A simulation combines the selected model with the records and conditions needed to answer a particular question. Confirm the model before interpreting the result: a membrane calculation, a bending calculation and a through-thickness transport calculation do not describe the same field. Establish the baseline with the intended initial and boundary conditions before changing numerical controls or material inputs.
5.1 Prepare, visualize, optimize, and run analysis cases.
04.5 / CDS User Guide
Define connected process and structural inputs, include cure-aware physics, optimize cycles, verify loads graphically, run the solver, and review result provenance.
06.1 Manuals · read online, preview or download →
03.62 · Thick laminate: reaction heating, cure gradient and process stress
Level 4AdvancedEst. 40 min
Only blocks on the exercise path are shown. This changes the view only, not the exercise records.
∑ Used models & submodels
Only models assigned to records used by this exercise are listed here. The full-layout option preserves the supplied starter records; no Workbench records are changed.
Halpin–Tsai · T700 / EP180 UD · Thermal processing
One compatible homogenization model per Micro recipe. Separate recipes compare models; their predictions are not blended.
∑ Theory & assumptionsCLT · Linear static with failure indices · Plate — Nx Static Validation · Thermal laminate warping
Shared laminate stiffness drives this membrane/CLT path. Failure criteria are independent comparisons, not blended models. Fatigue is a separate assessment.
∑ Theory & assumptions1D transient heat transfer · T700 Thermal Process · Thermal laminate warping
Needs linked laminate properties and a compatible process schedule. A linked cycle is not a solved temperature history.
∑ Theory & assumptionsMaximum stress · Plate — Nx Static Validation · Thermal laminate warping
Primary ply criterion for Plate — Nx Static Validation · Thermal laminate warping. Envelope comparisons are independent; criteria are not blended.
∑ Theory & assumptionsData travelling between blocks
Micro → Laminates
Predicted ply stiffness, strength, density and expansion properties.
Materials → Micro
Constituent stiffness, strength, density and thermal / moisture properties.
Mechanical → Simulation
SIMULATION selects this case and its analysis model; the case owns its applicable cycle and input references.
Laminates → Mechanical
Ply angles and thicknesses, stiffness, mass and ply properties.
Geometry → Mechanical
Part shape and dimensions, thickness or section definition, and model-specific geometric inputs. Each selected case consumes only the dimensions its model supports.
Thermal → Simulation
SIMULATION selects this case and its analysis model; the case owns its applicable cycle and input references.
Laminates → Thermal
Ply angles and thicknesses, stiffness, mass and ply properties.
Models → Micro
Applied model assignment: Halpin–Tsai. Model parameters and formulation are used by Micro.
Models → Mechanical
Applied model assignment: CLT · Linear static with failure indices. Model parameters and formulation are used by Mechanical.; Maximum stress
Models → Thermal
Applied model assignment: 1D transient heat transfer. Model parameters and formulation are used by Thermal.
Run the 6 mm laminate through the 120°C dwell with its linked resin reaction heat.
Models: Heat transfer · Classical laminate theory · Extension–bending coupling · Thermomechanical coupling
Study scope and limitations
Teaching inputs, not qualified allowables. Sequential coupling transfers the reported thermal/moisture state to laminate mechanics; it is not simultaneous 3D multiphysics. Inspect the transferred state and reference values before interpreting stress or curvature. Free laminate CLT curvature, not fixture-constrained distortion, a full tool-release simulation or calibrated cure-shrinkage prediction.
Use heating and cooling die equipment
Open Equipment below Geometry and select a Heater or Cooler record. Its contact length, width, temperature or signed surface flux, conductance, manufacturer, body material and finish belong to the hardware. The thermal case owns its position and surface.
Step-by-step instructions · 3 steps
- In Moving Process, set the material inlet state, laminate and speed. Select Contact equipment on the intended Upper or Lower boundary and place the linked die against that surface.
- In Live Process, use the inlet upper surface as the origin, grid and snap to seat the tool. The die is centred across the width. Double-click it to edit the hardware.
- Run and compare die setpoints with solved surface/core temperature and cure versus position. The multi-zone pultrusion exercise includes a separate cooling die over its final 0.2 m.
Navigate Live Process and thermal results
Side view pans with left drag; rotation belongs to 3D view. Use the grid spacing and position controls to place supported equipment. The scene follows the active simulation and boundary domain.
Step-by-step instructions · 4 steps
- Select Incoming, Upper or Lower to isolate relevant callouts. Click a scene callout to highlight the corresponding row; column Fill controls copy eligible values.
- Use Incoming to set tape angle, supply dimensions and optional preheat ahead of the nip. Vendor-spec deviations are shown. Laser geometry and equipment remain linked to the irradiation setup.
- Inspect pressure and temperature, tape/substrate comparisons, quality and flux through the result tabs and classified selectors. Surface flux maps require applicable current run data.
