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Files required to work on this tutorial can be downloaded from this website: http://support.ansys.com/
training.
2.1. Introduction
Molding is a process of forcing a preform or a parison (preshaped sleeve) into a mold cavity so that the
preform assumes the shape of the cavity. There are numerous molding methods, including blow
molding, compression and transfer molding, and slush and rotational molding. These methods differ
in the formation of the preform and the filling of the mold cavity. Also, each processing method is
suitable for a specific class of polymers.
Blow molding is an important processing method for molding hollow articles such as bottles. The preform
is usually made by extrusion and forced between the mold halves by pressurization (blowing air). The
polymer solidifies upon contact with the cold mold and the finished product is then ejected. The homo-
geneity and rheological properties of the preform along with the operating conditions (temperature
and pressure variations) are crucial in this step and will affect the design of the processing machinery.
This process reflects all facets of polymer processing the isothermal and transient flow of Newtonian
fluids in complex geometries with simultaneous structuring and solidification.
Set material properties and boundary conditions for a 2D axisymmetric blow molding problem.
2.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. ?). Some steps in the setup procedure
will not be shown explicitly.
A large pressure is applied to the preform, which enters the mold and eventually takes its shape. The
operating conditions must account for a low pressure drop at the entrance, low material waste, and
slow cooling to avoid premature solidification of the preform.
The cylindrical geometry of the preform (Figure 2.1: Problem Description (p. 2)) has an internal radius
of 2 cm and external radius of 3 cm (the initial thickness of the preform is 1 cm). The height of the
preform is 7 cm.
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2D Axisymmetric Blow Molding
The domain for the problem is divided into two subdomains: one for the fluid perform (subdomain 1)
and the other for the mold (subdomain 2). Incompressibility and momentum equations are solved in
subdomain 1 (the fluid preform). The problem involves two free surfaces (boundary 2 and boundary 4,
shown in Figure 2). boundary 2 will eventually come into contact with the mold, and its position is
calculated as a part of the solution.
The fluid preform has a density of =1 g/cm3 and a viscosity of = 100000 poise. Inertia terms and
the effects of gravity will be included in the calculation.
The boundary sets for the problem are shown in Figure 2.2: Boundary Set for the Problem (p. 3), and
the conditions at the boundaries of the domain (for the preform) are:
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Preparation
2.4. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
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2D Axisymmetric Blow Molding
7. Unzip the 2D-Axi-Blow-Molding_R150.zip file you have downloaded to your working folder.
8. Start Workbench from Start All Programs ANSYS 15.0 Workbench 15.0.
2. Save the ANSYS Workbench project using File Save, entering Final-blow-mold as the name of
the project.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
F.E.M. task
Time-dependent problem(s)
2D axisymmetric geometry
The Current setup is updated to reflect the selected options. This example is a simulation of blow
molding for a 2D axisymmetric bottle and the mold is two-dimensional. The problem is assumed
to be time-dependent.
Define molds
a. Create a mold.
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Step 2: Models
Adiabatic mold
c. When prompted, click OK to retain the default name for the mold (Mold 1).
SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that the mold is
defined as SUBDOMAIN_2.
e. Specify the boundary that represents the part of the mold that comes into contact with the fluid.
Polyflow uses this information to determine the penetration distance (into the mold) of every
point of the free surface (BOUNDARY2).
Contact conditions
The free surface, BOUNDARY2 of the preform comes into contact with the mold wall,
BOUNDARY5 (as shown in Figure 2.2: Boundary Set for the Problem (p. 3)).
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2D Axisymmetric Blow Molding
f. Click Upper level menu four times to return to the F.E.M. Task 1 menu.
Create a sub-task
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Step 3: Material Data
The domain is divided into two subdomains, one for the fluid preform (SUBDOMAIN_1) and the other
for the mold (SUBDOMAIN_2). In this problem, the sub-task applies only to the preform.
SUBDOMAIN_2 is moved from the top list to the bottom list, indicating that the sub-task is
defined on SUBDOMAIN_1.
