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Kontaktieren Sie den Administrator, wenn Sie glauben, dass hier ein Fehler vorliegt. ====== SIGMA3D-Interface ====== This section is divided into: * **[[.:sigma3d-interface#pre-processing|Pre Processing]]** (configuration of geometry, process parameters, solver settings) * **[[.:sigma3d-interface#simulation_execution_extrud3d| Solving]]** (starting and monitoring the Extrud3D solver) * **[[.:sigma3d-interface#post-processing| Post Processing]]** (slices, rendered geometry, particle tracking, report generation, result review) ===== Pre-Processing ===== Before a simulation can be started, a SIGMA3D configuration has to be created and parameterized. ==== Opening the SIGMA3D configuration ==== **Command path:** ''Simulation > open SIGMA3D-configuration'' When the command is executed, a dialog appears in which the configuration can be assigned to an existing process or created without process assignment. {{ :en:en_sigma151_dlg_sigma3d-interface_001.png?direct&400 |Manage SIGMA3D projects dialog}} In the Manage SIGMA3D projects dialog, the following functions are available (see screenshot): * Select an existing configuration in the **Configuration** list. * Manage entries using **Add (+)** and **Remove (-)**. * Manage result attachments in the **Attachments** area. * Attach generated result objects via: * **Attach slices** * **Attach 1D-Profiles** * Open the result folder via **Open map**. * Double-click an attachment to open it in a separate window. After selecting or creating a configuration, the SIGMA3D configuration dialog opens. {{ :en:en_sigma151_dlg_sigma3d-interface_002.png?direct&800 |SIGMA3D configuration dialog (pre-processing)}} ==== Configuration dialog overview ==== The configuration dialog contains all settings required to define the numerical simulation. If the configuration is assigned to a SIGMA process, machine and process data may already be pre-filled. === General data === At the top of the dialog the following information is shown: * **Name** of the SIGMA3D configuration * Assigned **Process** === Geometrical data source === Under **Geometrical data**, two options are available: * **choose from SIGMA elements** : Use standard SIGMA screw elements machine construction kit. * **choose from technical drawing** : Use imported CAD geometry (OBJ file). When **choose from SIGMA elements** is selected: * A **Machine configuration** can be loaded. * The **clearance (screw-screw)** must be defined (unit: mm). * Up to **three element pairs** can be selected for the simulation domain. * For each selected element, the dialog displays geometric properties such as: * Length * Diameter * Type (e.g. conveying, re-conveying) * Number of flights / kneading discs * Lead / width of discs / staggering angle (depending on element type) The lower part of the window shows cross-sectional previews for the selected element pairs (left and right screw). Alternatively, a CAD drawing can be used for the 3D simulation: * Select **choose from technical drawing** * Import an **OBJ file** Important requirements and notes: * The imported file must contain **one screw only** * Additional reconstruction parameters are required to restore the real machine dimensions * Ensure that the geometry orientation and dimensions are consistent with the machine coordinate system used in SIGMA3D === Process Parameters === The **Process Parameters** panel (right side of the dialog) contains the physical and operating conditions for the simulation. Typical fields include: * **Material** (imported SIGMA material data) * **Limits of viscosity (min / max)** [Pa·s] * **Screw speed** [1/min] * **Flow rate** [kg/h] * **Filling degree** * **Material temperature** [°C] * **Barrel temperature** [°C] * **Screw temperature** [°C] For barrel and screw temperature, **adiabatic** checkboxes are available. **Isothermal vs. non-isothermal setup** By default, SIGMA3D is commonly configured as an **isothermal simulation**: * The melt temperature is assumed constant and equal to the defined material temperature. * Thermal energy balance is not solved in full detail. For a **non-isothermal simulation**: * Uncheck the **adiabatic** boxes (barrel and/or screw) as required * Define thermal boundary conditions for barrel and screw temperatures * Shear heating (dissipation) is taken into account Technical consequence: * Non-isothermal calculations are significantly more computationally intensive. * Runtime and hardware requirements increase considerably. === Simulation settings (mesh resolution) === In the **Simulation settings** section, the **Mesh resolution** can be defined (default shown in the screenshot: **rough**). SIGMA3D provides multiple mesh quality levels (five grades in total, depending on software version). Increasing mesh resolution leads to: * finer spatial discretization * improved local result resolution * longer preprocessing and solver runtime * higher CPU and RAM demand Recommendation (engineering practice): * Use **rough/coarse** meshes for initial screening and parameter studies * Use finer meshes only for validated final evaluations or local detailed analysis ==== Melting simulation ==== === Activation === Activate melting by enabling: * **Simulate melting** (checkbox in section **Melting simulation**) === Physical model (overview) === When **Melting** is activated, SIGMA3D takes the solid fraction of the polymer into account and can simulate the transition from solid to melt (depending on the applied thermal boundary conditions). If barrel and/or screw temperatures are specified (non-adiabatic conditions), the software calculates: * heat transfer * temperature rise * melting progression