Improving Manufacturing by Simulation: Processes, Microstructure & Tooling
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This presentation, made at the inaugural Virtual Engineering Centre Workshop on 25-26th October 2011, provides an overview of the application of simulation to optimise manufacturing processes and determine mechanical properties that can affect in-service performance. These properties can be imported into structural FEA programs such as ANSYS for subsequent analysis of the final product. Wilde Analysis believes that simulation techniques can play an important part in ensuring that parts are produced to a required standard and in an efficient way. Many of us are aware of simulation techniques such as finite element analysis (FEA) and computational fluid dynamics (CFD) being applied to product design. These techniques are now used extensively in product development for applications such as checks on structural integrity or pressure drops in fluid applications. However, fewer people are aware of the application of these and similar techniques to design and optimise the manufacturing processes and how they can deliver benefits in areas such as metal forging, machining, heat treatment and the injection moulding. The simulation of any one of these processes is technically demanding, but is now used extensively by many manufacturers, some of whom will not commit to making tools to produce a new part without first ‘proving’ the process using simulation. These simulations require advanced techniques including the modelling of non linear materials, large displacements, evolving contact surfaces and material removal in a multi-physics environment. Having mastered the modelling of a single process, the technology is now being applied to multi-stage modelling to simulate multiple operations and predict final properties that can affect in-service performance. This presents many new challenges and for some applications it’s still at the research stage. Nevertheless, current technologies are now being used to optimise manufacturing processes.
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Improving Manufacturing by Simulation: Processes, Microstructure & Tooling
- 1. improving manufacturing by simulation: Process, Microstructure & Tooling Dr Brian Miller Sales & Marketing Director WildeAnalysis.co.uk WildeAnalysis.co.uk
- 2. Overview • Formed in 1980 as Finite Elements Ltd • 1000+ clients • Member of Wilde Group of 70+ employees and £10m + turnover • Value Added Reseller for ANSYS, Autodesk Moldflow, DEFORM & ReliaSoft • ISO 9001:2008 Approved Quality Management System • On UK-steering committee for NAFEMS and involvement with many industry associations. WildeAnalysis.co.uk
- 3. Wilde Analysis CFD FEA Probability Reliability WildeAnalysis.co.uk 0 L S Value
- 4. Benefits of Simulation • In Design – Improved product performance – optimised – Less R&D lead time, costs and prototypes – Lighter – reduced material and energy costs – More reliable, less requirement for replacement – Enables ‘design for manufacture’ • In Manufacture – Less shop trials – Reduced scrap rates – Less material waste (flash, swarf, runners) – Improved quality & material performance WildeAnalysis.co.uk
- 5. Applications in all Engineering Fields WildeAnalysis.co.uk
- 6. Manufacturing Simulation Topics Blow Moulding, Extrusion & Other Polymer Processes Shape & tooling optimisation (POLYFLOW) + initial property determination for structural analysis Plastic Injection Moulding (Unfilled + Fibre Filled) Shape & tooling optimisation + initial property determination for structural analysis Metal Forming + Heat Treatment + Microstructure Shape & tooling optimisation + initial property determination for structural analysis + multiple process chain WildeAnalysis.co.uk
- 7. Process Modelling • Design for Manufacture • Example: Plastics Design – Assess design – Non-uniform thickness – Poor draft angles / undercuts – Complex and expensive – Assess manufacturability – Areas difficult/impractical to manufacture Courtesy: Autodesk WildeAnalysis.co.uk
- 8. Microstructural Modelling • Provides detailed information about the microstructure during thermo-mechanical processing . • Opportunities to improve process design through understanding impact on material Courtesy: SFTC WildeAnalysis.co.uk
- 9. Tooling Analysis • A carbide insert failed consistently in a high volume steel automotive part. • DEFORM was used in 1996 to isolate the root cause - an axial tensile stress at the fracture initiation point. • After redesign, the life was increased more that ten-fold for the first three stations in the progression. WildeAnalysis.co.uk
- 10. Virtual Prototyping of Blow Moulding Process Simulation / Part Testing (Implicit / Explicit CAD Design Manufacturing structural analysis) modify process modify CAD Fail PASS Courtesy: ANSYS WildeAnalysis.co.uk
- 11. Blow Moulding Process Simulation Courtesy: ANSYS WildeAnalysis.co.uk
- 12. Location of Minimum Thickness Identification of location with smallest thickness. Would this virtual product satisfyingly pass the tests and behave properly under services? Courtesy: ANSYS WildeAnalysis.co.uk
- 13. Effect of Variable Thickness uniform variable thickness thickness Top load - total deformation WildeAnalysis.co.uk
