The simulation and optimization workflow for extrusion ... · The Extrusion Blow Molding Process 1....

Dr. Reinold Hagen Stiftung

Folie 1

ENGINEERING für die Blasformtechnik

The simulation and optimization workflow for extrusion blow molded parts and how it benefits from the VMAP Interface

Standard

1) Dr. Reinold Hagen Stiftung, Bonn

2) TREE-Institut Hochschule Bonn-Rhein-Sieg, Sankt Augustin

Dr. Olaf Bruch1,2

Patrick Michels1

Dirk Grommes1

Dr. Reinold Hagen Stiftung Kautexstraße 53

53229 Bonn www.hagen-stiftung.de

3DEXPERIENCE® Conference

Darmstadt, 19.-21. November 2019


Folie 2

Content

1. Introduction

2. CAE-Workflow of blow molded plastic parts

3. The demand for interfaces

• Process dependent material properties

• Local surface film coefficients

• Deformed structure and residual stresses

4. The VMAP interface standard

5. Summary and outlook


Folie 3

1. Introduction Extrusion Blow Molding

Consumer packaging

Industrial packaging

Technical parts and automotive


Folie 4

1. Introduction The Extrusion Blow Molding Process

1. extrusion of the parison

2. closing of the mold

3. inflation of the parison

4. opening of the mold / article removal

5. post-machining / deflashing

Wall thickness is a process dependent factor!

Picture source: Thielen, Michael; Hartwig, Klaus; Gust, Peter, Blasformen von Kunststoff-Hohlkörpern Carl Hanser Verlag, Munich, 2006


Folie 5

2. CAE-Workflow of blow molded plastic parts Blow molding simulation

Blow Molding Simulation

Cooling Simulation

Shrinkage and Warpage

Process Simulation Product Simulation Material Modelling and

Interfaces

Drop Test (crash)

Top Load Test (short-term)

Stacking Test (long-term)

Model Calibration

Spannungs - Dehnungs - Kurve des Gsell Materialmodells

0

10

20

30

40

50

60

70

80

90

100

0 0.2 0.4 0.6 0.8 1 1.2

Dehnung

Sp

an

nu

ng

in

N/m

m²

Dehnrate = 1/s

Dehnrate = 10 /s

Dehnrate = 100 /s

Dehnrate = 1000 /s

Blow Molding Simulation Mapping


Folie 6

2. CAE-Workflow of blow molded plastic parts Blow molding simulation

Feasibility studies and prediction of wall thickness distribution

Guide Wall in Dual Cavity

Automotive fuel tank

Optimization of wall thickness distribution


Folie 7

2. CAE-Workflow of blow molded plastic parts Shrinkage and Warpage


Cooling Simulation



Interfaces

Drop Test (crash)

Top Load Test (short-term) Model Calibration

Mapping


0

10

20

30

40

50

60

70

80

90

100

0 0.2 0.4 0.6 0.8 1 1.2

Dehnung

Sp

an

nu

ng

in

N/m

m²

Dehnrate = 1/s

Dehnrate = 10 /s

Dehnrate = 100 /s

Dehnrate = 1000 /s

Cooling Simulation



Folie 8

2. CAE-Workflow of blow molded plastic parts Shrinkage and Warpage

Process simulation Cooling Simulation Shrinkage & Warpage

Wall thickness distribution

Local strain and stresses

Temperatures

Residual stresses Displacements

fu

lly o

r se

qu

en

tial

ly c

ou

ple

d

CFD-Simulation of the cooling

channels


Folie 9

2. CAE-Workflow of blow molded plastic parts Virtual product testing


Cooling Simulation



Interfaces

Drop Test (crash)



Model Calibration

Mapping


0

10

20

30

40

50

60

70

80

90

100

0 0.2 0.4 0.6 0.8 1 1.2

Dehnung

Sp

an

nu

ng

in

N/m

m²

Dehnrate = 1/s

Dehnrate = 10 /s

Dehnrate = 100 /s

Dehnrate = 1000 /s

Drop Test (crash)




Folie 10

2. CAE-Workflow of blow molded plastic parts Virtual product testing

Top-Load-Test Internal pressure test

Drop test

Short term

Crash

Creep/Relaxation

Long term

Jerry can

Fuel tank


Folie 11

3. The demand for interfaces


Cooling Simulation



Interfaces

Drop Test (crash)



