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Chapter 2: 2D Axisymmetric Blow Molding

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.

In this tutorial you will learn how to:

Define a time-dependent problem.

Set material properties and boundary conditions for a 2D axisymmetric blow molding problem.

Set numerical parameters available in Polydata for a time-dependent 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.

2.3. Problem Description


This problem analyzes a blow molding simulation for a 2D axisymmetric bottle. The problem deals with
the cavity filling stage of the molding process and it is assumed that a preform has been positioned
inside the mold. The contact between the fixed mold and the preform is considered.

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

Figure 2.1: Problem Description

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:

boundary 1: symmetry axis

boundary 2: free surface

boundary 3: zero normal velocity and zero surface force

boundary 4: free surface

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Preparation

Figure 2.2: Boundary Set for the Problem

2.4. Preparation
To prepare for running this tutorial:

1. Prepare a working folder for your simulation.

2. Go to the ANSYS Customer Portal, https://support.ansys.com/training.

Note

If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.

3. Enter the name of this tutorial into the search bar.

4. Narrow the results by using the filter on the left side of the page.

a. Click ANSYS Polyflow under Product.

b. Click 15.0 under Version.

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2D Axisymmetric Blow Molding

5. Select this tutorial from the list.

6. Click Files to download the input and solution files.

7. Unzip the 2D-Axi-Blow-Molding_R150.zip file you have downloaded to your working folder.

The mesh file 2d-axi-blowmold.msh can be found in the unzipped folder.

8. Start Workbench from Start All Programs ANSYS 15.0 Workbench 15.0.

2.5. Step 1: Project and Mesh


1. Create a Fluid Flow - Blow Molding (Polyflow) analysis system by drag and drop in Workbench.

2. Save the ANSYS Workbench project using File Save, entering Final-blow-mold as the name of
the project.

3. Import the mesh file (2d-axi-blowmold.msh).

4. Double-click the Setup cell to start Polydata.

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.

2.6. Step 2: Models


In this step, define a new task representing the 2D axisymmetric time-dependent model. Then, define the
mold and a sub-task for the isothermal flow calculation.

1. Create a task for the model.

Create a new task

a. Select the following options:

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.

b. Click Accept the current setup.

2. Define the mold.

Define molds

a. Create a mold.

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Step 2: Models

Create a new mold

b. Select an adiabatic mold.

Adiabatic mold

c. When prompted, click OK to retain the default name for the mold (Mold 1).

d. Specify the solid region that represents the mold.

Domain of the mold

i. Select SUBDOMAIN_1 and click Remove.

SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that the mold is
defined as SUBDOMAIN_2.

ii. Click Upper level menu at the top of the menu.

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

i. Select No contact along BOUNDARY5 and click Modify.

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

ii. Select Contact.

f. Click Upper level menu four times to return to the F.E.M. Task 1 menu.

3. Create a sub-task for the isothermal flow.

Create a sub-task

a. Select Generalized Newtonian isothermal flow problem.

A panel opens, asking for the title of the problem.

b. Enter blow molding as the New value and click OK.

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Step 3: Material Data

The Domain of the sub-task menu item is highlighted.

4. Define the domain where the sub-task applies.

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.

Domain of the sub-task

a. Select SUBDOMAIN_2 and click Remove.

SUBDOMAIN_2 is moved from the top list to the bottom list, indicating that the sub-task is
defined on SUBDOMAIN_1.

b. Click Upper level menu at the top of the menu.

The Material data menu item is highlighted.

2.7. Step 3: Material Data


Polydata indicates which material properties are relevant for the sub-task by graying out the irrelevant
properties. In this case, viscosity, density, inertia terms, and gravity are available for specification.

Material data

1. Define the viscosity of the preform.

a. Click Shear-rate dependence of viscosity.

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b. Click Constant viscosity.

c. Click Modify fac to specify the value of , which is referred to as fac in the graphical user interface.

Polydata prompts for the new value of the viscosity.

d. Enter 100000 as the New value and click OK.

e. Click Upper level menu two times to continue with the Material Data specification.

2. Define the density of the preform.

a. Click Density.

b. Click Modification of density to specify the value of the density.

Polydata prompts for the new value of the density.

c. Enter 1 as the New value and click OK.

d. Click Upper level menu to continue with the Material Data specification.

3. Enable the calculation of the inertia terms in the momentum equation.

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

a. Click Inertia terms.

b. Select Inertia will be taken into account.

c. Click Upper level menu to continue with the Material Data specification.

4. Include the effects of gravity in the flow.

The fluid preform flows in the negative y direction under gravity, so specify the component of gravity
along the y direction ( ).

a. Click Gravity.

b. Click Modify gy to specify the value of gravity in the y-direction.

