integration of injection molding and structure analysis cae with

MSC Software Confidential MSC Software Confidential

Integration of Injection Molding and Structure Analysis

CAE with Considering Fiber Orientation Effects

2013 Regional User Conference

Presented By: Shih-Po Sun, Moldex3D

May 7, 2013

MSC Software Confidential

• Product lifecycle management of injection-molded part

• Integration of injection molding & structure analysis CAE

• Case of fiber-reinforced product

• Molding-induced variation

• Conclusion

Outline

2


Product Lifecycle Management (PLM)

of Injection-Molded Part

3


Product Lifecycle Management (PLM)

of Injection-Molded Part

4

Plastic


PLM – Injection Molding Process

Screw Screw simulation

Marc structural analysis

Performance

Mold Filling simulation


• Injection molding is a manufacturing technique for making parts

from thermoplastic material in production.

Plastics Injection Molding Process


Polymer Rheology

7

unoriented molecularchain before flow

oriented molecularchain after flow

velocityprofile

shear rateprofile

molecular chain orientation

decrease in orientation

Viscosity

Shear Rate

Lower Temp.

Higher Temp.

unoriented molecular chains

oriented molecular chains


Plastics Injection Molding Applications

8

Computers

Automotive

Consumer electronics Communication Consumer products

Lens

Micro-component

Semiconductor Aerospace

Others


• Linear stress analysis

• Non-linear stress analysis

• Buckle analysis

• Heat treatment analysis

• Shock and response analysis

• Frequency response analysis

• Impact analysis

• Crack analysis

Common Plastic Structural Analysis


Concept Design

PLM – without Considering Molding Effects

Production

Flow analysis Concept Design Concept Design Concept Design Concept Design Concept Design

Structural analysis Flow induced micro-structure ,e.g., fiber and weldline


• Residual stress:

– From volume shrinkage difference

– From flow induced molecular orientation

• Material anisotropy:

– Molecular orientation

– Filler orientation distribution

• Material inhomogeneity

– Weldline

– Matrix density

– Filler concentration distribution

– Filler size distribution

Things we should consider in structural

analysis

11


Integration of Injection Molding &

Structure Analysis CAE

12


PLM – Considering Molding Effects

Concept Design

Production MARC

Structure Analysis

Moldex3D Injection molding

How to connect this

process from injection

molding analysis to

structure analysis?

Moldex3D-FEA


To cover the process-induced variation during the processes

• Full Integration of injection molding analysis and structural analysis

• Cover polymer processing-induced properties for further structure

analysis

PLM – Injection Molding Process

Mesh,

Material,

Process…etc

Flow/Pack/Cool

Warp/Fiber

Simulation

Deformed geometry,

Fiber-reinforced

Material properties…etc

Structure analysis,

Drop test analysis,

Impact analysis…etc.


Better Procedure for Structure Analysis

Correct

Initial Condition

Correct

Material Properties

Proper

Mesh

Correct

Boundary Condition

Structure

Analysis

Solver

Accurate

Results


To cover the process-induced variation during the processes

• Fiber orientation output

• Optimized Material input reduction

• Map material properties between different meshes

• Thermal / Flow Residual stress output

• EOP Temperature output

• Initial strain output

• Multiple time step melt flow pressure output

• Moldbase related data output (pressure, temperature)

What Moldex3D-FEA can do?


Fiber-Reinforced Product Example

17


• Slot-loading CD-ROM drive bearing fastener

• Size: 50.5 × 5.1 × 44.6 mm

Product Case

18 18

Fixed

Up force

Spring

force

Fixed


• Minimize height difference under loading.

Product Quality

19

Height

difference

B

A


• Material: PA66 \ Ultramid A3WG10

• Processing conditions

– Filling time：

• 0.05 s, 0.2 s, 1 s

– Melt temperature：300 ℃

– Mold temperature：85 ℃

Moldex3D Injection Molding CAE analysis

20


• PA66 \ Ultramid A3WG10

Material Properties

21


• Melt front time

Moldex3D Results

22


Moldex3D Results

• 10X warp (mm)

23


Moldex3D Results

• Fiber orientation

24

MSC Software Confidential 25

Integration of Injection Molding & Structure

Analysis CAE via Moldex3D-FEA


Properties derivation

Element properties

Orientation information

Marc

Material parameters

Flow analysis

+


Fiber Orientation Effect

Fiber-reinforced No fiber

5X

Warp (mm)

Fiber

orientation

1.04 mm 0.30 mm


Fiber Orientation Effect

Material PA66

UltramidA3W

PA66

UltramidA3WG10

Fiber (%) 0 50

E modulus (dyne/cm2) 3.1e+010 1.96e+011 / 5.76e+010

Poisson's ratio 0.4 0.37(v12) / 0.56(v23)

CLTE (1/K) 8.5e-005 1.2e-005 / 5.5e-005

Warp (mm) 1.04 0.30

Fiber orientation warp (mm) X 0.13

Loading deformation (mm) 2.14 0.97


Molding-induced variation

How to estimate?

29


Molding-Induced Effects Different filling time

• Melt front time

0.05 sec 0.2 sec 1.0 sec


Molding-Induced Effects

Filling time (sec) 0.05 0.2 1.0

Warp (mm) 0.27 0.30 0.31

Fiber-induced warp (mm) 0.14 0.13 0.12

0.05 sec 0.2 sec 1.0 sec

10X

Warp (mm)

Fiber

orientation


Filling time (sec) 0.05 0.2 1.0

Loading Y-deformation (mm) 1.00 0.97 0.97

Von Mises stress (MPa) 98.0 74.5 86.6

Anisotropic Material Models

MARC Results – Loading Displacement

0.05 sec 0.2 sec 1.0 sec

Von Mises

stress (MPa)

Y-deformation

(mm)


• An approach to study Marc structural analysis with molding

effects for injection-molded plastic parts is proposed.

• Through the link between mold-filling analysis and structural

analysis, the molding-induced anisotropic characteristics can be

taken into account.

• The results from several demonstrations show that structural

analyses of fiber-reinforced plastic parts depend heavily on

molding conditions.

• Part designers are recommended to use this approach evaluating

the part design and mold design for an injection-molded plastic

part .

Conclusion

33

integration of injection molding and structure analysis cae with

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