Is "trimming" meshes possible? CoolFEM

[e_calle]

I have this study where the gates join the part in the "edge" face. I need to run a CoolFEM simulation so I created the surface mold mesh and found the following issue:

As you can see there is not a perfect joint between the mesh covering the part and the mesh covering the feed system.  Is there a way to trim those meshes so that you end with a good joint between the two? I am currently doing this:

1- creating lines in the element edges of both meshes.

2- Create nodes by intersecting those lines.

3- Delete the elements in the joint area and create new ones using Fill Hole with the nodes created in the previous step.

This is quite intensive, is there any other faster/less intensive method?

 

[mason.myers · Accepted solution]

Hello @e_calle

How are you creating your 3D mold mesh?  Have you ever tried the CAD as Mold Block approach?  This will create a 3D solid of the mold and "cut out" your cooling lines, runner, part, and any inserts.  You need to have a 3D CAD of the part, the analysis set to CoolFEM, make sure all your runner and cooling channel curves are visible, then go to Geometry tab - Mold Block.  You can put in the size and click the option to use CAD as Mold Block.  

Hopefully, this meshes directly to 3D via the Mold Mesh option.

Mason

[e_calle]

Hello Mason,

thanks for reminding me this option exists. I have used it a couple of times in the past but did not thought about it for this case. I am finishing with the surface mesh right now. Once I finish, I will try it just to see what Moldflow does in the area.

[e_calle]

Hello Mason,

The CAD option has done a much better job at "trimming" the area. I just meshed the CAD volume using the default "Auto Sizing" size:

I am used to define a outer and inner mold mesh size. That kind of defines three mesh sizes/densities. Along the cavity the mold mesh will copy as best as possible the surface size used in the part's mesh, the inner mold mesh size is mainly for cooling and feeding lines, and the outer mesh size is just for the skin. 

While working with CAD mold block, having three different mesh sizes is going to be very user intensive. I can see how the general element size can be used for the inner walls and define a different local density for the 6 outer faces of the mold. Any tips and tricks to create this mold mesh as best as possible? 

[mason.myers]

Hello @e_calle ,

Did you try to mesh the 3D Mold Block directly to 3D?  This is usually my first attempt, if the 3D Mold Block meshes cleanly to 3D, there should be no need for any cleanup.

I usually use the default mold mesh settings, I may adjust the default mold mesh auto size from 1 to 1.2.  This should provide a slightly more coarse mesh and take less time to mesh/solve.

Mason

[e_calle]

Hello @mason.myers Mason,

unfortunately it failed to go directly to 3D. The model I am currently working on is way too big to use it to do some testing and be quick. I will try different auto-sizes in a simpler model to see how well the mold mesh copies the cavity mesh and the possible intersections between the two meshes.

Thanks!