Modify gy

Polydata prompts for the new value of the gravity along the y-axis.

c. Enter -981 as the New value and click OK.

d. Click Upper level menu two times to return to the blow molding menu.

The Flow boundary conditions menu item is highlighted.

2.8. Step 4: Boundary Conditions


In this step, set the conditions at each of the boundaries of the domain. When a boundary set is selected, its
location is highlighted in red in the graphics window.

Flow boundary conditions

1. Retain the default condition Axis of symmetry along BOUNDARY1.

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 .

2. Set the conditions at the outer free surface (BOUNDARY2).

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 components of the direction of displacement along BOUNDARY1 and BOUNDARY3

the contact wall (the boundary of the mold along which the contact is detected)

the penalty coefficient

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This determines the accuracy of the contact; the smaller its value, the deeper the contact is.

The slipping coefficient

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.

b. Click Free surface.

c. Specify the contact detection problem.

i. Click Contact (Blow mold).

ii. Click Create a new contact problem.

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).

Click Select a contact wall.

iv. Select Mold 1 : Contact along BOUNDARY5 and click Select.

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).

v. Define the slipping coefficient.

Modify slipping coefficient

Retain the default value of 1e+09 and click OK.

With such a high value of the slipping coefficient, the fluid will stick to the contact wall.

vi. Define the penalty coefficient.

Modify penalty coefficient

Retain the default value of 1e+09 and click OK.

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

e. Click OK to accept the warning and continue.

3. Set the conditions at the top part of the preform (BOUNDARY3).

a. Select Zero wall velocity (vn=vs=0) along BOUNDARY3 and click Modify.

b. Click Normal velocity and tangential force imposed ( vn, fs ).

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, .

4. Set the conditions at the inner free surface (BOUNDARY4).

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.

b. Click Free surface.

c. Specify the normal force.

i. Click Normal force.

ii. Select Constant.

Polydata prompts for the new value of the normal force.

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2D Axisymmetric Blow Molding

iii. Enter -2e06 as the New value and click OK.

iv. Click Upper level menu.

d. Click Upper level menu to return to the Flow boundary conditions menu.

5. Click Upper level menu to return to the blow molding menu.

The Global remeshing menu item is highlighted.

2.9. Step 5: Remeshing


This model involves free surfaces for which the positions are unknown. A portion of the mesh is affected by
the relocation of these boundaries. Hence a remeshing technique is applied on this part of the mesh. The
free surfaces are entirely contained within SUBDOMAIN_1, and hence only SUBDOMAIN_1 is affected by the
relocation of the free surfaces.

Global remeshing

1. Specify the region where the remeshing is to be performed (SUBDOMAIN_1).

1st local remeshing

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Step 6: Numerical Parameters

Click Upper level menu to accept the default selection of SUBDOMAIN_1.

2. Click Lagrangian on the border only.

For information on remeshing techniques, see Appendix (p. 29).

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.

2.10. Step 6: Numerical Parameters


In this step, define the numerical parameters for the simulation.

Numerical parameters

1. Specify the parameters for the iterative scheme in the calculation of the free surface.

Modify the transient iterative parameters

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For information on time marching scheme, see Appendix (p. 29).

a. Specify the time limit.

This option specifies the time at which the solution procedure stops.

Modify the upper time limit

Polydata prompts for the new value of the time limit.

Enter 0.1 as the New value and click OK.

b. Specify the initial value of the time step.

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.

Modify the initial value of the time-step

Enter 1e-03 as the New value and click OK.

c. Specify the minimum value for the time step.

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.

Modify the min value of the time-step

Enter 1e-07 as the New value and click OK.

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Step 7: Outputs

d. Specify the maximum value for the time step.

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.

Modify the max value of the time-step

Enter 1e-03 as the New value and click OK.

e. Specify the tolerance for time marching.

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.

Modify the tolerance

Retain the default value of 1e-02 and click OK.

f. Specify the maximum number of successful steps.

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.

Modify the max number of successful steps

Retain the default value of 200 and click OK.

g. Enable Use of the implicit Euler method.

2. Click Upper level menu three times to return to the top-level Polydata menu.

2.11. Step 7: Outputs


You can specify how often Polyflow saves the solution data when it calculates a solution. In this tutorial,
save the results at every 10 time steps.

Outputs

1. Click Output Triggering.

a. Click Enter the number of steps.

Polydata prompts you for the number of steps.

b. Enter 4 as the New value and click OK.

2. Click Upper level menu twice.

3. Specify the system of units.

a. Click Modify system of units.

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b. Click Set to metric cm/g/s/A+Celsius.

4. Click Upper level menu twice to return to the top-level Polydata menu.

2.12. Step 8: Thickness Postprocessor


In this step create a postprocessor sub-task to compute the thickness of the blown product.

The results of this postprocessor are sent to CFD-Post as a value field.

