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Speaker:
Dr. Volker Gorzelitz
Dipl.-Ing. Stefan Vogler
November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
Simulation of plastic parts considering material and
production specific boundary conditions
2 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
M.TEC
Ingenieurgesellschaft für kunststoff-
technische Produktentwicklung mbH
Dornkaulstraße 4
D-52134 Herzogenrath / Aachen
Tel. +49 (0)2407/95 73-0
Fax +49 (0)2407/95 73-25
info@mtec-engineering.de
ENGINEERING FOR PRODUCT DEVELOPMENT
November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
3 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
INTEGRATED PRODUCT DEVELOPMENT
Project Management
Systematic development of concepts
Idea generation, TRIZ-Workshops
Industrial Design
Plastic Material & Processing
Mechanical Design (CAD)
Quality Management (FMEA)
Test & Trials
Tools & Production Engineering
ENGINEERING PERFORMANCES
CALCULATION AND SIMULATION
Finite Element Analysis (FEA)
Crash, Passenger Safety (explicit FEA)
Moldflow Analysis
Optical Fibers, Light Engineering
Fluid Dynamics (CFD)
Speaker:
Dr. Volker Gorzelitz
Dipl.-Ing. Stefan Vogler
November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
Initial Situation:
Deformation of a plastic roof frame due to thermal load
Simulation of plastic parts considering material and
production specific boundary conditions
5 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
TABLE OF CONTENTS
Introduction
Anisotropic simualtion of plastic parts
Material behaviour influenced by the injection moulding process
Anisotropic simulation based on part design and initial injection
moulding
Improvement of the injection moulding process and its influence on part
deformation
Conclusion
6 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
INTRODUCTION
Boundary Conditions
Material: PP GF 45
Material modell for FEA: isotropic,
linear behaviour
Elements: shell elements
(mainly square),
plastics: 40.000, metall: 4.000
Load: cool down from ambient
temperature (20°C) to -30°C
Fix X, Y, Z
Fix Z
Fix Y, Z
7 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
INTRODUCTION
Isotropic FEA, Cool Down
Pin deformation
< 0,001 mm
8 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
INTRODUCTION
Deformation due to Thermal Load (Cool Down)
Deformation 7 mm
9 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Material behaviour influenced by the Injection Moulding Process
Matrix
Fiber E║,α║
E┴, α┴
E║ > Eiso > E┴
α┴ > αiso > α║
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
0,0 2,5 5,0 7,5 10,0
Ten
sio
n [
MP
a]
Elongation [%]
PP
PP-GF20
10 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Moldflow Simulation (Initial Design and Process)
11 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Simulation Process
- Moldex 3D
- Sigma Soft
- Moldflow
- …
- Digimat
- Convers
- …
- Radioss
- Abaqus
- …
Fiber
orientation Mapping Anisotropic
FEA
+
12 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
FEA Initial Design and Process, Displacements
13 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Displacements (Cool Down)
Temperature [°C]
De
form
atio
n U
Z [m
] x10-3
14 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Fiber Orientation (Initial Part Design and Process)
Fiber Orientation 1/3
15 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Fiber Orientation (Initial Part Design and Process)
Fiber Orientation 2/3
16 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Fiber Orientation (Initial Part Design and Process)
Fiber Orientation 3/3
17 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Improvement of the Injection Molding Process (Changed Gate Position)
18 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Fiber Orientation (Gate Position Changed Only)
Fiber Orientation 1/3
19 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Fiber Orientation (Gate Position Changed Only)
Fiber Orientation 2/3
20 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Fiber Orientation (Gate Position Changed Only)
Fiber Orientation 3/3
21 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
FEA, Gate Position Changed, Displacements
Pin
22 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
ANISOTROPIC SIMULATION OF PLASTIC PARTS
Displacement of the Pin (Single and Total Deformations)
Direction U3
De
form
atio
n [m
m]
Temperature [°C]
23 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
CONCLUSION
Simulation of plastic parts considering material and production specific
boundary conditions
By applying thermal load on glass-fiber reinforced plastics the
deformation of the part depends very much on fiber orientation
To improve the knowledge of the deformation due to thermal load,
anisotropic material behaviour has to be taken into account when
performing a finite element analysis.
Simulation tools e.g. Moldflow and Moldex calculate the orientation of the
short glass-fibers. The transfer of this results to the finite element
analysis (mapping) is enabled by tools e.g. Digimat.
Experience on injection moulding process is very helpful when
developing a helpful approach for a changed injection concept.
24 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
Thank you for your attention
Many thanks for the friendly support
of Inalfa Roof Systems Groups
M.TEC
Ingenieurgesellschaft für kunststoff-
technische Produktentwicklung mbH
Dornkaulstraße 4
D-52134 Herzogenrath / Aachen
Tel. +49 (0)2407/95 73-0
Fax +49 (0)2407/95 73-25
info@mtec-engineering.de
Web
http://www.mtec-engineering.com
We invite you to visit our exhibition stand
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