- 14. Moldflow to Structural Analysis • Primary stiffening cover, essential for the entire phone stiffness Courtesy: Autodesk WildeAnalysis.co.uk
- 15. Moldflow to Structural Analysis • Material PA, Zytel HTN53G50HSLR (DuPont) (50%Glass) restraints Vertical force Courtesy: Autodesk WildeAnalysis.co.uk
- 16. Moldflow to Structural Analysis • Gate Location: Top Gate location Fiber orientation Poor orientation in this area Courtesy: Autodesk WildeAnalysis.co.uk
- 17. Moldflow to Structural Analysis • Gate Location: Bottom Gate location Fiber orientation Good orientation in this area Courtesy: Autodesk WildeAnalysis.co.uk
- 18. Moldflow to Structural Analysis • Gate Location: Mid Gate location Fiber orientation Good orientation in this area Courtesy: Autodesk WildeAnalysis.co.uk
- 19. Deflection Comparison • Deflections predicted by Moldflow for different fibre orientations compared to isotropic material Gate location Fiber orientation Max. deflection Bottom Good 4.95mm Mid Good 4.27mm Top Poor 5.29mm Isotropic material 3.45mm Courtesy: Autodesk WildeAnalysis.co.uk
- 20. Stress Comparison –Fully integrated analysis: svonmises=35.9 MPa –Traditional stress analysis: svonmises=14.4 MPa –Fully integrated analysis: svonmises=80.1 MPa –Traditional stress analysis: svonmises=17.2 MPa Courtesy: Autodesk WildeAnalysis.co.uk
- 21. Typical Metal Forming Applications Hot forging Thread rolling Mechanical joining Cogging Machining Other applications Courtesy: SFTC WildeAnalysis.co.uk
- 22. Typical Metal Forming Applications Hot forging Thread rolling Mechanical joining Cogging Machining Other applications Courtesy: SFTC WildeAnalysis.co.uk
- 23. Typical Metal Forming Applications Hot forging Thread rolling Mechanical joining Cogging Machining Other applications Courtesy: SFTC WildeAnalysis.co.uk
- 24. Typical Metal Forming Applications Hot forging Thread rolling Mechanical joining Cogging Machining Other applications Courtesy: SFTC WildeAnalysis.co.uk
- 25. Typical Metal Forming Applications Hot forging Thread rolling Mechanical joining Cogging Machining Other applications Courtesy: SFTC WildeAnalysis.co.uk
- 26. Typical Metal Forming Applications Hot forging Thread rolling Mechanical joining Cogging Machining Other applications Courtesy: SFTC WildeAnalysis.co.uk
- 27. Typical Metal Forming Applications Hot forging Thread rolling Mechanical joining Cogging Machining Other applications Courtesy: SFTC WildeAnalysis.co.uk
- 28. Integrated Process Modeling System Geometry Microstructure Properties Residual Stress Anomalies Cogging Forging Heat Treat Machining Spin Lifing Cogging Shape Cooling Rate Machining Mission Sequence Ram Speed Sequences Cycles Alloy Composition DOE Design Optimization Courtesy: SFTC WildeAnalysis.co.uk
- 29. Machining Distortion • A number of leading aero engine OEMs and disk manufacturers are managing residual stress and machining distortion on a production basis. • Three dimensional capabilities are being developed as an ongoing effort. Courtesy: SFTC WildeAnalysis.co.uk
- 30. Machining Distortion s l o w co o l fa s t q u e n c h residual stress residual stress machining distortion (magnified after heat treatment after machining 20X) Courtesy: SFTC WildeAnalysis.co.uk
- 31. Machining Distortion • Heat treat & machining • 2D 3D conversion can distortion can be modeled in be used to sweep the 2D as an axisymmetric geometry and interpolate model. the residual stress to a • Broaching is simulated using three dimensional model. a 3D model. WildeAnalysis.co.uk
- 32. Metal Forming Simulation – Future Heat Treatment Mechanical Forging Machining Joining Cogging Pull Test Furnace Milling Cold Forming Heating Inertia Welding Casting Life Extrusion Machining Ring Rolling Induction Spot Welding Spin Heating Distortion Testing Rolling Sheet Forming Resistance Stir Welding Heating Courtesy: SFTC WildeAnalysis.co.uk
- 33. Summary • Engineering analysis increasingly applied to both product design and also manufacture. • In the most critical service applications, product optimisation spans multiple dissimilar processes. • Simulating geometry through the manufacturing cycle is inadequate to accurately predict in-service performance. • Prediction of internal properties (microstructure/ residual stress / fibre orientation) is required to simulate the part behaviour through a range of processes. WildeAnalysis.co.uk
Editor's Notes
- Entry slide to leave on screen while waiting for audience to settle down. Change name to your own. General Notes for Presenters: 1. Speaker Notes - Comments in Italics are for your information only. Comments in normal text are suggestions for what you might want to tell your audience. Note that although much of the speaker notes are written in third party (i.e. ‘client’ or ‘customer’), I would recommend that you always try to address the audience as directly as possible using ‘you’ and ‘your company’ - emphasising/adapting points and examples so that they are relevant and show benefits to them directly. 