Dr. Mahesh Divekar of BASF India Ltd presents on computer aided engineering (CAE) simulations. CAE can help eliminate physical prototypes, save time and money, and provide insights earlier in development. Simulations include injection molding, structural analysis, and design optimization. CAE supports applications across industries by predicting performance and improving designs.

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Computer Aided Engineering (CAE) Filling olmuloUon
Or. Mahesh Olvekar
BASF India Lid.
Performance Materials - South Asia
Contact: +91-9930574643
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Performance,evaluation by local failura
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Computer Aided Engineering (CAE) FIiiing slmulatlon
Dr. Mahesh Divekar
BASF India Ltd.
Performance Materials - South Asia
Contact: +91-9930574643
CAD design
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Performance evaluation by local failure
criterion
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Glass fiber orientation
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3. Contents
• What is CAE and How its Work...!
• Application Development support through
CAE
• Injection Process Simulations
• Structural Simulations
• Design Optimizations
• CAE Support for All Industries
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4. Tool Development Cycle
- - - - -
Idea
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[ CAD Modelling 1
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[ Final Design 1
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Actual Experimental
Testing D•BASF
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5. Tool Development Cycle
Idea
CADMoclelNng
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[ Prototype
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[ Lab Test
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L Sample J
Manufacturing
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Testing
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PDC Approach
without Simulation
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6. ool Development Cycle
Idea
CAD Modelling
r Prototype ]
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[ LabTest 111
• •
rFinal Design7 -A
•
Sample
Manufacturing
Dr. Mahesh Divekar's screen
PDC Approach
without Simulation
• • • • • • • • • D•BASF

7. ool Development Cycle
Idea -
•
CAD Modelling
~
[ Prototype
7
C
C Lab Test
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[ Final DNlgn
..
L Sample
Manufacturing
..· - ■
Dr. Mahesh Divekar's screen
PDC Approach
without Simulation
• • • • •
- - - - - -
Idea
( CAD Modelling
~
lCAE Simulation
~
[ Final Design
..
Sample
Manufacturing
•
Actual Experimental
• •
Testing D•BASF

8. AE Simulation Example
Actual Experimental
Testing
Dr. Mahesh Divekar's screen
• • • • • • • • •
CAE Simulation

9. Advantages- Accurate and well in advance simu1
lation CCAE)
•
• Eliminate/Minimize physical prototype testing efforts
• Saves time and Money
• Design decisions can be made in earlier
• Can provide performance insights earlier in the development process.
• Made design evaluation easier.
• Reduce the costs associated with the product lifecycle.
C•BASF
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10. mm AiiiHH,IM 1111
How It Works...!
Autodesk Moldflow
•
• Processing
- F:lling/ Warpage
- Runner balance
- Weld line prediction
- Gate optimization
- Flber orientation
- PU Foam Simulation
- CFD
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11. M ,-- M'M·l·I··l:iA 1111...
How nWorks...!
Autodesk Moldflow Abaqus Implicit Abaqus explicit/ LS Dyna
Altair Optistruct
•
~
Ultraslme
Processing
~ • Basic structure • Shape
• Processing - Liner static strength - Pedestrian protection - Bead
- F1ll1
ng/ Warpage - Burst analysis - Drop test - Frequency
- Runner balance - Modal frequency - High speed burst
- Weld line prediction - V1
brat1on study
- Gate optimization - Seaflng and Creep
- Fiber orientation . Thannal analysis
- PU Foam Simulation
- CFO
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12. I •• s 11sss ez s ,,.,.. ME·ii,H:IM
CAE Support For Application Development
Simulation Capabilities - - - - - - - - - - - - - - - - - - - - - - - - - - - -
ULTRASIM®
The Solution
CAE Competence for
Your Innovative
Components
InJection Process
CAE
I I
Structural Simulation Design Optimization

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Plastic Processing Methods
Rotational Mold:ng

14. OCHl55
Injection Process Simulations
• Key Requirements
• Process results validation
• Gate and process optimization for new tool development
• Process Troubleshoot
• Warpage control and mold shrinkage for tool
• Type of Injection Process Simulations
• Injection process simulation for process validation
• Gate and Process parameter opt1mizat1on
• Runner balance analysis for family and multicavity molds
• Core shift analysis
• Sequential gating analysis
• Cooling system analysis
• Process trouble shooting by rnoldflow analysis
• Warpage prediction, Control guidelines
• Mold shrinkage prediction for tool cutting*
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15. Injection Process Simulations
Process Analysis Steps
30 CAD Data
Customer
Pre-processing
BASF
+
Moldflow Input
BASF/Customer
Moldflow Process Parameters :
• Gate Location
• Filling time
• Temperature etc
• Results
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Ill
• Filling Pattern
• Weld lines, Air Voids
• Warpages
• Shrinkage, etc.

