topic Re: Cooling channel and mold mesh in Moldflow Insight Forum

Cooling channel and mold mesh

mustafa.shapaan1 — Thu, 22 Feb 2024 15:11:41 GMT

hello everyone

I have some troubles creating the cooling channels both beam elements and 3D channels and meshing them in a way that makes the mold meshing consider them and subtract their volume from the mold volume. right now the mold mesh just ignore their existance,

first problem is that sometimes when creating 1D cooling channels the green check mark on the cooling inlet outlet is not done ... i don't understand where is the problem ....i run a cooling circuit analysis and it showed that there are no errors with the cooling circuit .... some tutorials i found that they don't put an outlet for each inlet... i don't understand based on what they decided to add an outlet or not ?

for 3D cooling channels do they have to be included within the mold without being protruded out of the mold boundaries ? can i connect them to hoes ? i actually tried but when inserting the inlets and outlets boundary conditions it just didn't show the inlets big arrow.

for the mold problem which doesn't subtract the part and cooling channels..can i just subtract them in the cad system and then mesh the mold in Moldflow ? is that an alternative solution ? or it has its drawbacks ? for example contact issues ?
when i used the mold wizard from the geometry tab, the mold mesh subtracted the cooling channels and the part so in your opinion is the problem related to the mold part that i imported ? it is just an extruded rectangle what could possibly go wrong ?

as you see everything here is green checked yet the mold mesh doesn't subtract the cooling channels volume ?

thanks

Re: Cooling channel and mold mesh

mason.myers — Thu, 22 Feb 2024 15:30:07 GMT

Hello @mustafa.shapaan1 ,

Do you have any 3D cooling channels meshed via 3D mesh? If so, you need to have 3D Cooling Inlets and 3D Cooling Outlets assign to each of these channels. While you can have 1D Beams as cooling and 3D channels modeled as cooling in the same study, you need to stay consistent within the circuit. 1D beams can't connect to 3D Cooling channels.

When you created your CAD as Mold block, you need to ensure your Part CAD, 3D Cooling CAD and cooling/runner curves (for beam elements) are visible before you create the mold block.

Mason

Re: Cooling channel and mold mesh

mustafa.shapaan1 — Thu, 22 Feb 2024 15:54:53 GMT

thanks for your response
well i had them all turned on even the mesh nodes, but the problem is still there could there be another problem ?

could you tell me why those 1D coolant channels not showing a green check mark are there any problems with the inlets and outlets, do i have to ignore the outlets sometimes ?

important note that those cooling channels were brought as solids and used the center line to extract the lines and then meshed them as 1D channel... is there any problem with that ?

Re: Cooling channel and mold mesh

mason.myers — Thu, 22 Feb 2024 16:03:17 GMT

Hello @mustafa.shapaan1 ,

Can you please confirm you have cooling line curves in your model and they were visible when you created the 3D Mold block.

Did you import your own mold block CAD or did you create one within Moldflow?

There is nothing wrong about using the centerline tool to create the cooling channels.

Regarding the green check not showing: Are you using 3D meshed cooling channels? If so, please try to add 3D cooling inlets and 3D outlets.

Mason

Re: Cooling channel and mold mesh

mustafa.shapaan1 — Thu, 22 Feb 2024 16:24:47 GMT

just to clarify
i am asking about two examples one with 3D cooling and the other with 1D cooling channels
regarding the inlets and outlets types, yes i am following the rules : and it is shown on the browser tab the type of inlets used whether it is a 3D or regular inlets outlets....

yes i imported my own block and it didn't work but when used the mold wizard tool it worked.

for the green check, i don't have a problem with 3D mesh, it only occurs when using 1D cooling channels
you could have a look at the image here

Re: Cooling channel and mold mesh

mason.myers — Thu, 22 Feb 2024 16:35:15 GMT

Thank you @mustafa.shapaan1 for clarifying,

I think the issue you are facing is due to the fact that you have some meshed body assigned to Channel 3D. If you are only using cooling beams, 3D Channels should not be listed in grey under Cooling Circuits.

Can you please try to remove unused properties or turn on all layers and try to find any meshed items assigned to Channel 3D.

Mason

Re: Cooling channel and mold mesh

mustafa.shapaan1 — Thu, 22 Feb 2024 17:02:17 GMT

thanks that actually helped solve the problem of the green check but until now partially :
i have to convert the cooling lines solid into 3D channel in order to use the centerline tool to convert them into lines after the conversion i turned the lines into channel properties and deleted the solid which were assigned as 3D channels then converted the study into a cool fill pack warp.... but still i can see the 3D lines under the inlet outlet ...and the problem still persist.. what else can i do after deleting the solids assigned as 3D channels to avoid that problem ?

Re: Cooling channel and mold mesh

mustafa.shapaan1 — Thu, 22 Feb 2024 17:50:05 GMT

well i just had to turn the properties back to solid from 3D channel before deleting it ...now the problem is solved thanks to you...
back to other problems :
about the inlets and outlets i saw some tutorials where they just ignore the outlets for some channels is there any reason behind that ?
for the mold mesh not subtracting the cooling lines ... do you have any other recommendations if i want to use my own mold not the mold wizard ... thank you so much

Re: Cooling channel and mold mesh

mason.myers — Thu, 22 Feb 2024 18:11:21 GMT

Hello @mustafa.shapaan1 ,

3D meshed Channels always need 3D inlets and 3D outlets.

Cooling beams always need inlets. If the beams have a clear flow path (no dead ends) you do not need outlets. If there are branches or dead ends in the flow path, beams need inlets and outlets.

If you want to use your own mold block, you need to cut out the part, runner, and cooling channels in your CAD before bringing into Moldflow. I highly suggest using the CAD as mold block option in Moldflow. This is an easy way to create a generic mold block with the part, runners, cooling cut out from the mold.

Mason

Re: Cooling channel and mold mesh

mustafa.shapaan1 — Thu, 22 Feb 2024 18:22:17 GMT

thank you so much