Autodesk Moldflow. Moldflow Research & Development. Dr Franco Costa. Senior Research Leader

Transcription

1 Autodesk Moldflow Moldflow Research & Development Dr Franco Costa Senior Research Leader Autodesk

2 Research & Development Research In-house 24 PhD employees in Moldflow development A Lab with state-of-the-art equipment Four modern injection molding machines for test & validation Establishing a network of third-party Labs Academic Research Collaboration Six Universities with seven PhD students Industrial Research Partnerships Over 20 companies and institutions Slide 2 of 67

3 Outline Solver Features in Recent Moldflow Releases Solver & Mesh Features under development Research Collaborations Slide 3 of 67

4 RTM and SRIM in 3D Features Apply properties of a dry fiber mat where needed. Anisotropic permeability follows the shape of the product. Detect areas where resin cannot penetrate. Includes Vacuum Infusion & Gravity effect. Results Degree of Cure, Volumetric shrinkage, Mat orientation, etc. Fiber Mat Orientation Resin Penetration Slide 4 of 67

5 Fiber orientation Improved 3D Fiber Orientation Position C3, orientation A11 Implementation of a New Model MRD (Moldflow Rotational Diffusion) Experiment 2017 FCS 2017 R2 (MRD) Through thickness, mm Measured data provided by BASF BASF PA 30%GF Slide 5 of 67

6 Improved 3D Fiber Orientation Average error of predictions for different releases and constitutive models. Results for the default models are in bold AMI release Constitutive model BASF Bradford Delphi DSM EMS Mechanical Plaque Number of cases Number of locations for each case FCS 2017 R2 F-T RSC F-T RSC MRD R2 halves the average error of fiber orientation predictions Slide 6 of 67

7 3D Residual Stress Prediction Molded-in residual stress prediction Measurement (literature) Generic shrinkage model Residual stress model σ xx Measurement (literature) Generic shrinkage model Residual stress model σ yy Experimental data using layer removal method from W.F.Zoetelief, L.F.Douven, and A.J. Ingen Housz. Polymer Engineering and Science, 36(14), Slide 7 of 67

8 3D Warp using Residual Stress Ultramid B3WG6 BK0056,BASF Since AMI : Residual Stress is the default 3D Warp model Extended to Thermoset materials Mesh Aggregation option enabled Slide 8 of 67

9 Powder Injection Molding (PIM ) Mold filling simulation of Metal Injection Molding (MIM) and Ceramic Injection Molding (CIM) materials Predict the powder concentration Material characterization for PIM is available 9 Powder concentration Slide 9 of 67

10 Including Wall Slip for PIM τ c Critical shear stress 0.01 MPa m Slip exponent 1 a Constant sip coefficient 1.0e-05 b Temperature dependency 0 c Pressure dependency 0 Failed to predict initial jetting without Wall Slip With Wall Slip, predicted initial jetting in PIM simulation, which matched reality better Slide 10 of 67

11 Multi-barrel Injection Molding Simulation Master Barrel with 4 sub-barrel Delay time 0.25 s and 0.5 s for sub3 and sub 4, respectively Slide 11 of 67

12 Preconditioning Reactive Compression Molding Use numerical simulation to calculate temperature and cure changes during preconditioning stage Either use contact conditions to automatically apply temperature boundary conditions or input value specified on elements for the thermal boundary conditions Result: Temperature and cure distribution at the end of preconditioning stage Temperature and cure distribution at the end of preconditioning. Initial melt temperature: 50 C Mold temperature: 175 C Delay time: 10 sec Slide 12 of 67

13 Solver API - Solidification You can now consider cooling rate and pressure effects on Solidification Polycarbonate: Infino EH-1050; Cheil Industries T t (P) T t (P) = b 5 + b 6 P van der Beek et. al. Inter. Polymer Processing, 20, , (2005). Slide 13 of 67

