process-structure interaction for injection molded plastics parts
TRANSCRIPT
© PART Engineering GmbH, www.part-gmbh.de
Altair ETHC
Bonn, 08.11.2011
Process-Structure Interaction
for Injection Molded Plastics Parts
Dr.-Ing. Wolfgang Korte
PART Engineering GmbH
Plastics
CAE Services & Software
Technical Simulation Contract Simulation Services
in FEA
CAE Staffing
Resident Engineers at
customers‘ sites
CAE Software - Process-Structure-Interaction
- Strength & Fatigue Assessment
Metals
S-Life
Elastomers
Influence of Injection Molding Process onto Part and Mold
properties (of the part)
- fiber orientation
- weldlines
- wall thicknesses
- shape
loads (on part and mold)
- pressure
- temperature
Fig. 2
Considering Process Data in Mechanical Simulation
Molding
Simulation
now
Mechanical
Simulation
Coupling
Software
improved
assessment of:
-strength
-deformation
- fiber orientation
- pressure
- temperature
- deformation
(shrinkage & warpage,
wall thicknesses)
- weldlines (indirectly)
past
Fig. 3
Overview
Considering Process-Induced Part Properties in FEA
• Influence of Fiber Orientation onto Mechanical Properties
• Obtaining Orientation and how to Handle them
• Example: Rotary Valve
Considering Process-Induced Loads in FEA
• Example: Pressure-Mapping for an Airintake Manifold
• Example: Pressure-Mapping for an Electronic Device
Fig. 4
Influence of Injection Molding Process onto Part and Mold
properties (of the part)
- fiber orientation
- weld lines
- wall thicknesses
- shape
loads (on part and mold)
- pressure
- temperature
Fig. 5
material:
PA6+GF30
perpendicular
parallel
Influence of Fiber Orientation onto Material Properties Fig. 6
Fiber Orientations in Injection Molded
Short-Fiber-Reinforced Components
S1
S2
S1
Flow Direction Wanddicke
S1 shear layer: fibers oriented parallel to flow direction
S2 mid layer: fibers oriented perpendicular to flow direction
Fig. 7
[DKI]
[BASF]
Example: Rotary Valve Fig. 8
material: Grivory HTV 3H1
force
test rig
Example: Rotary Valve – Mapping of Fibers Fig. 9
molding
simulation
mechanical
simulation
0
200
400
600
800
1000
1200
1400
0 1 2 3 4 5 6
forc
e [N
]
deflection [mm]
test sample #1
test sample #2
FEA w/o fibers (isotropic)
FEA w fibers (anisotropic)
Example: Rotary Valve - Stiffness Fig. 10
+60%
0
100
200
300
400
500
600
700
800
0 1 2 3 4 5 6
forc
e [N
]
deflection [mm]
test sample #1
test sample #2
FEA w fibers (anisotropic)
Example: Rotary Valve - Strength Assessment Fig. 11
Pos.1
Pos.1
precise
prediction
of failure
ma
trix
str
es
s [
MP
a]
strain [%]
Mapping of Fiber Orientations and Material Properties Fig.12
Consideration of Weldlines
weldline
isotropic anisotropic
molding
simulation
calculated fiber orientation
in the weld area
pressure
Fig.13
Influence of Injection Molding Process onto Part and Mold
properties (of the part)
- fiber orientation
- weld lines
- wall thicknesses
- shape
loads (on part and mold)
- pressure
- temperature
Fig. 14
Example: Core Shift of an Airintake Manifold Fig. 15
molding simulation pressure on core
mapping
of pressure
Example: Overmolding of an Electronic Device Fig. 16
calculated stresses in
electronic insert
molding simulation pressure on insert
mapping
of pressure
Mapping Temperatures and Pressures Fig.17
Add Value to Your Mechanical Simulation Fig. 18
consider the real part properties
get better predictions of strength
& deformation
at nearly no
additional costs
by using data
already available
integrates smoothly into your day-to-
day CAE routines
straigthforward easy-to-use
Moldflow
Cadmould
Sigma
Fluent
Abaqus
Ansys
Radioss
Marc
Interfaces
Thank you
Questions?