Adv Warp60 Practice

Moldflow Plastics Insight®
Release 6.0
Advanced Simulation: MPI/Warp Training

Practice
Advanced
Simulation:
MPI/Warp
P RACTICE FOR MPI 6.0
June 2006
Copyright © June 2006 Moldflow Corporation.
All Rights Reserved.
All rights reserved. No part of this may be reproduced in any form or by any means, electronic, mechanical photocopying or
otherwise, without prior written permission of the copyright owner.
Published by Moldflow Corporation,
While every effort has been made to avoid errors in the text, the author and publisher shall not be under any legal liability of any
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About this manual
The Advanced Simulation MPI/Warp manual is designed for current users of MPI. In
creating this manual, our goal was to introduce you to uses of MPI/Warp. The
information provided here is necessary to proceed to warpage.
There is a significant amount of information in this manual, more information than can
be absorbed during the class. This manual should be useful as a handy desk reference
when back in the office.
Using this manual

This manual is separated into several chapters and appendices. Each of the chapters
covers a specific topic and includes the following sections:
Aim
Describes the learning objectives of the chapter.
Why Do It
Outlines the reasons for following the prescribed guidance, suggestions, and
methodology within the chapter.
Overview
A complete outline of what will be covered within the chapter.
Practice
This section contains hands-on exercises used to reinforce what was learned. The
practice section guides the user through the steps necessary to complete a project.
v
Formatting used in this manual
Tasks
: To perform a step on the computer
1. When the Task icon is shown, below it is a list of numbered steps to complete the
task.
1.1. Tasks can have a sub-step,
• A bulleted list provides information on a step, or a non-sequential actions to be
done,
h A second level bulleted list to provide information on a sub-step.
2. A task is used in the practice section of a chapter to indicate steps to be done on the
computer.
Bulleted lists
• A bulleted list contains a number of items that have no particular order.

• It does not represent a list of steps that have to be followed in sequence.
Ruled paragraph
Text from a computer screen is shown between ruled lines.
Tip
/ A tip is a useful piece of information that is normally associated with a task or procedure.
Something that can be done to make a task easier or more efficient.
Note
3 A note is generally used to highlight some background or theoretical information.
vi
Training files setup
The files required for the Advanced Simulation:MPI/Warp class are organized into a
folder. The table below shows the required folder, study files, and results necessary for
the class. All the results that need to be run will be provided in class. However if for some
reason the results are not available, they can be obtained by analyzing the necessary
studies.
Table 1: Files Required for the Advanced Simulation:MPI/Warp Class
Folder name Study Files Needed Results needed

Warpage_Diagnostics Cover Original.sdy Cool + Flow on both
Dustpan Original.sdy
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Contents
About this manual ........................................................................................................................ v
Using this manual ......................................................................................................................... v
Formatting used in this manual ................................................................................................ vi
Training files setup ..................................................................................................................... vii
CHAPTER 1
Warpage Overview ................................................................................... 1
CHAPTER 2
Design Influences on Warpage .............................................................. 3
CHAPTER 3
Warpage Analysis Process ..................................................................... 5
CHAPTER 4
Determine the Magnitude of Warpage ................................................... 7
Practice - Determine the Magnitude of Warpage.................................................................... 9
Warpage analysis on the cover...................................................................................... 10
Design criteria .......................................................................................................... 10
Setup .......................................................................................................................... 11
Running the warpage analysis................................................................................ 11
View the results........................................................................................................ 11
Results discussion.................................................................................................... 14
Warpage Analysis on the Dustpan ............................................................................... 15
Design criteria .......................................................................................................... 15
Setup .......................................................................................................................... 16
View the Results ...................................................................................................... 17
Overall warpage results ....................................................................................... 17
Using an anchor plane ........................................................................................ 18
Using the query result command ...................................................................... 19
Using a path plot .................................................................................................. 20
Results discussion.................................................................................................... 22
Competency check - Chapter name ............................................................................. 23
Evaluation Sheet - Chapter name................................................................................. 25
CHAPTER 5
Determine the Cause of Warpage ........................................................ 27
Practice - Determine the Cause of Warpage.......................................................................... 29
Warpage analysis on the cover...................................................................................... 30
Design criteria .......................................................................................................... 30
Setup .......................................................................................................................... 31
View the results........................................................................................................ 31
ix
Path plots ...............................................................................................................33
Warpage Analysis on the Dustpan................................................................................ 35
Design criteria........................................................................................................... 35
Setup .......................................................................................................................... 36
Running the warpage analysis ................................................................................ 36
View the results ........................................................................................................ 37
Interpret the results ..............................................................................................38
Summary - Determine the cause of warpage results.................................................. 41
Cover.......................................................................................................................... 41
Dustpan ..................................................................................................................... 42
Competency check - Determine the Cause of Warpage ........................................... 43
Evaluation Sheet - Determine the Cause of Warpage ............................................... 45
CHAPTER 6
Reducing Warpage .................................................................................47
Practice - Reducing Warpage .................................................................................................... 49
Warpage Analysis on the Cover Model........................................................................ 50
Design criteria........................................................................................................... 50
Setup .......................................................................................................................... 51
Review the cause of warpage ................................................................................. 51
Solve the warpage problem .................................................................................... 51
Make a change ......................................................................................................51
Warpage Analysis on the Dustpan................................................................................ 53
Design criteria........................................................................................................... 53
Setup .......................................................................................................................... 54
Review the cause of warpage ................................................................................. 54
Solve the warpage problem .................................................................................... 54
Make a change ......................................................................................................54
Possible solutions ............................................................................................................ 56
Cover.......................................................................................................................... 56
Dustpan ..................................................................................................................... 58
Competency check - Chapter name.............................................................................. 61
Evaluation Sheet - Chapter name ................................................................................. 63
x
CHAPTER 1
Warpage Overview
There is no practice for this subject.
Warpage Overview 1
2 Chapter 1
CHAPTER 2
Design Influences on
Warpage
Design Influences on Warpage 3

