Post on 28-Apr-2022
Lanxess CAE Service Center Overview
High Performance Material (HPM), LANXESS Hong Kong
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HPM’s CAE service center offers high-end engineering at its best
� Park office and laboratory space: 220,000 m2
� More than 300 high-technology enterprises of all sizes
� Phase 1 & 2 completed and ~95% occupied, Phase 3 completed
Hong Kong Science & Technology Park LANXESS HPM development services
Concept Development
Computer Aided Engineering
Part Testing
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� Material development:
Tailored material solutions
� Concept development:Leading in lightweight
technology developments
� Computer Aided Engineering:Top-notch simulation methods
� Part testing:
State-of-the-art testing facilities
� Processing:
Development of material
process combinations for new
applications
Expertise for all stages of advanced component development
Our value proposition combines materials and high-end engineering know-how at its best
Tailored high-tech plastics
compounds and
composite sheets
Material development
Part testing
Concept develop-
ment
Processing
Computer aided
engineering
Computer Aided
Engineering
TEPEX®
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Top-notch simulation tools developed by LANXESS*
Tailored high-tech plastics
compounds and
composite sheets
* Special competence by LANXESS
Computer Aided Engineering
Developing advanced CAE tools to predict component
performance close to reality:
� Processing simulation e.g.
Injection molding (moldflow)
Forming simulation*
� Integrative simulation technology*
Short fiber reinforced plastics* Composite sheets*
� Structural simulation e.g.
Crash Fatigue life prediction
Feasibility studyDetailed
development Testing ProductionTooling
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HPM’s APAC engineering services for our customers
Tasks
Deliverables
Feasibility studyDetailed
development Testing / Approval Production
� Concept proposals
� Topology optimization� Structural & rheological
analysis on conceptual design
� Optimization of detailed design
� Virtual evaluation: mechanical analysis
� Virtual processing:
rheological analysis
� Part validation � Trouble shooting
– Processing
– Parts performance
� Preliminary design
� Material pre-selection� Processing technology
� Estimate of cost &
challenges
� Serial design of part & mold
� Grade selection� Guideline for processing
� Guideline for testing
� Challenges/Risks
� Durability*
� Compliance with customer specification
� Insight of material and parts
performance
� Analyze failure sources
� Find solutions
* Under various environmental conditions
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Feasibility studyDetailed
development Testing ProductionTooling
CAD and CAE development steps of air-intake manifolds
Computer Aided Design & Engineering (CAD & CAE)
Mechanical FE-analysis (Abaqus) – burst pressure
Mechanical FE-analysis (Abaqus) – eigen mode extraction
Product design review
Mechanical FE-analysis (Abaqus)– noise power extraction
Mechanical FE-analysis (Abaqus) – modal analysis (force response)
Rheological FE-analysis (Moldflow)– molding simulation
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CAE and Design Service Support
Finite-Element Analysis
• Rheological FE-Analysis (Moldflow)
– Filling pattern (optimizing machine size and surface quality)
– Glass fiber orientation
– Shrinkage and warpage
– Cooling system and cycle time improvement
• Mechanical/Fluid FE-Analysis
– Thermal expansion
– Stiffness and strength
– Creep
– Impact simulation
– Dynamical behaviour
– Noise
Part design
• Development of detailed solutions
• Material optimized design
• Incorporation of FE-results into
design
• Investigation of joining alternatives
Tool design
• Gate design
• Hot runner systems
• Stiffness of tool
• Demolding techniques
Part and Mold Design
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Key Facts
Hardware
• Fujitsu Linux System• 2 calculation nodes• Max. 2 CPUs with 12 cores each• Max. 128 GByte main memory• 20 TB storage capacity• Graphic workstations
Software
• SolidWorks• CATIA• ANSA• Hyperworks• Moldflow• ABAQUS / LS-Dyna
Simulation types
• Rheology• Topology- / Parametric Optimization• Linear/Non-linear static• Crash Simulation• Acoustic / NVH
Special services
• Development and advancement of material data cards for various simulation codes
• Help with applying material data cards / trouble shooting
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HPM’s top applications in automotive for the APAC region
Oil filter modules
Air intake manifolds
Oil pans
(engine & transmission)
Structural Parts, frontends
Door handles
Lamp bezels
Cylinder head cover
air intake cover
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Rheology
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Injection Molding Simulation
Rheology
Simulation of the injection molding process allows:
� Determining process ability of a molding (processing window)
� Identification of problem areas (weld lines, entrapped air, warpage,…)
� Determining optimum gate positions and runner dimensions
� Using of calculated fibre orientation in other FEM simulations for more accurate
predictions (integrative simulation)
� Evaluate design alternatives without cutting steel
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Base Plate – Geometry
Rheology Example
Wall thickness distribution(each color indicates one wall thickness)
Part shows high variations in wall
thickness
Material: 30% glass filled PBT (Pocan B4235)
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Rheology Results
Filling pattern, white arrow indicates gate position
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Rheology Results
Filling pattern, white arrow indicates gate position
entrapped air
weld line
core displacement
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Rheology Results
Pressure at injection location
Warpage due to glass
fiber orientation
deformed (warpage)undeformed
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Topology Optimization
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How does topology optimization works?
Topology Optimization
Load F
Boundary conditions: Fixation
Design space: Within this space (volume) material
can be placed or displaced
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How does topology optimization works?
