Faculté des Sciences, de la Technologie et de la Communication Dynamic Simulation of an Injection...

Faculté des Sciences, de la Technologie et de la Communication

Dynamic Simulation of an

Injection Molding Machine

GAMM2005

Mehrkörpersysteme und Kinematik

29. März - 01. April 2005, Luxemburg

C. HostertH. KollmeierS. MaasR. NordmannA. Zürbes Université du

Luxembourg


Index

1. Projecta) Description of project

b) QUADLOC™ clamp unit

c) Simulation tools

2. Modelsa) Multi-Body Simulation model

b) Integration of flexible bodies in MBS

c) Hydraulic model

d) Controls model

3. Simulationa) Results / Comparison with measurements

b) Prospects

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Project

dynamic simulation of a QUADLOC clamp unit

integration of mechanical, hydraulic and controls systems

combination of commercial software

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects

3 partners: HUSKY Injection Molding Systems TU-Darmstadt Université du Luxembourg


QUADLOC™ clamp unit

2-platen design

moving platen

stationary platen

4 tie bars

4 integratedclamp pistons

2 stroke cylinders

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Software

combination of commercial simulation programs

ADAMSADAMSMulti-Body

SimulinkSimulinkcontrols

UnigraphicsUnigraphicsgeometries for models

DSHDSHplusplus

hydraulics

measurememeasurementsnts

validation

flexibility of components

co-simulationof mechatronic

systems

data for stress analysis

ANSYSANSYSFinite Element

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


MBS model of clamp locking

1 rigid-body DOF + 57 flexible-body DOFs

revolute jointwith friction

sperical joint

sperical jointwith joint motion

hydraulic force

flexible body

rigid body

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


MBS model of moving platen stroke

6 rigid-body DOFs + 150 flexible-body DOFs

rigid body

contact forces

flexible body

hydraulic force

bushings

rigid body

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


FE-model for moving platen stroke

SOLID 187

BEAM 188

SHELL 63

COMBIN 14 : connecting substructures

BEAM 4 : interface nodes

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


1st step: Component Mode Synthesis

i interiorb boundaryC constraintN normal

qq

q0I

u

uu

N

C

NCi

b

called Craig-Bampton approach:

constraint modes &

fixed normal modes

NN

CCT

K0

0KkK

NNNC

CNCCT

MM

MMmM

siehe auch R.Gasch, Strukturdynamik – Band 2gemischte statische und modale Kondensation

Flexible bodies in MBS1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Craig-Bampton modal basis difficult to implement in MBS code

MqKq qqN ˆ qqu ˆ̂

synthesized from fixed normal and constraint modes are:

6 rigid body modes; can now be disabled in MBS,

free normal modes,

mode shapes of the boundary,

modes with no apparent physical meaning.

solving the following eigenvalue problem:

so that thus

2ndstep: Mathematical Transformation


a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


G

PB

Ps Pu

r

position: where

orientation: 3-1-3 Euler Angles ( transformation matrix A)

angular velocity:

linear velocity:

PPP usArr qu ˆˆPP

T~ AA

qAqsArv ˆˆˆ~ˆ~

PPPP

n,1i,q̂

z

y

x

i

q

p

ˆ

PPPP

ˆˆ~ˆ~ ABqsAIvgeneralized

coordinate set

3rd step: Integration in ADAMS


a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Theory of Flexible Bodies

3rd step: Integration in ADAMS

0QFLL T

dt

dLagrange's equations for a flexible body:

V P

TP dVvvT

2

1

V PPP

TTP

TT

PPT dVˆABq̂

~ˆs~AI

Aˆ

Aq̂~ˆs~B

I

MT T

2

1

T2

1

q̂Dq̂F T 2

1

kinetic energy:

potential energy: dissipative energy:

q̂Kq̂VV Tg 2

1

QDV

KM

MM

TG

T

2

1

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


automatic meshing

2. ANSYS/Workbench

Parasolid

FE-model of a connecting bar

1. CAD model

SOLID 187

BEAM 4

interface nodefor MBS model

3. ANSYS/Classicmanual generationof BEAM elements

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Integration of ANSYS-models in ADAMS

ADAMS-interface available in ANSYS

assembly of flexible body into MBS-model

1. generation of FE-model

2. ADAMS-interface:

selection of interface nodes

reduction of FE-model

transfer of reduced matrices (mnf-File)

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Verification of reduced model

modal analysis of assembled connecting bar

ANSYS(25000 DOF)

ADAMS(25 DOF)

MeasureMode shape

26.8 Hz 5.9 % 26.7 Hz 5.5 % 25.3 Hz 1. z

39.5 Hz 0.0 % 39.5 Hz 0.0 % 39.5 Hz 1. x

106.5 Hz 9.8 % 106.5 Hz 9.8 % 97.0 Hz 2. z

151.1 Hz 1.8 % 151.2 Hz 1.8 % 148.5 Hz 2. x

244.8 Hz 244.7 Hz ? 3. z

331.4 Hz 3.4 % 331.4 Hz 3.4 % 320.5 Hz 3. x

y

z

x

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Moving platen and tie bar sliding

modelled in ADAMS with IMPACT statement

non-linear spring-damper

maintains continuous contact between 2

geometries

1

1e

1contact

xx0

xxxcxxkF

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects



1

1e

contactxDY0

xDYVYcDY1xkF

own-programmed statement using IMPACT

clamp base

moving platen shoe

node

d1 d2

d3 d4

DY,VYDZ

contact force permanently calculated

only applied to node when necessarythrough a weighting function

d1 d2

d3 d4

1

0

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects



disadvantges: - huge number of DOFs

- discontinuous contact forces

use of slave nodesfor sliding

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Body

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Hydraulic model

DSHplus by FLUIDON GmbH

differential cylinder

modeling of cylinder cushion

hoses

pilot operated43 proportional valve

pipes and hoses

pump andpressure-reducing valve

Spin-off of IFAS, RWTH-Aachen

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


2H QRp

dtQC

1p

H

dt

dQLp H Inductance :

Capacitance :

Resistance :

iQ Up

model of components:

pipe

valve

LH RH

CH

RH

Hydraulic model

formulas based on

- one-dimensional flow theory

- supplemented by empirical considerations

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Co-simulation

SIMULINK

Controls

ADAMS

Mechanics

DSHplus

Hydraulics

position of cylinder velocity of cylinder input voltage valve

cylinder force moving platen position

input voltage valve

1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


Comparison with measurements1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects


interest of integrated simulations :

get full understanding of dynamics of complete system, difficult to assess with simple calculations

analyse influence of one parameter on behaviour of complete system

analyse interactions between sub-systems, e.g. hydraulics and mechanics

work-out improvements

replace costly prototypes

Simulation of Mechatronic Systems1.Project

a)Project

b)QUADLOC

c)Software

2.Models

a)MBS

b)Flexible Bodies

c)Hydraulics

d)Controls

3.Simulation

a)Results

b)Prospects

Faculté des Sciences, de la Technologie et de la Communication Dynamic Simulation of an Injection...

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