The melting calculation is based on the **KARRENBERG melting model**. Model concept (simplified engineering description): * The solid phase is represented as an **extremely high-viscosity fluid** * Thermodynamic properties of the solid are preserved * The transition region is modeled using a **melt fraction function** * This function blends rheological and thermodynamic properties of solid and melt * The melt fraction function is derived from the **specific heat capacity vs. temperature** data stored in the SIGMA material dataset This means the melting behavior is **material-specific** and responds differently for different polymers. ==== Finalizing / saving the configuration ==== If the configuration is assigned to a process, the setup can be completed by clicking **Ok**. A warning dialog appears: {{ :en:en_sigma151_dlg_sigma3d-interface_003.png?nolink |Warning: process data cannot be edited afterwards}} The warning indicates that after leaving the dialog, the data can no longer be edited in the same way. The option **Save process** is available. Practical implication: * Confirming with **Ok** saves the process and assigns the SIGMA3D configuration to the process. * Subsequent edits may require creating or cloning a new configuration. ==== Import / Export configuration ==== At the bottom of the configuration dialog: * **Import configuration** : Imports previously saved SIGMA3D configuration settings. * **Export configuration** : Saves the current SIGMA3D configuration as an *.e3d file for simulation on a cluster or another workstation. ==== Opening the SIGMA3D process window ==== To start a simulation, expand the **SIGMA3D** tab in the project data. All created **Extrud3D** processes are listed there. {{ :en:en_sigma151_dlg_sigma3d-interface_001.png?nolink&400 |SIGMA3D main window (Pre-Processing / Post-Processing tabs)}} By double-clicking a configuration name, the SIGMA3D main window opens: {{ :en:en_sigma151_dlg_sigma3d-interface_004.png?nolink&1000 |SIGMA3D main window (Pre-Processing / Post-Processing tabs)}} ===== Simulation execution (Extrud3D) ===== The SIGMA3D main window contains two tabs: * **Pre-Processing (Configuration)** * **Post-Processing** The left panel contains the **Extrud3D Simulation** status and controls. ==== Minimum requirements / status ==== In the **Extrud3D Simulation** section, the UI shows: * **Min. req.** : At least a CPU with 8 cores and 32 GB RAM are necessary for a simulation * **Current status** : Status of the simulation (Not started / running / crashed/ finished) * **Progress** : Progress of the simulation * Input fields for: * **Number of CPU cores** * **Number of time levels** ==== CPU cores ==== Set the number of CPU cores to be used for the calculation. * The available core count depends on the workstation / server. * At least **3 CPU cores** must be available for simulation (as specified in the original workflow description). * Higher core count generally reduces runtime, but scaling depends on problem size and hardware architecture. ==== Number of time steps ==== The field **Number of time steps** defines the angular discretization of one screw revolution (i.e. screw positions evaluated by the solver). The information dialog (see screenshot) explains: {{ :en:en_sigma151_dlg_sigma3d-interface_005.png?nolink&600 |Information about time steps and particle tracing recommendation}} For subsequent evaluation using **particle tracing**, at least **36 time levels** are recommended. ==== Starting the simulation ==== Start the solver by clicking: **Start Extrud3D simulation** While the simulation is running, the status area updates continuously. Example of a running simulation: {{ :en:en_sigma151_dlg_sigma3d-interface_006.png?nolink&1000 |Running simulation example (Momentum Solver, Stage 1/1)}} Typical runtime indicators shown in the UI: * current solver stage * elapsed time * progress percentage * active CPU core count * configured number of time steps ==== Monitoring and runtime tools ==== During or after the simulation, the following buttons may be available (depending on status): * **Logfile** Opens the solver log for diagnostics and progress review. * **Open in Para View** When simulation has finished, generated results can be opened in Para View * **Create error report** Creates a diagnostic package for troubleshooting. ==== Completed simulation ==== After a successful calculation, the status line changes to a stopped/completed state (wording depends on version), and the progress reaches **100.0%**. {{ :en:en_sigma151_dlg_sigma3d-interface_007.png?nolink&1000 |Completed simulation example (status stopped at 100%)}} ===== Post-Processing ===== After the simulation has been completed, various post-processing operations can be performed in the **Post-Processing** section. The left side of the main window provides selectable post-processing tasks, each with a corresponding **Configure...** button. Typical tasks shown in the UI: * **Slices in Z-direction** * **Slices in X-direction** * **Slices in channel direction** * **Create image** * **Particle tracking** * **Generate PDF report** The center/right area contains: * **Attachments** list (generated result objects) * **Logging** window (post-processing progress/messages) ==== General post-processing workflow ==== - Select one or more post-processing tasks (checkbox) - Open **Configure...