For Dual Domain meshes, the accuracy of Autodesk Moldflow analyses highly depends on elements match.
The accuracy of Fill, Fill+Pack, Cool and Warp analyses, especially when using fiber-filled materials, depends highly on the correct representation of thickness throughout the part. In the case of a Dual Domain mesh, the thickness of a given area of the part is determined by first associating elements on each side of the part ("mesh matching"), and then calculating the distance between the matched elements.
Figure 1: Dual Domain mesh before and after using Imprint tool
Use Mesh Statistic dialog to see what percentage of elements are successfully matched, and the Mesh Match diagnostic tool see the mesh match results graphically. The goal is to maximize this percentage, but there is no threshold limit. In general, if the ratio is <80%, investigate why and try to improve it. It may not be possible to increase the match ratio for chunky models.
To improve the mesh match quality:
- Use the Imprint tool to improve mesh matching.
- Suppress small radii and rounds from the original CAD model before importing into Autodesk Moldflow Insight.
- Try different mesh generation settings to see which offers the best quality.