Simulation of plastic parts considering material and production specific boundary conditions

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  • 1.Simulation of plastic parts considering material andproduction specific boundary conditions Speaker:Dr. Volker GorzelitzDipl.-Ing. Stefan Vogler November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany

2. ENGINEERING FOR PRODUCT DEVELOPMENT M.TEC Ingenieurgesellschaft fr kunststoff- technische Produktentwicklung mbH Dornkaulstrae 4 D-52134 Herzogenrath / Aachen Tel. +49 (0)2407/95 73-0 Fax +49 (0)2407/95 73-25 E-Mail info@mtec-engineering.de2 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 3. ENGINEERING PERFORMANCES 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 CALCULATION AND SIMULATION Finite Element Analysis (FEA) Crash, Passenger Safety (explicit FEA) Moldflow Analysis Optical Fibers, Light Engineering Fluid Dynamics (CFD)3 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 4. Simulation of plastic parts considering material andproduction specific boundary conditionsInitial Situation:Deformation of a plastic roof frame due to thermal loadSpeaker: Dr. Volker Gorzelitz Dipl.-Ing. Stefan Vogler November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 5. TABLE OF CONTENTSIntroductionAnisotropic simualtion of plastic partsMaterial behaviour influenced by the injection moulding processAnisotropic simulation based on part design and initial injectionmouldingImprovement of the injection moulding process and its influence on part deformation Conclusion5 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 6. INTRODUCTIONBoundary ConditionsMaterial: PP GF 45 Fix X, Y, ZFix Y, Z Material modell for FEA: isotropic,linear behaviour Elements: shell elements(mainly square),plastics: 40.000, metall: 4.000 Load: cool down from ambienttemperature (20C) to -30CFix Z6November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 7. INTRODUCTIONIsotropic FEA, Cool DownPin deformation< 0,001 mm7November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 8. INTRODUCTIONDeformation due to Thermal Load (Cool Down)Deformation 7 mm8November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 9. ANISOTROPIC SIMULATION OF PLASTIC PARTSMaterial behaviour influenced by the Injection Moulding Process 80,0 70,0 MatrixE, 60,0 Fiber 50,0 Tension [MPa] 40,0PP E, 30,0PP-GF20 20,0E > Eiso > E 10,0 > iso > 0,00,0 2,55,0 7,5 10,0Elongation [%]9November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 10. ANISOTROPIC SIMULATION OF PLASTIC PARTS Moldflow Simulation (Initial Design and Process)10November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 11. ANISOTROPIC SIMULATION OF PLASTIC PARTS Simulation Process FiberAnisotropicMappingorientationFEA+ -Moldex 3D -Digimat-Radioss -Sigma Soft-Convers-Abaqus -Moldflow-- -11November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 12. ANISOTROPIC SIMULATION OF PLASTIC PARTS FEA Initial Design and Process, Displacements12November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 13. ANISOTROPIC SIMULATION OF PLASTIC PARTS Displacements (Cool Down)x10-3 Deformation UZ [m]Temperature [C]13November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 14. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Initial Part Design and Process) Fiber Orientation 1/314November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 15. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Initial Part Design and Process) Fiber Orientation 2/315November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 16. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Initial Part Design and Process) Fiber Orientation 3/316November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 17. ANISOTROPIC SIMULATION OF PLASTIC PARTS Improvement of the Injection Molding Process (Changed Gate Position)17November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 18. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Gate Position Changed Only) Fiber Orientation 1/318November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 19. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Gate Position Changed Only) Fiber Orientation 2/319November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 20. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Gate Position Changed Only) Fiber Orientation 3/320November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 21. ANISOTROPIC SIMULATION OF PLASTIC PARTS FEA, Gate Position Changed, Displacements Pin21November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 22. ANISOTROPIC SIMULATION OF PLASTIC PARTS Displacement of the Pin (Single and Total Deformations)Deformation [mm] Direction U3 Temperature [C]22November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 23. 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.23November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany 24. Thank you for your attentionMany thanks for the friendly supportof Inalfa Roof Systems Groups M.TEC Ingenieurgesellschaft fr kunststoff- technische Produktentwicklung mbH Dornkaulstrae 4 D-52134 Herzogenrath / Aachen Tel. +49 (0)2407/95 73-0 Fax +49 (0)2407/95 73-25 E-Mail info@mtec-engineering.de We invite you to visit our exhibition stand Web http://www.mtec-engineering.com24November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany