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Moldex3D, Structural Analysis, and HyperStudyIntegrated in HyperWorks PlatformAnthony YangMoldex3D
CoreTech System and Moldex3D The world’s largest injection molding CAE ISV 80% experienced engineering professionals 50...
1,200+ Global Customers in various industry
Moldex3D leads the way of Technology development                                 2003: 1st complete 3D CAE for plastic mol...
How Moldex3D Can Help?   Aesthetics and dimensional concerns       Weld line, air trap, flow mark       Flow balance an...
Moldex3D Flow Analysis   Moldex3D-Flow predicts melt front, weld line, air trap,    short shot and process window…
Moldex3D Packing Analysis       Moldex3D-Pack simulates the density variation and melt        flow due to material compre...
Moldex3D Cooling Analysis• Moldex3D-Cool simulates mold temperature, cooling efficiency, hot spot,  cooling time …
Moldex3D Warpage Analysis   Moldex3D-Warp simulates the part warpage due to volumetric shrinkage    and further help to c...
Moldex3D Fiber Analysis        Moldex3D-Fiber simulates the 3D fiber orientation and calculates the         process-induc...
MCM Analysis in Moldex3D   Moldex3D-MCM simulates the Multi-Component Molding, Insert molding    and over molding process.
Exclusive Moldex3D Features
Quick True 3D Analysis in Minutes:                  Create Runner                  Create          Run     Import STL     ...
Automatic 3D hybrid meshing capability
eDesign:Intelligent Gate Wizard
eDesign:Intelligent Runner Wizard
Accuracy - by running FULL 3D analysis High temperature resolution in runners
eDesign:Intelligent Cooling System Wizard                   Support the ALL cooling                       system in 3D
SMP/DMP Parallel Computing with excellentacceleration ratio                         Moldex3D R9.1 Solid-Flow Parallel Comp...
Moldex3D Application Examples20
BASF – New material development for automotivebumper                         Füllverhalten bei 50% Füllung                ...
Moldex3D:Danfoss                         Improve design from one                          material molding into two      ...
Moldex3D User: Connector Case                                       The area                                     suggested...
Moldex3D User: Unilever Temperature difference :45oC ->15oC Cooling time reduced by 25% (from 5 to 3 sec) Save 4 millio...
FEA Integration Analysis
What can Moldex3D-FEA Interface to Abaqus do?• To consider the process-induced variation during the processes    – Mesh ou...
Moldex3D-FEA Interface-Anisotropic material     properties     • Based on the fiber orientation and proper micro-mechanics...
Moldex3D-FEA Interface Orientation tensor (forDigimat)• Orientation tensor can be output to composite modeling software  (...
Moldex3D-FEA Interface-Material Reduction     • Material Reduction        – Moldex3-FEA Interface can reduce the anisotrop...
Technology Link of FEA Interface                                                   Structure        Moldex3D Simulation   ...
Moldex3D-FEA Interface-Interface to Abaqus                                  3. Select output meshtype        2. Select Aba...
Tensile Bar - Wend Line strength reduction                                              Weld Line Location32
Fiber Orientation around the weld line                                              Weld Line Location33
Major Modulus34
Tensile Bar – Stress     30MPa Load Applied     Yield at 80 Mpa                                    47 MPa                 ...
Thrust Pedal – Filling Animation36
Thrust Pedal – Fiber Orientation37
Thrust Pedal – Major Modulus38
Thrust Pedal – Minor Modulus39
Thrust Pedal – Model Setup                                  Fix the pin slot                                              ...
Thrust Pedal – Displacement & Stress     200lbf (900 N) Force Applied             Displacement                       Stres...
Integration between Moldex3D andHyperStudyImproving Part Quality for InjectionMolding
Introduction: Moldex3D and HyperStudy• Moldex3D   •   Moldex3D is the world leading CAE product for the plastics injection...
Workflow between Moldex3D and HyperStudy                   Create an initial run and perform a preliminary analysis  Copy ...
Integrating Moldex3D and HyperStudy:DOE Study
Case Study• An injection molded part from a speed meter shows potential warpage  problem from preliminary Moldex3D analyse...
Design of Experiments Conditions• DOE Class: 9-run Fractional Factorial• Initial Design Variables    •   Filling Time: 2 s...
DOE Study: Create a DOE Study                                    Select DOE Class                   Detail setting of the ...
DOE Study: Controlled Variables• Define Design Variables:                   Select Design variables                       ...
DOE Study: DOE Run Table
Design of Experiments: Run ResultsRun Summary                                     This chart indicates the melt           ...
DOE Optimal Results                          Variables                           Initial Results   DOE Results            ...
Integrating Moldex3D and HyperStudy:Optimization Study
Create an Optimization Study• The same optimization target can be achieved by employing an  Optimization Study. For exampl...
