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Moldflow CAD Doctor™ Version 2.0 3D CAD Model Fixing, Healing and Simplification Software

Moldflow CAD Doctor™ Version 2.0 3D CAD Model Fixing, Healing and Simplification Software. Table of Contents. The Problem & The Moldflow Solution CAD Doctor Workflow and Key features Case Study Licensing, Supported Hardware & Languages CAD Doctor Benefits Summary. Problem Definition.

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Moldflow CAD Doctor™ Version 2.0 3D CAD Model Fixing, Healing and Simplification Software

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  1. Moldflow CAD Doctor™ Version 2.03D CAD Model Fixing, Healing and Simplification Software

  2. Table of Contents • The Problem & The Moldflow Solution • CAD Doctor Workflow and Key features • Case Study • Licensing, Supported Hardware & Languages • CAD Doctor Benefits Summary

  3. Problem Definition • Problem: • Time spent in creating a “suitable” analysis mesh is too long • Causes: • Increasing complexity of plastic parts • Intricate features • Highly contoured • Fillets & Blends & Chamfers • Geometry translation issues • Minimal MPI & MPA geometry clean-up functionality

  4. Introducing Moldflow CAD Doctor • CAD Doctor Allows you to: • Check • Correct & • Simplify 3D CAD models • Export high quality models for use with MPI or MPA

  5. Target User • MPA users who prefer to work with native CAD or IGES models • MPI/Fusion & MPI/3D users • Nearly 60% models imported into MPI are IGES or native CAD format • CAD Doctor is best suited for such solid models

  6. UDM Moldflow CAD Doctor 2.0 • CAD Doctor Allows you to: • Check, Correct & Simplify 3D CAD models • Export high quality models for use with MPI or MPA ・IGES ・CATIA V４ ・Parasolid ・STEP ・Pro/E ・SolidWorks ・CATIA V5 MDL

  7. MPA MPI Supported Models • Input • IGES • CATIA V4 (requires add-on license) • CATIA V5 ** • Parasolid ** • Pro/ENGINEER ** • SolidWorks ** • STEP ** ** Requires MDL • Output • MPI – solid surfaces • MPA – faceted (STL) mesh

  8. Table of Contents • The Problem & The Moldflow Solution • CAD Doctor Workflow and Key features • Case Study • Licensing, Supported Hardware & Languages • CAD Doctor Benefits Summary

  9. Typical Usage Workflow • Step 1 – Check Geometry for errors • Step 2 – Stitch free edges • Step 3 – Heal geometry to ensure model integrity • Step 4 – Identify complex geometry features • Step 5 – Simplify model by suppressing complex geometry features • Step 6 – Export a fixed and optimized model for use with MPI or MPA

  10. Step 1 - Geometry Checking • Check for 30 different types of model quality issues, e.g., • Free edges • Intersecting edges • Intersecting surfaces • Overlapping edges • Duplicate edges • Sliver edges • Etc.

  11. Can compromise mesh quality Problems in Geometry Impact of Geometry Errors in MPI • Uncorrected geometry errors lead to… • Gaps in mesh • Unmeshed surfaces • Overlaps and intersections in mesh • Poor aspect ratios

  12. After Free Edge Stitching Before Free Edge Stitching Step 2 - Stitch Free Edges • Automatically stitch free edges in the model • Free edge stitching will not fix all issues, but the healing step will

  13. Drill-down to correct challenging problems After Healing Before Healing Step 3 - Geometry Healing • Healing is a crucial step to ensure the integrity of the model • Healing targets the following problems: • Self intersecting surfaces and curves • Gaps between trim curves and base surfaces • Sliver Faces • Short Curves

  14. And remove them Identify small features Steps 4 & 5 - Geometry Simplification • Optimize the model for use with MPA or MPI by simplifying features that add complexity to the geometry • Automatically Identify & Remove: • Small fillets, radii, slivers • Holes • Boss/Ribs • Chamfers • Tool symbols • Embossing • Logos • Lettering

  15. After Simplification Before Simplification Geometry Simplification Example

  16. Miscellaneous Features • Geometry Creation Tools • Create simple geometry • Create points, curves, faces and surfaces • Measurement Tools • Distance between two entities • Enclosed angle between two curves • Highlight shortest curve in the model and display its dimensions • Normal vector of a surface • Curvature of a selected curve on a graph

  17. Example # 1 Before using Moldflow CAD Doctor Input model: IGES After using Moldflow CAD Doctor Input model: IGES # of Elements: 7206 Analysis CPU time: 314 sec Max. Aspect Ratio: 185.2 Av. Aspect Ratio: 3.05 Mesh Match Ratio: 88.4% # of Elements: 6322 Analysis CPU time: 267 sec Max. Aspect Ratio: 94.8 Av. Aspect Ratio: 2.86 Mesh Match Ratio: 90.0%  All statistics improved. Analysis time reduced by 15%.

