Set up a Cool (FEM) analysis with induction heating

Make sure you have a CAD model that includes the part, induction coil, feed system, cooling channels and mold.

Part meshing

1. Create a new project.
2. Import a model that includes the part, feed system, and induction heating components.
3. In the Import dialog, select Solid 3D from the drop-down menu, then click OK.
4. From the Layers pane, hide all but the part model.
5. Set the injection location.
6. Click (Geometry tab > Selection panel) and select CAD face from the drop-down list.
7. Click (Mesh tab > Mesh panel > Density) to open the Define Mesh Density dialog.
8. Click the model to populate the left-hand area of the dialog box.
9. Select all the elements of the feed system, by holding down the Ctrl button and clicking each relevant line on the left side of the dialog box, or on the relevant area of the model. Click Add>> to create a mesh control group with the selection.
10. Make sure that the Edge length of the Mesh control group settings section is sufficiently small, and smaller than the Edge length of the Global mesh settings. Then click Ok to Apply and close.
11. Click (Mesh tab > Mesh panel > Generate Mesh) to open the Generate Mesh dialog.
12. If possible, and if the part surface is simple, change the Global edge length on surface to a higher value to reduce the mesh time.
13. Click Mesh Now, then click Close to close the Mesh Generation dialog box.
14. Click OK to close the Mesh complete announcement.
15. Select an analysis sequence that includes Cool (FEM).

Induction coil meshing

16. In the Layers pane, hide all layers except the induction coil layer.
17. Click (Mesh tab > Mesh panel > Generate Mesh) to open the Generate Mesh dialog.
18. Click OK to close the Mesh complete information dialog box.
19. Click (Geometry tab > Selection panel > Properties), select Body, then click OK.
20. With the induction coil still selected in the model pane, click (Geometry tab > Properties panel > Change), select Induction coil (3D) from the list, then click OK.
21. Click OK to close the information dialog.
22. Click (Geometry tab > Properties panel > Edit) and in the Induction Coil (3D) dialog box, enter the current frequency, in Hz, set on the induction coil.
23. Click Specify associated with Induction coil control, enter the Switch off time and the Switch on time, then click OK.
24. Confirm the other entries, save to a unique name, then click OK to close the Induction Coil (3D) dialog box.

Set the terminals

25. Click (Boundary Conditions tab > Cooling/Heating panel > Induction Heating High Potential Terminal) and click the relevant place on the induction coil.
26. Right-click on the high potential terminal icon, and select Finish from the drop-down menu.
27. Select the high potential terminal icon and click (Geometry tab > Properties panel > Edit).
28. Select either Specify electric current or Specify voltage and enter the relevant value in the data entry box.
29. Click (Boundary Conditions tab > Cooling/Heating panel > Induction Heating Low Potential Terminal) and click the other end of the induction coil.
30. Right-click on the high potential terminal icon, and select Finish from the drop-down menu.

Magnetic plate meshing

31. In the Layers pane, hide all layers except the magnetic plate layer.
32. Click (Geometry tab > Selection panel > Properties), select Body, then click OK.
33. With the magnetic plate still selected, click (Geometry tab > Properties panel > Change), select Mold insert (3D) then click OK.
34. Click OK to close the information dialog.
35. Click (Mesh tab > Mesh panel > 3D Mold Mesh).
36. Enter appropriate values using the meshing guidelines. The number of enhancement layers is set on the Tetra tab.
37. Click Mesh Now, then click Close to close the Mesh Generation dialog box.
38. Click OK to close the Mesh complete announcement.

Mold meshing

39. In the Layers pane, turn on all the layers containing the part, induction coil and magnetic plate tetras, the cooling channels and the mold surface.
40. Click (Mesh tab > Mesh panel > 3D Mold Mesh).
41. Enter appropriate values using the meshing guidelines. The number of enhancement layers is set on the Tetra tab.
42. Click Mesh Now, then click Close to close the Mesh Generation dialog box.
43. Click OK to close the information dialog.
44. Click (Geometry tab > Selection panel > Properties), select Tetrahedral element on the left side, and Mold block (3D) on the right side, then click OK.

Set the component materials

45. For each component, select all the associated elements, click (Geometry tab > Properties panel > Edit), and change the Mold material option to Select a different mold material.
46. Click Select to open the Select Local Mold Material dialog box.
47. Click Select to open the Select Mold material dialog box, choose the correct material from the list, then click Select.
48. In the Select Local Mold Material dialog box, and associated with the material you have selected, click Edit to open the Mold material dialog box.
49. Select the Electrical tab, enter data in the two entry boxes, then click OK on each dialog box until they are all closed.
50. Repeat for the mold block, the magnetic plate, the induction coil, and any other mold components.
51. Click (Home tab > Molding Process Setup panel > Process Settings), and select the Mold temperature options from the drop-down menu, then click OK.
52. Click (Home tab > Analysis panel > Start Analysis) to start the analysis.