Simulation of plastic parts considering material and production specific boundary conditions

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

E-Mail

[email protected]

ENGINEERING FOR PRODUCT DEVELOPMENT



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


Initial Situation:

Deformation of a plastic roof frame due to thermal load

Simulation of plastic parts considering material and

production specific boundary conditions


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


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


INTRODUCTION

Isotropic FEA, Cool Down

Pin deformation

< 0,001 mm


INTRODUCTION

Deformation due to Thermal Load (Cool Down)

Deformation 7 mm


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



Moldflow Simulation (Initial Design and Process)



Simulation Process

- Moldex 3D

- Sigma Soft

- Moldflow

- …

- Digimat

- Convers

- …

- Radioss

- Abaqus

- …

Fiber

orientation Mapping Anisotropic

FEA

+



FEA Initial Design and Process, Displacements



Displacements (Cool Down)

Temperature [°C]

De

form

atio

n U

Z [m

] x10-3



Fiber Orientation (Initial Part Design and Process)

Fiber Orientation 1/3











Improvement of the Injection Molding Process (Changed Gate Position)



Fiber Orientation (Gate Position Changed Only)












FEA, Gate Position Changed, Displacements

Pin



Displacement of the Pin (Single and Total Deformations)

Direction U3

De

form

atio

n [m

m]

Temperature [°C]


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.


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

E-Mail

[email protected]

Web

http://www.mtec-engineering.com

We invite you to visit our exhibition stand

Technology

Simulation of plastic parts considering material and production specific boundary conditions