Optimization Study: Define Design Variables• Define Design Variables:    •   Filling Time (Range: 1.7, 2.3 sec)    •   Mel...
Settings for Objectives• Objectives:   •   Goal: Minimum Standard Deviation (SD) for Total Displacement   •   Maximum Iter...
Optimal ResultsHistory Plot                    History Table                  Optimized design factors
Optimal Results                           Variables                         Initial Run   Optimal Run                     ...
Summary
Comparison                     Variables                         Initial Results    DOE Results             Optimal Result...
Conclusion•   The integration between Moldex3D and HyperStudy helps users to find out the    optimal process conditions fo...
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Moldex3D, Structural Analysis, and HyperStudy Integrated in HyperWorks Platform

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In recent years, with the increasing variety, complexity, and precision requirement on plastic products, CAE tools have been widely used for solving product design and manufacturing issues. The structural designs or molding process parameters for products can be optimized efficiently through CAE analyses. Plus the reliable and correct verification with experiments, the directions or guidance in designs or process condition settings can be provided prior to the real moldings. However, sometimes it is not efficient to find an optimized set of parameters through traditional CAE analyses. A novel integration between Moldex3D and HyperStudy allows for more quick and efficient parameter optimization which will save time, increase product quality, and increase productivity.

Also, traditional CAE analyses do not consider the molding properties influence on structural analysis, such as material property variations caused by fiber orientation and residual stresses. Accordingly, an integrated technology is proposed to bridge molding and structural analysis. Through the integration of Moldex3D and structural analysis in HyperWorks platform, the important effects from molding process can be transferred to structural analysis for more accurate and realistic predictions of the product behaviors. This integration provides a virtual product development platform for users to increase profits as well as enhance productivity.

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Transcript of "Moldex3D, Structural Analysis, and HyperStudy Integrated in HyperWorks Platform "

  1. 1. Moldex3D, Structural Analysis, and HyperStudyIntegrated in HyperWorks PlatformAnthony YangMoldex3D
  2. 2. CoreTech System and Moldex3D The world’s largest injection molding CAE ISV 80% experienced engineering professionals 50% of employees involved in R&D activities 9 global offices, local support from Michigan 1,200+ global customers 6,000+ industrial projects validation
  3. 3. 1,200+ Global Customers in various industry
  4. 4. Moldex3D leads the way of Technology development 2003: 1st complete 3D CAE for plastic molding(Solid) 2005: 1st SMP/DMP 3D CAE for plastic molding 2007: propriety automatic 3D meshing (eDesign) 2009: exclusive compatibility with multiple 3D CAD
  5. 5. How Moldex3D Can Help? Aesthetics and dimensional concerns  Weld line, air trap, flow mark  Flow balance and part weight  shrinkage and warpage control  Fiber orientation Being more competitive  Cycle time reduction by removing hot & cold spots  Mold structure optimization  Reduce mold trial & tooling cost Reaching Lean Production  Injection conditions optimization  Clamping force reduction  Machine selection
  6. 6. Moldex3D Flow Analysis Moldex3D-Flow predicts melt front, weld line, air trap, short shot and process window…
  7. 7. Moldex3D Packing Analysis  Moldex3D-Pack simulates the density variation and melt flow due to material compressibility7
  8. 8. Moldex3D Cooling Analysis• Moldex3D-Cool simulates mold temperature, cooling efficiency, hot spot, cooling time …
  9. 9. Moldex3D Warpage Analysis Moldex3D-Warp simulates the part warpage due to volumetric shrinkage and further help to control these defects before mold is built
  10. 10. Moldex3D Fiber Analysis  Moldex3D-Fiber simulates the 3D fiber orientation and calculates the process-induced anisotropic properties10
  11. 11. MCM Analysis in Moldex3D Moldex3D-MCM simulates the Multi-Component Molding, Insert molding and over molding process.
