1 + (ETAo*GAMMA/TAUS)^(1-n)
- A1*(T-TS)
- where ETAo = D1*EXP (-----------)
- A2+(T-TS)
- TS = D2 + D3*p
- A2 = A2T + D3*p
- n = 1.3132E-01
- TAUS = 7.4844E+05 Pa
- D1 = 1.7800E+12 Pa-s
- D2 = 4.1715E+02 K
- D3 = 0.0000E+00 K/Pa
- A1 = 2.9398E+01
- A2T = 5.1600E+01 K
-
- Transition temperature
- Ttrans = 4.1715E+02 K
-
- Isotropic elastic tensor
- E = 2.3500E+09 Pa
- v = 4.1900E-01
-
- Isotropic thermal expansion coef.
- a1 = 7.0000E-05 1/K
- --------------------------------------------------------
- (3) Process conditions : Description of TCODE ....
- ------------------
- Machine parameters :
- ------------------
- Max machine clamp force (4.905E+07) = 1.0784E+06 N
- Max machine injection volume (0.02) = 2.0000E-02 m^3
- Max machine injection pressure (1.800E+08) = 1.8637E+08Pa
- Max machine injection rate (6.667E-03) = 2.2890E-04 m^3/s
- Machine hydraulic response time (0.2) = 2.0000E-01 s
- Process parameters :
- ------------------
- Fill time = 2.0000E+00 s
- Post-fill time = 2.3000E+01 s
- F/P switch over by % volume = 9.9000E+01 %
- Timer for hold pressure = 5.0000E+00 s
-
- Ram speed profile (rel):
- % stroke % speed
- -------- --------
- 0.0000E+00 5.9610E+01
- 1.0430E-01 5.9270E+01
- 4.0000E+01 9.8260E+01
- 6.0000E+01 9.5910E+01
- 8.0000E+01 1.0000E+02
- 1.0000E+02 4.2250E+01
-
- Pack/hold pressure profile (abs):
- % time % max pres
- ------ ----------
- 0.0000E+00 5.0000E+01
- 1.0000E+02 5.0000E+01
-
- Ambient temperature = 2.9800E+02 K
- Inlet melt temperature = 5.7315E+02 K
-
- Coolant manifold control:
- ID Temperature Flow rate Pres drop CID
- -- ----------- --------- --------- ---
- 1 3.6815E+02 K 6.3083E-05 m^3/sec 0.0000E+00 Pa 1
- 2 3.6815E+02 K 6.3083E-05 m^3/sec 0.0000E+00 Pa 1
- 3 3.6815E+02 K 6.3083E-05 m^3/sec 0.0000E+00 Pa 1
-
- Average coolant temperature = 3.6815E+02 K
-
- Hot runner manifold control:
- ID Temperature Insulation thickness
- -- ----------- --------------------
- 1 5.7315E+02 K 7.9248E-03 m
- 2 5.7315E+02 K 7.9248E-03 m
-
- C-MOLD Cooling mold wall temp data was used.
- --------------------------------------------------------
- (4) Finite-element mesh : .FEM file for model: bottom
- -------------------
- Total number of nodes = 1170
- Total number of polymer entrance nodes = 1
- Polymer entrance nodal numbers are: 1026
- Total number of elements = 2085
- Total number of part elements = 1942
- Total number of sprue/runner/gate elements = 11
- Total number of channel elements = 132
- Total number of connector elements = 0
- Parting plane normal (dx) = 0.0000E+00
- (dy) = 0.0000E+00
- (dz) = 1.0000E+00
- Average aspect ratio of 2D elements = 1.2204E+00
- Maximum aspect ratio of 2D elements = 5.3628E+00
- 2D element number w/ max. aspect ratio = 1551
- Minimum aspect ratio of 2D element = 1.0001E+00
- 2D element number w/ min. aspect ratio = 1891
- Total volume = 1.0279E-04 m^3
- Total volume filled initially = 5.0901E-05 m^3
- Total volume to be filled = 5.1885E-05 m^3
- Part volume to be filled = 5.1825E-05 m^3
- Sprue/runner/gate volume to be filled = 6.0243E-08 m^3
- Total projected area = 9.4097E-03 m^2
- --------------------------------------------------------
-
-
- C-MOLD Filling
- C-MOLD Post-filling
- C-MOLD Residual Stress analysis is beginning ....
-
- At time = 1.7051E-01 s, 6.3548E+00 % of volume filled,
- entrance pressure = 1.1343E+07 Pa,
- total clamp force = 2.4180E+02 N,
- filling under ram speed control.
-
- At time = 3.3543E-01 s, 1.3242E+01 % of volume filled,
- entrance pressure = 1.2871E+07 Pa,
- total clamp force = 4.8029E+02 N,
- filling under ram speed control.