4 Chapter 2
CHAPTER 3
Warpage Analysis
Process
Warpage Analysis Process 5

6 Chapter 3
CHAPTER 4
Determine the Magnitude

of Warpage
Aim
The aim of this chapter is to learn how to determine how much a part will warp using
both Fusion and Midplane models.
Why do it
Determining the magnitude of warpage is the first warpage analysis that is done. The
results are compared to the design criteria of the part to determine if the warpage is
acceptable or not. If the warpage is not acceptable, the warpage must be reduced.
Overview
In this chapter you will look at and use the procedures for determining the magnitude of
warpage for both Midplane and Fusion type models. The techniques are different due to
the different structural analysis capabilities of Midplane and Fusion models.
With midplane models an automatic warpage analysis is performed. This is a
combination of small deflection, buckling and possibly large deflection analysis.
The warpage analysis performed on Fusion models is done using a small deflection
analysis only.
Determine the Magnitude of Warpage 7

8 Chapter 4
Practice - Determine the Magnitude of
Warpage
This chapter has several models that are used for practice and are described below. At
least the first one should be analyzed. Do the others as time permits.
Table 1: Models used for molding window analysis

Description Model
Cover: starts on page 10
The cover is midplane model using a fiber filled nylon
material.
Dustpan: starts on page 15

The dustpan is a Fusion model using an unfilled
polypropylene.
Practice - Determine the Magnitude of Warpage 9

Warpage analysis on the cover
Design criteria
The cover will be assembled with other components along the bottom edge of the part.
To meet assembly requirements the bottom edge needs to be flat within the warpage
specifications. If changes need to be made to reduce the warpage, the part design cannot
change but the gate location and processing conditions can. The current gate location is
through a pin on the underside of the part. Subgates can also be used in the side of the
part, and a hot drop can be used on the top of the part.
Table 2: Design Criteria

Project/Design Parameters
Model Type Midplane
Material 33% Glass Filled Nylon
Minimum warpage criteria Part bottom edge must be flat within 1.0 mm total variation in
the global Z direction as defined by 3 corners of the bottom
edge.
Figure 1: Cover model
In this chapter you will run a warpage analysis to determine:

• If the part will buckle or not.
• If the magnitude of warpage in the part will meet the specified minimum warpage
criteria.
10 Chapter 4
Setup
To open a project
1. Click the file open icon or File ¨ Open Project, and navigate to the folder My
MPI 6.0 Projects\MPI_Warp\Warpage_Diagnostics.
2. Double click the project file Warpage_Diagnostics.mpi.
3. Click File ¨ Preferences and ensure that System Units are set to Metric.
To review the model

1. Open the model Cover Original.
2. Investigate the model geometry using the model manipulation tools.
3. Turn on and off the layers.
• Notice there are several layers for the part itself.
• These can be used to aid in the interpretation of the results.
Running the warpage analysis

Since this is a midplane model, the warpage analysis used will determine if the part
buckles or not. The results summary file will be reviewed to determine if the part buckles.
To run the warpage

1. Double-click the Analysis Sequence task and change the analysis sequence to
Cool + Flow + Warp.
2. Double-click the Process Settings Wizard.
3. Navigate to the Warp Settings page.
4. Set the Warpage analysis type to Automatic.
5. Check the Consider corner effects box.
6. Click Finish.
7. Double-click Continue analysis! to run the warpage analysis.
• The analysis will take a short time to finish.
View the results
To determine if the part has buckled

1. Click the Logs box in the study tasks list.
2. Click the Warp tab.

3. Locate the critical load factor.
• This is the lowest positive eigenvalue lambda.
• Be careful to check the exponent.
h An example is given below:
Lowest 2 eigenvalue(s) and corresponding eigenvector(s):

Eigenvalue lambda 1 = 7.96970987e+00
Eigenvalue lambda 2 = -8.60492992e+00
4. Compare the critical load factor to 1.

• If the critical load factor is below 1, the part buckles.
5. Record the results in the table below.
Critical Load Factor Has the part Buckled (Y/N)
The results for the automatic warpage analysis will depend on if the part buckled or not.
Assuming the part did not buckle the warpage results are:
• Deflection, all effects: Deflection.
• Deflection, all effects: X Component.
• Deflection, all effects: Y Component.
• Deflection, all effects: Z Component.
Since the primary warpage criterion is for the part to set flat, the Z component deflection
results are the most important.
To view the deflection results

1. Click on the Deflection, all effects: Z Component results.
2. Open the Warpage Visualization tools with the icon or

Results ¨ Warpage Visualization Tools.
2.1. Click the Scale tool.
2.2. Set the scale factor to 10.
2.3. Uncheck The X and Y directions.
2.4. Click Apply.
• Notice that the deflection has been significantly exaggerated. Since there is a
raised section in the middle of the part, some of the Z deflection is not warpage
but shrinkage.
3. Uncheck all the layers except the Sides layer.
• Now it is much easier to see the deflection of the bottom edge of the part. The
trouble is it is not possible to know how flat it is since you don’t know where 0 Z
is. An anchor plane can be set to define the 0 Z.
You will set an anchor plane in 3 of the 4 corners of the cover at the parting line. With the
anchor plane set the flatness of the cover can be easily determined.
12 Chapter 4
To set the anchor plane
1. Ensure a deflection plot is displayed.
• Anchor planes can only be defined if a deflection plot is displayed.
2. Ensure the Warpage Visualization Tools are open.
3. Enter the nodes 1649, 2250 1573 in the anchor nodes field and hit the Enter key.
These should be 3 of the 4 corners of the cover. See Figure 21.
/ If the node numbers are not known, the best way to assign the anchor plane is with a
deflection scale of 0 and the element lines turned on so you can see the location of the nodes.
Figure 2: Cover anchor locations with Z deflection of the cover sides
The deflection plot can be displayed in another manor to aid in the interpretation of the
flatness of the front edge. This is the path plot. Use the following procedure to set up the
path plot. In the case of the cover, the method used above gives you the results needed,
but the path plot can be a very useful tool.
To use the path plot

