What's New

Click2Extrude Metal 2017.3 Release Notes

The following enhancements were made in this release:

Extrusion

Result Callouts
Post-processing has been enhanced to support display results at specified points. This feature is called callouts, and is used to query results accurately at any given node or point in the domain.
Bearing Profile Enhancements
Click2Extrude automatically extracts bearing profiles from the die assembly. Improvements have been made to this bearing profile extraction. In addition, the HM Batch interface has been enhanced to correctly identify the bearing profile corresponding to each hole.
Negative Billet Taper
Axial billet taper is often specified such that the temperature increases from the dummy block end to the die end. The application requires a positive temperature value to impose this taper. Under some circumstances, the taper can be in the opposite direction. Previous versions did not allow negative values for the taper temperature. This is now resolved, and the user can specify negative values as needed.
Bearing Regions with Choke
The application has been enhanced to detect bearing regions with choke more accurately. When bearing regions have choke, a different meshing strategy is used to create bearing and profile regions.
Quick Help for Dialogs
Access to context-sensitive help pages has been enabled for dialogs. When a dialog is open, pressing the F1 key will open the respective help page in the browser.
SimLab Upgrade
Click2Extrude uses SimLab in the background for meshing. In this release, SimLab was upgraded to its latest available version (2017.1) to resolve critical meshing issues and improve meshing performance.

Tool Deflection

Improvements to Automatic BC Creation
Extrusion loads are applied to the surfaces of the tool assembly that comes in contact with the workpiece. These surfaces are identified automatically by the application when options such as mapped loads and linearly interpolated loads are used. These surfaces are tagged at the time of export. This tagging of load surfaces was improved and made identical to the methodology used for coupled models.
In addition, improvements were made to the specification of constraints in pin/bolt holes that are used to hold the die assembly.
Tool Deflection Meshing
The accuracy of tool deflection analysis has been greatly improved with second order elements. This option is now supported by both batch meshing tools (HM and SimLab). With one click, the user can choose the first order (faster) or second order (accurate) option.

Quenching

Units for Coolant Flow Rate
The coolant flow rate for spray cooling is specified in Liters Per Minute (lpm) for SI and Metric unit systems. It is specified in Gallons Per Minute (gpm) for the British unit system. In the previous release, flow rates were exported in Liters Per Minute for all unit systems. This bug is now resolved.
Resizing of Quench Box
When the Quench Box was resized in the previous release, line and nozzle set entities were not correctly redrawn along with the box modification. This issue has been resolved in this release.

Click2Extrude Metal 2017.2 Release Notes

The following enhancements were made in this release:
Quenching Interface
Every extruded metal part is rapidly cooled soon after extrusion. The industry uses different types of quenching mechanisms to cool the profile, including spray cooling, air nozzle cooling, air fan cooling, and immersion quenching. In this release, a new interface has been added to setup a quenching analysis, and it supports spray cooling.
You can either start with a 2D surface of the profile shape, or a 3D profile solid from which you can setup the model with a few mouse clicks. A quenching analysis helps you to understand and improve the performance of quench systems. Results computed by the solver include temperature history, cooling rates, grain size, and quench factor analysis. The solver can also be dynamically or statically linked with OptiStruct to do a residual stress analysis.
The quenching interface uses its own license strings for the GUI and interface, which are different from the extrusion license codes.
Temperature Unit in Post-processing
Temperature results are now displayed in user units. Click2Extrude Metal exports data in three different unit systems: Metric, British, and SI. Corresponding temperature units are °C, °F, and K. It is recommended that you solve in either Metric or British unit systems.
Results Availability
When a model file is loaded (or after the analysis is in a session) from the run status, Click2Extrude Metal will automatically check for the availability of the results in that folder and indicate it with a green flag.
Automatic Meshing Improvements
Click2Extrude Metal uses two different meshing strategies to automatically mesh the model (HyperMesh and SIMLAB). Even though the SIMLAB strategy takes more time, it is more robust and produces a better quality mesh. This strategy is now enabled as the default strategy for use in extrusion, tool deflection, and coupled analysis. This enhancement has resolved many meshing issues.
Results Visualization and Section Cuts
Section cut can now be applied while visualizing the results. This will help you to look at the results.
Workflow help for contexts
A single line of help will now be displayed when you activate a tool from the ribbon. Clicking the line of help will display additional information.
The following issues were resolved in this release:
  • Resolved the issue where the auto-scale factor is automatically set to 1.0 when results are displayed, and the display of deformation (nose cone) is turned off and could only be enabled by clicking the Deformation tool.
  • Resolved the issue for Fit Material in the material database.
  • Project names in selected preferences can now be exported. The necessary input files for HyperMesh will now be exported in English names.
  • In the Export dialog, saved materials are also populated for material selection.
  • Issues regarding saving data to a model file has been resolved. Any changes made to a model will now be saved to a STMOD file after export. No changes will be saved to the imported CAD file.
  • Additional data checks have been added to Click2Extrude Metal. Part names will automatically be corrected during export if Pocket1 and Pocket2 are organized incorrectly. You will also be warned if a part is organized as Weld Chamber without Portholes.

Click2Extrude Metal 2017.1 Release Notes

The following enhancements were made in this release:
  • The License Wizard has been added to the Start menu. This helps you setup license variables easier.
  • While loading results for post-processing, a cursor indicating the status is shown. This helps you know that results are being loaded and the interface is waiting for the operation to complete.
The following issues were resolved in this release:
  • After exporting the data deck, a status symbol in the Export panel showed the image corresponding to a failed status. This is resolved.
  • The Post-processing window was not exiting the context either with right click or escape key. A workaround was to click any other icon again. This is now resolved. Both right click and escape will get the user out of this context.
  • It was possible to switch to the Inspire user profile, but there was no mechanism to return to the Click2Extrude Metal profile. This is option is disabled as switching profiles is not recommended.
  • Model configuration was removed from the View menu in this release, as it was not working as intended. This will be restored in the next major release.