- Use prescribed roller temperature for the default controlled-temperature estimate. Enable the rotating model and optional N-cycle preconditioning only when roller thermal evolution is required.
Select compatible processing quality models
Thermoset processing uses cure kinetics, cure-dependent viscosity and the selected modulus law. Thermoplastic processing can use melt viscosity, crystallization, intimate contact, healing/bonding and void consolidation where supported.
Step-by-step instructions · 4 steps
- Review the linked material models in Incoming material conditions. A single available model may be presented as an enable switch; multiple choices use a selector with equation/help access.
- For film impregnation, link dry reinforcement with z-permeability and the Darcy model. Per-ply average temperature drives viscosity and fill; finite-film supply limits the available resin.
- Inspect void consolidation separately from Darcy fill. For ATP, inspect the newly formed tape/substrate interface separately from existing laminate interfaces.
- Keep illustrative optical, permeability, viscosity and kinetic values identified as examples. Rerun after changing any connected model input.
Geometry and case controls
Geometry defines dimensions and model-specific shape. Cases selects Thermal, Moisture, Mechanical or EM theory, then links the compatible laminate, geometry and conditions required by that theory. Favorites sort first in every compatible selector.
Step-by-step instructions · 5 steps
- Choose the case type and analysis model before entering model-specific fields.
- Use link icons beside selectors to open the chosen laminate, geometry, process boundary or material source.
- Review LiveLoad or the geometry preview after changing type, dimensions, supports, loads or boundary conditions.
- Case-owned cycles use tabs and tables for time, temperature, moisture, pressure or load conditions. Time must increase monotonically.
- Use right-click Help for the control explanation and the ∑ theory link for equations and limits.
SIMULATE workflow controls
SIMULATE assembles the active run from connected Materials, Micro, Laminates, Geometry, Equipment, Models and Case blocks. The plus action adds available records to a block; each selector changes the run connection; link icons open sources. Used identifies records consumed by the selected run.
Step-by-step instructions · 6 steps
- Use the simulation picker to choose the active study. Use None for unused Thermal, Moisture, Mechanical or EM slots.
- Show or hide connections, key data, unused blocks and model details with the workflow toolbar. The fixed workflow layout keeps Equipment directly below Geometry; use the detail slider and pan/zoom to reveal more information.
- Use Titles, Table, Details and zoom controls to change presentation. These controls do not change inputs.
- Use Hide summary or Show summary beside the workflow controls. Drag the divider when Summary is open; Notes edits the model, goal, objectives and student guidance; Show me how starts the walkthrough.
- Read Solver status before Run. Live paused, live updates, run required, running, completed and outdated are distinct states.
- Use Export for PNG or JPEG workflow, workflow with Summary, Summary only, or editable workflow PowerPoint. Use Snapshot for a reusable run and Report for a full engineering report.
Oven-cycle studies
The core curriculum includes gentle-ramp, two-stage dwell and unequal-convection oven studies, with their thermal cases in Ovens.
Step-by-step instructions · 3 steps
- Open the exercise from Training and inspect the prescribed air-temperature schedule, upper/lower convection coefficients and linked laminate.
- Run and compare air, surface and core temperatures, conversion and reaction heating through ramp, dwell and cooling.
- Refine thickness nodes and check sensitivity. Extend cooling before interpreting a final state as room-temperature residual stress.
Use the shared workspace procedures in Section 1.2 to inspect the model, select cases and manage connected records before continuing with this part of the study. Read Section 1.2 Read Section 1.2
Create a case with its own cycle
Choose a Thermal, Moisture, Mechanical or EM case. Each case selects one analysis model and owns its applicable conditions and cycle. There is no separate Process block.
Edit the cycle inside the case
In a thermal case, use Incoming material conditions for the initial state and model selections, Incoming for a moving tape and its optional preheat, and Upper and Lower for substrate surface schedules. Set each surface condition and film coefficient in this case. Moisture and mechanical schedules belong to their own cases and do not share the thermal cycle.
Step-by-step instructions · 4 steps
- Enter increasing time for Stationary Process or distance for Moving Process, and set the pulling speed for moving material. See screenshot
- Choose Step to hold a row value or Ramp to approach the next value. Roller rows use applied force; the resulting nip pressure is shared through the thickness. See screenshot
- Set Upper and Lower boundary types, or enable mirror Symmetry. Moving processes permit rollers; Stationary Process does not. Use the field or model help to distinguish a setpoint from a predicted result. See screenshot
- Inspect the plot beside the table for discontinuities or unit errors. See screenshot
Assemble a simulation input record
In SIMULATION select Thermal, Moisture, Mechanical and EM cases, each with None available. The other blocks hold used and available records. Check the model, laminate and applicable geometry beneath each selected case.