-
- At time = 5.0385E-01 s, 2.1063E+01 % of volume filled,
- entrance pressure = 1.4210E+07 Pa,
- total clamp force = 9.8898E+02 N,
- filling under ram speed control.
-
- At time = 6.7282E-01 s, 2.9748E+01 % of volume filled,
- entrance pressure = 1.6181E+07 Pa,
- total clamp force = 2.9011E+03 N,
- filling under ram speed control.
-
- At time = 8.3554E-01 s, 3.8968E+01 % of volume filled,
- entrance pressure = 1.8556E+07 Pa,
- total clamp force = 7.4729E+03 N,
- filling under ram speed control.
-
- At time = 1.0002E+00 s, 4.8827E+01 % of volume filled,
- entrance pressure = 2.0345E+07 Pa,
- total clamp force = 1.3435E+04 N,
- filling under ram speed control.
-
-
- At time = 1.1680E+00 s, 5.8742E+01 % of volume filled,
- entrance pressure = 2.2127E+07 Pa,
- total clamp force = 2.1205E+04 N,
- filling under ram speed control.
-
- At time = 1.3334E+00 s, 6.8522E+01 % of volume filled,
- entrance pressure = 2.4220E+07 Pa,
- total clamp force = 3.0627E+04 N,
- filling under ram speed control.
-
- At time = 1.5026E+00 s, 7.8726E+01 % of volume filled,
- entrance pressure = 2.6542E+07 Pa,
- total clamp force = 4.2738E+04 N,
- filling under ram speed control.
-
- At time = 1.6706E+00 s, 8.7964E+01 % of volume filled,
- entrance pressure = 2.5917E+07 Pa,
- total clamp force = 5.4744E+04 N,
- filling under ram speed control.
-
- At time = 1.8348E+00 s, 9.4484E+01 % of volume filled,
- entrance pressure = 3.1214E+07 Pa,
- total clamp force = 1.2282E+05 N,
- filling under ram speed control.
-
- At time = 1.9772E+00 s, 9.9004E+01 % of volume filled,
- F/P switch over by volume.
-
- At time = 2.0009E+00 s, 9.9621E+01 % of volume filled,
- entrance pressure = 3.9088E+07 Pa,
- total clamp force = 1.7614E+05 N,
- filling under pack/hold pressure control.
-
- At time = 2.0151E+00 s, cavity is completely filled,
- entrance pressure = 4.3465E+07 Pa,
- total clamp force = 1.9617E+05 N,
-
- At time = 2.0153E+00 s, 0.0000E+00 % of post-filling time,
- entrance pressure = 4.3526E+07 Pa,
- total clamp force = 1.9702E+05 N,
- At time = 2.2197E+00 s, 8.8870E-01 % of post-filling time,
- entrance pressure = 9.3186E+07 Pa,
- total clamp force = 6.7756E+05 N,
-
- At time = 3.9245E+00 s, 8.3009E+00 % of post-filling time,
- entrance pressure = 9.3186E+07 Pa,
- total clamp force = 7.2177E+05 N,
-
- At time = 5.9245E+00 s, 1.6997E+01 % of post-filling time,
- entrance pressure = 9.3186E+07 Pa,
- total clamp force = 7.1255E+05 N,
-
- At time = 6.9772E+00 s, holding pressure is released.
-
- At time = 7.1818E+00 s, 2.2463E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 5.5921E+05 N,
-
- At time = 7.8866E+00 s, 2.5527E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 3.7031E+05 N,
-
- At time = 9.6366E+00 s, 3.3136E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 2.1863E+05 N,
-
- At time = 1.1637E+01 s, 4.1832E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 1.3374E+05 N,
-
- At time = 1.3637E+01 s, 5.0527E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 9.0669E+04 N,
-
- At time = 1.5387E+01 s, 5.8136E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 7.0423E+04 N,
-
- At time = 1.7387E+01 s, 6.6832E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 5.6460E+04 N,
-
- At time = 1.9387E+01 s, 7.5527E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 4.8676E+04 N,
-
- ** WARNING ** Pressure does not converge after 4000 iterations.
-
- At time = 2.1137E+01 s, 8.3136E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 4.3959E+04 N,
-
- ** WARNING ** Pressure does not converge after 4000 iterations.
-
- At time = 2.3137E+01 s, 9.1832E+01 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 3.9850E+04 N,
-
- At time = 2.5137E+01 s, 1.0053E+02 % of post-filling time,
- entrance pressure = 0.0000E+00 Pa,
- total clamp force = 3.6777E+04 N,
- --------------------------------------------------------
- Beginning of preparing the interface data ....
- Preparing PFC file for C-MOLD Cooling ....
- Preparing NEU file for structural analysis ....
- Preparing INP file for ABAQUS ....
- End of preparing the interface data.
- --------------------------------------------------------
- C-MOLD Filling
- C-MOLD Post-filling
- C-MOLD Residual Stress is successfully completed.
