Cool+Fill+Pack+Warp analysis is stuck at 10% from more than 24 hours

[Anonymous]

Hello,

I am running a moldflow analysis (Cool+Fill+Pack+Warp). Cooling step is stuck at 10% from more than 24 hours.

Part is a RAD Grille, 7 SVG, Dual domain analysis.

This is what I see:

Number of nodes = 35098
Number of beam elements = 1351
Number of triangular elements = 67568
Number of tetrahedral elements = 0

Reading nodal data...
Reading beam element data...
Reading triangular element data...

Analysis has detected a mesh change since initial mesh
generation ... recalculating mesh match and thickness information
Processing Dual Domain mesh...
Computing match using the maximal-sphere algorithm
... finished processing Dual Domain mesh
Method of calculating geometrical influence = Ideal

Cool analysis type = Manual

Total number of part elements = 67960
Total number of runner elements = 392
Total number of mold elements = 1307
Total number of circuit elements = 959
Co-ordinates of part extremity:
X Y Z
Maximum -560.18972 mm 530.85887 mm 900.44999 mm
Minimum -919.42036 mm -530.85947 mm 618.39908 mm
Orientation -200.95909 mm 1592.57722 mm 1182.50084 mm
Co-ordinates of mold extremity:
X Y Z
Center -739.80498 mm -0.00024 mm 759.42457 mm
Right corner 414.30539 mm 1154.11019 mm 1913.53500 mm
Left corner -1893.91541 mm -1154.11067 mm -394.68586 mm

Using mesh aggregation

Total Mbytes required for Cool analysis = 3165.24
Total Mbytes of RAM available for analysis = 22612.49
Total Mbytes of disk space available for analysis = 88451.62
Cool will attempt to solve analysis in RAM.

I am not sure if it is still solving or if there is a issue with this.

Any help is appreciated.

[bernor_mf]

Hi,

your study is not very big in number of elements, so it should pass in a reasonable short time.

Hard to estimate as depending on model complexity, hardware resources and computer load,

but I would  say roughly around 1 - 3 hours as a rough guide.

Which release are you using?

Could check that Synergy and Insight are both on same version?

Analyses not solving after installing Moldflow 2019.0.1 update

There are no warnings in information provided.

After "Cool will attempt to solve analysis in RAM."
and some blank rows it should say " Now beginning the task: Input part model"

Could you share your study file?

Hope this helps.

Regards,

Berndt

[Anonymous]

Hello Berndt,

I am using Moldflow Insight 2018.2 currently and this is what I see for Insight and synergy version:

Please see attached .sdy file.

[bernor_mf · Accepted solution]

Hello @Anonymous,

the versions looks ok to me.

You can confirm solvers running by using a simplifed cooling study on a plate or so,  that all runs as it should.

When doing Bubbler/Baffle Diagnostic is shows invalid sections.

This has to be fixed first.

(In tab Mesh, Mesh Diagnostics, expand selection to find Bubbler/Baffle Diagnostic )

 

Review the study, and fix the Baffle beams.

Rereun, to see if it passes.

If no progress after a few hours, the study could be corrupt for some unknown reason.

Sometimes when having a corrupt study, and what you could try as a workaround is to export the study to Patran format.
Then reimport the patran file .
This cleans up the study.
The boundary conditions are lost when exporting to Patran format.
You need to setup boundary conditions again, such as:
Injection Location, Cooling Inlets, Valve Gates etc.
You could to a Copy Study settings to set up analysis sequence, material data, process settings.

Keep us posted of the progress.

Regards,

Berndt

[Anonymous]

Hello @ bernor_mf,

That totally worked. After I fixed the baffles, cool analysis took 10 min to solve. (I cant beleive that it didnt give me an error and just got stuck like that)

Thank you so much!!!! I was worrying about this from 2 days. I really appreciate your help!!! 🙂

-Sonakshi

[bernor_mf]

Hello Sonakshi,

happy to hear your issue were resolved.

Happy to help.

I did a simplified study too, by just removing baffles with overlapping beams and merge channel beams.

This analysis was working too.

It seems as the underlying reason was overlapped lines for baffles.

Four curves for the baffle, instead of two. Meshed to more overlapped beams

causing Cool to hang or get stuck

The construction of bubblers and baffles has been greatly simplified to Synergy 2018.2.
Have a look at: Bubblers and Baffles
You are no longer required to create a curve for the upward path and a second curve for the downward path.

Even with the bubbler or baffle being modeled as a single element, the analysis can proceed.

Regards,

Berndt