1. Click Results ¨ New Plot.
1.1. Click the result Deflection, all effects: Z Component.
1.2. Click Path plot as the plot type.
1.3. Click on the Plot Properties tab.
1.4. Click on the Mesh Display tab.
1.5. Select Element lines for the undeformed part.
1.6. Click OK.

2. Pick the nodes you would like to include.
2.1. Start with the Anchored node.
• It will not be shown as anchored, but pick that location.
2.2. Go around the part and pick nodes. You don’t need to pick every one on the
edge, every 3 to 5 nodes is fine.
• Make sure you pick the four corners.
• The last node picked should be next to the first node. You can’t pick a node to be
first and last.
3. Open the Plot Properties when done picking nodes.
4. Select the Path plot tab.
5. Click Overlay with color plot.
6. If necessary, assign the anchor to the result.
• When this is done, the results will use as a reference the same anchor used
before.
• Figure 3 shows an example of a path plot on the cover.
• With the plot properties, you can now control both the path plot and contour
plot. For instance, you can turn off the element lines.
Figure 3: Path plot of the cover
Results discussion
It is clear from the deflection and path plots that the cover is not flat at all. The bottom
edge deflects well above the tolerance.
14 Chapter 4
Warpage Analysis on the Dustpan
Design criteria
The dustpan must have a flat front edge and a straight handle within the warpage
specifications. If changes need to be made to reduce the warpage, the gate may not
change but the water line locations, water flow rate / temperatures, and processing
conditions can be changed.
Model Type Fusion
Material Unfilled Polypropylene
Minimum warpage criteria Front edge must be flat -0 +0.5 mm relative to the Z direction as
defined by two nodes at both ends of the front edge. Any
deviation in flatness, the center of the dustpan should go in the
positive Z direction.
Handle must flat relative to the Z direction within 0.5 mm along
the length of the handle.
Figure 4: Dustpan model
In this chapter you will run a warpage analysis to determine:

• The magnitude of warpage in the part.
• Whether the part will meet the specified minimum warpage criteria.

Setup
To open a project
To review the model

1. Open the model Dustpan Original.
• Notice there are several layers for the part itself.

Currently with Fusion models, we have to assume the part will not buckle. The vast
majority of parts do not buckle so the assumption is reasonable. Most parts that buckle
are molded with a material with low modulus, or have little structure to the part.
To run the warpage

1. Double-click the Analysis Sequence task and change the analysis sequence to
Cool + Flow + Warp.
4. Check the Isolate cause of warpage box.
5. Check the Consider corner effects box.
6. Click Finish.
7. Double-click Continue analysis! to run the warpage analysis.
• The analysis will take a short time to finish
3 Isolating the cause of warpage being checked is not necessary it just saves a step. If the
warpage is not acceptable, the next step is to isolate the cause. It is being done here so
you don’t need to run another analysis you can just look at the results.
16 Chapter 4
View the Results
The results from a Fusion small deflection analysis will be:
• Deflection, all effects: Deflection.
• Deflection, all effects: X Component.
• Deflection, all effects: Y Component.
• Deflection, all effects: Z Component.
Overall warpage results

Since the primary warpage criterion is for the part to have a flat handle and front edge,
the Z component deflection results are the most important.
To view the deflection results

1. Click on the Deflection, all effects: Z Component results.
2. Open the Warpage Visualization tools with the icon or

Results ¨ Warpage Visualization Tools.
2.1. Click the Scale tool.
2.2. Set the scale factor to 10.
2.3. Uncheck The X and Y directions.
2.4. Click Apply.
• Notice that the deflection has been significantly exaggerated.
• The front edge of the dustpan has a bow in it.
• The handle bends up a bit.
3. Uncheck the result.
• Unchecking the result is done to make it faster to turn on and off layers. If the
computer’s graphics card is very fast, you may not notice a delay when turning
on and off layers when a result is on.
4. Uncheck all the layers except the Lip layer.
• It is easier to see the flatness of the front edge.
5. Click on the Deflection, all effects: Z Component plot.
• Compare the flatness of the front edge compared to the flatness guideline.
• Even without the anchor plane, it is clear the edge is above the limit.
6. Uncheck the result.
7. Uncheck all the layers except the Handle layer.
• It is easier to see the flatness of the handle.
• Compare the flatness of the handle to the straightness guideline.
• Even without the anchor plane, it is clear the handle is above the limit.

