Meaning
Data transfer between different manufacturing meshes is achieved through a specific computational alignment and interpolation process. Solid mesh mapping allows the results of a filling and packing analysis to be used as the starting point for a warpage or structural analysis. This step is necessary because the optimal mesh for fluid flow often differs from the mesh required for structural mechanics.
It ensures that the fiber orientation and residual stresses from the moulding process are correctly accounted for in the final performance check.
Fiber Orientation
Data integration of fiber orientation tensors is the most critical part of this procedure. Because these fibers dictate the local stiffness and thermal expansion, an error in mapping will lead to incorrect warpage predictions. The software must interpolate the tensor values from the integration points of the source mesh to the target mesh.
Geometric Alignment
Spatial precision is mandatory to ensure that the two meshes occupy the exact same coordinate space. Even a small offset or rotation between the fill mesh and the structural mesh will cause the mapping to fail or produce nonsensical data. Modern simulation suites automate this alignment but still require manual verification for complex assemblies.
Interpolation Error
Differences in mesh density between the two models can introduce small numerical inaccuracies.