  18. Example # 2 Model quality problems Uneven fill pattern STL Moldflow CAD Doctor Regular STL model ・Poor model quality ・Asymmetric fill pattern & temperature profile Model fixed & optimized in Moldflow CAD Doctor ・ Improved model quality ・ Uniform fill pattern & temperature profile

  19. Table of Contents • The Problem & The Moldflow Solution • CAD Doctor Workflow and Key Features • Case Study • Licensing, Supported Hardware & Languages • CAD Doctor Benefits Summary

  20. Case Study • Objective • Compare mesh quality before and after using Moldflow CAD Doctor • Model Details • Medium-size automotive Front Grille • Numerous small features: • Fillets • Unbendable Curves • Sliver faces • Chamfers • Etc.

  21. Table of Contents • The Problem & The Moldflow Solution • CAD Doctor Workflow and Key Features • Case Study • Without CAD Doctor • WITH CAD Doctor • Licensing, Supported Hardware & Languages • CAD Doctor Benefits Summary

  22. Working withoutCAD Doctor

  23. Poor surface quality Many gaps in the model Import IGES directly to Moldflow Plastics Insight

  24. Mesh the model • Global edge length: 5 mm • Chord height: 1 mm

  25. Problems with Generated Mesh 1 2 3

  26. Issue # 1 Model details lost in translation

  27. Issue # 2 High Aspect ratio elements caused by small fillets

  28. Issue # 3 Holes/Gaps in the mesh

  29. Checking Mesh Statistics • Numerous Mesh Errors • High element count: 50393 • Free edges: 2182 • Non-manifold edges: 7 • Overlaps: 1 • Intersections: 502 • High aspect ratio: 447.58 • Mesh Match ratio: 87% • Reciprocal ratio: 81.7%

  30. Working without CAD Doctor causes… • Unproductive time fixing the mesh models • Long analysis times due to high number of elements • Poor mesh model causes unreliable results • Incorrect thickness auto-determination (fusion) • Bad results from unnecessary small features such as fillets, chamfers, sliver faces, holes etc. • Reciprocal percentage too low for warpage analysis Use CAD Doctor to get good data, fast!

  31. Table of Contents • The Problem & The Moldflow Solution • CAD Doctor Workflow and Key Features • Case Study • Without CAD Doctor • WITH CAD Doctor • Licensing, Supported Hardware & Languages • CAD Doctor Benefits Summary

  32. Working withMoldflow CAD Doctor

  33. Automated Work Flow Import Moldflow CAD Doctor High Quality CAD data CAD data Check Simplify Heal Export Perfect mesh !!! Mesh MPI

  34. Checking Model for Problems Identify errors in the model automatically

  35. After Stitching & Healing Steps All errors are fixed Perfect surface finish !!! Model is now ready for simplification

  36. Geometry Simplification Small features detected

  37. Suppress Small Features Small features removed

  38. Importing Revised Model into MPI No gaps in the model Very good surface quality

  39. Remeshing the Model • Global edge length: 5 mm • Chord height: 1 mm

  40. Regenerated Mesh

  41. Mesh Statistics WITH CAD Doctor • Mesh statistics are very good (no need for any further mesh editing) • # of elements: 50393  31920 • Free edges: 2182  0 • Non-manifold edges: 7  0 • Overlaps: 1  0 • Intersections: 502  0 • Aspect ratio: 447.58  13.09 • Mesh Match ratio: 87%  92.5% • Reciprocal ratio: 81.7%  88%

  42. Table of Contents • The Problem & The Moldflow Solution • CAD Doctor Workflow and Key Features • Case Study • Licensing, Supported Hardware & Languages • CAD Doctor Benefits Summary

  43. Hardware, Licensing & Language Options • Supported Hardware • Windows 2000 and XP • Licensing • Uses Moldflow Product Security • Node-locked and Floating versions available • Supported Languages • English • German • Japanese

  44. Table of Contents • The Problem & The Moldflow Solution • CAD Doctor Workflow and Key Features • Case Study • Licensing, Supported Hardware & Languages • CAD Doctor Benefits Summary

  45. Benefits of Using Moldflow CAD Doctor • Get highly reliable analysis results, fast! • Drastically reduce project time • Reduce mesh modification time from ~1 day to ~ 10 minutes • Reduce model clean up time from ~ 3 days to ~ 2 hrs • Correct issues related to small features easily • Meshing is not a problem any more creating better market opportunity • … and get started right away because the SW is very easy to use!

  46. Thank you Beginning of presentation

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