Benjamin: “Yes, sir.”

Mr. McGuire: “Are you listening?”

Benjamin: “Yes, I am.”

Mr. McGuire: “Plastics.”

- The Graduate, 1967

Dassault Systemes SolidWorks Corp this week announced a new product: SolidWork Plastics.

Actually, it’s not strictly new, and it’s not just one product. SolidWorks Plastics was developed and originally sold by Simpoe, a provider of plastics injection molding simulation software. Dassault entered into an agreement whereby SolidWorks will now sell the software under their banner.

There are two versions of SolidWorks Plastics. The Professional version (US$4,995.00) is for people who design plastic injection molded parts. The Premium version (US$14,995.00) is for mold designers.

If you’ve been using SolidWorks for a few years, you might remember that the 2007 version came with MoldflowXpress, a limited function molding simulation tool that included a generic materials database, part-only analysis, single gate location, and a go/no go result, showing whether a part would fill. MoldflowXpress was what you might call a “good enough to be useful, not good enough to take sales from our more expensive products” tool. Still, it was pretty useful, and nicely integrated into SolidWorks. It became unavailable about the same time SolidWorks’ arch-competitor Autodesk purchased Moldflow. (Imagine that!)

After MoldflowXpress went away, Simpoe was one of the companies that stepped up to the plate, to offer a “gold” partner product for plastics simulation running embedded in SolidWorks.

I’m guessing that users were happy enough with the Simpoe products that Dassault decided to bring them into the fold.

SolidWorks Plastics Professional is quite a bit more capable than MoldflowXpress ever was. It allows parts designers to verify uniform wall thickness (a fundamental best practice of plastics part design), optimize the thickness of features such as reinforcing ribs to avoid sink marks, and predict (and either minimize or eliminate) weld lines. It includes a material database with around 5,000 grades of commercial plastic. It has a very useful set of capabilities for people who design plastic injection molded parts. (And SolidWorks is probably the leading CAD tool for this purpose.) The important thing about SolidWorks Plastics Professional is that it lets parts designers verify manufacturability early in the design process, long before cutting any tool steel. It’s not trivially inexpensive, but compared to the cost of a few trashed molds it’s a bargain.

SolidWorks Plastics Premium is for mold designers. It’s a big-time full-function mold analysis tool, supporting analysis of single-cavity, multi-cavity and family mold layouts, runner balance analysis, and providing a wide range of report plot types for identifying and rectifying problems. It comes with automated report generation capabilities, for sharing results with others. A significant benefit of SolidWorks Plastics Premium, when compared to standalone analysis solutions, is that runs embedded inside of SolidWorks, and uses familiar workflows. Its learning curve should be comparatively easy for experienced SolidWorks users. It should go without saying (but probably doesn’t) that learning curve and usability are exceedingly important, even for people who are domain experts.

While SolidWorks Plastics isn’t technically an entirely new product, now that it’s part of the SolidWorks family, it’ll probably get more attention from resellers, and more awareness among users.  All told, a good thing.

DS SolidWorks Corp. www.solidworks.com/sw/products/plastics-injection-molding.htm

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A couple of years ago, Autodesk Labs previewed a product, Project Krypton, which ran inside of 3D CAD programs (including Autodesk Inventor, DS SolidWorks, and PTC Pro/E), and gave real-time feedback on manufacturability, cost, and sustainability of plastic injection molded parts.

Project Krypton has now reappeared, in commercial form, as Autodesk Simulation DFM (Design For Manufacturing.) It works as a plug-in, running in a number of versions of Inventor, Inventor LT, Wildfire, Creo, and SolidWorks. It is available as a subscription benefit for Autodesk Simulation Moldflow Adviser 2013 subscribers, or as a stand-alone product, at US$2,000 for a license to run on any of the supported CAD platforms.

