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Improved Quality Prediction of Injection Molded Fiber Reinforced Components by Considering Fiber Orientations
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Improved Quality Prediction of Injection Molded Fiber Reinforced Components by Considering Fiber Orientations

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For fiber reinforced parts the consideration of anisotropic material behavior is required to receive reliable results. In the scope of this fact a procedure is described how to consider these effects …

For fiber reinforced parts the consideration of anisotropic material behavior is required to receive reliable results. In the scope of this fact a procedure is described how to consider these effects in terms of process-structure interaction and how to achieve possible benefits such as weight reduction and shorter development cycles shown for examples of the industry . The developed procedures show how to consider the anisotropic mechanical behavior of injection molded short-fiber-reinforced plastics parts in FE analysis. It is shown how the existing information, which is provided by injection molding simulation software, can be processed and transferred into mechanical simulation models. The procedure is outlined with practical applications.

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  • 1. Improved Quality Prediction of Injection Molded Fiber Reinforced Components by Considering Fiber Orientations Sascha Pazour Wolfgang Korte PART Engineering GmbH pazour@part-gmbh.de 0049 2204 30677 26 © PART Engineering GmbH, www.part-gmbh.de
  • 2. Plastics CAE Services & Software Technical Simulation Contract Simulation Services in FEA CAE Staffing Resident Engineers at customers‘ sites CAE Software - Process-Structure-Interaction - Strength & Fatigue Assessment Metals S-Life Elastomers
  • 3. Material: PA6+GF30 perpendicular parallel Influence of Fiber Orientation onto Material Properties Fig. 2
  • 4. Fiber Orientations in Short-Fiber-Reinforced Plastics S1 Shear layer: Fibers oriented parallel to flow direction S2 Mid layer: Fibers oriented perpendicular to flow direction Fig. 3 Flow Direction X X Cut View X Flow Direction S1 S2 S1 Example Micrograph Pictures: Thick Mid Layer Thin Mid Layer
  • 5. Isotropic and Orthotropic Material Models Isotropic Material Model Orthotropic Material Model Fig. 4 needs 2 material properties: Tensile Modulus E and Poisson ratio  needs 9 material properties: Tensile modulii the 3 orthotropic axes E1, E2, E3 Shear modulii the 3 orthotropic planes G12, G13, G23 Poisson ratios 12, 13, 23 Further the position of the orthotropic axes (local element coordinate sytem) with reference to the global coordinate system is needed
  • 6. Degree of Orientation Fig. 5           33 2322 131211 .. . a aa aaa           000 000 001           33.000 033.00 0033.0 2 31 general case unidirectional quasi-isotropic -90° +90°-45° +45°0° -90° +90°-45° +45°0°-90° +90°-45° +45°0° 2 1
  • 7. Example: Weld Lines Isotropic Approach Fig. 6 Common Approach: Isotropic
  • 8. Example: Weld Lines Anisotropic Approach Fig. 7 CONVERSE Approach: Anisotropic
  • 9. Fig. 8 Orientation and Degree of Orientation from Injection Molding Simulation shear layer mid layer [Part: Mann & Hummel]
  • 10. Fiber Orientation and Anisotropic Material Fig. 9 Converse Graphical User Interface [Part: Mann & Hummel]
  • 11. Mesh Topology Fig. 10 ConverseIM solver mechanical solver shell (mid-plane/surface) => shell (tria, quad) shell (mid-plane/surface) => solid (tet, hex) solid => solid (tet, hex) unequal meshes possible
  • 12. Material Dialog Fig.11
  • 13. Mechanical SolverInjection Moulding Solver - Moldflow - Cadmould - Sigma - Moldex - Fluent - Simpoe - 3D Timon - Ansys - Abaqus - Optistruct - Nastran - Marc - Samcef - FEMFat - Ncode - Virtual.Lab Orientations Pressures Temperatures Wall Thicknesses Residual Stresses Shrinkage & Warpage Weld Lines Fig. 12 Converse Features and Interfaces
  • 14. 0 200 400 600 800 1000 1200 1400 0 1 2 3 4 5 6 Kraft[N] Verschiebung [mm] Messung 1 Messung 2 isotrop orthotrop Example: Rotary Valve Material: Grivory HTV 3H1 force[N] displacement [mm] test 1 test 2 FEA isotropic FEA anisotropic Fig. 13 [Part: Mann & Hummel]
  • 15. Example: Air Intake Manifold Material: Ultramid A3WG6 Fig. 14 [Part: Mann & Hummel]
  • 16. Eigenfrequencies and Eigenmodes 0 100 200 300 400 500 600 700 800 900 1000 250,00 270,00 290,00 310,00 330,00 350,00 370,00 390,00 effektiveMasse[g] Frequenz [Hz] x-Richtung - isotrop y-Richtung - isotrop z-Richtung - isotrop x-Richtung - orthotrop y-Richtung - orthotrop z-Richtung - orthotrop x-direction-isotropic x-direction-anisotropic y-direction-isotropic y-direction-anisotropic z-direction-isotropic z-direction-anisotropic frequency [Hz] effectivemass[kg] Fig. 15 [Part: Mann & Hummel]
  • 17. Example: Burst Pressure Material: PP + GF20 Fig. 16
  • 18. Cyclic Utilization Ratio for N=80000 A cycl,max (N) = 91% Fatigue strength assessment satisfied! A cycl(N) X(N)=63 MPa Y(N)=42 MPa S(S)=24 MPa Fig.17 [Part: Mann & Hummel]
  • 19. Failure Assessment Fig. 18 [Part: Mann & Hummel]
  • 20. Lens Bracket Example Fig. 19 Part Geometry Fiber Orientation in Converse [Valeo Lighting Systems]
  • 21. Lens Bracket Example Fig. 20 Frequency correlation – simulation to Xp. modal analysis +5Hz +30Hz Converse Isotropic Average error – 4 Modes Mode Experimental (Hz) Isotropic (Hz) Converse (Hz) 1 44 76 60 2 56 77 62 3 91 114 94 4 224 270 218 [Valeo Lighting Systems]
  • 22. Influence Of Production on Fiber Orientation Fig. 21 Supplier 2Supplier 1 • Two suppliers but parts are geometrically up to 95% equal. • Same material supplier, same mashine settings, etc. • Different gating location means two completly different engine components! Water pump housing Gate location Gate location Moldflow results show different orientation
  • 23. Influence Of Production on Anisotropic Part Stiffness Fig. 22 Blue – Supplier 1 Red – Supplier 2 Dotted – Isotropic material fiber orientation and material model by 4. isotropic vs. anisotropic results ∆ - 62% Untolerable error if homogeneous isotropic material is used! 3. displacements 1. distributed pressure on sealing contact surface 2. results evaluated on a path Displacement True distance along path
  • 24. Fig. 23 www.part-gmbh.de What´s New? Converse Installation
  • 25. consider the real part properties get better predictions of strength & deformation by using data already available integrates smoothly into your day-to-day CAE routines straigthforward easy-to-use Fig. 24 Add Value to Your Mechanical Simulation
  • 26. Fig. 25 Thank you for your Attention! Questions?

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