  12. 12. Exclusive Moldex3D Features
  13. 13. Quick True 3D Analysis in Minutes: Create Runner Create Run Import STL Meshing Set Melt Etrn Cooling System Simulation13
  14. 14. Automatic 3D hybrid meshing capability
  15. 15. eDesign:Intelligent Gate Wizard
  16. 16. eDesign:Intelligent Runner Wizard
  17. 17. Accuracy - by running FULL 3D analysis High temperature resolution in runners
  18. 18. eDesign:Intelligent Cooling System Wizard Support the ALL cooling system in 3D
  19. 19. SMP/DMP Parallel Computing with excellentacceleration ratio Moldex3D R9.1 Solid-Flow Parallel Computing Performance on an Intel Core i7 Cluster - Speed Up Ratio 1.00 Car Grill (elements: 713,558, R9.1 Solid-Flow Enhanced) 1 Core (1 CPU) 1.00 16-cavity Lens (elements: 1,066,448, R9.1 Solid-Flow Standard) 1.00 Tray (elements: 1,422,416, R9.1 Solid-Flow Standard) Benchmark Hardware - One BoxClusterNX (www.boxcluster.com) 2.01 - 4-node PC cluster 2 Cores (2 CPUs) 1.89 - one Intel Core i7 940 CPU on each node - 12 GB DDR3 RAM on each node - Gigabit network 4.00 4 Cores (4 CPUs) 3.65 6.98 8 Cores (4 CPUs) 6.81 7.64 10.40 16 Cores (4 CPUs) 10.92 11.75 0.00 4.00 8.00 12.00 16.00 Speep Up Ratio19
  20. 20. Moldex3D Application Examples20
  21. 21. BASF – New material development for automotivebumper Füllverhalten bei 50% Füllung Füllverhalten bei 75% Füllung
  22. 22. Moldex3D:Danfoss  Improve design from one material molding into two color molding  Reduce cycle time of the molding by 43%. Shorten time to the market.  Reduce material cost by 11% via product geometry optimization22
  23. 23. Moldex3D User: Connector Case The area suggested to be cored out Warpage improved by 20% after thickness cored out23
  24. 24. Moldex3D User: Unilever Temperature difference :45oC ->15oC Cooling time reduced by 25% (from 5 to 3 sec) Save 4 million sec24
  25. 25. FEA Integration Analysis
  26. 26. What can Moldex3D-FEA Interface to Abaqus do?• To consider the process-induced variation during the processes – Mesh output • Original / deformed mesh • Mesh mapping – Material properties output • Anisotropic properties • Fiber Orientation tensor – Result output • Thermal/Residual stress • Temperature (Part/Mold) • Pressure history (Part/Mold)
  27. 27. Moldex3D-FEA Interface-Anisotropic material properties • Based on the fiber orientation and proper micro-mechanics models, Moldex3D-FEA Interface can output – Stiffness matrix – Thermal expansion coefficient27
  28. 28. Moldex3D-FEA Interface Orientation tensor (forDigimat)• Orientation tensor can be output to composite modeling software (Digimat) to perform more accurate micro mechanical properties calculation
  29. 29. Moldex3D-FEA Interface-Material Reduction • Material Reduction – Moldex3-FEA Interface can reduce the anisotropy scale by homogenizing the similar anisotropic properties so as to improve the computational efficiency Total material number from Total material number from 76,150 to 1,866 3,392 to 66829
  30. 30. Technology Link of FEA Interface Structure Moldex3D Simulation Ejection Application Analysis Flow Pack Cool Warp FEA- ANSYS Warpage FEA- ABAQUS Mold Deform FEA-MSC Structural Nastran FEA-MSC Modal Analysis Marc Drop Test FEA LS-DYNA Impact FEA-NX Paddle-Shift Nastran Core-Shift FEA- RADIOSS
  31. 31. Moldex3D-FEA Interface-Interface to Abaqus 3. Select output meshtype 2. Select Abaqus Solver 4. Select output data 1. Click FEA Interface Icon 5. Export .inp file
  32. 32. Tensile Bar - Wend Line strength reduction Weld Line Location32
  33. 33. Fiber Orientation around the weld line Weld Line Location33
  34. 34. Major Modulus34
  35. 35. Tensile Bar – Stress 30MPa Load Applied Yield at 80 Mpa 47 MPa 30 MPa Load Yield at 80 Mpa 79 MPa 30 MPa Load35 0-80 MPa Range displayed
  36. 36. Thrust Pedal – Filling Animation36
  37. 37. Thrust Pedal – Fiber Orientation37
  38. 38. Thrust Pedal – Major Modulus38
  39. 39. Thrust Pedal – Minor Modulus39
  40. 40. Thrust Pedal – Model Setup Fix the pin slot Apply a force on the Pedal40
  41. 41. Thrust Pedal – Displacement & Stress 200lbf (900 N) Force Applied Displacement Stress isotropic anisotropic41 0-50 mm range 0-100 MPa range
  42. 42. Integration between Moldex3D andHyperStudyImproving Part Quality for InjectionMolding
  43. 43. Introduction: Moldex3D and HyperStudy• Moldex3D • Moldex3D is the world leading CAE product for the plastics injection molding industry• HyperStudy • HyperStudy is software to perform Design of Experiments (DOE), optimization, and stochastic studies in a CAE environment • HyperStudy is a member of the HyperWorks suite of software products• Benefits of Moldex3D and HyperStudy Integration • Users can employ HyperStudy to perform a series of Moldex3D analyses systematically for improving part qualities • Process conditions can be optimized automatically • Moldex3D supports all study types for HyperStudy
  44. 44. Workflow between Moldex3D and HyperStudy Create an initial run and perform a preliminary analysis Copy new design factor file and Do Study setup, DOE setup and call Moldex3D as the solver others setups through script function Output response factor Finish all runs and obtain optimal results
  45. 45. Integrating Moldex3D and HyperStudy:DOE Study
  46. 46. Case Study• An injection molded part from a speed meter shows potential warpage problem from preliminary Moldex3D analyses. • Dimension: 400 x 126 x 76 mm• The target is to reduce warpage through optimizing process conditions with HyperStudy and Moldex3D using DOE study.