It’s reasonable to argue that engineers who are designing plastic parts should know enough to be able to recognize manufacturability, cost, or sustainability problems. And, if they don’t, they should take the time to learn (for example, by taking a few hours to read any of the many freely available books on the subject, such as General Design Principles for DuPont Engineering Polymers.) Even though that argument is reasonable, it doesn’t recognize human nature. People, even engineers who should know better, don’t always take the time to “read the manual.” Often, it makes sense to build the “manual” into the tools that engineers use every day. Simulation DFM does that, and quite a bit more.

For inexperienced designers, Simulation DFM provides quick feedback to help them avoid rookie mistakes. It’s sort of like an “idiot light” on a car’s dash, that warns you when something is wrong. And while old-hands might say they prefer gauges to idiot lights, experience has shown that idiot lights are useful to experts (even F1 drivers and fighter pilots) for catching their attention, and getting them to actually look at the gauges.

Simulation DFM doesn’t require that users have any background in molding simulation. It uses “green is good, yellow is not so good, and red is bad” indicators to identify potential manufacturing, cost and sustainability issues, showing the source and location of the problem. Any issues that pop-up can be expanded upon, to provide more detail on the exact source of the problem, even showing, for example, mold filling analyses.  The software requires no additional training, and doesn’t require much user input.

The open question with Simulation DFM is “how good is it?” Since it’s based on the Autodesk Moldflow simulation engine, it should be quite good, even for relatively complex parts (though it doesn’t support multi-body parts.) Yet, even if its capabilities were modest, it would still be of value, in either helping beginning designers to learn good design practice, or helping old-hands catch mistakes they might have otherwise missed.

As an engineer, I’ve long had the habit of using the “anything I can see” test to evaluate the usefulness of software. I look around the room, looking at anything I see, and ask myself “would this software have helped the engineers who designed these things?” In this case, as I sit in my office, I can see at least 20 items (without even turning to look behind me), each with multiple injection molded parts, that would have been quicker, easier, and less-expensive to design, had their engineers had access to up-front DFM software, such as Autodesk Simulation DFM.

The most significant benefit of Autodesk Simulation DFM comes not from its detailed capabilities, but rather from its clean integration into the design workflow. A user need not press a button, or take any specific action when designing a plastic part to benefit from it. All they need to do is notice, as they design, whether the software has picked up any obvious red-flags.

That Autodesk decided to make Simulation DFM available for Pro/E, Creo, and SolidWorks (as well as Inventor) shows that rational minds sometimes do prevail: There are untold thousands of PTC and SolidWorks customers who design plastic injection molded parts, and who are unlikely to switch primary CAD tools any time soon. The challenge Autodesk is going to face is in getting Simulation DFM in front of those users (since PTC and SolidWorks sales reps and dealers are not likely to recommend it.) Maybe not so much of a challenge: Many of Autodesk’s existing Moldflow customers are Pro/E and SolidWorks users.

There’s a certain charm to software that does something of great value, but does not impose any extra demands on its users. Autodesk Simulation DFM looks like it may be that kind of product.

Autodesk www.autodesk.com

Autodesk SimSquad simsquad@autodesk.com

3D CAD Tips

The software is an application-specific extension to the Opera electromagnetic simulation package. It provides a front-end to the simulator that speeds design entry by means of Wizard-style dialog boxes. Users select the style of motor or generator they want to design from a library of all common types, including induction, brushless permanent magnet and switched reluctance motors, and synchronous motors or generators. Then, dialog boxes allow you to enter parameters to define mechanical geometry, material properties and electrical data, and the FEA model is automatically created.

The use of parameterized models and the ability to load and modify previous designs have made it possible for users to perform ‘what-if?’ design investigations. Cobham has integrated a unique optimization tool that makes it simple for users to find the best solution across the design space. While auto-optimization tools are not new, they usually require manual intervention if the globally optimal solution is to be found, and the simulation times involved often make this impractical. The Optimizer selects and manages multiple goal-seeking algorithms including stochastic, descent, particle swarm, and Kriging to eliminate the need for manual intervention.

