An Integrated Solution of Automotive Composites Processing
Transcript of An Integrated Solution of Automotive Composites Processing
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 [email protected]
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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!