PREDICTION OF WARPAGE IN WELDED ASSEMBLIES
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PREDICTION OF WARPAGE IN WELDED ASSEMBLIES

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PREDICTION OF WARPAGE IN WELDED ASSEMBLIES PREDICTION OF WARPAGE IN WELDED ASSEMBLIES Presentation Transcript

  • PREDICTION OF WARPAGE IN WELDED ASSEMBLIESAmin Sedighiamiri*, Dave Brands *, Tim Dassen§* GApT – Reinforced Plastics Center§ CODE Product Solutions, Geleen, The Netherlands
  • No. 1OUTLINE• SABIC, who are we?• Long glass fiber polypropylene (STAMAX™).• What is Warpage?• Secondary operations: factors influencing warpage.• Welding process.• Welding simulation methodology.• Implementation in Hyperworks.• Application: “air duct – IP carrier” welded assembly.• Conclusions
  • No. 2WE ARE SABICChemicals, polymers, fertilizers, metals1976, our beginning37 years of growth2nd largest global diversified chemical company*88th largest public company in the world*62 world-class plants worldwide8,000 global patents* Forbes 2012
  • No. 3OUR GLOBAL OPERATIONSSABIC Global Headquarters (1)Technology Centers (13)Application Centers (4)SABIC Corporate Researchand Innovation Center (1)Distribution, Storage Facilitiesand Logical Hubs (51)International Subsidiaries andSales Offices (84)Manufacturing and CompoundingCompanies (62)40,000 employees40 countries1 Corporate Research & Innovation Center17 Technology and Application Centers150 new products each year
  • No. 4SABIC INNOVATIVE PLASTICSBase materials:PE, PP, PC, PBT, ABS, PEI, etc. and numerous blends.Automotive materials:• LEXAN™ - Glazing• NORYL™ - Fenders• PP Compounds - Bumpers• etc.• VERTON™ Long Glass Reinforced Polyamide 6,6• STAMAX™ Long Glass Reinforced Polypropylene
  • No. 5TYPICAL STAMAX™ PP-LGF APPLICATIONSinstrument panel carrierdoor modulefront-end moduleTail gate
  • No. 6WHAT IS WARPAGE?Fiber reinforced materials- anisotropic shrinkagesHigh thicknessshrinkageLow in-plane shrinkageInjection molding fiber orientationLow fiberalignmentHigh fiberalignment12 3
  • No. 7PRODUCTION OF IP CARRIERS1234™
  • No. 85 mm4 mm12SECONDARY OPERATIONS: FACTORS INFLUENCING WARPAGE™
  • No. 9Warpage after assemblyNew SABIC unique differentiatorWarpage prediction of PP-LGF partsSECONDARY OPERATIONS: FACTORS INFLUENCING WARPAGE™
  • No. 10air ductIP carrierPress: welding tools closeJoining: Parts heatedRelease: welding tools openExample: Instrument panel carrierPart positioning in toolsWarped parts to be weldedWELDING PROCESS
  • No. 11WELDING SIMULATION METHODOLOGYairductIP carrierPress analysisAnisotropic mechanical simulationJoining analysisApplying boundary conditions at weldlocations to connect partsTool release analysisSpring back analysis using predictedstiffness and stress from press analysisWarpage analysisWarped shape of individual parts andfiber orientation dependent stiffnessgraphical user interface• Import Moldflow files• Pressing individual parts• Define welding locations• Apply boundary conditions
  • No. 12IMPLEMENTATION IN HYPERWORKS
  • No. 13IMPLEMENTATION IN HYPERWORKS
  • No. 14APPLICATION: “AIR DUCT – IP CARRIER” ASSEMBLYAir ductMaterial: SABIC™STAMAX™ 20YK2705 dropsInjection time: 2.6 sIP carrierMaterial: SABIC™STAMAX™ 30YK2707 dropsInjection time: 5.9 s
  • No. 15APPLICATION: “AIR DUCT – IP CARRIER” ASSEMBLY-5.08.04.751.5-1.750.32.5 0.2mm
  • No. 16NEXT STEP …Method validation3D laser scan measurements Moldflow z-deflectionMeasured normal deflection
  • No. 17CONCLUSIONS• Warpage of assembled part could significantly differ from that of the individual parts.• We developed a predictive engineering method to predict warpage in weldedassemblies.• The whole procedure is implemented and automatized in Altair Hyperworkssoftware:• Graphical User Interface.• Reduce the chance of user errors.• Fast and easy: implementation time within 2 hours• Feasible for application in engineering projects.• Further validation is ongoing.
  • No. 18Thank you for your attention!
  • No. 19DISCLAIMERTHE MATERIALS, PRODUCTS AND SERVICES OF SABIC INNOVATIVE PLASTICS HOLDING BV, ITS SUBSIDIARIES AND AFFILIATES(“SELLER”), ARE SOLD SUBJECT TO SELLER’S STANDARD CONDITIONS OF SALE, WHICH CAN BE FOUND AT http://www.sabic-ip.com .AND ARE AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION OR RECOMMENDATION CONTAINED HEREIN IS GIVEN INGOOD FAITH, SELLER MAKES NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (i) THAT THE RESULTS DESCRIBED HEREINWILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGNINCORPORATING SELLER’S PRODUCTS, SERVICES OR RECOMMENDATIONS. EXCEPT AS PROVIDED IN SELLER’S STANDARDCONDITIONS OF SALE, SELLER SHALL NOT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS PRODUCTS ORSERVICES DESCRIBED HEREIN.Each user is responsible for making its own determination as to the suitability of Seller’s products, services or recommendations for the user’sparticular use through appropriate end-use testing and analysis. Nothing in any document or oral statement shall be deemed to alter or waive anyprovision of Seller’s Standard Conditions of Sale or this Disclaimer, unless it is specifically agreed to in a writing signed by Seller. No statementby Seller concerning a possible use of any product, service or design is intended, or should be construed, to grant any license under any patent orother intellectual property right of Seller or as a recommendation for the use of such product, service or design in a manner that infringes anypatent or other intellectual property right.SABIC and brands marked with ™ are trademarks of SABIC or affiliates