Hello!

I was wondering if anyone has run into this problem in Plastics.

I have a less than ideal part that I have received form a customer which includes widely varying wall thicknesses and knife edges. When I run the simulation using a virtual mold and cooling channels, it runs just fine and gives me fairly decent results. However, since the mold design involves multiple materials (copper mold inserts for heat dissipation) I had hoped to run the simulation with the mold included to get a bit more accurate results.

This is where the problem occurs, when I run FLOW, PACK, and WARP I get no errors but COOL stops with this message:

Melt Part:

!! ERROR !! Cell 12, Volume = -0.464234 < 0

ievtxs = 6 iFaces = 5

To make matters more complicated, the part I am using involves imported geometry, so it is difficult to suppress features to find out where the specific error lies.

1. So, why does it run fine with a virtual mold but break with the full mold?

2. Is there anything I can do to improve the full mold meshing? (No matter what I do it shows a high number of "unmatched" elements, can this be the issue?)

3. How can the other processes finish if COOL fails?

Thanks!