Process Automation with HyperWorks for   Blow Moulding of Plastic Containers            Claudius Oblasser, Alpla          ...
OUTLINE Alpla Introduction Customisation example ConclusionsOctober 11                2 of 20
VISION      „We create plastic packaging solutions     to our customers’ complete satisfaction.     Our goal is to attain ...
FACTS 2010 Total sales 2010: 2.560 billion € 12000 employees 134 production sites in 37 different countries One of the...
CORE TECHNOLOGIES               EBM  EXTRUSION BLOW MOULDING               SBM    STRETCH BLOW MOULDING               IM  ...
INTRODUCTION Alpla started FEA with Altair products in 2010 Save costs          Reduce development time          Reduc...
INTRODUCTION Focus on flexibility (open source, interface, customisation)          Process manager          Customised ...
CUSTOMISATION EXAMPLE    Steps through an EBM to Top Load Simulation - Overview                Bottle CAD model          ...
CUSTOMISATION EXAMPLE    Steps through an EBM to Top Load Simulation - Parison                Bottle CAD model           ...
CUSTIOMISATION EXAMPLE    Steps through an EBM to Top Load Simulation - Parison                Bottle CAD model          ...
CUSTIOMISATION EXAMPLE    Steps through an EBM to Top Load Simulation - Parison                Bottle CAD model          ...
CUSTIOMISATION EXAMPLE    Steps through an EBM to Top Load Simulation - Parison                Bottle CAD model          ...
CUSTIOMISATION EXAMPLE    Steps through an EBM to Top Load Simulation                Bottle CAD model                Crea...
CUSTIOMISATION EXAMPLE    Steps through an EBM to Top Load Simulation - mapping           Result from      Thickness for ...
CUSTOMISATION EXAMPLE    Steps through an EBM to Top Load Simulation - mapping      Result from          Thickness for   ...
CONCLUSION What´s behind all this - TCL                                  Simple and programmable syntax                 ...
CONCLUSION What´s behind all this - Tk                                   Graphical user interface (GUI) toolkit         ...
CONCLUSION Customisation of Hyperworks is not as difficult as it seems to be Huge time savings in modelling repeating ta...
THANK YOU FOR                YOUR ATTENTION!October 11                        19 of 20
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Process Automation with HyperWorks for Blow Moulding of Plastic Containers

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Process Automation with HyperWorks for Blow Moulding of Plastic Containers

  1. 1. Process Automation with HyperWorks for Blow Moulding of Plastic Containers Claudius Oblasser, Alpla European HTC 2011
  2. 2. OUTLINE Alpla Introduction Customisation example ConclusionsOctober 11 2 of 20
  3. 3. VISION „We create plastic packaging solutions to our customers’ complete satisfaction. Our goal is to attain global market and technology leadership“. 1955 – Alpenplastik Lehner Alwin OHG was founded by Alwin and Helmuth Lehner, Cap production started for local mustard maker, Lustenauer companys founder Alwin Lehner
  4. 4. FACTS 2010 Total sales 2010: 2.560 billion € 12000 employees 134 production sites in 37 different countries One of the largest global rigid packaging manufacturerOctober 11 4 of 20
  5. 5. CORE TECHNOLOGIES EBM EXTRUSION BLOW MOULDING SBM STRETCH BLOW MOULDING IM INJECTION MOULDINGOctober 11 5 of 20
  6. 6. INTRODUCTION Alpla started FEA with Altair products in 2010 Save costs  Reduce development time  Reduce number of prototypes Generate Know-How  “Keep it simple”  Identification of significant parameters  Information on process Software evaluation  What are our topics?  Comparison of leading FEA-Tools depend on  Flexibility (open source, interface, customisation)  Pre-, Post processor (modelling time, ease of learning)  Solver performance (elapse time, precision)  Help system and support!October 11 6 of 20
  7. 7. INTRODUCTION Focus on flexibility (open source, interface, customisation)  Process manager  Customised GUI´s For our core technologies we currently use customised GUI´s Example of EBM simulationOctober 11 7 of 20