Using an anchor plane
An anchor plane will be created on the bottom plane of the dustpan. This plane can be
used to get an overall sense of the warpage of the part, with the reference of the dustpan
setting on the floor.
To set the anchor plane

1. Click off the Result.
2. Click on all the part layers:
• Bottom.
• Inside.
• Sides.
• Edge.
• Lip.
• Handle
• Anchor planes can only be defined if a deflection plot is displayed.
4. Open the Warpage Visualization tools.
4.1. Click the Anchors tool.
4.2. Enter the nodes 756, 779, 1746 in the anchors nodes field.
4.3. Press Enter.
• The node locations should be similar to the ones shown in Figure 5.
4.4. Click Manage Anchor Planes.
4.5. Highlight the Anchor just defined.
4.6. Click Rename.
4.7. Enter the name Back plane and Click OK.
4.8. Click Close.
/ If the node numbers are not known, the best way to assign the anchor plane is with a
deflection scale of 0 and the element lines turned on so you can see the location of the nodes.
18 Chapter 4
Figure 5: Dustpan back plane anchor
Using the query result command

Use the Query Result command to determine the exact values for the handle flatness.
To determine the handle flatness

1. Ensure the Z-component results are on.
2. Click the Scale tool on the Warpage Visualization tools dialog.
2.1. Set the Scale factor to 0.
2.2. Ensure all the scale directions are checked.
2.3. Click Apply.
3. Click the query result icon .

3.1. Enter the Nodes 1652, and 2332.
3.2. Click Query.
h Round red markers show the location of the picked nodes.
4. Set the information to Coordinates+Distance+Shrinkage in the pull down list at
the bottom of the dialog.
5. Set the Coordinates to Global in the pull down list at the bottom of the dialog.
• Your results should look similar to Figure 24.
• The distance in Global Z direction represents the flatness of the handle. It
should be within the flatness guideline.
• Record your results in Table 3 on page 22.

Figure 6: Handle query of the deflection
Using a path plot

Use of the path plot is a good way to look at the flatness of the front edge.
To use the path plot

1. Rotate the part to -40 -40 -40.
2.4. Click on the Mesh Display tab.
2.5. Select Element lines for the undeformed part.
2.6. Select Solid for the element surface display.
2.7. Click OK.
3. Pick the nodes the nodes along the front edge of the dustpan.
3.1. At the rotation of -40 -40 -40, start with the right end of the front edge.
3.2. Pick the nodes that are on the bottom of the dustpan, at the current rotation
they are closest to the top of the screen.
3.3. Pick every other node.
• Make sure you pick both corners.
20 Chapter 4
4. Open the Plot Properties when done picking nodes.
4.1. Select the Path plot tab.
4.2. Click Overlay with color plot.
4.3. Select the Mesh Display tab.
4.4. Select Transparent for the Element surface display.
4.5. Select Feature lines for the undeformed part.
5. Open the Mesh Visualization tools.
5.1. Click the Anchors tab.
5.2. Click the New Button.
5.3. Click OK to accept the Anchor plane name.
5.4. Enter the nodes 184, 284, 723 then press enter.
5.5. Click Manage Anchor Planes.
5.6. Highlight the Anchor just defined.
5.7. Click Rename.
5.8. Enter the name front edge and Click OK.
5.9. Click Close.
5.10.Click the Scale tool.
5.11.Set the Scale factor to 10.
5.12.Uncheck X, and Y directions.
• By defining a new anchor plane, the ends of the front edge have a zero deflection
as there start and end points.
• The plot should look similar to
6. Determine the maximum deflection of the front edge using the path plot results.
Record the results in Table 3 on page 22.

Figure 7: Path plot of the dustpan’s front edge
Table 3: Dustpan Results

Feature Warpage [mm]
Handle
Front edge
Results discussion
Both the front edge and the handle warp well above the tolerances for the features. The
warpage must be reduced.
22 Chapter 4
Competency check - Chapter name
1. On a midplane model, what analysis is run, and what result is looked at to determine if the
part has buckled?
2. For a Fusion model, how do you determine if the part has met the warpage design criteria?

24 Chapter 4
Evaluation Sheet - Chapter name
1. On a midplane model, what analysis is run, and what result is looked at to determine if the
part has buckled?
Answer:
To determine if a midplane model has buckled you should run an automatic analysis. This is a
buckling analysis that runs a large deflection analysis if needed. Then to determine if the part has
buckled, look at the Results summary and look for the lowest positive Eigenvalue Lambda. If it is
less than one, the part has buckled.
2. For a Fusion model, how do you determine if the part has met the warpage design criteria?
Answer:
With a Fusion model, you would compare the deflection results to the design criteria. Normally
an anchor plane needs to be defined so there is a reference for comparing the warpage. When an
anchor plane is used, most of the time the Z deflection will represent warpage.

26 Chapter 4
CHAPTER 5
Determine the Cause of

Warpage
Aim
The aim of this chapter is to learn how to determine the cause of warpage for midplane
and Fusion models.
Why do it
Once we know that the part warps outside of the design criterion, understanding the
causes will enable you to solve the problem.
Overview
To determine the cause of the warpage we need to know if it is a Fusion, or midplane

model. If it is a midplane model, we must also know if the part has buckled or not. The
method of determining the cause of warpage differs depending on whether the part has
buckled or not.
Determine the Cause of Warpage 27

28 Chapter 5
Practice - Determine the Cause of
Warpage

Description Model
material.

polypropylene.
Practice - Determine the Cause of Warpage 29

Warpage analysis on the cover
Design criteria

Model Type Midplane
edge.
In this chapter you will run a warpage analysis to determine the cause of warpage by a
combination of these four variants:
• Differential cooling.
• Differential shrinkage.
• Orientation effects.
• Corner effects.
30 Chapter 5
Setup
To open a project
To review the model

1. Open the model Cover Original.
• Notice there is several layers for the part itself.

Since this is a midplane model, and the cover did not buckle based on the analysis in the
Determine the magnitude of warpage chapter, you will run a small deflection analysis to
isolate the cause of warpage.
To run an isolate cause warpage analysis

3. Set the analysis type to Small Deflection.
4. Ensure the Isolate cause of warpage box is checked.
5. Ensure the Consider corner effects box is checked.
6. Click Finish.
7. Click Create Copy when prompted to delete the existing results.
8. Enter the name Cover Original_SDIW.
• To indicate that it is a Small Deflection, Isolate Warpage analysis.
9. Double-click Analyze now!
• Notice that the previous cool and flow analyses are automatically reused as input
for the warpage analysis as none of the initial inputs have changed.
View the results
To create a 4 windowed plot

1. Turn off all the layers except the Sides layer.
• Now the warpage on the bottom edge of the part will be easier to interpret.