Model Calibration

Mapping


0

10

20

30

40

50

60

70

80

90

100

0 0.2 0.4 0.6 0.8 1 1.2

Dehnung

Sp

an

nu

ng

in

N/m

m²

Dehnrate = 1/s

Dehnrate = 10 /s

Dehnrate = 100 /s

Dehnrate = 1000 /s


Folie 12

3. The demand for interfaces Process dependent material properties

Varying wall thicknesses and stretching ratios result in

varying local material properties

780790800810820830840850860870

1 1,5 2 2,5 3 3,5 4Ela

stic M

od

ulu

s [N

/mm

² ]

Degree of stretching λ / stretching ratio Φ [ - ]

E1(Φ) E2(Φ)

experimentally

confirmed

a) b) c)

d)

Distribution of elastic modulus in a typical blow molded bottle a) Stretching ratio b) Local elastic moduli in principal directions c) Regression function

F[-] E1 [N/mm²] E2 [N/mm²]

Process simulation of a handle bottle


Folie 13


Interface Dr. Reinold Hagen Stiftung:

Identification of the degree of stretching and

the orientation

Mapping of: • Local wall thickness • Local strain and stress • Local orientation • Local temperatures

Input Data (Struct. FEA) • Local wall thickness • Local elastic moduli • Local orientation • Local temperatures

ABAQUS Simulation Model

Material Data: Calculation of the

process-dependent elastic modulus

Loads, boundary conditions etc.

Process Mesh

Structural Analysis

Mesh

Process Simulation B-SIM (Accuform)

Data Exchange Interface

Model alignment

Data transfer

Interface Dr. Reinold Hagen Stiftung

Procedure:

• Deformation state

• Deformation gradient

• Polar decomposition

• Main axes transformation

Undistorted mesh (parison)

Distorted mesh (blown part)

Fraunhofer SCAI MpCCI Mapper

Interface between Acuform/BSIM and Simulia/Abaqus


Folie 14


Principal Direction 1 (max. stretch)

Principal Direction 2 (min. stretch)

Orientation of maximum and minimum stretch in principal directions Mapped onto structural mesh of an typical blow molded bottle

Import into Abaqus: e.g. *Elastic in combination with *Distribution


Folie 15

Deformed shape after the shrinkage and

warpage simulation

3. The demand for interfaces Deformed structure and residual stresses

Transfer of • deformation state • residual stresses

Top-Load-Test Internal pressure

Drop test

Short term

Crash

Creep/Relaxation

Long term

Import into Abaqus: *Import or *Initial conditions in combination with SIGINI User Subroutine


Folie 16

3. The demand for interfaces Local surface film coefficients

Cooling simulation

Determination of local heat transfer coefficients

Mapping

CFD simulation Flow of cooling water

inside of mold

Altair/AcuSolve

Abaqus

Import into Abaqus: *CFILM


Folie 17

4. The VMAP interface standard

Interoperability of Engineering Data within Integrated CAE Workflows

• defined international standard

• integrated import/export and translation tools

• supported by leading software vendors

The VMAP standard and import/export interface tools will provide users with a vendor-neutral methodology of transferring material and engineering data between different CAE software along the whole simulation process chain.

http://vmap.eu.com/

• hybrid modelling of consumer products (Philips) • composite component in aerospace (Convergent) • additive manufacturing (Bosch)

29 Partners from 6 countries The VMAP project will be demonstrated by different manufacturing use cases:

• extrusion blow molding (Rikutec, Hagen Stiftung) • composite light weight vehicles (AUDI, KIT) • injection molding (Bosch)


Folie 18

4. The VMAP interface standard CAE-Workflow Extrusion blow molding

Process Simulation Process dependent

material Cooling

Warpage

Structural Analysis

Top-Load Test/ Internal Pressure Test (short-term)

Drop Test (crash)

Creep Test (long term)

B-SIM Custom

Tool CFD simulation


Folie 19

o Better simulation results through integrative modelling of blow molded parts and utilizing of specialized CAE-Tools

o High demand for data transfer between different simulation tools

o Deformations o Stretches and Strain o (Residual) stresses o Temperatures o Surface heat coefficients o …

o Interface development especially between different CAE-Tools can be very time consuming

o Reduced development time through utilization of standard interfaces like VMAP

o VMAP interface standard offers enhanced flexibility to use different simulations tools

Outlook

o Further support of VMAP through leading ISVs is desirable and needed

o Simulia/Abaqus currently supported through external Wrapper tool

o Extension of VMAP standard to other domains (machine and sensor data, particle and molecular dynamics, multiscale modelling New proposal: VMAP analytics

5. Summary and outlook


Folie 20

Thank you for your Attention!

The simulation and optimization workflow for extrusion ... · The Extrusion Blow Molding Process 1....

Documents

Transcript of The simulation and optimization workflow for extrusion ... · The Extrusion Blow Molding Process 1....