14 New Features for Recent Releases Autodesk Moldflow Simulation 2017 R2 1. Wall Slip 2. Resin transfer molding 3. Thermocouple-controlled cooling 4. Heater wattage specification for heater element Autodesk Moldflow Simulation 2017 R3 5. CAD meshing support for Linux 6. Synergy Support for Delete CAD bodies 7. Synergy Support for Copy of CAD bodies 8. Support the exporting of STEP files 9. Powder injection molding support Autodesk Moldflow Simulation Multi-step large vector deformation support (modelling) 11. Multistage support for normal deformations (modelling) 12. User defined initial strain support for Anisotropic inserts (Warp) 13. Preconditioning analysis for reactive compression molding 14. Injection compression overmolding (3D) Slide 14 of 67

15 Research

16 Disclaimer We may make statements regarding planned or future development efforts for our existing or new products and services. These statements are not intended to be a promise or guarantee of future delivery of products, services or features but merely reflect our current plans, which may change. Purchasing decisions should not be made based upon reliance on these statements. The Company assumes no obligation to update these forward-looking statements to reflect events that occur or circumstances that exist or change after the date on which they were made. Slide 16 of 67

17 Centerline Extraction for CAD Cooling System Extracting Center Lines of CAD Cooling System Slide 17 of 67

18 Faster Conformal (3D) Coolant Flow Solver Supports Linux, & Parallelization Use the Autodesk Flow Design Voxel CFD Solver Pressure Moldflow 3D Channel mesh Moldflow results Cross section Voxel mesh Voxel results Voxel solve Velocity Slide 18 of 67

19 Underflow Diagnostic Plot Underflow severity as a result Underflow region viewmold.com Slide 19 of 67

20 Fiber orientation tensor components Skin Skin Adaptive Fiber Model Orientation Prediction Shell Core Shell Skin Orientation Believed to be due to fountain flow Shell Orientation Strong alignment in flow direction Alignment controlled by fiber interactions, CI, ARD bi, MRD Di A11 (Data) A11 (2018) A11 (Dev) A22 (Data) A22 (2018) A22 (Dev) Core Orientation Transverse or random orientation dependent on flow near gate Width Controlled RSC factor κ Normalized thickness Slide 20 of 67

21 Fiber Concentration Higher concentration at core while lower concentration at shear region. Fiber concentration, orientation, & breakage affect mechanical properties. Measured data: G.M. Vélez-García, Compos. Part A-Appl. Vol 43: (2012) Slide 21 of 67

22 Corner angle Corner Angle Warp Accuracy: Thickness Shrinkage for Warpage MF 2 4mm corner mold (MAT5322 PP) F. van der Veen corner mold (CM1160 PP) 6 MF 2x4mm Corner Mold with unfilled PP 6 F. van der Veen Corner PP 5 Experiment Generic shrinkage RS with thickness shrinkage 4 2 Experiments AMI2017 Generic shrinkage TP2017 Residual Stress with thickness shrinkage Wrong bending direction Cycle -12 Cycle Slide 22 of 67

23 Warp Accuracy - Shrinkage Correction by Machine Learning Parallel shrinkage 0.70% 0.60% 0.50% 0.40% 0.30% Use Machine Learning to estimate molded shrinkage Provide CRIMS correction for non-shrinkage characterized grades 0.20% Experiment No CRIMS 0.10% Machine Learning CRIMS 0.00% Slide 23 of 67

24 Warp Accuracy - Anisotropic Thermo-Viscoelastic Stress Model Stress relaxation (viscoelastic) 40.0 Long cooling time effect In-mold shrinkage Liquid portion at ejection Solidification sequence effect STRESS_22 (MPa) DIMENSIONLESS THICKNESS, z/h DISTANCE FROM GATE, x/l Slide 24 of 67

25 Ejection Force Automatic Detecting based on ejectors movement direction User check, add or remove surface elements manually Final contact surface Von Mises Stress During Ejection Slide 25 of 67