Click2Extrude Metal 2017 Release Notes

Today's extrusion companies are required to coextrude profiles made of multiple polymers with metal inserts in shorter product development cycles while simultaneously reducing their production costs. Click2Extrude Metal is a simulation tool developed to analyze and validate the design of these coextrusion dies and process.

The HyperXtrude solver enables production engineers to analyse material flow and heat transfer inside a die during extrusion to validate die designs which in turn helps to reduce or eliminate costly and time-consuming die trials.

Click2Extrude Metal is easy to use CAD based interface. You won't be required to complete steps such as meshing or boundary condition creation manually. All these operations are completely done in the background with no user intervention.

Key features of Click2Extrude Metal 2017 include:
Choked Bearing
Click2Extrude Metal can automatically handle bearing regions with choke
Variable Bearing Start
Models with bearing starting at different Z-coordinates (variable bearing start) is supported and this will require manual manipulation of bearing region.
Charge Weld Analysis
With a click of a button, any model can be submitted for transient analysis and charge weld analysis is automatically enabled.
Billet Skin Tracking
While creating the billet, a skin layer can be added with no additional effort. This automatically enable billet skin tracking analysis, which is used for predicting back end defects, butt length, and any potential issues with the die design.
Starter Billets
Multi-cycle analysis with different billet lengths for each cycle up to five cycles.
Tapered Billet Heating
Click2Extrude Metal now supports specification of tapered heating: axial, lateral, and radial. Specification used can be different from cycle to cycle up to a maximum of five cycles. For axial taper, five linear taper zones are supported.
Tool Deflection Analysis
This release supports an easy to use tool deflection interface. You can import the model, specify constraints, and submit for analysis. The load surface will be automatically determined. This analysis supports mapped loads, linearly interpolated loads, and manually specified constant surface loads. In addition, you can do either an elastic analysis or an elasto-plastic analysis.
Bearing Optimization Analysis
Easy to use interface for setting up bearing optimization
Ram Speed Control
In a full cycle analysis, based on the computed load curve and press tonnage, ram speed can be automatically restricted during the ram acceleration stage to meet the press tonnage requirements.
Coupled Analysis
This release enables coupled extrusion and tool deflection analysis. Extrusion analysis is performed by HX solver and it will automatically call OptiStruct to perform tool deflection analysis. Results from tool deflection analysis is used to consider the effect of deflection on bearing gap opening and thereby, on the predicted profile nose cone.
Press Database
Allows you to load press data. It enables Click2Extrude Metal to verify data consistency and check whether the extrusion assembly under study works with the selected press.
Post-Processing
Results visualization for analysis types.
Meshing
Click2Extrude Metal enables meshing in SimLab® which is very powerful tool for generating good meshes for complex geometries. Using this tool will require additional installation.

Click2Extrude Metal 2016 Release Notes

Today's extrusion companies are required to coextrude profiles made of multiple polymers with metal inserts in shorter product development cycles while simultaneously reducing their production costs. Click2Extrude Metal is a simulation tool developed to analyze and validate the design of these coextrusion dies and process.

The HyperXtrude solver enables production engineers to analyse material flow and heat transfer inside a die during extrusion to validate die designs which in turn helps to reduce or eliminate costly and time-consuming die trials.

Click2Extrude Metal is easy to use CAD based interface. You won't be required to complete steps such as meshing or boundary condition creation manually. All these operations are completely done in the background with no user intervention.

Key features of Click2Extrude Metal 2016 include:
Choked Bearing
Click2Extrude Metal can automatically handle bearing regions with choke
Variable Bearing Start
Models with bearing starting at different Z-coordinates (variable bearing start) is supported and this will require manual manipulation of bearing region.
Charge Weld Analysis
With a click of a button, any model can be submitted for transient analysis and charge weld analysis is automatically enabled.
Billet Skin Tracking
While creating the billet, a skin layer can be added with no additional effort. This automatically enable billet skin tracking analysis, which is used for predicting back end defects, butt length, and any potential issues with the die design.
Starter Billets
Multi-cycle analysis with different billet lengths for each cycle up to five cycles.
Tapered Billet Heating
Click2Extrude Metal now supports specification of tapered heating: axial, lateral, and radial. Specification used can be different from cycle to cycle up to a maximum of five cycles. For axial taper, five linear taper zones are supported.
Tool Deflection Analysis
This release supports an easy to use tool deflection interface. You can import the model, specify constraints, and submit for analysis. The load surface will be automatically determined. This analysis supports mapped loads, linearly interpolated loads, and manually specified constant surface loads. In addition, you can do either an elastic analysis or an elasto-plastic analysis.
Bearing Optimization Analysis
Easy to use interface for setting up bearing optimization
Ram Speed Control
In a full cycle analysis, based on the computed load curve and press tonnage, ram speed can be automatically restricted during the ram acceleration stage to meet the press tonnage requirements.
Coupled Analysis
This release enables coupled extrusion and tool deflection analysis. Extrusion analysis is performed by HX solver and it will automatically call OptiStruct to perform tool deflection analysis. Results from tool deflection analysis is used to consider the effect of deflection on bearing gap opening and thereby, on the predicted profile nose cone.
Press Database
Allows you to load press data. It enables Click2Extrude Metal to verify data consistency and check whether the extrusion assembly under study works with the selected press.
Post-Processing
Results visualization for analysis types.
Meshing
Click2Extrude Metal enables meshing in SimLab® which is very powerful tool for generating good meshes for complex geometries. Using this tool will require additional installation.