2. Split the display window into 4 components using the command Window ¨ Spit.
• Click the left-mouse button to create the split in the middle to create 4 equally
sized panes.
• If the mouse is moved, the windows will not be the same size.
3. Click Lock ¨ Views ¨ All views.
3 If there is more than one study open, do not use the Lock all views command. Lock
each of the four panes individually, or close the other studies. Rotation performance will
improve if only the 4 windows are locked together.
4. Rotate, pan, and zoom the model to a suitable location so you can see the part
warpage.
To plot the results

1. Plot the Deflection, all effects: Z Component in the upper left window.
2. Plot the Deflection, differential cooling: Z-Component result in the upper right
window.
3. Plot the Deflection, differential shrinkage: Z-Component result in the lower
right window.
4. Plot the Deflection, orientation effects: Z-Component result in the lower left
window.
5. Check to see the if the anchor and scale factor are set.
• If they are not set, do the following:
5.1. Open the Warpage Visualization tools.
5.2. Click the Manage Anchors Planes button.
5.3. Click Anchor(N1649, N2250, N1573).
5.4. Click Activate then Close.
5.5. Click the Scale tab.
5.6. Enter a Scale factor of 10 and Ensure only the Z direction is checked.
5.7. Select Apply on all deflection plots in this study.
5.8. Click Apply then Close.
6. Review the variants and compare them to the All effects. Determine which variant
has the smallest influence on the all effects plot, and click in its window.
6.1. Note the minimum and maximum deflections for the result with the smallest
influence on the all effects plot.
32 Chapter 5
7. Plot Deflection, corner effect: Z-Component in the window that has the smallest
7.1. Ensure the anchor plane and scale factor are applied.
7.2. Compare the deflections of corner effects to the result it replaced.
7.3. Keep the result that has the larger influence on the warpage. If the min. and max
values are smaller for corner effects compared to the plot corner effects
replaced, re-plot the original result.
The four windows should contain the all effects plot and the three highest contributors
to the part’s warpage.
To query the results
1. Use the query results command to pick the bottom node in the corner that
does not have an anchor plane definition in each of the 4 windows. This should be
node 2353.
2. Record the global Z component deflection in Table 6.
3. Determine the primary cause of warpage by the variant that has a Z-component
deflection value closest to that of the All effects.
Table 6: Determine the cause of warpage for the cover

Plot Deflection at Node 2353
All effects: Z Component
Differential Cooling: Z Component
Differential Shrinkage: Z Component
Orientation effects: Z Component
Corner effects: Z Component
The Primary Cause of Warpage is
Path plots
Path plots can be very useful for determining the cause of warpage. If a path plot has
already been created for the mesh, the nodes can be copied from one result to another to
quickly produce the path plot results.
To create path plots

1. Select the list of nodes to create the path plot for.
1.1. Open the Cover Original result.
1.2. Plot the Deflection, all effects:Path Plot result.
1.3. Select the entire list of nodes used to create the path plot.
h Press the Home key.
h Hold the Shift key and press the End key.
h Right click over the list and select Copy, or press Ctrl + C.

2. Activate the Cover Original_SDIW study.
2.1. Ensure the study window is split into 4 windows with no results in the windows.
2.2. Click in the upper left window.
3.5. Click OK.
3.6. Paste the list nodes you copied into the Entity IDs field and press Enter.
h Ensure the anchors are applied and if not apply the anchor.
4. Click in another window and create the path plot for the 4 variants.
See page 41 for a summary of the results.
34 Chapter 5
Design criteria
Model Type Fusion
In this chapter you will run a warpage analysis to determine the cause of warpage by a
combination of these three variants:
• Corner effects.

Setup
To open a project
To review the model

1. Open the model Dustpan Original.
• Notice there are several layers for the part itself. These can be used to aid in the
interpretation of the results.

Currently with Fusion models, we have to assume the part will not buckle. The vast
majority of parts do not buckle so the assumption is reasonable. Most parts that buckle
are molded with a material with low modulus or have little structure to the part. A small
deflection analysis will be run to isolate the cause of warpage.
In the Determine the Magnitude of Warpage chapter, it instructed you to ensure the
Isolate cause of warpage was checked. If this was done, no analysis needs to be done
here.
To determine if an analysis is necessary

1. View the warp results in the study tasks list.
2. Verify the presents of deflection results with the following name in the results
indicating the isolate warpage was run.
• Corner effects.
If the isolate warpage analysis was done the next step is not required.
To run an isolate cause warpage analysis

3. Ensure the Isolate cause of warpage box is checked.
4. Click Finish.
36 Chapter 5
5. Click Create Copy when prompted to delete the existing results.
6. Enter the name Dustpan Original_IW.
• To indicate that it is a Isolate Warpage analysis.
7. Double-click Analyze now!
• Notice that the previous cool and flow analyses are automatically reused as input
for the warpage analysis as none of the initial inputs have changed.
View the results
To create a 4 windowed plot

1. Ensure that only the layers forming the part are on:
• Bottom.
• Inside.
• Sides.
• Edge.
• Lip
• Handle.
2. Split the display window into 4 components using the command Window ¨ Spit.
• Click the left-mouse button to create the split in the middle to create 4 equally
sized panes.
• If the mouse is moved, the windows will not be the same size.
3. Click Lock ¨ Views ¨ All views.
3 If there is more than one study open, do not use the Lock all views command. Lock
each of the four panes individually, or close the other studies. Rotation performance will
improve if only the 4 windows are locked together.
4. Rotate, pan, and zoom the model to a suitable location so you can see the part
warpage.
To plot the results

1. Plot the Deflection, all effects: Z Component in the upper left window.
2. Plot the Deflection, differential cooling: Z-Component result in the upper right
window.
3. Plot the Deflection, differential shrinkage: Z-Component result in the lower
right window.
4. Plot the Deflection, orientation effects: Z-Component result in the lower left
window.