2. Objective of this Presentation This corporate presentation is a template you may wish to use during your meetings and before training courses. In many cases you may choose to adapt the content to the audience and time available. The overall objective of this presentation to emphasis the core values and services that we offer customers and to build credibility. As software becomes increasingly commodity based, we want companies to want to work with us rather than somebody else because of our unique offering as an FEA, CFD and Reliability Engineering consultancy and value added reseller. If time is short and you choose not to deliver all of the slides, you should still ensure the audience knows about our strengths and USPs i.e. We are unique in combining FEA, CFD and Reliability Engineering solutions. With a 30 year history and almost 1000 clients we have a longer track record and more experience than most. We are renowned for our professional, friendly and flexible approach, have worked with many OEMs and blue chips and can provide testimonials and references of our work. As we deliver software, training and consulting services, we can provide a total solution which best suits our customers needs rather than a company that always focuses on selling software (e.g. Autodesk or ANSYS) or services (e.g. Bennetts, Engenuity, PDL). We are independent of software developers and therefore are not constrained to fit a solution around a single product offering. We have the strongest and most comprehensive engineering analysis software portfolio in the UK, with genuinely market leading products such as ANSYS, Moldflow, DEFORM, PLAXIS and ReliaSoft. We also have the flexibility to add new products to reflect technology and market changes, and help our clients in new ways. Good luck! Note: If you do develop additional material for a specific application or industry, please send this to Brian Miller so that over time we can expand and share the presentations we have available to staff.
- Formed in 1980 as Finite Elements Ltd 1000+ clients Member of Wilde Group of 70+ employees and £10m + turnover 24 employees involved in analysis sales, services and administration 21 are qualified engineers with significant experience using analysis software ISO 9001:2008 Approved Quality Management System On UK-steering committee for NAFEMS and involvement with many industry associations.
- Through FEA, CFD and Reliability Engineering technologies and methods, we can help design and maintainability in a wide range of applications, including: - mechanical and electrical components and systems, and large scale structures manufacturing operations such as hot and cold metal forming, plastic injection moulding and extrusion, machining and heat treatment chemical, water treatment and other processes excavation, stability and foundation design problems involving soils and their interaction with structures.
- The Design Adviser in Autodesk Moldflow Adviser software helps you quickly identify areas of plastic parts that violate design guidelines related to the injection molding manufacturing process. This powerful tool for part design validation helps you examine: Thickness – Excessive variations in wall thickness can cause part warpage and surface blemishes as well as problems with the flow of melted plastic. By examining nominal wall thickness results, you can identify any region of the part that varies beyond acceptable limits and help avoid potential defects. Draft angle – Display variations in draft angle so you can easily identify features or regions that will be difficult to eject from the mold. Such difficulty can cause excessive stresses in the part as well as the ejection system and can lead to potential premature failure of parts and molds. Undercut – Features that cast shadows on other features of the part are undesirable because they often require complex and expensive mold components. By examining undercut results, you can identify the location of these features and determine whether they are necessary; and, if so, help ensure more complex tooling is designed in order to properly form such features in a way that the part can be successfully ejected. <Next Slide>
- Part completely formed (Handle, corners) Knitlines?? Parison/mold alignment Parison size etc…
- Finally, the process simulation reveals the thin sections as well as the minimum thickness and its location. Notice that there are thin sections near the handle. This may cause a problem for example during transportation and may be the cause for a weak, rejected part. Keep in mind that bad reputation is very hard to earase.
- Conclusions to gate location with fiber filled material: Influence of gate location is significant 23% on deflection Expected higher influence on fiber orientation Effects of fiber orientations can be quantified Isotropic, homogenous material definition Results differs significantly from models with fiber orientation
- Wilde Analysis can summarised by a ‘sandwich of technologies’, delivered as a flexible solution with an overall objective of helping you improve your design activities. This is backed by - A large team of highly skilled engineers 30 years relevant experience as an engineering analysis consultancy, working with almost 1000 companies and universities A professional and independent approach, supported a number of software suppliers and associates. A rigorous QA system approved to ISO9001 Either leave this slide up during questions or perhaps the next one if preferred.