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Injection Process Simulations
Process Analysis Steps
30 CAD Data
Customer
Actual part manufacturing
Customer
Pre-processing
BASF
IOpti~ization
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Moldflow Input
BASF/Customer
Moldflow Process Parameters :
• Gate Location
• Filling time
• Temperature etc
• Results
'
II
• Filling Pattern
• Weld lines, Air Voids
• Warpages
• Shrinkage, etc.
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Injection Process Simulations
Moldflow
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Gate Optimization Sequential Gates Runner Balance
Cooling System Advanced Simulations Shrinkage Recommendation

18. e
Gate Optimization
Adjusting Lever
Adjusting Lever
IFIii Pattern I
Original
IFiber Orientation Tensor I
....
Modified
IWeld-Lines I
• Proposed design shows significant warpage improvement.
• Maintained circularity and reduced injection pressure.
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Proposal
IPart Warpage J
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Sequential!Gates
Roof Rail
Adjusting Lever Option 1 Option 2 Option 3
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Ultramld 8267GHS
IResults: FIii Pattern IResults : Warpage In All Direction I
t 7
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Warpage in All direction is 0.262mm to 7.945mm
• Proposed option 1 sequential gating design shows significant warpage improvement.
• Option 1 is better considering warpages, pressure, clamp force and cost point of view. D•BASF
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Internal

20. II e
Runner Balance
Multicavity runner balance
Ultramid 83WG7
Optimized runner dimensions : Balanced flow
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Uniform runner dimensions : Unbalanced flow
• Uniform runner and gate dimensions results
into unbalanced flow causing into high
pressure and clamp force in the cavity.
• Optimized runner and gate dimensions gives
balanced flow in the cavity.
C•BASF
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21. e
Cooling System
SuccessfuJ case ot Office Chair Lifter Module
Original
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-
• Form latches directly during mo
lding process.
Positive mold trial feedback from customer
Warpage: improve obviously.
Cycle time: 155s ➔ 47s.
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■ Improve Assembly Efficiency
■ Reduce Cycle Time & Warpage
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• Proposed design shows significant warpage improvement.
• The cycle time is predicted to have 57% reduction.
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22. 8
Structural Simulation
Structural Analysis Steps
3D CAD Data
Customer
Pre-processing
BASF
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Actual part manufacturing
Customer
I
IOpti~ization
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Structural Input
BASF/Customer
Loading and Fixed locations
•
-
-
Load
e Fix
• Results
• Displacement
• Stress
• Pressure
• Life, etc.
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23. 8
Stati·c simulation
I· What is static simulations? I
• Analysis to evaluate the progressive failure of the component under the static
loads
• Burst pressure analysis
• Weld bead strength analysis
• Point load analysis
• Torque load analysis
I· Inputs from customer I
• Temperature condition of test
• Load : Pressure, Force, Torque
• Fixation Locations
I· BASF Output I
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• Failure criteria
• Results:
• Displacement, Stress, Failure if any.
• Design suggestions
• Recommendations in design if failure occurs.
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24. 8
Advanced Simulations
I• Insert shift/ Core shift analysis I I• Mucell I
I• Conformal Cooling I • Transient Ultrasim• Warpage simulations
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Internal

25. 8
Non-Linear static simulation
PAIM: Bursi Pressure Analysis
PAIM: Model
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.6. Fix Points
Recommendations
Flange shell
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The maximum stress observed at nange shell on s~ffener/ribs. it is 121.32 MPa. This stress
is higher than allowable limit of the material (115 MPa)
Add round cross section as highlighted
In crease lhewith of lhe stiffener.; above atsharp section beads
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