5. Ensure the anchor on the bottom of the dustpan and scale factor are set.
• If they are not set, do the following:
5.1. Open the Warpage Visualization tools.
5.2. Click the Manage Anchors Planes button.
5.3. Click Back Plane.
5.4. Click Activate then Close.
5.5. Click the Scale tab.
5.6. Enter a Scale factor of 10 and Ensure only the Z direction is checked.
5.7. Select Apply on all deflection plots in this study.
5.8. Click Apply then Close.
6. Review the variants and compare them to the All effects. Determine which variant
has the smallest influence on the all effects plot, and click in its window.
6.1. Note the minimum and maximum deflections for the result with the smallest
7. Plot Deflection, corner effect: Z-Component in the window that has the smallest
7.1. Ensure the anchor plane and scale factor are applied.
7.2. Compare the deflections of corner effects to the result it replaced.
7.3. Keep the result that has the larger influence on the warpage. If the min. and max
values are smaller for corner effects compared to the plot corner effects
replaced, re-plot the original result.
The four windows should contain the all effects plot and the three highest contributors
to the part’s warpage.
Interpret the results

There are several ways that the primary cause of warpage can be determined.
1. Graphically look at the four plots and compare the area of interest to the scale.
2. Determine what is the cause of warpage for both:
• The handle.
• The front edge.
• In this case, the maximum deflection for each variant and the all effects is
estimated.
3. Use the query results command.
• Select the same nodes for the all effects results and the variants.
4. Use the path plot type for viewing the deflections.
• Path plots can be very useful for determining the cause of warpage. If a path plot
has already been created for the mesh or another result, the nodes can be copied
from one result to another to quickly produce the path plot results.
38 Chapter 5
To determine the main cause of warpage for the handle
1. Plot the result Deflection, all effects: Z Component.
2. Click the query results command.

3. Enter the nodes 1652, and 2332 then click Query
4. Set the coordinate system to Global.
5. Record the distance in Table 7.
• The represents the warpage of the handle.
6. Repeat the query for the variant Z component results.
To determine the main cause of warpage for the front edge using a path plot
1. Plot the Deflection, all effects:Path Plot result.
2. Select the entire list of nodes used to create the path plot.
2.1. Press the Home key.
2.2. Hold the Shift key and press the End key.
2.3. Right click over the list and select Copy, or press Ctrl + C.
3.1. Click the result Deflection, differential cooling: Z Component.
3.5. Click OK.
3.6. Paste the list nodes you copied into the Entity IDs field and press Enter.
h Ensure the anchors are applied and if not apply the anchor.
4. Open the Warpage visualization tools.
4.1. Click the Anchors tool.
4.2. Click Manage Anchor planes button.
4.3. Activate the Anchor with nodes 184, 284, and 723.
5. Click the query results command and select the maximum value on the curve
and record the value in Table 7.
6. Create the path plots for the other variants.

Table 7: Determine the cause of warpage for the dustpan
Plot Maximum Deflection Maximum Deflection
of the Handle of the Front edge
All effects: Z Component
Differential Cooling: Z Component
Differential Shrinkage: Z Component
Orientation effects: Z Component
Corner effects: Z Component
The Primary Cause of Warpage is
See page 42 for a summary of the results.
40 Chapter 5
Summary - Determine the cause of warpage
results
Cover
Table 8: Determine the cause of warpage for the cover

Plot Deflection at Node 2353
All effects: Z Component ~-2.6 mm
Differential Cooling: Z Component ~-0.1 mm
Differential Shrinkage: Z Component ~-0.6 mm
Orientation effects: Z Component ~-1.6 mm
Corner effects: Z Component ~-0.2 mm
The Primary Cause of Warpage is Orientation effects
Figure 10: Path plots of the cover edge indicating the cause of warpage

Dustpan
Table 9: Determine the cause of warpage for the dustpan

Plot Maximum Deflection Maximum Deflection
of the Handle of the Front edge
All effects: Z Component ~-4.3 mm ~2.0 mm
Differential Cooling: Z Component ~-4.5 mm ~0.8 mm
Differential Shrinkage: Z Component ~0.4 mm ~0.2 mm
Orientation effects: Z Component ~-0.1 mm ~1.0 mm
Corner effects: Z Component ~-0.2 mm ~0.1 mm
The Primary Cause of Warpage is Differential Cooling Orientation then Cooling
Figure 11: Path plots for the dustpan front edge
42 Chapter 5
Competency check - Determine the Cause of
Warpage
1. On a Midplane model that buckles, how is the cause of warpage determined?
2. For a Midplane model that does not buckle or a Fusion model, how do you interpret the
results to determine the cause of warpage?

