With the advent of efficient and robust numerical analysis techniques such as finite element analysis (FEA) and the increased computing power of today’s hardware solutions, it has become practical to simulate thermo-mechanical behaviors of plastics and rubbers that can capture the physical reality of such materials with high fidelity. Replicating physical behavior of highly complex and non-linear materials such as plastics have positioned FEA tools to create life like models that will behave like the real part or product. Such simulation can compare very well with the physical test. Therefore, using FEA techniques one can perform virtual testing to design plastic products and also can use simulation techniques to optimize design based on a mathematically robust approach instead of heuristic, experience based approach only. Using FEA one can address the needs of the product development lifecycle from concept through detailed design capturing realistic simulation of underlying complex physics.

1. REALISTIC SIMULATION SOLUTIONS FOR
DESIGN, OPTIMIZATION, AND FABRICATION
OF PLASTICS
Arindam Chakraborty, PhD, PE
VP of Advanced Engineering, VIAS
Houston, TX
www.viascorp.com
achakraborty@viascorp.com
May 10, 2018

2. © 2018 Virtual Integrated Analytics Solutions Inc.
Agenda
• VIAS Overview
• Realistic Simulation & Optimization
• Collaborative Innovation
• Examples-
✓ Simulation for Injection Molding
✓ Injection Molding Demo
✓ Simulation based Optimization
• Concluding Remarks
2

3. WHO WE ARE

4. © 2018 Virtual Integrated Analytics Solutions Inc.
Who We Are
Engineering
Consultancy
Training
Automation
&Customization
Software
• Multiple Industry Experience
• Oil & Gas,
• Machinery & Equipment
• Petrochemical & Process
• Consumer Goods
• Aerospace
• Medical Devices
• Automotive
• Presence in Houston, Chicago, Cincinnati, San Francisco,
Portland
• Provides Engineering Consultancy, Automation and
Customization, Training
• Team consists of PhD’s and MSc’s in Solid Mechanics,
Fluid Mechanics, Materials & Corrosion, Numerical
Analyses, Optimization & Reliability, Data Analytics
• Solution partner of Dassault Systèmes SIMULIA – Abaqus,
Isight, fe-safe, Tosca, CATIA, DELMIA, 3DEXPEREINCE
• Provide AM Simulation and 3D Printing Services
4

5. © 2018 Virtual Integrated Analytics Solutions Inc.
VIAS Capabilities
Design Analysis and
Validation using Simulation
FEA based Fracture /
Damage Mechanics
Fluid Structure Interaction
(FSI)
Multi-physics Simulations
(CFD, Thermal Analysis)
Additive Manufacturing
Simulation
Material Modeling and
Process Simulation
S-N and e-N based Fatigue
Analysis (varying
temperatures)
Simulation Automation
CATIA Design and Analysis
Product Lifecycle
Management (PLM)
5

6. REALISTIC SIMULATION
& OPTIMIZATION

7. © 2018 Virtual Integrated Analytics Solutions Inc.
What is Realistic Simulation?
“Realistic Simulation” is a simulation that is physically
realistic and “life like” in every way
• Enables engineers to create life like models that will behave similarly to the
real part / product.
• Typically, start with simple models and increase the complexity, model size
and the physics as confidence in simulation results increase their
• Enables building up expertise and most importantly find value in simulation
7

8. © 2018 Virtual Integrated Analytics Solutions Inc.
Why Realistic Simulation?
• Designers often create innovative
concepts, but retreat to conventional
shapes due to limited time and resources
for physical prototyping and testing
• Simulation enables designers to virtually
test new innovative concepts
▪ Reduces design time and the
expensive cost of physical testing
▪ Lowers material cost and improves
sustainability by light-weighting
▪ Reduces damage cost during
production and transport by
eliminating bad designs quickly Courtesy Mechanical Design and Analysis Corporation, 2010 SCC
8

9. © 2018 Virtual Integrated Analytics Solutions Inc.
Challenges in Modelling Plastics and Polymers
• Polymeric materials are complex in their
mechanical behavior
• Exhibit large strain, anisotropic and
irreversible response; often accompanied by
stable localized necking behavior
• Modelling failure and fracture a challenge
• Simulation models must deal with severe
non-linearities
Blow Molding
(Plastic Bottle)
Necking (ASTM D638
Hyperelastic)
Viscoelastic Rubber
Seal Insertion
Fracture /
Delamination
Crimping