  47. 47. Design of Experiments Conditions• DOE Class: 9-run Fractional Factorial• Initial Design Variables • Filling Time: 2 sec • Melt Temperature: 230˚C • Mold Temperature: 70˚C • Packing Pressure Profile %: 75%• Design Variables • Number of Variables: 4 • Filling Time: 1.7, 2, 2.3 sec (3 levels) • Melt Temperature: 220, 240˚C (2 levels) • Mold Temperature: 65, 75˚C (2 levels) • Packing Pressure Profile %: 70, 75, 80 % (3 levels)• Response Variable • Standard deviation for total displacement (mm) • In other words, the target is to have as uniform displacement as possible
  48. 48. DOE Study: Create a DOE Study Select DOE Class Detail setting of the Study setup is shown in appendix
  49. 49. DOE Study: Controlled Variables• Define Design Variables: Select Design variables Setup Design variable bounds and level values
  50. 50. DOE Study: DOE Run Table
  51. 51. Design of Experiments: Run ResultsRun Summary This chart indicates the melt temperature and packing pressure profile are the most sensitive factors Main Effects
  52. 52. DOE Optimal Results Variables Initial Results DOE Results Filling Time (sec) 2 2.3 Melt Temperature (˚C) 230 220 Design Variables Mold Temperature (˚C) 70 65 Packing Pressure Profile (%) 75 80 Response Variable SD for Total Displacement (mm) 0.354 0.262• HyperStudy DOE study will lead to minimum standard deviation (SD) for Total Displacement. It implies that the part deformation will become more uniform in general. Initial Results DOE Results
  53. 53. Integrating Moldex3D and HyperStudy:Optimization Study
  54. 54. Create an Optimization Study• The same optimization target can be achieved by employing an Optimization Study. For example: Adaptive Response Surface Method (ARSM) Select Optimization Engine Other optimization engines available in HyperStudy are
  55. 55. Optimization Study: Define Design Variables• Define Design Variables: • Filling Time (Range: 1.7, 2.3 sec) • Melt Temperature (Range: 220, 240˚C) • Mold Temperature (Range: 65, 75˚C) • Packing Pressure Profile % (Range: 70, 80 %)
  56. 56. Settings for Objectives• Objectives: • Goal: Minimum Standard Deviation (SD) for Total Displacement • Maximum Iterations: 20 • Absolute Convergence: 0.001 • Relative Convergence: 1.0%
  57. 57. Optimal ResultsHistory Plot History Table Optimized design factors
  58. 58. Optimal Results Variables Initial Run Optimal Run Filling Time (sec) 2 2.3 Melt Temperature (˚C) 230 220 Design Variables Mold Temperature (˚C) 70 65 Packing Pressure Profile( %) 75 80 Response Variable SD for Total Displacement (mm) 0.354 0.262• Recommended optimal results will lead to the minimum standard deviation (SD) for Total Displacement. It means that the part deformation will become more uniform in general. Initial Results Optimal Results
  59. 59. Summary
  60. 60. Comparison Variables Initial Results DOE Results Optimal Results Filling Time (sec) 2 2.3 2.3 Melt Temperature (˚C) 230 220 220Design Variables Mold Temperature (˚C) 70 65 65 Packing Pressure Profile( %) 75 80 80Response Variable SD for Total Displacement (mm) 0.354 0.262 0.262Warpage Improvement 0% 26% 26%{[0.354-(Other results)]/0.354}*100% Initial results DOE/Optimal results Upper and lower limit values fixed to initial results
  61. 61. Conclusion• The integration between Moldex3D and HyperStudy helps users to find out the optimal process conditions for injection molding systemically.• Both DOE Study and Optimal Study can reduce maximum displacement from 1.4 mm (initial design) to 1.0 mm (optimal design), which is a 27% improvement.• According to the DOE Study results, melt temperature is the most important and filling time is the least important factor for warpage of this case.• Both DOE Study and Optimization Study can reduce warpage by 26%. However, please note it’s likely to find different optimization studies lead to slightly different optimized results.
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