Setting up an Optimizer run from the Machines Environment is easier. Because most FEA simulations can take as little as a few seconds, the integrated software makes it possible to thoroughly explore the design space. Thousands of simulations can typically be executed within hours, making the perfect solution achievable for all users – without expert assistance.

 The 2D Machines Environment has an extensive library of rotating machine design styles and design components. However, if there are still any unusual features that need to be incorporated in designs, users also have open access to the scripts that generate the models, and can modify them at will to automate proprietary motor and generator design concepts. A library of common material properties is also included in the design software. Again, if users employ any special materials, such as an unusual grade of steel for laminations, then a new menu item can be created. Cobham will also generate custom scripts for users on request. A 3D version of the Machines Environment is available.

Cobham Technical Services

www.cobham.com/technicalservices

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Dassault Systèmes worked with Mougin and his team to simulate the iceberg’s trajectory and its evolution by taking into account data such as variations in ocean temperatures, wind force and direction, sea currents, and boat drag force. They inserted this data into a 3D model of the iceberg to simulate what would happen all along the voyage.

The critical challenge presented to Dassault Systèmes’ engineers was to demonstrate, using virtual technology, the technical feasibility of displacing the iceberg in a controlled manner while reducing its melting. The project, managed by Cédric Simard, Interactive Strategy & Marketing Project Director at Dassault Systèmes, involved a number of steps:

1. Model the iceberg with CATIA based on a cloud of points obtained by scanning a real iceberg with radar.
2. Calculate and simulate the way the iceberg would melt using CATIA Systems and SIMULIA.
3. Simulate the way the iceberg would melt if surrounded by a protective isothermal “skirt” imagined by Mougin to slow the melting process.
4. Calculate how much fuel the boats would consume depending on the winds and currents encountered along the way

Various scenarios were simulated, such as number of boats needed, different departure dates and climate conditions, and the behavior of the boats and iceberg in the event of a storm or turbulence. In addition to enabling the team to visualize these scenarios, the simulation also allowed the scientists to test how to deploy the isothermal skirt around the iceberg.

Dassault Systemes

www.3ds.com

3D CAD Tips

The ability to model the mechanical responses of cells to physical stimuli presents many opportunities to the world of medical research. Chief among these is the ability to further our understanding of the etiology of many diseases. There are a wide variety of diseases whose etiology or clinical presentation are either known or suspected to be related to abnormal cellular mechanics, alteration of the cellular processes that regulate transmission of mechanical stimuli into biochemical responses, or changes in tissue structure. Because physical distortion can affect cell how cells grow, specialize themselves for specific tasks, move, and whether they live or die, the ability to predict the mechanical behavior of cells in response to pathological conditions and medical treatments may be critical to prevention and treatment of many of these diseases.

VSMCs are modeled here using a linear elastic material model together with truss elements in Marc which simulate the cytoskeletal fiber network that provides the cells with much of their internal structural support. Geometric characterization of single VSMCs in 2D cell culture is achieved using confocal microscopy in conjunction with novel image processing techniques. These techniques allow for the creation of representative 3D model structures consisting of the cell nucleus, cytoplasm, and actin stress fiber network of each cell, which are then imported into Patran for structural analysis with Marc. Mechanical characterization is achieved using atomic force microscopy (AFM) indentation and stress relaxation techniques. Material properties for each VSMC model are input based on values individually obtained through experimentation, and the results of each model are compared against those experimental values.

This study is believed to be a significant step towards the viability of finite element models in the field of cellular mechanics because the geometries of the cells in the model are based on confocal microscopy images of actual cells with mechanical data obtained immediately prior to imaging and thus, the results of the model can be compared against experimental data for those same cells. These types of models could one day be used to decrease the cost and speed the development of new drug discovery and regenerative medicine therapies, as well as increase our understanding of the relationship between the structure and function of biological cells.