Review the LiveLoad schematic
The LiveLoad block appears beside Loads and Thermal inputs for analysis cases. Its plate, cylinder, or thermal schematic updates with the selected geometry, boundary conditions, loads, and directions. A zero-valued load vector is greyed so active loading is immediately recognizable.
Run the model
Resolve missing selections, invalid numbers, broken references, invalid ply angles, and zero laminate thickness before choosing Run. Use the Simulation workflow for a final dependency and model check.
Step-by-step instructions · 4 steps
- Confirm the LiveLoad schematic matches the intended model.
- Keep the desired Results tab selected. See screenshot
- Choose Run when required; the interface preserves that tab while the model executes. See screenshot
- Review result values, freshness and solver messages.
Understand solver provenance
A live preview and a saved simulation answer different questions. Check the run status, model assumptions and input revision before using a result. Resolve reported errors and rerun after changing connected inputs.
Check thermal setup and accuracy
A thermal result needs a compatible thermal case model, linked laminate, transport properties, initial conditions and its embedded cycle where required by that model. Missing setup is not a zero-temperature result.
Step-by-step instructions · 4 steps
- Follow the missing-setup message to the linked source record rather than interpreting an empty plot.
- After upstream edits, rerun before using a saved temperature, cure or moisture history.
- Refine through-thickness resolution and review temperature gradients and numerical diagnostics.
- Output spacing controls saved samples; it is not the integration accuracy target. The transient solver checks full-step/two-half-step agreement.
Include cure exotherm and evolving modulus
Transient thermal analysis can include the heat released by cure. The selected cure-dependent modulus model then changes the stiffness used to develop process stress as degree of cure evolves.
Step-by-step instructions · 4 steps
- Assign a cure-kinetics model, total heat of reaction, density and heat capacity to the material or ply.
- Enable cure exotherm when the thermal solution should include reaction heat; leave it off for externally imposed thermal histories that intentionally exclude self-heating. See screenshot
- Assign the cure-dependent modulus model and review its editable transition, rubbery/glassy modulus and shape parameters.
- Rerun after changing kinetics, transport, cure heat, modulus evolution or shrinkage. These inputs affect later residual-stress and failure results.
Optimize an oven or process cycle
Process optimization varies selected surface-cycle controls to meet a target core temperature or cure state while reducing time, overshoot or other configured penalties.
Step-by-step instructions · 6 steps
- Choose Process in Optimize Inputs and select the thermal case and its laminate. Review the cycle owned by that case. See screenshot
- Choose a target such as core temperature, degree of cure, maximum temperature difference, overshoot or total cycle time. See screenshot
- Select the editable boundary variables—surface temperatures, ramp rates, dwell temperatures or dwell durations—and define bounds and constraints. See screenshot
- Choose steady-state only for equilibrium targets. Use transient mode for ramps, dwells, core lag, cure exotherm, evolving modulus and stress development.
- Run the bounded search, inspect feasibility and convergence, save a snapshot, then apply the candidate to the case-owned cycle and review the resulting case.
- Rerun the full coupled simulation before accepting residual stress, distortion or failure results from the optimized cycle.
Thermal, moisture, EM and mechanical case controls
Each CASES record owns its model, laminate, applicable geometry, loads, initial state and schedule. Dropdowns link existing records; the plus action creates a new record and favorites appear first in every compatible selector.
Step-by-step instructions · 5 steps
- Model chooses the formulation for that case and controls which inputs and theory help appear.
- Laminate and Geometry link the physical definition. A missing or incompatible link prevents a valid run rather than acting as a zero input.
- Thermal and moisture boundary tabs define independent upper and lower histories. Add, remove and reorder schedule rows carefully; time must increase monotonically.
- Mechanical load fields and selectors define the active load state. Use LiveLoad to check sign, axis and boundary-condition meaning.
- None in the SIMULATION block disconnects an optional case. Changing a current case marks dependent results stale until Run completes.
SIMULATION workflow controls
The SIMULATION block combines case selection, dependency inspection, notes, summary, model layers and execution. Its toolbar changes presentation or navigation unless the control explicitly says Run, Save, Export or Apply.
Step-by-step instructions · 5 steps
- Select Thermal, Moisture, Mechanical and EM cases in the SIMULATION block; favorites are shown first and None disconnects an unused branch.
- Use the workflow layout, data, model-layer, pause-animation, equation and book controls to inspect the graph. These controls do not alter the engineering records.
- The book button opens the resizable Summary panel. Notes contains summary, goals, objectives and supporting details; Lock prevents unintended editing; Show me how starts the guided walkthrough.
- Undo and Redo reverse or restore supported data and scene actions in order. Disabled arrows mean no eligible action exists in that direction.
- Run executes the current compatible simulation. Cancel stops an active run. Read freshness and solver status before exporting or reporting.