  8. 8. CUSTOMISATION EXAMPLE  Steps through an EBM to Top Load Simulation - Overview Bottle CAD model Create parison with assumptions Extrusion Blow Molding simulation to estimate the wall thicknessWorkflow Mapping the thickness to the bottle Check of the weight and distribution Top load simulation Results comparison with hardware bottle if avalible October 11 8 of 20
  9. 9. CUSTOMISATION EXAMPLE  Steps through an EBM to Top Load Simulation - Parison Bottle CAD model Create parison with assumptions (geometry/mesh)  Enter node coordinates by HM/Geom/nodesWorkflow  Create line  Rotate line  Mesh surface October 11 9 of 20
  10. 10. CUSTIOMISATION EXAMPLE  Steps through an EBM to Top Load Simulation - Parison Bottle CAD model Create parison with assumptions (geometry/mesh)  GUI for EBM SimulationWorkflow October 11 10 of 20
  11. 11. CUSTIOMISATION EXAMPLE  Steps through an EBM to Top Load Simulation - Parison Bottle CAD model Create parison with assumptions (thickness)  Thickness by Components/Property  To many components for discrete field!Workflow  Thickness on element by using  Mesh/Card edit/Element  A lot of work for no. of Elements > 10.000 October 11 11 of 20
  12. 12. CUSTIOMISATION EXAMPLE  Steps through an EBM to Top Load Simulation - Parison Bottle CAD model Create parison with assumptions (thickness)  Thickness on each element  By calculation of thickness = f(x, y, z) + “empirically modelled relations” from 3rd party (Alpla internal) products and individualWorkflow parameters Par A Par B Par C Par D Par E Par F October 11 12 of 20
  13. 13. CUSTIOMISATION EXAMPLE  Steps through an EBM to Top Load Simulation Bottle CAD model Create parison with assumptions Extrusion Blow Molding simulation to Estimate the wall thickness  Same procedure for other tasks likeWorkflow  Boundary conditions  Import models (forms)  Create contact / Rigid bodies  Check mass / Update mass  Export model file  Create batch files for “closed loop” applications (EBM > mapping on Top Load) October 11 13 of 20
  14. 14. CUSTIOMISATION EXAMPLE  Steps through an EBM to Top Load Simulation - mapping Result from Thickness for EBM simulation Top Load simulation Mapping the thickness to the bottle Check of the weight and distribution  Currently “Results Mapper” does not support Radioss A00* files  Solution  Automatic export of nodal coordinates, elementWorkflow connectivity and element thickness values from Hyperview into *.csv file  Import of *.csv files into Hyperworks  Mapping of thickness  Interactive with GUI  In batch mode (5 times faster) October 11 14 of 20
  15. 15. CUSTOMISATION EXAMPLE  Steps through an EBM to Top Load Simulation - mapping Result from Thickness for EBM simulation Top Load simulation Mapping the thickness to the bottle Check of the weight and distribution  CommandsWorkflow Run Hyperview in Run tcl script Result file background (-b)  Commands Run Hypermesh in Run tcl script background October 11 15 of 20
  16. 16. CONCLUSION What´s behind all this - TCL  Simple and programmable syntax  Can be used as standalone application or embedded in programs  Open source  Interpreted language  New TCL commands can be implemented using C languageOctober 11 16 of 20
  17. 17. CONCLUSION What´s behind all this - Tk  Graphical user interface (GUI) toolkit  Tk adds about 35 TCL commands  Create and manipulate widgets  Widget is a window in GUI with particular appearance and behaviorOctober 11 17 of 20
  18. 18. CONCLUSION Customisation of Hyperworks is not as difficult as it seems to be Huge time savings in modelling repeating tasks can be measured Consistence of simulation models from different users is given New team members will be guided to defined tasks  They become more familiar with simulation processes within a shorter time period Help can be found at  http://www.tcl.tk/  ../hw11.0/help/hwdref/hwdref.htm  Review your command.cmf  Every mouse click in Hypermesh is written into this file  Use macro to convert these lines into TCL language for Hypermesh  Copy paste into new fileOctober 11 18 of 20
  19. 19. THANK YOU FOR YOUR ATTENTION!October 11 19 of 20
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