TUTORIAL [Performance Adviser
TUTORIAL
[Performance Adviser]
Introduction:
In this tutorial, you will use the Performance Adviser functionality to run a filling and packing analysis on the dustpan model shown below. You will then assess the predicted warpage of the part based on the following design criteria:
The warpage of the front edge must be no more than 0.5 mm (0.02 inch).
The handle must project straight to within 0.5 mm (0.02 inch).
After viewing various Performance Adviser results to diagnose the cause(s) of warpage, you will analyze and assess a revised model which incorporates some measures to correct the warpage.
Task List
3. Investigate differential cooling
4. Investigate differential shrinkage
5. Review revised dustpan model
6. Analyze revised dustpan model
7. Reduce differential shrinkage
Task 1: Analyze dustpan model
The warpage of the front edge must be no more than 0.5 mm (0.02 inch). The handle must project straight to within 0.5 mm (0.02 inch). In this task you will open the supplied dustpan model, briefly review the model and processing conditions, then launch a Performance Adviser analysis.
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1. Click 2. Click Open to continue. 3. Rotate the model and examine the geometry. The green arrow at the start of each cooling channel is the coolant inlet. 4. Click
5. Rotate, and zoom in on the model as shown below: 6. Click · Cooling Circuit Adviser (Part+Mold+Circuits). · Performance Adviser (Fill+Pack). · Performance Adviser (Warpage). 7. Click Next to step through the Analysis Wizard and confirm the following analysis inputs:
8. On the final page of the Wizard, click Finish to launch the analysis. |
The analysis will take several minutes to run. Please click the right arrow below to continue to the next task where we begin with a brief overview of the available Performance Adviser results.
Task 2: Assess part warpage
In this task you will assess the predicted warpage of the dustpan. Click on a triangle to see a description of the result:
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1. When the analysis is complete, the Results Summary dialog appears and the Warpage Indicator page is selected. You now need to specify the following two warpage assessment criteria: · A reference plane which is used to calculate out-of-plane deflections. · A nominal maximum deflection value which is a design tolerance for the out-of-plane deflections. 2. Click Set/Modify Warpage Constraints. The Warpage Constraints dialog appears. 3. Click 4. Click on the 3 locations shown in the image below. Ensure the Z coordinate value for each location, as shown in the status bar, is 45.80 mm (1.80 inch). If the coordinate is incorrect, click and drag the symbol to the correct location. To accurately assess out-of-plane deflections, it is essential that all three reference locations lie on the same XY plane. Note: If the coordinates are not displayed in the status bar, right-click on the warpage constraint symbol and select Properties. 5. Click Next to advance to the Nominal Max. Deflection page of the Warpage Constraints dialog. 6. Deselect the Default option, specify a Nominal max. deflection value of 0.5 mm (0.02 inch), and then click Finish. 7. Click Close to close the Results Summary dialog. 8. Select Deflected Shape in the Result Types drop-down menu, then click 9. Select Warpage Indicator, All effects. 10. Click 11. Select Warpage Indicator, Cooling. 12. Select Warpage Indicator, Shrinkage. 13. Select Warpage Indicator, Orientation.
14. Click 15. Click Back to return to the Reference Plane page, then click Reset, and then click on the three reference plane locations shown below (ensure that the z coordinate of all locations is 0.0): 16. Click Next, check that the nominal max. deflection value is 0.5 mm (0.02 inch), and then click Finish. 17. Click Close to close the dialog, and then view the Warpage Indicator, All effects result. |
The results have shown that the warpage of the part is unacceptable, and that differential shrinkage and differential cooling effects are contributing to the warpage. In the next two tasks you will investigate each of these two sources of warpage in more detail.
You have completed this task. Click the right arrow below to move on to the next task.
Task 3: Investigate differential cooling
In this task you will investigate the problem of differential cooling, which is a major contributor to the warpage of this model.
The following results are useful for investigating the causes of differential cooling in the part:
You will now examine the above plots for the dustpan model.
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1. Click 2. Select Circuit Reynolds Number in the Result Types drop-down menu. 3. Select Circuit Coolant Temperature. 4. Select Part Surface Temperature. Tip: When viewing model result plots, the cooling system is shown transparent to provide a better view of the result plots. To review the position of the cooling lines in the problem area, select Solid Model in the Result Types 5. Select Freeze Time. Tip: This can be seen more clearly when results are scaled. Click |
The results show that the cooling circuits are performing efficiently, but that the layout of the cooling circuits is not providing sufficient heat extraction in the interior area of the dustpan. The resultant temperature gradients across the thickness will cause the part to warp.