5.2 Pultrusion heating and cooling dies
06.1 Manuals · read online, preview or download →
Processing / Equipment
Use linked Equipment records to define the stationary tools around a moving composite section. The thermal solver predicts the material temperature and cure history as it passes through their contact footprints.
Separate the tool from its installation
A Heater or Cooler record owns contact length, width, body thickness, thermal control, body temperature or signed surface heat flux, and contact conductance. It also stores manufacturer, part number, specification source, body material, surface finish material and finish details. The thermal case links that record and owns its Upper or Lower placement and enabled state. Multiple placements can share one record; duplicate the hardware when its settings should vary independently.
Equipment is below Geometry in the fixed workflow. Rollers remain Geometry records. A heating die is a Heater installation and a cooling die is a Cooler installation. These are rectangular thermal-contact bodies; their name does not add die-cavity geometry, resin-flow or pulling-force physics.
Locate contact from the inlet surface
The Live Process origin is the width centre of the inlet upper surface. Positive x follows travel, y spans width and z is normal to the upper surface. Tool x is its centre; a tool of contact length L covers x minus L/2 to x plus L/2. Upper contact is at z = 0; lower contact is at minus the laminate thickness. Tools remain centred across the width. Seat them on the surface using the grid and snap controls. A lifted tool contributes no contact heat.
Choose Contact equipment on the appropriate boundary and link or place the tool. The active footprint is determined by the seated body, not by changing the composite to a prescribed temperature. Dragging the tool changes its installation; double-clicking opens the linked hardware record. Select Upper or Lower to see that domain's markers and click a marker to find its table row.
Finite contact exchange
For prescribed tool temperature, heat flows into the composite according to the difference between tool temperature and the current solved surface temperature:
q″ = hc (Tdie − Tsurface)
Here q″ is inward heat flux in W/m², hc is contact conductance in W/(m² K), and temperatures may be in °C when used as a difference. A 150°C die does not instantly impose 150°C on every ply. The material surface and core may lag the tool; enabled cure exotherm can also raise the material above a setpoint. A lower die setpoint removes heat when the surface is hotter than the tool.
Surface heat flux instead prescribes q″ directly: positive adds heat and negative removes it. Do not interpret this mode as temperature control or a prediction of electrical heater power. Contact width smaller than the part width is averaged over the modelled width, with the uncovered portion retaining its background condition. Same-side overlapping seated contact bodies are rejected rather than counted twice.
Convert line position to residence time
At constant speed v, elapsed residence time is x/v. If x is in metres and v is in m/min, time is in minutes. Each contact edge becomes a boundary event in the thermal integration. Step rows hold their value until the next station; Ramp rows interpolate eligible boundary values. The example dies use explicit constant intervals so a cooling region cannot be swallowed by the preceding hot zone.
| Example | Heating die intervals | Cooling die interval | Residence at 0.1 m/min |
|---|---|---|---|
| Heated and cooled starter | 0–0.8 m at 150°C | 0.8–1.0 m at 40°C | 10 min |
| Multi-zone pultrusion | 0–0.4 m at 80°C; 0.4–1.0 m at 150°C; 1.0–1.4 m at 180°C | 1.4–1.6 m at 40°C | 16 min |
Both faces use separate die installations, a 300 mm illustrative width and 500 W/(m² K) contact conductance. Initial material temperature is 23°C. These editable teaching settings are not qualified production recipes. Use Review library updates to replace old examples and dependencies without overwriting custom work.
Evaluate the process and its limits
Run the active simulation, then compare surface and core temperatures, through-thickness gradients, cure state and reaction heat against axial position. Change pulling speed, contact length, conductance or setpoint one at a time. Review the connected laminate and its cure, viscosity and modulus models before interpreting a process-to-structure transfer. Quality outputs exist only for enabled compatible models; a cured-looking temperature plot does not prove impregnation or low void content.
The moving-section thermal model resolves through-thickness conduction and enabled reaction sources. It excludes axial conduction, die thermal mass and internal temperature gradients, coolant circuits, feedback control, die friction, pulling load and general resin flow. Body and finish material selections document the tool; they do not derive contact conductance or solve heat storage in the die. A prescribed tool temperature represents a controlled boundary. Predicting die warm-up or repeated-pass die temperature requires a separate conjugate tool model.
Open the multi-zone pultrusion exercise · Follow the Equipment workflow
Chapter review
Read the solver messages first, then the overall response and the relevant local quantities. Record the time, location, axes and units associated with every reported peak. Use linked heating and cooling dies for pultrusion. Confirm seating, contact conductance, exposure length and speed; distinguish controlled tool temperature from solved material temperature.
Current Workbench model references
These model-specific guides describe the documented Workbench controls. Read their calibration requirements and coupling limits; release notes distinguish announced releases from development previews.
References and source sections
References are retained with the formulations they support. Software instructions describe implementation scope; a cited source does not establish independent validation of a CDS calculation.