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RHEOMOLD ENGINEERING SOLUTIONS LLP

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Content

• Rheomold Services & Capabilities

• Rheomold Capacity

• Design Projects executed

• CAE Projects executed

• Manufacturing Simulations (Moldflow, Casting & Forming)

• Customers

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Rheomold - Services

Services

Manufacturing Simulations

Moldflow

Forming

Casting

General CAE Services

Structural, NVH, Crash & Safety & CFD

• Product Development

• Mold Design & Press tools

• Fixture Design

Rheomold offers complete solution from Design, Development, CAE, Manufacturing & Testing support

Manufacturing of

Fixtures

Onsite Deputation to customer site on Tooling, DFM

Hyper mesh, Moldflow & CAE

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Rheomold – Services

Manufacturing Simulations

• Plastics – Moldflow

• Casting Simulations

• Forming Simulations

CAE Services

• Modal Analysis

• NVH Analysis

• Thermal Analysis

• CFD Analysis

CAE Meshing (FE modelling)

• Detailed Mid-Plane meshing

• 3D Tetra & HEX meshing skill

• Thermal meshing

• CFD modeling skill

CAD Development & Services

• Product development (Plastics & Sheet Metal)

• Mold, Sheet metal tools & Fixture design

Manufacturing Support

• Vibration fixture Manufacturing, testing & validation

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Rheomold - Capacity

Office :

Located in Pune, India

Software :

• Autodesk Moldflow Plastic Insight 2016

• Standard

• Performance

• Synergy

• Hyper mesh & Ansa

• Radioss & Abaqus

• Hyper form

• ProCast

• Star CCM+

• Solid works, ProE & Catia

Hardware :

• DELL Work Stations

Resources :

• 22 Engineers working in 2 shifts

• 6 days in a week

• Systematically trained Engineers

with average 4+ years of experience

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Rheomold – Product Development

CAD Development & Services

• Plastic product development (Plastic & Sheet metal)

• Mold design, Sheet metal & Fixtures

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Part Design

• Concept design

• Plastic Part design

• B-surface creation and its attachment scheme

• Reverse Engineering

• Solid Modeling

• Feasibility Study (DFM)

• Parametric Modeling

• Drawing generation with GD&T

Rheomold Services - CAD

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Sample Mold Design

Rheomold Services – Mold Design

Part Image

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Rheomold – CAD ( Fixtures Development)

Design

FE Model and Simulation Result

ManufacturingVibration Testing & Fixture Validation

Rheomold offers complete solution from Design, Development, CAE, Manufacturing & Testing support

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Rheomold – CAE

• Static (Linear & Non Linear)

• NVH (Modal & Vibration)

• Crash & Safety

• CFD services

Automotive Expertise @ Rheomold…

Power train

Modeling & Analysis

Vehicle Interiors Analysis

NVH (Modal & Vibration

Analysis) and Random

Response

Manufacturing Simulations

Structural Optimization

CFD

Vehicle Exterior Analysis

Full spectrum of vehicle modeling includes Interiors, Exteriors, Power train, Climate

and Electronic components…

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Rheomold Services – CAE (Wedge Analysis)

ModelMaximum Stress in the critical region (Von-Mises)

[MPa]

Old Wedge 211.9 (FAILS)

New Wedge 104.2 (SAFE)

Old Wedge (FAILS)

New Wedge (SAFE)

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Rheomold – FEA on Hanger

HVAC Inlet Duct Assembly1st Mode Shape

Circled in ‘Red’ are mounts

Stress contour plot at 50 Hz

Frequency Response

Rheomold Services – CAE (Vibration Analysis)

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CFD studies

Inputs required:

1.CAD models & different mode configuration

2.Blower performance/curve

3.Temperature inputs (Heater & Evaporator)

Results:

1.Flow lines

2.Pressure & temperature drop calculation

3.Flow splits between ducts

4.Design optimization

Vehicle interior simulation has traditionally helped Tier 1 suppliers over a variety of

product groups & load cases

Inst

rum

en

t P

an

el

FMVSS 201 : Interior impact on instrument panels, seat backs and sun visors

FMVSS 202 & 203: Steering column impact

Safety plastic design for headliner and pillar trims

Product durability analysis expertise for various OEM specifications

Typical Project Responsibilities

Do

or

Pan

el

Crash & Safety

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Rheomold – Mfg. Simulations

• Complete Moldflow Services

• Die Casting Simulations

• Forming Simulations

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Rheomold Services – Moldflow

• Best Gate Location Analysis

• Fill Analysis

• Pack Analysis

• Cool Analysis

• Warpage Analysis

• Thin Wall Molding Analysis

• Core Deflection & AMSA Analysis

(Residual Stress analysis)

• Over Molding Analysis

• Molding Window Analysis

Manufacturing Simulations - Moldflow Services using Autodesk Moldflow

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Rheomold Services – Casting

Manufacturing Simulations - Casting Simulations using Quick Cast

• Gravity sand casting

• High Pressure die casting

• Low Pressure die casting

Following direct improvements could be gained by Casting Simulation:

• Improvement of the casting quality by minimizing the entrapped air

• Minimizing set up time during the start of casting process

• Possibility to control HPDC machines more precisely

• Optimization of the whole casting process by

• Controlling filling with optimal plunger movement

• Shorter lead time during the tool designing process

• Less scrap and waste production when new design is taken on the use.

Simulation Reality

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Rheomold Services – Forming

Manufacturing Simulations - Forming Simulations using Hyperform

A. One Step Forming Simulation

One Step forming Simulation is a fast Directional Indicator of the forming issues. This gives a quick idea

of the potential areas of forming issues.

Blank Development

Formability Plot with FLD Diagram

Trim Line Prediction

Report with Unit Cost and Mass calculated

Blank Nesting in a Strip

B. Incremental Formability Analysis (Virtual tryouts)Detailed Deep Drawing and Forming Simulations on tooling

Thinning Percentage Plots

Thickness Plots

Wrinkles and Compression Zone Prediction

Trimline prediction and Optimization

Process Parameter Optimization for a given tooling concept

Die Entry radius

Blank Holding Pressure

Binder Shape Validation and Optimization

Part Modification for better formability

Tool geometry Modification Suggestions

Multi Stage Forming Simulation and Process Optimization

Blank Shape Optimization

Spring Back Prediction

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Our Privileged Customers

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THANK YOU

Contact : Krishnamoorthy

RheomoldNo 313/314,

City Square

Off.K.B.Joshi Road

Shivaji Nagar

Pune – 411005, India

Cell : 9881122240

E-mail : krishna@rheomold.com

Website : www.rheomold.com