You have completed this task. Click the right arrow below to move on to the next task.
Task 4: Investigate differential shrinkage
In this task, you will investigate the problem of differential shrinkage, which is also a major contributor to the warpage of this model.
The following result is useful for investigating the areas of differential shrinkage in the part:
You will now examine the above plot for the dustpan model.
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1. Click 2. Select Volumetric Shrinkage in the Result Types 3. Click Tip: To find results values to scale, right-click in the display area, select Result Value, and then click on different locations in the model. 4. Deselect Constrain to actual result data range, enter suitable minimum and maximum volumetric shrinkage values, and then click OK to close the dialog and update the results display. |
The Volumetric Shrinkage result shows substantial differences in the model shrinkage levels, particularly in the handle and along the front edge of the dustpan. This will cause internal stress within the part, and will cause it to warp.
You have completed this task. Click the right arrow below to move on to the next task.
Task 5: Review revised dustpan model
In this task, we will summarize the measures that can be taken to reduce the three contributors to warpage. You will then open the supplied revised dustpan model and review the design changes that have been made.
Measures to reduce differential cooling
To reduce differential cooling problems in the part, you should concentrate on improving the cooling in those areas of the model that you have identified as being hotter than the rest of the model. This can be achieved by:
Measures to reduce differential shrinkage
To reduce differential shrinkage problems in the part, you should concentrate on achieving a more uniform distribution of volumetric shrinkage in the model. This can be achieved by:
Measures to reduce orientation effects
To reduce orientation related problems in the part, you need to take suitable measures to modify the filling patterns in the model and thereby avoid undesirable molecular orientation or fiber alignment. This can be achieved by:
Review of the modified dustpan model
You will now open and review the revised dustpan model which incorporates a number of the differential cooling reduction measures described above.
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1. Select Solid Model in the Result Types 2. Click File Note: Do not close the model. You will be using tiled panes to compare the original and revised models. 3. Click 4. Click Open to continue. 5. Click Windows 6. Click in the dustpan_original.adv pane and then click 7. Repeat the previous step for the dustpan1.adv pane. 8. Click 9. For each coolant inlet in the dustpan1 model, select the coolant inlet, right-click and select Properties, then verify that the coolant inlet settings are now:
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You have completed this task. Click the right arrow below to move on to the next task.
Task 6: Analyze revised dustpan model
In this task, you will analyze the revised dustpan model and assess whether the design modifications have adequately resolved the warpage problems.
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1. Click · Cooling Circuit Adviser (Part+Mold+Circuit). · Performance Adviser (Fill+Pack). · Performance Adviser (Warpage). 2. Click Next four times to advance to the final page of the Analysis Wizard, then click Finish. 3. When the analysis has completed, close the Results Summary dialog. 4. Zoom in on the model. 5. Click 6. Click 7. Specify a Nominal max. deflection value of 0.5 mm (0.02 inch), then click Finish. 8. When the warpage assessment has completed and the Results Summary dialog appears again, click Close. 9. Click File Note: Do not close the model. You will be using tiled panes to compare the results for the original and revised models. 10. For the dustpan_original model, click 11. Click 12. Click Back to return to the Reference Plane page, then click Reset, and redefine the reference plane on the front section of the dustpan model (again ensure that the z coordinate of all locations is 48.5). 13. Close the Result Summary dialog. 14. For each model, click 15. Display the Deflected Shape result and use the animation tools to magnify the display of the deflected shape. 16. Display the Warpage Indicator, All effects plot and compare the results. 17. Display the Warpage Indicator, Cooling plot. 18. Display the Part Surface Temperature and Solid Model plots and consider what further design changes could be made to the cooling system layout to address the cooling problem on the front edge. 19. Display the Warpage Indicator, Shrinkage plot to assess what effect the design changes have had on differential shrinkage in the part. |
You have completed this task. Click the right arrow below to move on to the next task.
Task 7: Reduce differential shrinkage
In this task, you will adjust the packing profile as a measure to reduce the amount of differential shrinkage in the back area of the dustpan, reanalyze the dustpan model and then assess the results.
You have completed this task. Click the right arrow below to move on to the next task.
Task 8: Tutorial overview
In this tutorial, you have learnt how to use the Performance Adviser analyses and results to assess whether the part will meet a specified warpage tolerance and to diagnose the cause(s) of warpage.
Congratulations! You have completed all of the tasks in this tutorial. Click here to return to the course map and proceed with another tutorial.