44 Chapter 5
Evaluation Sheet - Determine the Cause of
Warpage
1. On a Midplane model that buckles, how is the cause of warpage determined?
Answer:
After an isolate warpage bucking analysis is run, the summary file is viewed and the sensitivity
factors are compared. The variant with the highest sensitivity factor is the cause of warpage.
2. For a Midplane model that does not buckle or a Fusion model, how do you interpret the
results to determine the cause of warpage?
Answer:
A small deflection analysis is run. The deflection results are plotted in 4 windows, all effects,
differential cooling, differential shrinkage, and orientation effects. Set up an anchor plane that
relates to the design criterion. Compare the variants to the all effects according to the design
criterion. The variant with the highest magnitude is the dominant cause of warpage.

46 Chapter 5
CHAPTER 6
Reducing Warpage
Aim
The aim of this chapter is for you to learn some techniques to reduce the warpage of a
part. This chapter applies to Midplane and Fusion models.
Why do it
Once you know that a part is going to warp outside the design criteria for that part,
something will need to be changed with the part design, mold design, or processing to
reduce the warpage. In this chapter, you will explore some of the diagnostic tools
available to help reduce the warpage and look at the procedure for reducing warpage.
Overview
You will start by looking at the four causes of warpage:

• Corner effects.
You will look at some of the diagnostic results available to help understand the cause of
the warpage problems. For the cover and dustpan models used in other warpage
chapters, you will develop a solution to the warpage problems.
Reducing Warpage 47
48 Chapter 6
Practice - Reducing Warpage

Description Model
material.

polypropylene.
Practice - Reducing Warpage 49

Warpage Analysis on the Cover Model
Design criteria

Model Type Midplane
edge.
In this chapter you will find a solution to the warpage problem for the cover, following
the limitations specified in the design criteria. Follow these basic steps:
• Review the cause of warpage.
• Look at plots to help understand the cause of warpage.
• Determine a course of action to solve the warpage problem.
• Run the necessary analyses.
• Determine if the warpage has been reduced within the design criteria.
50 Chapter 6
Setup
To open a project
To review the model

1. Open the model Cover Original_SDIW.
Review the cause of warpage

If necessary, plot the results on the study to determine the cause of warpage. You should
find that the cause of warpage for this part is orientation effects.
Solve the warpage problem

Since this is a fiber filled material, and the cause of warpage is orientation, concentrate on
the fiber results, but look at volumetric shrinkage injection time and mold temperature
results as well.
Make a change
Decide what you want to change to try to reduce the warpage. Keep track of your
changes below in Table 12. Run the warpage analysis as necessary to see the effect of
your changes. Repeat as necessary to solve the warpage problem.

Table 12: Results for cover warpage solutions
Study Cause of warpage / Deflection Gate Location
Processing Conditions
Mold ºC Melt ºC Inj. Sec. V/P % Packing Profile
1. Cover OriginalSDIW
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
52 Chapter 6
Design criteria
Model Type Fusion
In this chapter you will find a solution to the warpage problem for the dustpan following
the limitations specified in the design criteria. Follow these basic steps:
• Review the cause of warpage.
• Look at plots to help understand the cause of warpage.
• Determine a course of action that will solve the warpage problem.
• Run the necessary analyses.
• Determine if the warpage has been reduced within the design criteria.

Setup
To open a project
To review the model

1. Open the model Dustpan Original_IW.
Review the cause of warpage

If necessary, plot the results on the study to determine the cause of warpage. You should
find that the cause of warpage for this part is differential cooling.
Solve the warpage problem

Look at the temperature (Top) and Temperature Profile as an XY plot in key areas.
Also look at the inlet properties of the water channels. The water line configuration can
be changed as necessary to get a better result, just as long as the water lines can be cut.
Up to 3 different coolant inlet temperatures can be used. An insert can be used if desired.
Make a change
changes below in Table 1. Run the warpage analysis as necessary to see the effect of your
changes. Repeat as necessary to solve the warpage problem.
To determine how to solve the warpage problems

Look at the temperature (Top) and Temperature Profile as an XY plot in key areas. Also
look at the inlet properties of the water channels. Should they be changed? The water line
configuration can be changed as necessary to get a better result, just as long as the water
lines can be cut. Up to 3 different coolant inlet temperatures can be used. An insert can
be used if desired.
Make a change
changes in Table 13. Run the warpage analysis as necessary to see the effect of your
changes. Repeat as necessary to solve the warpage problem.
54 Chapter 6
Table 13: Results for dustpan warpage solutions
Study Cause of warpage / deflection
Water line layout Packing profile
1. Dustpan Original_IW
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Possible solutions
This section will describe the process followed to solve the warpage problems for each
part. There is undoubtedly more than one way to solve the problems. Below will show
one way for each part.
Cover
The analysis on the cover original indicated that the part did not buckle. Because the
bottom edge needed to remain flat, 3 corner nodes on the bottom edge were used to
define the anchor plane. The layer Sides was used with the Z deflection plots in addition
to path plots of nodes along the bottom edge.
A second analysis was used to isolate the cause of warpage because the first analysis could
only determine if the part buckled or not and what the magnitude of warpage is.
Orientation effects caused most of the warpage.
Possibly a change in gate locations could be used to solve the orientation problems.
Looking at the fiber orientation results, the distribution did not look as uniform as it
could have. Changing the gate locations was investigated first. Several gate locations were
investigated. to see the influence of the gate location on fiber orientation and warpage.
The gate locations investigated are shown in Figure 14A to F. Four of the six gate
locations shown in Figure 14, are used to create a path plot of the bottom edge in
Figure 15. In the examples shown, both the fiber orientation plots and anisotropic
shrinkage plots were used to determine that the gate location in Figure 14F has the lowest
anisotropic in most of the part, in particular the center and the fiber orientation was fairly
symmetric, resulting in a lower overall warpage.
56 Chapter 6
A B C
D E F
Figure 14: Gate locations investigated for the cover
Figure 15: Warpage of the cover edge of four gate locations