- --------------------------------------------------------
- real 6706.4
- user 6385.2
- sys 69.2
- --------------------------------------------------------
- C-MOLD Weld-line and air trap
- (c)1987-1994 by Advanced CAE Technology, Inc.
- --------------------------------------------------------
- Beginning of reading the input data ....
- File name : bottom
- Reading finite-element mesh ....
- Reading flow analysis output ....
- End of reading the input data.
- --------------------------------------------------------
- Beginning of weld-line/air-trap analysis ....
- End of weld-line/air-trap analysis.
- --------------------------------------------------------
- Beginning of preparing the output data ....
- End of preparing the output data.
- --------------------------------------------------------
- C-MOLD Weld-line and air trap is successfully completed.
- --------------------------------------------------------
- real 23.0
- user 12.0
- sys 0.6
- --------------------------------------------------------
- C-MOLD Shrinkage and Warpage
- (c)1987-1994 by Advanced CAE Technology, Inc.
- --------------------------------------------------------
- Date : MAY11-95
- Time : 20:34:33
- --------------------------------------------------------
- Beginning of reading the input data ....
- File name : bottom
- Reading finite-element mesh ....
- Reading parameters ....
- Reading C-MOLD Residual Stress data ....
- End of reading the input data.
- --------------------------------------------------------
- Beginning of memory allocation for analysis ....
- End of memory allocation for analysis.
- --------------------------------------------------------
- Beginning of checking input data ....
- End of checking input data.
- --------------------------------------------------------
- Beginning of re-numbering elements and nodes ....
- End of re-numbering elements and nodes.
- --------------------------------------------------------
- Beginning of calculating boundary conditions ....
- End of calculating boundary conditions.
- --------------------------------------------------------
- Beginning of calculating geometry info ....
- End of calculating geometry info.
- --------------------------------------------------------
- The analysis will be based on :
- (1) Parameters :
- ----------
- Isolate mechanism for warpage? (W) (1) = 1
- --------------------------------------------------------
- (2) Material :
- --------
-
- Polymer 1 :
- ---------
-
- Isotropic elastic tensor
- E = 2.3500E+09 Pa
- v = 4.1900E-01
- Transversely-iso thermal expansion coef.
- a1 = 7.6369E-05 1/K
- a2 = 7.6369E-05 1/K
- --------------------------------------------------------
- (3) Process conditions : N O N E
- ------------------
- --------------------------------------------------------
- (4) Finite-element mesh : .FEM file for model: bottom
- -------------------
- Total number of nodes = 1024
- Total number of elements = 1942
- --------------------------------------------------------
- C-MOLD Shrinkage and Warpage
- analysis is beginning ....
- --------------------------------------------------------
- Non-uniform shrinkage :
- analysis is beginning ....
-
- Beginning of iterative analysis ....
-
- Iteration number 1, convergence parameter = 4.7526E-01
- Iteration number 101, convergence parameter = 5.2031E-03
- Iteration number 201, convergence parameter = 3.2782E-03
- Iteration number 301, convergence parameter = 1.6856E-03
- Iteration number 401, convergence parameter = 5.1798E-04
- Iteration number 501, convergence parameter = 3.2583E-04
- Iteration number 601, convergence parameter = 3.3092E-04
- Iteration number 701, convergence parameter = 3.7651E-04
- Iteration number 801, convergence parameter = 2.4835E-06
- Iteration number 806, convergence parameter = 9.7585E-07
-
- End of iterative analysis.
- --------------------------------------------------------
-
-
-
- Unbalanced cooling :
- analysis is beginning ....
-
- Beginning of iterative analysis ....
-
- Iteration number 1, convergence parameter = 3.4963E-01
- Iteration number 101, convergence parameter = 5.3951E-03
- Iteration number 201, convergence parameter = 1.3361E-03
- Iteration number 301, convergence parameter = 1.5292E-03
- Iteration number 401, convergence parameter = 2.0324E-03
- Iteration number 501, convergence parameter = 1.0278E-03
- Iteration number 601, convergence parameter = 4.3316E-04
- Iteration number 701, convergence parameter = 1.2457E-05
- Iteration number 801, convergence parameter = 5.0603E-06
- Iteration number 808, convergence parameter = 8.8481E-07
-
- End of iterative analysis.
- --------------------------------------------------------
- Total process-induced effects :
- analysis is beginning ....
- --------------------------------------------------------
- Analysis is successfully completed.
- --------------------------------------------------------
- Beginning of preparing the output data ....
- End of preparing the output data.
- --------------------------------------------------------
- C-MOLD Shrinkage and Warpage is successfully completed.
- --------------------------------------------------------
- real 122.7
- user 109.6
- sys 1.6
- --------------------------------------------------------
- PRESS RETURN KEY TO EXIT ANALYSIS LAUNCHER.
-
-
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Copyright © 1995, 1997 Advanced CAE Technology, Inc. All rights
reserved.