F.E.M. Task 1

1. Create a new sub-task.

Create a sub-task

a. Click No when asked whether you want to copy an existing sub-task.

b. Click Postprocessor.

c. Enter parison thickness as the New value for the title and click OK.

2. Click Parison thickness.

3. Click parison #01.

4. Click OK twice to accept the warnings about defining the borders.

You will have to define these borders at a later stage.

5. Specify the region where the postprocessor sub-task applies.

Domain of the sub-task

Accept the default of SUBDOMAIN_1 by clicking Upper level menu.

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.

Borders for thickness calculation

a. Select BOUNDARY2: not used and click Modify.

b. Click Starting border.

c. Select BOUNDARY4: not used and click Modify.

d. Click Ending border.

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Step 11: Postprocessing

7. Click Upper level menu five times to return to the top-level Polydata menu.

2.13. Step 9: Save the Data and Exit Polydata


After defining your model in Polydata, you need to save the data file. In the next step, you will have to read
this data file into Polyflow and calculate a solution.

Save and exit

Polydata asks you to confirm fields that are to be saved to the results file for postprocessing.

1. Click Accept.

This confirms that the default Current field(s) are correct.

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).

2.14. Step 10: Solution


In this step, run Polyflow to calculate a solution for the model you just defined using Polydata.

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).

2. Check for convergence in the listing file.

a. Right-click the Solution cell and select Listing Viewer....

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.

2.15. Step 11: Postprocessing


Use CFD-Post to view the results of the Polyflow simulation.

1. Double-click the Results cell in the Workbench analysis system.

CFD-Post reads the solution fields that were saved to the results file.

2. Align the view as shown in the following figure.

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2D Axisymmetric Blow Molding

3. Display contours of thickness in the fluid region (SUBDOMAIN_1).

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

c. Specify the following settings under the Geometry tab:

i. Select SUBDOMAIN_1_surf from the Locations drop-down list.

ii. Select estim. THICKNESS from the Variable drop-down list, or click the ellipsis button ( )
on the right and select estim. THICKNESS.

iii. Click Apply.

d. Annotate the display.

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.

iii. Enable Embed Auto Annotation under the Definition tab.

iv. Select Time Value from the Type drop-down list.

v. Click Apply.

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Figure 2.3: Contours of Thickness at the Final Time-step t = 0.1 s

4. Show contours of thickness on the full blown bottle.

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.

d. Retain the default value of 0.0 m for X.

e. Click Apply.

f. Click the button to center the view.

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Figure 2.4: Contours of Thickness on the Full Blown Bottle at t = 0.1 s

5. Display contours of thickness at various timesteps.

Display the results at several time steps to see the shape and thickness of the parison during the blow
molding process.

Tools Timestep Selector or click the button.

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Step 11: Postprocessing

a. Select the 20th timestep and click Apply.

b. Select the 40th timestep and click Apply.

c. Select the 60th timestep and click Apply.

d. Select the final timestep and click Apply.

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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Figure 2.5: Contours of Thickness at the 20th Timestep

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Step 11: Postprocessing

Figure 2.6: Contours of Thickness at the 40th Timestep

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2D Axisymmetric Blow Molding

Figure 2.7: Contours of Thickness at the 60th Timestep

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Step 11: Postprocessing

Figure 2.8: Contours of Thickness on the Full Blown Bottle at t = 0.1 s

6. Create and save an animation.

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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c. Click the start button .

d. Enable Save Movie to save the animation as a file.

7. Display contours of velocity in the fluid region.

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

Figure 2.9: Final Velocity Distribution

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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2.17.1. Remeshing Technique


2.17.2. Master Moving Surface
2.17.3.Time Marching Scheme

2.17.1. Remeshing Technique


The purpose of the remeshing technique is to relocate internal nodes according to the displacement
of the boundary nodes due to the motion of the free surface. In blow molding applications, the finite-
element mesh undergoes large deformations, especially extension. Thin-shell remeshing is designed to
handle blow molding simulations and is able to cope with such large nodal displacements.

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.

2.17.2. Master Moving Surface


In this problem, the intersection of SUBDOMAIN_1 with BOUNDARY2 is a free surface that comes into
direct contact with the mold. This surface undergoes maximum deformations and so it is defined as
the master moving surface.

2.17.3. Time Marching Scheme


Since this problem is time-dependent, parameters such as flow rate, boundary conditions, or material
data are time-dependent. In such problems, the solution of the partial differential equations has to be
satisfied at a discrete set of times starting from an initial time. The solution of the equations is obtained
by specific integration methods known as predictor-corrector methods. The predictor method calculates
a first guess of the solution at a specific time step. This guess is then used by the corrector method to
compute the real solution at the time step considered. The data for the time marching scheme is
provided in this menu.

Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
30 of ANSYS, Inc. and its subsidiaries and affiliates.

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