Dustpan
An anchor plane along the front edge and path plots indicate that the flatness of the front
edge is well above the front edge tolerence and the primary cause of the warpage is
differential cooling followed closely by orientation effects. All four variants contribute to
the front edge bowing upwards.
Figure 16 shows the original cooling line layout, and two possible solutions. Possible
solution 1 adds cooling in the core and adjusts the position of the other circuits. Possible
solution two used a copper alloy insert to improve the heat extraction of the part. Both
solutions 1 and 2 also need to increase the packing time and pressure to better pack out
the part. As a result of the changes, the warpage contributions of differential cooling,
differential shrinkage, and corner effects bow the corner down, off setting orientation
effects which still bow up. The resulting warpage of the front edge still bows up but only
slightly, well under the tolerence.
The handle is with tolerence with orentation effects and differential shrinkage being off
set be differential shrinkage.
Original layout Possible solution 1 Possible solution 2

Figure 16: Water line layouts for the dustpan
58 Chapter 6
Figure 17: Warpage of the front edge of the dustpan

60 Chapter 6
Competency check - Chapter name
1. If the cause of warpage for a part is orientation effects and the material is an unfilled
amorphous material, what should be investigated, and what possible solutions should be
used?

62 Chapter 6
Evaluation Sheet - Chapter name
1. If the cause of warpage for a part is orientation effects and the material is an unfilled
amorphous material, what should be investigated, and what possible solutions should be
used?
Answer:
One of the first things to check out would be the processing conditions. Look at the
temperatures and shear stress for the part. A molding window analysis could be run to see the
trend of shear stress and temperatures. Possibly molding conditions could be found that would
produce lower levels of shear stress and more uniform temperatures.
The packing should be investigated. Has the gate frozen before packing has been removed? Is
the volumetric shrinkage uniform, or is there a significant gradient in a short distance,
particularly around the gate?
If the processing looks reasonable, look at the filling pattern. If there is significant radial flow
this could be contributing to the orientation problems. If the gate location can be moved to
create a more uniform flow try that.

64 Chapter 6
Index
A
Anchor plane ................................................. 13, 18
Anchors .................................................................32
Automatic, analysis type .....................................11
C
Consider corner effects .......................................31
Corner effects .......................................................11
D
Deflection plots as path plots ............................33
E
Eigenvalue lambda ..............................................12
F
Fusion, determine cause of warpage .................36
I
Isolate cause of warpage .............................. 16, 31
M
Midplane, Isolate warpage ..................................31
P
Path plot ...................................................13, 20, 33
Q
Query result ................................................... 19, 33
S
Scale .......................................................................32
Small deflection analysis .....................................31
W
Warpage
Settings ...........................................................31
Warpage visualization tools ................................12
65
66

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Moldflow Plastics Insight®

Advanced Simulation: MPI/Warp Training

P RACTICE FOR MPI 6.0

All Rights Reserved.

Published by Moldflow Corporation,

Using this manual

Describes the learning objectives of the chapter.

A complete outline of what will be covered within the chapter.

• A bulleted list contains a number of items that have no particular order.

Text from a computer screen is shown between ruled lines.

3 A note is generally used to highlight some background or theoretical information.

Table 1: Files Required for the Advanced Simulation:MPI/Warp Class

Folder name Study Files Needed Results needed

There is no practice for this subject.

There is no practice for this subject.

Design Influences on Warpage 3

There is no practice for this subject.

Warpage Analysis Process 5

Determine the Magnitude

Determine the Magnitude of Warpage 7

Table 1: Models used for molding window analysis

Dustpan: starts on page 15

Practice - Determine the Magnitude of Warpage 9

Table 2: Design Criteria

Figure 1: Cover model

In this chapter you will run a warpage analysis to determine:

 To review the model

Running the warpage analysis

 To run the warpage

View the results

 To determine if the part has buckled

Practice - Determine the Magnitude of Warpage 11

Lowest 2 eigenvalue(s) and corresponding eigenvector(s):

4. Compare the critical load factor to 1.

Critical Load Factor Has the part Buckled (Y/N)

 To view the deflection results

2. Open the Warpage Visualization tools with the icon or

Figure 2: Cover anchor locations with Z deflection of the cover sides

 To use the path plot

Practice - Determine the Magnitude of Warpage 13

Figure 3: Path plot of the cover

Figure 4: Dustpan model

In this chapter you will run a warpage analysis to determine:

Practice - Determine the Magnitude of Warpage 15

 To review the model

Running the warpage analysis

 To run the warpage

Overall warpage results

 To view the deflection results

2. Open the Warpage Visualization tools with the icon or

Practice - Determine the Magnitude of Warpage 17

 To set the anchor plane

Using the query result command

 To determine the handle flatness

3. Click the query result icon .

Practice - Determine the Magnitude of Warpage 19

Using a path plot

 To use the path plot

Practice - Determine the Magnitude of Warpage 21

Table 3: Dustpan Results

To review the model

To run the warpage

To determine if the part has buckled

To view the deflection results

To use the path plot

To review the model

To run the warpage

To view the deflection results

To set the anchor plane

To determine the handle flatness

To use the path plot

To review the model

To run an isolate cause warpage analysis

To create a 4 windowed plot

To plot the results

To query the results

To create path plots

To review the model

To determine if an analysis is necessary

To run an isolate cause warpage analysis

To create a 4 windowed plot

To plot the results

To review the model

To review the model

To determine how to solve the warpage problems