Topology Optimization
Load F
Boundary conditions: Fixation
After the automatic iterative optimization process, material is
placed in areas contributing to the part‘s
stiffness
In areas with no static function, material is
displaced
• After the automatic iterative optimization process, material is placed in areas contributing to the part‘s stiffness
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Topology optimization of thermostat housing under gasket and water load
Topology optimization example
Pressure from Gasket (Groove)
Pressure from Water
Recommendation
Automated Optimized Ribbing
Gasket-Pressure Water-Pressure
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Example 1
Using topology optimization for design of rib patterns
Fixation
Fixation
Hood latch retention force: FZ = 4000 N
Ribs placed in optimal position within the design space
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Example 2
Using topology optimization for design of rib patterns
Current Rib Structure
Optimized Rib Structure
Material in the non-allowable areas are removed in the optimization analysis as shown below.
Part is loaded in z-direction at original loading point (Hood Latch test).
Loading Point is connected to the volume by a multiple point constraint.
Part is fixed in x,y,z (Translation & Rotation)
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Example 3
Replacement of Steel Pedal with PMH Design Process
Requirements
Manual design
Optimized design
Prototype
Preliminary design�Too heavy
�Producability�Over-engineered
Steel: 506g
Plastic: 302g
Steel: 506g
Plastic: 202g
Optimization• Stiffness
• Moldability
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Hybrid Technology
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Plastic Keeps Metal in Shape
Hybrid Technology Principle
geometry collapses at much higher forcesimproved utilization of sheet metal structure properties
low forces keep
structure in shape
light weight design(thin wall thickness)
tends to buckling
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The Best of Two Worlds
Hybrid Technology Principle
• design freedom
• low density
• good impact strength and stiffness
• excellent performanceunder dynamic loading
• high ageing resistance
• resistance against oil,grease and detergent
Metal
• high strength and stiffness in a wide temperature range
• ductile crack behaviour
• low CLTE
• good deep drawing behaviour
Hybrid
• reduced tendency to buckling ofthin wall metal structures
• high energy absorption
• high temperature resistance(e-coating capability)
• low part weight by thin walls
• high precision inproduction and use
• high integration offunctional elements
Polyamid 6 GF
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Hybrid Technology Principle
Hybrid Technology
+
Possibility A : parallel to each other
CompressionBendingTorsion
Q: What is the most effective combination of plastic and metal?
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Hybrid Technology Principle
Hybrid Technology
0
50
100
150
200
250
300
350
400
450
0 1 2 3 4 5
Polyamid 6 GFshort-term
long-term
cond., 23°CSteel
Str
es
s
[M
Pa
]
Strain [%]
82 MPa
0,2
35 MPa
Steellong-term
Steelshort-term
Comparison of Plastics with Metal
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Hybrid Technology Principle
Hybrid Technology
Possibility B : In an angle to each other
Q: What is the most effective combination of plastic and metal?
+
CompressionBendingTorsion
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Hybrid Technology Principle
Hybrid Technology
Deflection Behavior in 3-Point Bending Test
Fo
rce
F
[k
N]
4,0
3,0
2,5
2,0
3,5
1,5
0,5
0
Deflection f [mm]80 2 4 6 10 12 14 16 18 20
50
Metal/plastic Hybrid profile
Closed metal profile
Open metal profile
340
f
F
40
30
Hybrid Technology Principle
Hybrid Technology
Deflection Behavior Compression
Fo
rce
F
[k
N]
25
20
15
10
5
0
Deflection f [mm]
2,40 0,8 1,6 3,2 4 4,8
340
50
40
Metal/plastic Hybrid profile
Closed metal profile
Open metal profile
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Hybrid Technology Principle
Hybrid Technology
Mo
me
nt M
[N
m]
40
25
20
15
30
10
5
0
Rotation Angle ϕϕϕϕ [°]80 2 4 6 10 12 14 16
340
35
50
40
Metal/plastic Hybrid profile
Closed metal profile
Open metal profile
Deflection Behavior Torsion
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Weight related performance comparison
Hybrid Technology
Beanspruchung
loadProfilart
profile style
Biegungbending
Belastbarkeitloading capacity
Druckpressure
Belastbarkeitloading capacity
Torsiontorsion
Steifigkeitstiffness
PA-GF 30%x-verripptribbedStahl / steels = 0,7 mm
Stahl / steels = 0,7 mm
Stahl / steels = 0,7 mm
w/ face sheetmetal
w/o face sheetmetal
1,81,8
1
8,5
1
1 1
1,1
13
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Hybrid Technology Principle
Hybrid Technology
Injection Molding Process:
Dimensional changes of the plastic component due to shrinkage are being limited by the strenght/stiffness of the metal profile.
Forming Process:
Stretching, compression and punching of the sheet metal
Dimensional inaccuracy of the sheet metal will be eliminated during the molding process.
Influencing Factors on Tolerances:
Application:
Dimensional changes due to climatic variations (temperature, humidity) are small because of the dimensional stability of the sheet metal.
TolerancesWarpageHeat StabilityCreeping
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Smart solutions for a sustainable future of mobility –energized by LANXESS
Picture/Artwork size:
Height = 12.29 cm Width = 9.11 cm
Innovative concepts support sustainable mobility
trends
Computer Aided Engineering pushes boundaries
for cost-effective and efficient solutions
Customized top-notch simulation tools
Contributing to innovations with new technologies and high performance materials
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