Improved Quality Prediction of Injection Molded Fiber Reinforced Components by Considering Fiber...
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Transcript of Improved Quality Prediction of Injection Molded Fiber Reinforced Components by Considering Fiber...
Improved Quality Prediction of Injection Molded Fiber Reinforced
Components by Considering Fiber Orientations
Sascha Pazour
PART Engineering GmbH
0049 2204 30677 26
© PART Engineering GmbH, www.part-gmbh.de
Plastics
CAE Services & Software
Technical Simulation Contract Simulation Services
in FEA
CAE Staffing Resident Engineers at
customers‘ sites
CAE Software - Process-Structure-Interaction
- Strength & Fatigue Assessment
Metals
S-Life
Elastomers
Mechanical Solver Injection Moulding
Solver
- Moldflow
- Cadmould
- Sigma
- Moldex
- Fluent
- Simpoe
- 3D Timon
- Abaqus
- Ansys
- Radioss
- Nastran
- Marc
- FEMFat
- Ncode
Orientations
Pressures
Temperatures
Wall Thicknesses
Residual Stresses
Shrinkage & Warpage
Fig. 2
material:
PA6+GF30
perpendicular
parallel
Influence of Fiber Orientation onto Material Properties Fig. 3
Fiber Orientations in Short-Fiber-Reinforced Plastics
S1 Shear layer: Fibers oriented parallel to flow direction
S2 Mid layer: Fibers oriented perpendicular to flow direction
Fig. 4
Flow Direction X
X
Cut View X
Flow Direction
S1
S2
S1
Isotropic and Orthotropic Material Models
for Multiaxial Loading
s11
s33
s22
t32
t13
t12
t23 t21
t31
Isotropic Material Model
Orthotropic Material Model
Fig. 5
2*
3* 1*
local system
(orthotropic system)
needs 2 material properties: Tensile Modulus E and Poisson ratio
needs 9 material properties:
Tensile modulii the 3 orthotropic axes E1, E2, E3
Shear modulii the 3 orthotropic planes G12, G13, G23
Poisson ratios 12, 13, 23
Further the position of the orthotropic axes (local element coordinate sytem)
with reference to the global coordinate system is needed
1
3 2 global system
(part coordinate system)
Influence of Weld Lines
weld line
isotropic orthotropic
injection molding simulation simulated fiber directions in
the weld area
radial
displacement
Fig. 6
Fiber Orientation and Anisotropic Material
Fig. 7
Orientations and Degree of Orientations
from Injection Molding Simulation
shear layer mid layer
Fig. 8
Mesh Topology Fig. 9
Converse IM solver mechanical solver
shell (mid-plane/surface) => shell (tria, quad)
shell (mid-plane/surface) => solid (tet, hex)
solid => solid (tet, hex)
unequal meshes
possible
Material Dialog Fig.10
0
200
400
600
800
1000
1200
1400
0 1 2 3 4 5 6
Kra
ft [N
]
Verschiebung [mm]
Messung 1
Messung 2
isotrop
orthotrop
Rotary Valve
material: Grivory HTV 3H1
forc
e [N
]
displacement [mm]
test 1
test 2
FEA isotropic
FEA anisotropic
Fig. 11
Example: Air Intake Manifold
material: Ultramid A3WG6
shear layer mid layer
Fig. 12
Comparison of Eigenfrequencies and Eigenmodes
for Isotropic and Orthotropic Analysis
0
100
200
300
400
500
600
700
800
900
1000
250,00 270,00 290,00 310,00 330,00 350,00 370,00 390,00
eff
ektive M
asse
[g]
Frequenz [Hz]
x-Richtung - isotrop y-Richtung - isotrop z-Richtung - isotrop
x-Richtung - orthotrop y-Richtung - orthotrop z-Richtung - orthotrop
x-direction-isotropic
x-direction-anisotropic
y-direction-isotropic
y-direction-anisotropic
z-direction-isotropic
z-direction-anisotropic
frequency [Hz]
effe
ctive
ma
ss [kg
]
Fig. 13
Benefit of Anisotropic lin.-elast. FEA
• determination of initial part stiffnesses Stiffness
• application in the scope of strength assessments Strength
• unrestricted application in the scope of eigenfrequency extraction and response behavior analyses (due to linearization and small displacements/ amplitudes)
Frequency
• Significantly improved estimation of design limits Design
Fig. 14
Fig. 15
www.part-gmbh.de What´s New?
consider the real part properties
get better predictions of
strength & deformation
by using data already
available
integrates smoothly into
your day-to-day CAE routines
straigthforward easy-to-use
Fig. 16