Simulation of plastic parts considering material and production specific boundary conditions

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Simulation of plastic parts considering material and production specific boundary conditions

  1. 1. Simulation of plastic parts considering material andproduction specific boundary conditions Speaker: Dr. Volker Gorzelitz Dipl.-Ing. Stefan Vogler November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  2. 2. ENGINEERING FOR PRODUCT DEVELOPMENT 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 info@mtec-engineering.de2 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  3. 3. ENGINEERING PERFORMANCES 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 CALCULATION AND SIMULATION Finite Element Analysis (FEA) Crash, Passenger Safety (explicit FEA) Moldflow Analysis Optical Fibers, Light Engineering Fluid Dynamics (CFD)3 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  4. 4. Simulation of plastic parts considering material andproduction specific boundary conditions Initial Situation: Deformation of a plastic roof frame due to thermal load Speaker: Dr. Volker Gorzelitz Dipl.-Ing. Stefan Vogler November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  5. 5. 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 Conclusion5 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  6. 6. INTRODUCTION Boundary Conditions Material: PP GF 45 Fix X, Y, Z Fix Y, Z 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 Z6 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  7. 7. INTRODUCTION Isotropic FEA, Cool Down Pin deformation < 0,001 mm7 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  8. 8. INTRODUCTION Deformation due to Thermal Load (Cool Down) Deformation 7 mm8 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  9. 9. ANISOTROPIC SIMULATION OF PLASTIC PARTS Material behaviour influenced by the Injection Moulding Process 80,0 70,0 Matrix E║,α║ 60,0 Fiber 50,0 Tension [MPa] 40,0 PP E┴, α┴ 30,0 PP-GF20 20,0 E║ > Eiso > E┴ 10,0 α┴ > αiso > α║ 0,0 0,0 2,5 5,0 7,5 10,0 Elongation [%]9 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  10. 10. ANISOTROPIC SIMULATION OF PLASTIC PARTS Moldflow Simulation (Initial Design and Process)10 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  11. 11. ANISOTROPIC SIMULATION OF PLASTIC PARTS Simulation Process Fiber Anisotropic Mapping orientation FEA + - Moldex 3D - Digimat - Radioss - Sigma Soft - Convers - Abaqus - Moldflow - … - … - …11 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  12. 12. ANISOTROPIC SIMULATION OF PLASTIC PARTS FEA Initial Design and Process, Displacements12 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  13. 13. ANISOTROPIC SIMULATION OF PLASTIC PARTS Displacements (Cool Down) x10-3 Deformation UZ [m] Temperature [°C]13 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  14. 14. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Initial Part Design and Process) Fiber Orientation 1/314 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  15. 15. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Initial Part Design and Process) Fiber Orientation 2/315 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  16. 16. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Initial Part Design and Process) Fiber Orientation 3/316 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  17. 17. ANISOTROPIC SIMULATION OF PLASTIC PARTS Improvement of the Injection Molding Process (Changed Gate Position)17 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  18. 18. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Gate Position Changed Only) Fiber Orientation 1/318 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  19. 19. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Gate Position Changed Only) Fiber Orientation 2/319 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  20. 20. ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Gate Position Changed Only) Fiber Orientation 3/320 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  21. 21. ANISOTROPIC SIMULATION OF PLASTIC PARTS FEA, Gate Position Changed, Displacements Pin21 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  22. 22. ANISOTROPIC SIMULATION OF PLASTIC PARTS Displacement of the Pin (Single and Total Deformations) Deformation [mm] Direction U3 Temperature [°C]22 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  23. 23. 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.23 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany
  24. 24. 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 info@mtec-engineering.de We invite you to visit our exhibition stand Web http://www.mtec-engineering.com24 November 9th, 2011 | Altair - 5th EHTC | Bonn, Germany

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