10. © 2018 Virtual Integrated Analytics Solutions Inc.
Optimization – Deterministic and Probabilistic
10
Flexible automated design exploration strategies combining DOE,
surrogate models, multi-objective optimization and stochastics.
Y1
Constraint
Boundary
Y2
Initial Design
Search for solution
Optimization
Robust/Reliability Design
(Quality Engineering)
Feasible Infeasible
(safe) (failed)
X2
X1
DOE:
Critical Factors
And Initial Design

11. © 2018 Virtual Integrated Analytics Solutions Inc.
Automation and Optimization - Isight
11
• Process Integration and Design Optimization
• Integrate Disparate Simulation Tools without
programming
• Automate Simulation Process Flows

12. COLLABORATIVE
INNOVATION

13. © 2018 Virtual Integrated Analytics Solutions Inc.
Collaborative Innovation
13
Perfect
Production
Perfec
t Lab
Perfect
Shelf
Perfect
Product
Perfect
Package
Perfect
Value Chain
Local
Teams
3DEXPERIENCE : Collaborative Innovation
LAUNCHDEVELOP PRODUCE ADAPT / REPLICATEIDEATE
Scientists
Formulators
Artwork
Designers
Production
Transportation
Sales
Planning
Stores
Materials
suppliers
Agencies
Management
Local
markets
Digital
Equipment
Suppliers
Packaging
suppliers
LAUNCHDEVELOP PRODUCE ADAPT / REPLICATEIDEATE
FIRST
MARKET
Packaging
Engineers
Legal

14. © 2018 Virtual Integrated Analytics Solutions Inc.
SIMULIA Product Portfolio Overview
Access to Technology through multiple
user interfaces facilitates migration
• Transition to 3DEXPERIENCE as applications
mature and customers are ready
• Enable existing SIMULIA portfolio within
3DEXP platform
3DEXPERIENCE provides
integration of applications and
technology in an open and
extensible environmentDelivering
trusted, proven,
robust,
dependable
technology on
an open
platform to
connect 3rd party
technologies
3DS Simulation Portfolio
Multiphysics Simulation
Applications
delivering a
comprehensive
environment for
multiphysics
simulation
Product Design Simulation
Applications tailored
to guide product
design from concept
through validation
Simulation Process
Integrate applications,
disciplines and data to enable
collaborative decision making
through analytics
Isight
Automate and explore design alternatives
and identify optimal performance
parameters through simulation process
flows
Abaqus Solvers
Abaqus Standard
Abaqus Explicit
Abaqus CFD
Solidworks Simulation
Simulation solutions providing
seamless integration within the
Solidworks V1 environment
V5 Analysis
Finite element simulation within the V5
environment providing seamless
integration
Tosca
Simulate the right design more
efficiently through design exploration
and optimization
fe-safe
Accurately determine the fatigue life of
components under complex cyclic
loading
Abaqus/CAE
Finite element modeling,
visualization and process automation
for Abaqus
14

15. © 2018 Virtual Integrated Analytics Solutions Inc.
Design Validation using Simulation
15
Design of the package
• Design the package with
the CATIA app:
Structural package
design
• Apply material with
rendering and
simulation properties
Model
preparation• Meshing of the Model,
• Preparation of the
connection and
properties
Scenario definition
• Visualization of the stresses,
displacement
• Validation of the structure
• Optimization of the design• Application of
forces,
restraints
• Definition of the
scenario
(dynamic, static)
Results Analysis

16. SIMULATION FOR
INJECTION MOLDING

17. © 2018 Virtual Integrated Analytics Solutions Inc.
Injection Molding - Capabilities using FEA
• Optimize design of parts and molds
• Design complex shapes - get the best design
without doing “trial and error” prototyping
• Simulate filling and packing phases
• Ascertain pressure requirements for uniform
filling
• Gain insights into the thermal gradient of the
part cross-section
• Develop cooling solution for solidification
• Automatic report generation with HTML, PPT
and Word Formats
17

18. © 2018 Virtual Integrated Analytics Solutions Inc.
Simulation in Injection Molding - Filling
• Different polymers have varying properties and process
requirements
• Plastics Simulation can answer the following questions:
• Will my part fill completely?
• Where are the parting lines?
• Will there be air traps?
• Where are the best gate locations?
• Do all my cavities fill equally?
• How much pressure and clamping force will I need?
• What happens if I change materials?
Sink marks and air traps Temperature growth Bulk temperature
18

19. © 2018 Virtual Integrated Analytics Solutions Inc.
Filling Examples
Will my part fill completely?
Will there be short shots?
Predict the weld lines, possible air traps
and structural weakness
Air Trap Locations
19
1.
2.
3.