MSC Software

www.mscsoftware.com

3D CAD Tips

The software also provides a secure Proctored Browser which reduces cheating by ensuring students stay inside the Maple T.A. environment until the test or assignment is completed. While using this browser, students cannot access other web sites or programs on their computer. Other security enhancements include the ability to require that Maple T.A. tests are taken from a specified list of IP addresses, to ensure students can take assignments only from approved computers or labs. These and other security features are also available in the Maple T.A. MAA Placement Test Suite for institutions that want greater security in their placement testing process.

Maplesoft

www.maplesoft.com

3D CAD Tips

SimPowerSystems lets engineers model and simulate electrical power ystems in Simulink for automotive, aerospace, defense, and industrial applications. SimPowerSystems models can connect to models built using Simscape and other domain-specific add-on products such as SimMechanics and SimHydraulics.  This helps engineers to detect integration issues between electrical, mechanical, and control systems early in the development process before any physical hardware is built.

Key new capabilities include:

Interface Elements to connect SimPowerSystems and Simscape circuits, enabling engineers to more easily extend SimPowerSystems models to other physical domains and create custom physical modeling components using the Simscape language

Support for Simscape Editing Mode, allowing all other Simscape users to work with SimPowerSystems models including viewing, simulating, changing numerical parameters, and generate C code from the model.

MathWorks

www.mathworks.com

3D CAD Tips

“Autodesk provides the technology and expertise to streamline our entire design process, so we can beat our competition on the track and in the marketplace. Now that we have incorporated Autodesk Product Design Suite, it has enabled us to further enhance our workflow.”

Following a race weekend, the drivers brief Kelly Racing’s in-house design and engineering team on what precisely went right and wrong during the race. The designers then set to work with Inventor Professional software to make modifications to the existing car parts that can enhance performance and save the team time. For example, improvements to the front end of the car, in particular the suspension assembly, has increased traction and grip by 8%, leading to faster lap times or shaving 1% of total car weight through design and material optimization.

Even the most minor modifications play a vital role in a sport where a fraction of a second can be the difference between first and 21^st place. Engineers then test revised designs with Autodesk Simulation CFD to optimize aerodynamic performance and ensure the components are able to perform at speeds of up to 300 kilometers (188 miles) per hour. Autodesk Simulation Multiphysics software is also used to predict and validate the mechanical performance of the new components. Autodesk Vault Professional data management software helps manage the design process from initial concept to final release, providing the engineering team with greater control over the design process right up until the component or part is manufactured, released to the race department and put on the car.

Embracing Digital Prototyping has been a winning strategy for Kelly Racing. A new racing team typically takes six or more years to register its first win, but just barely into its third season, Kelly Racing has already scored two victories along with nine podium finishes.

Autodesk, Inc.

www.autodesk.com

3D CAD Tips

According to Alan McKim, SimuTech vice-president of customer service, “We were pleased to work with Toyota and Tiercon to assure they achieved the results they were looking for. SimuTech is ideally positioned to help other companies realize that upfront analysis in the design process helps them save time and money, as well as optimize designs. ANSYS’ advanced physics modeling capabilities combined with engineering expertise can eliminate the need for trial and error testing. Though the majority of our work is providing engineering technical support and guidance to our ANSYS software users, were more than happy to work the Tiercon and Toyota by providing advanced consulting services for this particular analysis.”

SimuTech Group
www.SimuTechGroup.com

3D CAD Tips

All parameters specified in Creo can be interactively linked with your simulation geometry which enables multiphysics simulations involving parametric sweeps and design optimization to sync up with the CAD program. The LiveLink for Creo includes all the capabilities of the Comsol CAD Import module and enables import and defeaturing of CAD files from all major CAD packages.

In addition, the Parasolid geometry kernel from Siemens PLM Software is now the default geometry kernel for those who use the CAD Import module and the LiveLink products for CAD. Parasolid enables the handling of more advanced geometry objects for any of the LiveLiink products, including versions for AutoCAD, Inventor, Creo Parametric, Pro/E, SolidWorks, and SpaceClaim.

Comsol

www.comsol.com

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