26 Mold Fatigue Calculate the mold life and approximated range of cycles. Thermal Stress Pressure-induced Stress Clamping-forceinduced Stress Mold Fatigue Slide 26 of 67

27 Cooling Network Only Analysis Features: Minor Loss, Friction formula, Simulate energy equation, & Simulate gravity New results: K factor, & Friction factor Slide 27 of 67

28 Overview of Moldflow External Research Collaborations Completed Projects Long Carbon Fiber Orientation and Breakage - PNNL Ongoing Projects Composites Injection Overmodling TPRC Microcellular Foaming Univ of Toronto Fiber Effect on Viscosity RMIT (Melbourne) Composites Compression Overmolding HUST Fiber breakage in Barrel Univ of Bradford SMC Compression Molding Ford Long Carbon Fiber Orientation and Breakage GM Yokoi Injection Molding Consoritum Univ of Tokyo Slide 28 of 67

29 Long Carbon Fiber Thermoplastic: Fiber Length Prediction of fiber orientation and breakage during injection molding of long carbon fiber thermoplastics Comparison of measured and predicted fiber length distribution Slide 29 of 67

30 Fiber Breakage in Barrel Prediction of long fiber breakage during melting in injection barrel Aim: Initial fiber length distribution for polymer at the sprue tip Slide 30 of 67

31 Yokoi Injection Molding Consortium Fiber breakage in barrel Observing Fountain Flow Oscillation (Tiger Stripe) Flow Imbalance (Race-Track) Yokoi et al. PPS-31, & Slide 31 of 67

32 Filler Effect on Viscosity - RMIT Model the change in viscosity due to filler migration, fiber orientation and fiber breakage Slide 32 of 67

33 Composite Overmolding Model non-recoverable deformation and resistance of a continuous fiber composite (pre-preg) being compression overmolded 320mm Slide 33 of 67

34 Microcellular Injection Molding Bubble effects on fiber orientation Bubble nucleation or growth and the final foam structure (Microcellular Plastics Manufacturing Lab, Univ. Toronto) Slide 34 of 67

35 Injection Overmolding on Continuous Fibers Composites Interfaces AniForm draping solution to Moldflow Warp analysis of the combined structure Models bond strength G/PA6 laminate + unfilled PA6 Slide 35 of 67

36 Chopped Carbon Fiber Compression US DOE funding to develop ICME for carbon fiber draped and compression molded parts (Automotive) Autodesk Moldflow was invited to provide process modeling of Compression molding, Fiber Orientation, & Local fiber volume fraction Slide 36 of 67

37 Surface Appearance (Tiger Stripes) Flow instability mechanism understood. Potential collaboration to study appearance factors (aimed at Automotive parts) Slide 37 of 67

38 Academic Research Collaborations University of Bradford (UK) Long Fiber Orientations, & Fiber breakage in barrel Tokyo University Fiber breakage visualization, & Race track visualization RMIT University (Australia) Effect of fiber and filler migration to change viscosity, & Thermal stresses in SLM 3D Printed parts Huazhong University of Science and Tech Compression Overmolding of Continuous Fiber Composites University of Toronto Microcellular bubble formation University of Wyoming Progressive failure of composites Slide 38 of 67

39 Industry Research Partnerships Long Carbon Fiber Thermoplastics (Injection Molded) Pacific Northwest National Labs, & GM Chopped Carbon Fiber Thermoset (Compression Molded) Ford, Dow, Northwestern University Microcellular Trexel, University of Toronto, & Ford Thermoplastic Composite Overmolding TPRC (The Netherlands), Boeing, Fokker, Johnson Controls, Victrex Slide 39 of 67

40 Autodesk and the Autodesk logo are registered trademarks or trademarks of Autodesk, Inc., and/or its subsidiaries and/or affiliates in the USA and/or other countries. All other brand names, product names, or trademarks belong to their respective holders. Autodesk reserves the right to alter product and services offerings, and specifications and pricing at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document Autodesk. All rights reserved.