20. © 2018 Virtual Integrated Analytics Solutions Inc.
Simulation in Injection Molding – Packing & Cooldown
• Plastics Simulation can answer the following
questions:
• What is the time required for the part to cool
down?
• What is the effect of a packing pressure profile?
• When do gates and other regions freeze?
• What is my process cycle time?
• Are there hot spots that delay ejection?
• Where do residual stresses develop?
• How much volumetric shrinkage do I have?
20

21. © 2018 Virtual Integrated Analytics Solutions Inc.
Packing & Cooling Examples
o Achieving uniform density
o Uniform dimensional stability
o Minimizing sink marks
How long must I pack the part?
Zeroing in on the gate will permit the user
to identify the when the gate freezes off
Temp at end of packingPressure after filling
Pressure at end of packing Volume shrinkage
21
1. 2.

22. © 2018 Virtual Integrated Analytics Solutions Inc.
SIMULIA Simpoe-Mold
• SIMULIA provides a module to simulate the injection
molding process
“Simpoe-Mold also allows simulation of more advanced
processes, such as gas-assisted injection, co-injection
molding, bi-refringance, overmolding, multi-shots or multi-
domain injection”.
• Imports common CAD geometries
• Large, customizable material database
• Predicts process cycle time
• Can be integrated with structural analysis using Abaqus
22

23. © 2018 Virtual Integrated Analytics Solutions Inc.
Simpoe has been available since 1995 – first as a standalone now
available on the 3DEXPEREINCE platform.
The 3DEXPERIENCE platform is a business experience platform. It provides software
solutions – from marketing to sales to engineering – that help in your value creation
process. With a single, easy-to-use interface, it powers Industry Solution Experiences –
based on 3D design, analysis, simulation, and intelligence software in a collaborative,
interactive environment.
Products Powered by SIMPOE Technology
3DEXPERIENCE Apps
Plastic Part Filling (FPP)
Plastic Part Injection (INK)
Plastic Mold Injection (IME)
23

24. PLASTIC MOLD
INJECTION DEMO

25. Plastic Mold Injection
(IME)
Demo

26. SIMULATION BASED
OPTIMIZATION

27. © 2018 Virtual Integrated Analytics Solutions Inc.
Bottle Ideation
•Capture the design ideas with
CATIA Application: Natural Sketch
•Define the material properties
Configure the bottle with different sections
•Based on Previous Results,
configure the bottle with some
market information.
•Create and assemble several
bottles.
•With the SIMULIA Application
Process composer Optimize the
design of the bottle by changing
parameters Optimize the volume
(Minimize) and the reaction force
(Maximize)
Design Optimization
Management of Parameters
•With CATIA Knowledge
Parameters, we can manage
the parameters of each
sections to adjust the size of
the bottle
Validation Simulation
•With the SIMULIA Physical
applications create a top
compression test
•Export Reaction Force
(RF3)
•Blow molding process
Simulation compression
•With the SIMULIA Physical
applications create several
validation simulation
(caping, wrapping)
•Test the consumer usage
with handling tests.
Rendering
•Creation of
realistic
rendering
Bottle Design With the 3DEXPERIENCE platform

28. © 2018 Virtual Integrated Analytics Solutions Inc.
Case Study: Thickness Optimization for Blow
Molded Bottle
• Top Load (TL) thickness optimization
• Vary thickness smoothly along bottle height
▪ Use 5 thickness values as
optimization parameters
• Constraints – minimum TL force > 100 N
• Optimization target – minimize mass
2828

29. © 2018 Virtual Integrated Analytics Solutions Inc.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0 50 100 150 200 250
Target Thickness
STH
Case Study: Thickness Optimization for Blow
Molded Bottle
• Mass: 43% reduction
• Meets target Top Loading Force
2929

30. CONCLUDING
REMARKS

31. © 2018 Virtual Integrated Analytics Solutions Inc.
• For companies that design plastic parts or injection molds, INK or IME can
help users:
➢ Predict and avoid manufacturing defects during the earliest stages of
part and mold design
➢ Eliminate costly mold rework
➢ Improve part quality
➢ Decrease time to market
• Business value
➢ More than 80% of plastic parts are injection molded
➢ Injection molding is a complex mix of time, temperature, pressure,
material & tooling variables
➢ Injection molds range in cost from >$10K to $1M+ and mold rework is
costly and time-consuming
Plastic Injection Molding Simulation Value Proposition
Avoiding Just One Round of Mold
Rework can result in a Positive ROI
31

32. THANK YOU