Material data
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2D Axisymmetric Blow Molding
c. Click Modify fac to specify the value of , which is referred to as fac in the graphical user interface.
e. Click Upper level menu two times to continue with the Material Data specification.
a. Click Density.
d. Click Upper level menu to continue with the Material Data specification.
In this problem, inertia plays an important role. When internal pressure is applied, the preform expands,
and the fluid accelerates towards the mold. In order to obtain a realistic blowing time, inertia must be
taken into account.
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Step 4: Boundary Conditions
c. Click Upper level menu to continue with the Material Data specification.
The fluid preform flows in the negative y direction under gravity, so specify the component of gravity
along the y direction ( ).
a. Click Gravity.
Modify gy
Polydata prompts for the new value of the gravity along the y-axis.
d. Click Upper level menu two times to return to the blow molding menu.
No action is required to accept the default value. You can simply proceed to the next step. For 2D
axisymmetric models, Polydata recognizes the axis of symmetry from the mesh file and automatically
imposes the symmetry condition along the line .
The free surface boundary condition in contact detection problems is different from their simulations
in Polyflow. In blow molding problems, a free surface comes into contact with a solid mold. Polyflow
applies a contact detection algorithm at each location of the surface to detect the occurrence of the
contact.
You need to specify the following for the free surface on BOUNDARY2:
the contact wall (the boundary of the mold along which the contact is detected)
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2D Axisymmetric Blow Molding
This determines the accuracy of the contact; the smaller its value, the deeper the contact is.
The fluid may slip along the contact wall, so to take this factor into account, a slipping coefficient
must be specified along the tangential direction.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY2 and click Modify.
iii. Specify where the free surface will contact the mold.
Polyflow uses the definition of the contact wall in the determination of the penetration distance
(into the mold) of every point of the free surface (BOUNDARY2).
As shown in Figure 2.2: Boundary Set for the Problem (p. 3), the free surface (BOUNDARY2)
of the perform comes into contact with the mold (BOUNDARY5).
With such a high value of the slipping coefficient, the fluid will stick to the contact wall.
vii. Click Upper level menu two times to return to the Kinematic condition menu.
d. Click Upper level menu to return to the Flow boundary conditions panel.
In contact detection problems, abrupt changes in the velocity field occur at the contact points
between the fluid preform and the mold. Polydata gives the warning message shown below. Since
the prediction of the velocity field in such cases destroys the prediction scheme, you can continue
by clicking OK.
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Step 4: Boundary Conditions
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY3 and click Modify.
c. Click Upper level menu to accept the default value of 0 for the normal velocity, .
d. Click Upper level menu to accept the default value of 0 for the tangential force, .
This boundary of the preform is subjected to pressure by the application of a normal force, so specify
a normal force along this boundary.
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY4 and click Modify.
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2D Axisymmetric Blow Molding
d. Click Upper level menu to return to the Flow boundary conditions menu.
Global remeshing
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Step 6: Numerical Parameters
a. Click Accept the current setup in the Element distortion check menu.
In blow molding simulations, the finite-element mesh can undergo great deformations. The Element
distortion check menu deals with the detection of all possible distortions of the elements. In this
problem, you can accept the default options and proceed to the next step.
b. Click Upper level menu two times to return to the F.E.M. Task 1 menu.
Numerical parameters
1. Specify the parameters for the iterative scheme in the calculation of the free surface.
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2D Axisymmetric Blow Molding
This option specifies the time at which the solution procedure stops.
This option is used to define the initial time step, which is used for the calculation of the next two
time steps. After that, the step size is automatically calculated by Polyflow. This first time step
should be set according to the characteristic time scale of the process considered.
If a calculated value for the time step falls below the minimum for the time step at any point in
the calculation, the iterative scheme stops since this might be a symptom of calculation difficulties.
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Step 7: Outputs
In order to guarantee accuracy of the time-marching scheme and to avoid useless calculations
(rejection of inaccurate time steps), you can limit the growth of the time increment.
The tolerance is the admissible error between the predicted solution and the exact solution at a
particular time step. A very small value of the tolerance can result in large computational costs
and a very large value can result in wrong solution.
