06.2 / CDS Training Manual

Exercises

Choose a question to work through. Open its connected study, change the prescribed inputs and use the checkpoints to explain the result.

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Exercise curriculum

Shared CDS database

CREATEDesign a starting point DISCOVERExplore the live laminate SIMULATELaunch Workbench

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Exercises

Choose an exercise to see its setup. Double-click or press Enter to open it in Workbench.

Exercise · 25 min

03.02 · Pultrusion: resin injection, heating and cooling

Level 3
IntermediateEst. 25 min

03 · Advanced & coupled studies · 07-pultrusion-intro

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About this workflow view

All blocks keep the CREATE / DISCOVER / SIMULATE positions, with Equipment below Geometry; unused records remain disconnected. This changes the view only, not the exercise records. The diagram shows the setup, not solved results.

∑ Used models & submodels

Only models assigned to records used by this exercise are listed here. The full-layout option preserves the supplied starter records; no Workbench records are changed.

Halpin–Tsai · T700 / EP180 UD · Thermal processing

One compatible homogenization model per Micro recipe. Separate recipes compare models; their predictions are not blended.

∑ Theory & assumptions

1D pultrusion thermal cure · Heated-die pultrusion load · injection-box infusion

Needs linked laminate properties and a compatible process schedule. A linked cycle is not a solved temperature history.

∑ Theory & assumptions

Data travelling between blocks

Micro → Laminates
Predicted ply stiffness, strength, density and expansion properties.

Materials → Equipment
Constituent stiffness, strength, density and thermal / moisture properties.

Laminates → Geometry
Ply angles and thicknesses, stiffness, mass and ply properties.

Materials → Models
Constituent stiffness, strength, density and thermal / moisture properties.

Materials → Micro
Constituent stiffness, strength, density and thermal / moisture properties.

Thermal → Simulation
SIMULATION selects this case and its analysis model; the case owns its applicable cycle and input references.

Laminates → Thermal
Ply angles and thicknesses, stiffness, mass and ply properties.

Equipment → Thermal
Linked lasers, IR/UV lamps, heaters, coolers and molds: dimensions, radiant power or prescribed temperature / heat flux, contact conductance, body and surface materials. Each boundary keeps its own placement, side and exposure.

Geometry → Thermal
Part shape and dimensions, thickness or section definition, and model-specific geometric inputs. Each selected case consumes only the dimensions its model supports.

Materials → Thermal
Constituent stiffness, strength, density and thermal / moisture properties.

Models → Micro
Applied model assignment: Halpin–Tsai. Model parameters and formulation are used by Micro.

Models → Thermal
Applied model assignment: 1D pultrusion thermal cure. Model parameters and formulation are used by Thermal.

What this exercise will help you understand

In a pultrusion study, pulling speed connects a position along the die to the time experienced by a moving material section. The exercise uses that relationship to examine residence time, heating and cure, with a structural comparison only where the selected simulation supports that transfer.

Application: Pultrusion
Baseline models: Halpin–Tsai · 1D pultrusion thermal cure
Geometry: Infinite beam · finite width and laminate thickness

Reference validation · 2026-10-31

Not benchmark validated

No matched quantitative reference comparison completed for the full exercise.

Recorded baseline only—not a certification of the current database, edited inputs, or every output. Analytical agreement is not experimental material or failure validation.

Source validation, comparisons and tested inputs

Execution: Completed (not validation)

A coupled, damage, transport or local-field comparison needs matched constitutive data, boundary conditions and field/mesh convergence. Execution alone is insufficient.

Tested inputs

Input SHA-256: 174f0e7506c6bad11e871d07431e70faffa754645a1ecf39db3674b99097309e
Solver source SHA-256: cde316d69ee40b2714f26fd4d6d822f774242b37323c9419f2b6142aff317ca9

Illustrative constant-speed T700/epoxy process. Uniform face-fed, through-thickness Darcy infusion uses prescribed Kz, a continuous resin manifold and local ply-average cure viscosity; pressure or total flow controls the inlet and pump limits are reported. Fixed equivalent-composite thermal properties; no dry-to-wet feedback, resin heat advection, axial flow, leakage, die thermal mass or pulling-force prediction. Not a calibrated production recipe.

Download source-validation results (JSON) · Full 184-exercise study

Preparing a meaningful comparison

Check the die length, inlet state, pulling speed and boundary stations before changing between length and time views. Keep the intended coordinate basis fixed while comparing speeds. Record the computed outlet state for each run; a prescribed die temperature is not an imposed core temperature or a guarantee of complete cure.

Before editing, open the exercise in Workbench and check which simulation is selected. Follow the map above to see how its inputs connect; the map shows the setup, not a solved result. Read the input summary and validation notices. Make an independent copy when you need a separate variation, so shared reference records stay available.

Working through the exercise

Step 1
Trace the dry reinforcement creels to the injection box, then heating and cooling dies. Inspect the laminate, dry through-thickness permeability and pore fraction. Incoming material conditions start at 23°C and 0.1 m/min; the inlet is a dry preform, not prepreg.
Step 2
Open Incoming material conditions → Pressure or flow rate controlled input: resin, 0.6 MPa absolute inlet, 0.1 MPa absolute vent, X=0 and 250 mm exposure. The Injection box hardware remains in Equipment. Switch to Flow rate to compare demanded and absorbed resin throughput. The box occupies 0–0.25 m (0–2.5 min at 0.1 m/min). Its pressure difference drives Darcy impregnation only in that interval; mold compression is separate.
Step 3
Inspect paired dies: 150°C heating over 0.25–1.05 m and 40°C cooling over 1.05–1.25 m. Run and inspect per-ply fill at box exit, temperature, cure and resin use. Finite contact conductance determines material temperature.
Step 4
Double speed to 0.2 m/min. Total residence becomes 6.25 min; box exposure becomes 1.25 min. Compare fill at injection-box exit and final cure independently.

