2014国际CAE模具成型技术研讨会

An Integrated Solution of Automotive Composites Processing 汽车复合材料工艺件结构一体化方针解决方案

May Tsai (蔡穎玫) 2014/03/21 maytsai@moldex3d.com

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> Product lifecycle management of injection-molded part

> Integration of injection molding & structural analysis CAE

> Case of fiber-reinforced product

> Conclusion

Outline

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Product Lifecycle Management (PLM) of Injection-Molded Part

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PLM – without considering molding effects

Concept Design

Production

Injection Molding

http://www.ebay.com

Structural Analysis There are some process-induced variation effects! (fiber, weldline...)

Ideal case, in reality it doesn’t exist.

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PLM – Injection molding process

Screw

Screw simulation

Performance

Structural analysis

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Polymer rheology & Fiber orientation

unoriented molecularchain before flow

oriented molecularchain after flow

velocityprofile

shear rateprofile

molecular chain orientation

decrease in orientation

Viscosity

Shear Rate

Lower Temp.

Higher Temp.

unoriented molecular chains

oriented molecular chains

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Fiber orientation parameter, fp

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> To cover the process-induced variation during the processes – Full Integration of injection molding analysis and structural

analysis – Including ABAQUS, ANSYS, MSC. Nastran, NENastran, NX-Nastran, LS-Dyna, Marc, RADIOSS, and DIGIMAT

PLM – Injection molding process

Mesh, Material,

Process…etc

Flow/Pack/Cool Warp/Fiber Simulation

Deformed geometry, Fiber-reinforced

Material properties… etc.

Structure analysis, Drop test analysis, Impact analysis…

etc.

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> Residual stress – From volume shrinkage difference – From flow induced molecular orientation

> Material anisotropy

– Molecular orientation – Filler orientation distribution

> Material inhomogeneity

– Weldline – Matrix density – Filler concentration distribution – Filler size distribution

Things we should consider in structural analysis

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Integration of Injection Molding & Structural Analysis CAE

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PLM – considering molding effects

Concept Design

Production

Injection Molding

http://www.ebay.com

Structural Analysis Connect the injection molding analysis to

structural analysis by Moldex3D-FEA !

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> To cover the process-induced variation during the processes

– Fiber orientation output – Material reduction – Mesh mapping – Residual stress output – EOP Temperature output – Initial strain output (as temperature difference) – Multiple time step melt flow pressure output – Moldbase related data output (pressure, temperature)

What Moldex3D-FEA can do?

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Better procedure for structural analysis

Correct Initial Condition

Correct Boundary Condition

Structural Analysis Solver

Accurate Results

Proper Mesh

Correct Material Properties

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Fiber-Reinforced Product Example

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> Car door handle – Size: 138 × 60 × 42 mm

Product Case

B.C. Fixed location

Loading 2 kg force

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> Material: PP \ Celstran GF30-02 > Processing conditions

– Filling time: 0.428 s – Melt temperature: 210 ℃ – Mold temperature: 70 ℃ – Packing time: 5.0 s – Cooling time: 20.0 s

Moldex3D injection molding CAE analysis

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> PP \ Celstran GF30-02

Material properties

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> Melt front time

Moldex3D results

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Moldex3D results

> 5X warp (mm)

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Moldex3D results

> Fiber orientation

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Moldex3D results

Fiber orientation Fiber orientation – x dir.

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Integration of Injection Molding & Structural Analysis CAE via Moldex3D-FEA

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Properties derivation

Structural analysis

Flow analysis

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Orientation information

Material parameters

Element properties

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Fiber orientation effect

Fiber-reinforced Non-considering fiber

1X Warp (mm)

Fiber orientation

Max.= 3.21 mm Max.= 1.79 mm

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Structural analysis results (Digimat to Marc)

Max.= 3.66 mm Max.= 1.18 mm

Deformation (mm)

Von Mises stress (MPa)

Non-considering fiber Fiber-reinforced

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> Considering molding-induced variation is important to Product Lifecycle Management (PLM) of injection molded part.

> The integration of Moldex3D injection molding and MSC

Marc structure analysis, provides an entire CAE method of PLM.

> Moldex3D is capability to help people solving problems in

the life cycle management for injection molding product development.

Conclusion

Thank you for your attention!