** for each selected task and define parameters - Start post-processing (button availability depends on generated outputs) - Review generated items in **Attachments** - Open results via: * double-click attachment * **Open results** * **Open in Para View** (where applicable) ==== Slices in Z-direction ==== Z-slices are cross-sectional evaluations at defined axial positions. Configuration dialog: {{ :en:en_sigma151_dlg_sigma3d-interface_008.png?nolink |Configure slices in Z-direction}} Configurable parameters (as shown in the dialog): * **Number of slices (n)** * **Z-position of first slice (pos)** [mm] * **Gap between slices (gap)** [mm] * **Angle** [°]: Screw angle position * **Split up slices** (checkbox): Splits slices into cross channel and radial gap view === Result Slices in Z-direction === * **XY / full slice contour plot** with selectable variable and slice index: {{ :en:en_sigma151_dlg_sigma3d-interface_013.png?nolink&1000 |Example slice viewer: viscosity contour and statistics}} ==== Slices in X-direction ==== X-slices provide cross-sections normal to the X direction (depending on the internal coordinate system). Configuration dialog: {{ :en:en_sigma151_dlg_sigma3d-interface_009.png?nolink |Configure slices in X-direction}} Configurable parameters: * **Number of slices (n)** * **X-Position first slice (pos)** [mm] * **Gap between slices (gap)** [mm] * **Angle** [°]: Screw angle position === Result Slices in X-direction === **X-direction slice set**: {{ :en:en_sigma151_dlg_sigma3d-interface_014.png?nolink&1000 |Example slice viewer: channel-direction velocity slices}} ==== Slices in channel direction ==== Channel-direction slices evaluate the flow in the local screw channel coordinate system. Configuration dialog: {{ :en:en_sigma151_dlg_sigma3d-interface_010.png?nolink |Configure slices in channel direction}} Configurable parameters: * **Number of slices (n)** * **Area** : Channel, cross section or both === Result view of slices in channel direction === * **Single channel slice with numerical statistics**: {{ :en:en_sigma151_dlg_sigma3d-interface_015.png?nolink |Example slice viewer: velocity contour with averaged quantities}} Depending on the result type, the viewer may provide: * Variable selection (e.g. viscosity, velocity magnitude) * Slice selection * View mode selection (e.g. full slice) * Numerical statistics such as: * area * mass flow rate (conveying direction / channel direction) * average viscosity * average shear rate * average velocity components / magnitude * **Open in Para View** button for advanced 3D inspection ==== Generate rendered screw element ==== This function creates a rendered image of the selected screw element geometry. Configuration dialog: {{ :en:en_sigma151_dlg_sigma3d-interface_011.png?nolink |Create rendered screw element}} Parameter: * **Name** of the generated image Example output (rendered geometry image): {{ :en:en_sigma151_dlg_sigma3d-interface_016.png?nolink&1000 |Rendered screw element image}} ==== Generate PDF report ==== SIGMA3D can generate a PDF report with a summarized evaluation of the flow simulation. Configuration dialog: {{ :en:en_sigma151_dlg_sigma3d-interface_012.png?nolink&400 |Configure PDF report}} Configurable parameters: * **Language** * **Title of the report** * **Rotation angles** (availability may depend on result setup/version) Example output (PDF cover and table of contents): {{ :en:en_sigma151_dlg_sigma3d-interface_017.png?nolink&1000 |Example SIGMA3D PDF report}} ==== Particle tracking ==== Particle tracking is used to evaluate residence and transport behavior, mixing paths, and qualitative dispersive/distributive mixing effects. {{ :en:en_sigma151_dlg_sigma3d-interface_019.png?nolink&1000 |Particle tracking result visualization example}} === Mixing ratio / Mixing quotient === The software provides a **mixing quotient** evaluation after running a particle tracking simulation. {{ :en:en_sigma151_dlg_sigma3d-interface_018.png?nolink&800 |Mixing quotient evaluation (cross-section + curve over timestep)}} The displayed delaunay evaluation typically consists of: * a geometric/cross-sectional representation * a graph of **mixing quotient vs. timestep** ==== Shear stress ==== A shear-stress evaluation can also be generated (e.g. histogram-based output depending on the configured post-processing options and software version). {{ :en:en_sigma151_dlg_sigma3d-interface_020.png?nolink&800 |}} ==== Result file location ==== You can access the location of generated files by: * clicking **Open results** / **Open map** (depending on the dialog) * using the command path: ''Simulation > open SIGMA3D diagram'' ==== Managing SIGMA3D projects ==== To manage created SIGMA3D projects/calculations, use: * the **Manage SIGMA3D calculations** icon * or the command path: ''Simulation > SIGMA3D manager'' This opens the management dialog shown at the beginning of this page. ===== Quick access through displayed screw ===== As an alternative workflow, individual screw elements can be selected directly in the displayed screw configuration. Procedure: - Select a screw element in the visual screw layout - Right-click the element - Choose the option to create a **SIGMA3D configuration** from the context menu This is a fast method for local element studies and comparative investigations of specific screw sections. ===== Recommendations for numerical simulation with SIGMA===== **For setup and runtime** * Start with a **coarse / rough mesh** for initial feasibility studies. * Use a limited number of **time steps** for quick screening runs. * Increase resolution only after the setup has been validated. **For thermal simulations** * Use non-isothermal simulation only when thermal effects are process-relevant. * Check CPU/RAM availability before enabling thermal and melting calculations simultaneously and keep in mind, that this simulation can take time. **For particle tracking and mixing analysis** * Ensure sufficient **time step resolution** ( 36 for particle-tracing evaluation are recommended).