Understanding your results

Explain the process result using the reported residence time and surface/core histories. For coupled variants, also record the actual state and stiffness passed into the structural calculation. Separate changes caused by section thickness or applied load from changes caused by cure, and do not infer an acceptable production speed without calibrated requirements.

Use the checkpoints to see whether your explanation fits the intended comparison. Put the relevant result beside each one. If a result differs, work back through the inputs, model assumptions and numerical settings to explain why.

At 0.1 m/min, the full 1.25 m line takes 12.5 min.
Dry creels supply reinforcement; the injection box supplies liquid resin. Darcy flow stops at box exit even though curing continues in the heated dies. Insufficient fill is a predicted outcome to investigate.
Die setpoints are Equipment inputs. Injection driving pressure is inlet minus vent, independent of the shared compression pressure. Do not add upper and lower pressures.
Compare fill, cure and temperature as speed changes. Repeat with a finer thermal grid and shorter Darcy time step; example completion alone is not proof of process quality.

Writing your conclusion

Explain what you changed, what happened and why. Compare the baseline with your new result, and say where the behaviour agrees with the selected formulation or needs another check. Include a labelled plot or table with units and its input state so someone else can follow the work.

Save the study with the solver notices and your checks. State the limits that affect this result, including illustrative data or missing calibration. Completing the exercise shows the comparison you made; claim benchmark validation only where the source-validation panel explicitly supports it.

Theory for this exercise

Transient heat conduction and boundary conditions
Relates heat capacity, through-thickness conductivity, flux and convection to the temperature history.
Cure kinetics, reaction heat and evolving resin state
Connect degree of cure and temperature to reaction rate, exotherm and calibration limits.
Darcy filling and temperature-dependent viscosity
Derives the one-dimensional front law and explains permeability, viscosity and coupled temperature effects.

Model limits

Illustrative constant-speed T700/epoxy process. Uniform face-fed, through-thickness Darcy infusion uses prescribed Kz, a continuous resin manifold and local ply-average cure viscosity; pressure or total flow controls the inlet and pump limits are reported. Fixed equivalent-composite thermal properties; no dry-to-wet feedback, resin heat advection, axial flow, leakage, die thermal mass or pulling-force prediction. Not a calibrated production recipe.

Operating guidance and source references

How the shared curriculum works

Read the reference
Select an exercise from the shared CDS database
Trace inputs in Simulation
Run and inspect fields
Compare checkpoints and record limits

SIMULATION selects the Thermal, Moisture, Mechanical and EM cases to run, with None available in each slot. Geometry owns shared specimen dimensions; Laminate owns plies and thickness. Equipment, directly below Geometry, owns reusable laser, IR/UV lamp, heater, cooler and mold specifications. Cases link that hardware to its placement and exposure; a boundary temperature alone does not imply a hardware model. Each case owns one analysis model, its applied conditions and its applicable cycle; there is no separate Process block. Surrounding blocks manage available records. Run updates results; completed does not mean validated or passed.

You work from one shared default database across all 184 exercises, examples and case studies. Opening an exercise selects its connected records without adding duplicate materials. An edit to a shared record affects every study that uses it, so duplicate the record for an independent variation. Downloads contain self-contained subsets and require sign-in with an active CDS license. Exercise links open the guide; they do not run the solver or replace your database. Historical files remain in the separate portal archive.

Catalogue revision 2026-09-20. Source-data case studies require the setup and calibration described in their guides.

For ATP frame comparisons, use the compact ATP curriculum and retained sensitivity references.

Keep the results and checks with your saved study so you can explain how you reached the conclusion. Use the User Guide for the controls and the Theory Manual for the mathematics.

Choose the run in the SIMULATION block

SIMULATION is the control point for the run. Select a Thermal case, Moisture case, Mechanical case and EM case, or None in any slot. Each selected case shows its analysis model, laminate and applicable geometry.

Step-by-step instructions · 4 steps

Keep candidate records in the surrounding blocks. Adding a candidate does not select it for execution.
Select the required cases in SIMULATION and review their inputs before Run. At least one case is required.
Use the same laminate for a supported combined run. Run standalone studies separately with the other selectors set to None.
Run executes the selected combination. A connection or Used marker is not confirmation of a successful solve.

Review every downstream geometry dependency

A geometry record can be shared by several cases and simulations. Editing its dimensions or type affects all linked consumers, including studies that are not currently open. Unrelated records are unchanged.

Step-by-step instructions · 4 steps

After editing geometry, open Solver messages and expand Review affected cases and simulations. Select a linked name to inspect that record.
Check the selected model, load basis, dimensions and boundary conditions. Loads are not automatically replaced when the geometry changes.
Resolve incompatible geometry and model combinations before running. An I-section does not turn a plate theory into a beam theory.
Rerun affected simulations before relying on previous results. Inputs changed warnings indicate that stored results no longer match their connected inputs.

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