Simulation of plastic parts considering material and production specific boundary conditions

Transcription

1 Simulation of plastic parts considering material and production specific boundary conditions Speaker: Dr. Volker Gorzelitz Dipl.-Ing. Stefan Vogler November 9th, 2011 Altair - 5th EHTC Bonn, Germany

2 ENGINEERING FOR PRODUCT DEVELOPMENT M.TEC Ingenieurgesellschaft für kunststofftechnische Produktentwicklung mbh Dornkaulstraße 4 D Herzogenrath / Aachen Tel. +49 (0)2407/ Fax +49 (0)2407/ info@mtec-engineering.de 2 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

3 ENGINEERING PERFORMANCES INTEGRATED PRODUCT DEVELOPMENT Project Management Systematic development of concepts Idea generation, TRIZ-Workshops Industrial Design Plastic Material & Processing Mechanical Design (CAD) Quality Management (FMEA) Test & Trials Tools & Production Engineering CALCULATION AND SIMULATION Finite Element Analysis (FEA) Crash, Passenger Safety (explicit FEA) Moldflow Analysis Optical Fibers, Light Engineering Fluid Dynamics (CFD) 3 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

4 Simulation of plastic parts considering material and production specific boundary conditions Initial Situation: Deformation of a plastic roof frame due to thermal load Speaker: Dr. Volker Gorzelitz Dipl.-Ing. Stefan Vogler November 9th, 2011 Altair - 5th EHTC Bonn, Germany

5 TABLE OF CONTENTS Introduction Anisotropic simualtion of plastic parts Material behaviour influenced by the injection moulding process Anisotropic simulation based on part design and initial injection moulding Improvement of the injection moulding process and its influence on part deformation Conclusion 5 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

6 INTRODUCTION Boundary Conditions Fix X, Y, Z Fix Y, Z Material: PP GF 45 Material modell for FEA: isotropic, linear behaviour Elements: shell elements (mainly square), plastics: , metall: Load: cool down from ambient temperature (20 C) to -30 C Fix Z 6 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

7 INTRODUCTION Isotropic FEA, Cool Down Pin deformation < 0,001 mm 7 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

8 INTRODUCTION Deformation due to Thermal Load (Cool Down) Deformation 7 mm 8 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

9 Tension [MPa] ANISOTROPIC SIMULATION OF PLASTIC PARTS Material behaviour influenced by the Injection Moulding Process 80,0 Matrix Fiber E,α 70,0 60,0 50,0 E, α 40,0 30,0 PP PP-GF20 E > E iso > E 20,0 10,0 α > α iso > α 0,0 0,0 2,5 5,0 7,5 10,0 Elongation [%] 9 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

10 ANISOTROPIC SIMULATION OF PLASTIC PARTS Moldflow Simulation (Initial Design and Process) 10 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

11 ANISOTROPIC SIMULATION OF PLASTIC PARTS Simulation Process Fiber orientation Mapping Anisotropic FEA + - Moldex 3D - Sigma Soft - Moldflow - - Digimat - Convers - - Radioss - Abaqus - 11 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

12 ANISOTROPIC SIMULATION OF PLASTIC PARTS FEA Initial Design and Process, Displacements 12 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

13 Deformation UZ [m] ANISOTROPIC SIMULATION OF PLASTIC PARTS Displacements (Cool Down) x10-3 Temperature [ C] 13 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

14 ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Initial Part Design and Process) Fiber Orientation 1/3 14 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

15 ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Initial Part Design and Process) Fiber Orientation 2/3 15 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

16 ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Initial Part Design and Process) Fiber Orientation 3/3 16 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

17 ANISOTROPIC SIMULATION OF PLASTIC PARTS Improvement of the Injection Molding Process (Changed Gate Position) 17 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

18 ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Gate Position Changed Only) Fiber Orientation 1/3 18 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

19 ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Gate Position Changed Only) Fiber Orientation 2/3 19 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

20 ANISOTROPIC SIMULATION OF PLASTIC PARTS Fiber Orientation (Gate Position Changed Only) Fiber Orientation 3/3 20 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

21 ANISOTROPIC SIMULATION OF PLASTIC PARTS FEA, Gate Position Changed, Displacements Pin 21 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

22 Deformation [mm] ANISOTROPIC SIMULATION OF PLASTIC PARTS Displacement of the Pin (Single and Total Deformations) Direction U3 Temperature [ C] 22 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

23 CONCLUSION Simulation of plastic parts considering material and production specific boundary conditions By applying thermal load on glass-fiber reinforced plastics the deformation of the part depends very much on fiber orientation To improve the knowledge of the deformation due to thermal load, anisotropic material behaviour has to be taken into account when performing a finite element analysis. Simulation tools e.g. Moldflow and Moldex calculate the orientation of the short glass-fibers. The transfer of this results to the finite element analysis (mapping) is enabled by tools e.g. Digimat. Experience on injection moulding process is very helpful when developing a helpful approach for a changed injection concept. 23 November 9th, 2011 Altair - 5th EHTC Bonn, Germany

24 Thank you for your attention Many thanks for the friendly support of Inalfa Roof Systems Groups M.TEC Ingenieurgesellschaft für kunststofftechnische Produktentwicklung mbh Dornkaulstraße 4 D Herzogenrath / Aachen Tel. +49 (0)2407/ Fax +49 (0)2407/ We invite you to visit our exhibition stand info@mtec-engineering.de Web 24 November 9th, 2011 Altair - 5th EHTC Bonn, Germany