2024-06-07
All Mesh Types in Moldflow: Warpage Solvers, Accuracy, and Linear vs Nonlinear Calculations
Moldflow offers several mesh types for injection molding simulation, each with unique strengths and solver options for warpage analysis. Understanding the differences between Midplane, Dual Domain, and 3D Tetrahedral meshes—and how linear and nonlinear calculations work—helps engineers choose the most accurate and efficient approach for their plastic part analysis.
Main Mesh Types in Moldflow
- Midplane Mesh:
2D shell elements placed at the part’s center. Best for thin-walled parts. Fastest to compute, but less accurate for thick or complex shapes.
- Dual Domain Mesh:
2.5D shell mesh using both surfaces. Most common mesh for general injection molding simulation. Good for predicting weld lines, air traps, and flow balance.
- 3D Tetrahedral Mesh:
Full 3D solid mesh (tetrahedral elements). Required for thick, complex, or highly detailed parts. Highest accuracy for warpage, fiber orientation, and temperature distribution, but requires more computation time.
Warpage Solvers for Each Mesh Type
- Midplane & Dual Domain Meshes:
- Linear Solver: Standard warpage analysis, fast and suitable for early design or simple parts.
- Nonlinear Solver: Accounts for large deformation and constraints, more accurate for assembly or gage conditions.
- 3D Tetrahedral Mesh:
- Linear Solver: Available for 3D mesh, suitable for most cases.
- Nonlinear Solver: Highest accuracy, especially for complex parts and real-world constraints.
Linear vs Nonlinear Calculations
- Linear Calculation: Assumes small deformations and linear material behavior. Fast and suitable for most early-stage or simple analyses.
- Nonlinear Calculation: Considers large deformations, nonlinear material properties, and complex boundary conditions. Essential for predicting assembly fit, gage conditions, and highly accurate warpage results.
Which Mesh Type is Most Accurate?
3D Tetrahedral Mesh with Nonlinear Solver provides the highest accuracy for warpage and deformation prediction, especially for thick, complex, or highly constrained parts. For thin, simple parts or early design, Dual Domain or Midplane with Linear Solver is often sufficient and much faster.
Summary
Choosing the right mesh type and solver in Moldflow depends on your part geometry, required accuracy, and simulation goals. For the best results, consult with Moldflow experts like Kaiseki Giken to select the optimal mesh and calculation method for your project.
← Back to Blog