This option is used to select the maximum number of converged steps. If this value is reached, the
calculation stops, even if the upper time limit has not been reached.
2. Click Upper level menu three times to return to the top-level Polydata menu.
Outputs
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2D Axisymmetric Blow Molding
4. Click Upper level menu twice to return to the top-level Polydata menu.
F.E.M. Task 1
Create a sub-task
b. Click Postprocessor.
c. Enter parison thickness as the New value for the title and click OK.
6. Specify the boundary sets representing the starting and ending borders to be used in the thickness
calculation.
Polyflow evaluates the distance between these borders at a point between them to determine the
thickness at that location.
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Step 11: Postprocessing
7. Click Upper level menu five times to return to the top-level Polydata menu.
Polydata asks you to confirm fields that are to be saved to the results file for postprocessing.
1. Click Accept.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and the Polyflow format results file is (res).
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
Workbench opens the View listing file panel, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the
following printed at the bottom of the listing file:
The computation succeeded.
CFD-Post reads the solution fields that were saved to the results file.
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2D Axisymmetric Blow Molding
a. Click the Insert menu and select Contour or click the button.
b. In the box that opens, click OK to accept the default name (Contour 1) and display the details
below the Outline tree.
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Step 11: Postprocessing
ii. Select estim. THICKNESS from the Variable drop-down list, or click the ellipsis button ( )
on the right and select estim. THICKNESS.
i. Click the Insert menu and select Text or click the button.
ii. Click OK to accept the default name (Text 1) and display the details view below the Outline
tab.
v. Click Apply.
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2D Axisymmetric Blow Molding
a. Double-click Default Transform in the Outline tree tab, under User Locations and Plots (or right-
click Default Transform and select Edit).
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Step 11: Postprocessing
b. Disable Instancing Info From Domain under the Definition tab in the details of Default Transform.
c. Enable Apply Reflection, and select YZ Plane from the Method drop-down list.
e. Click Apply.
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Display the results at several time steps to see the shape and thickness of the parison during the blow
molding process.
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Step 11: Postprocessing
On these figures, the thickness is integrated from the moving master surface towards the other
free surface. This explains the color fringes appearing through the parison. The thickness decreases
as the parison inflates. At the final time step, the thickness is smallest where the parison has been
the most extended, (in the corner of the bottle). It is largest at the top where the deformation was
much less important due to the small diameter here.
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Step 11: Postprocessing
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Step 11: Postprocessing
a. Click the Tools menu and select Animation or click the button.
b. Enable Quick Animation and select Timesteps in the Animation dialog box.
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a. Double-click Contour 1 under the Outline tab to display the details view.
b. Select VELOCITIES from the Variable drop-down list and click Apply.
There is zero velocity at the contact between the parison and the mold, but the velocity magnitude
is still important where the fluid does not yet touch the mold.
There is zero velocity at the contact between the parison and the mold, but the velocity
magnitude can still be important where the fluid does not yet touch the mold. At the final
time of the simulation, the velocity is near zero, which indicates that the contact is completed.
The residual value originates from the penalty formulation used for the contact, as explained
in 3D Thermoforming of a Blister (p. ?).
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Appendix
2.16. Summary
This tutorial introduced a time-dependent problem with a 2D axisymmetric geometry for the mold.
Suitable assumptions were made regarding the nature of the preform and the operating conditions.
You analyzed the factors affecting the process in the postprocessing section. An optimization of the
preform shape could be performed in order to minimize the weight of the bottle while avoiding weak
(too thin) bottle walls.
You used a remeshing method that is most suited for contact detection problems. This problem also
introduced the concept of the calculation of free surfaces for contact detection problems. You used
efficient numerical techniques to more accurately solve a time-dependent problem.
2.17. Appendix
The appendix covers the following topics:
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Remeshing is carried out in the tangential direction along the free surface that is expected to undergo
large deformations (the master moving surface) and the internal nodes are relocated along spines in a
direction normal to the master moving surface.
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