Process Simulation of a large part

[Anonymous]

Hello,

I will soon be conducting a Reactive Compression Moulding simulation with a large part. I started practising with a simple geometry. However, creating a mesh with the smallest mesh size available on MF still gives aspect ratio of the elements to be over 100.

I have tried reducing the Global Edge Size, and increase the number of elements thru thickness in the part and charge. I have attached screenshots to assist further. 

Is there a limit on the size MF is able use for fibre orientation analysis. I have noticed MF maxes out on the number of elements regardless of the geometry of the part and charge.

Any assistance is appreciated

Thank you

[harald_goetz]

Hi gl13215,

there are maybe tiny edges or other glitches in your cad geometry.

You can try to make your cad part "cleaner" or just find and repair those elements.

I would prefer to mesh 3D, but with the radio button "Stop after surface meshing" (haven't got MF running at home, but you should find something similar in the first mesh tab).

Then check for triangles with ab AR of (I use 20 usually, but even 50 should be fine).

If there are 2 or 3 - just repair them by connecting nodes or other mesh operations.
If there are like 20 or more - put them as result on a new layer and get rid of the high AR parts due to manual repair.

If there are liek 100 or more - clean your CAD part or try different meshing settings.

About the setting of 40 layers for plastic parts and 20 for inlays:

Usually you should have 12 layers (min. 10) - I have used 20 and 25 (3D) layers, but that adds a lot of elements.

If your part is that simple - maybe you can post it / upload it - so others could give hints on how much layers seems to be useful?!

Best regards

Harald

[Anonymous]

Hi @harald_goetz ,

I've not tried to simulate anything fancy, but a large plate (1m*1m*3mm) to check what can be done with MF (I am a newbe here). Geometry is attached. It might be important mentioning that I am conductive a Fill+Pack analysis in Reactive Compression Moulding, and I have to use 3D tet elements.

The data above is for the finest mesh, and I have tried the numbers suggested in the last paragraph, but this gives similar results.

I am aware that a large part will be computationally expensive, but at the moment MF seems to max out on the number of elements in the part. Please let me know for any advice.

Thanks