Lanxess CAE Support Overview General

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


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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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?


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?


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


• 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

+

Possibility A : parallel to each other

CompressionBendingTorsion

Q: What is the most effective combination of plastic and metal?

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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

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

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

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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



Open metal profile

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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



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

28

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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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Lanxess CAE Support Overview General

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