PLASTURGIE DU FUTUR September 2016 Paris Dashboard

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1 PLASTURGIE DU FUTUR September 2016 Paris MASTERCLASS LIGHTWEIGTHING & RESISTANCE CONTRIBUTION OF SOFTWARE TO THE PREDICTION OF FINAL IN-USE PROPERTIES Dr Richard DUCLOUX Directeur Applications Clients Dashboard SOFTWARE by Transvalor

2 OUTLINE : FROM DESIGN TO FINAL PRODUCT PROPERTIES Transvalor profile Unique feature to simulate innovative processes Determine final part properties Optimize foam injection-expansion process : From design to analysis the final properties (of use) Others applications & Questions & Discussions 2

3 ABOUT TRANSVALOR Rooted in Research Driven by Innovation Dedicated to Services From industry challenges Research labs +140 Scientists Source : forum-plastique.in-goo.com to efficient software solutions Transvalor S.A. is a company founded in 1984 with head office in Sophia-Antipolis (France). We develop & provide software solutions for process design to the Material Forming Industries. Besides its headquarters located in France, Transvalor has a worldwide presence with a network of distributors, offices and subsidiaries. Our flagship product, FORGE, is a reference in Material Forming Simulation Worldwide with more than 500 licenses worldwide. is the latest Transvalor s solution dedicated to the polymers forming industry. 3

4 REM3D FEATURE: AUTOMATIC REMESHING & OPTIMIZED PARALLELIZATION End-users expect simplified setups without numerical parameters and initial meshing steps. Thanks to Automatic Meshing, preparation time is shortened => Mesh adaptation is triggered all along the process time with smaller elements to guarantee the most accurate results. Design SOFTWARE by Transvalor Transvalor is market leader in parallel computation and numerical techniques to shorten computation time. is based on a performance-optimized architecture and can be operated on one or many cores, providing the level of simulation power you need without limitation! 4

5 REM3D FEATURE : SHRINKAGE & WARPAGE PREDICTION To simulate the full injection cycle, it s necessary to have fully coupled mold/part thermal analysis to provide accurate thermal profile and describe realistic material flow during the process in order to uncover: underfilling, shrinkage, warpage, cooling effect, optimum gate location Design Temperature distribution inside the part and at the wall during the filling Part visualization before & after warpage Export of the final shape after warpage for further structural or thermal analysis! 5

6 6 REM3D FEATURE : HANDLE CO-INJECTION 1/2 Thanks to AAA Meshing, sharp interface representation and mold/part coupled thermal resolution: predicts all multi-fluids positions and optimize final properties of the part. Design Co-injection of an handle

7 Mass of the first melt (g) Mass of the second melt (g) 7 REM3D FEATURE : HANDLE CO-INJECTION 2/2 Thanks to AAA Meshing, sharp interface representation and mold/part coupled thermal resolution: predicts all multi-fluids positions and optimize final properties of the part. Design , ,6 65,8 67,4 69, ,5 133,2 134,6 134, Time (s)

8 REM3D FEATURE : ASSISTED INJECTION 1/2 Design FROM SOFTWARE TO by Transvalor Cross section: Red= melt, Blue= gas or air 8

9 9 REM3D FEATURE : ASSISTED INJECTION 2/2 Simulation Result Design Volume shrinkage created by cooling impacts vein s shape Von Mises Stress distribution : Wall thickness distribution has a significant influence on stress distribution Reasonable assumption

10 REINFORCED POLYMERS : 3D FIBERS ORIENTATION PREDICTION With a real native full 3D Design and AAA Meshing, fibers distribution is computed across the thickness. Skin-Core effect is not limited to an average value but is also predicted across the 1 thickness. 0,8 0,6 0,4 0, ,001 0,002 0,003 0,004 Skin-Core effect Unique intuitive 3D tensor visualization dedicated to fibers orientation! 10

11 CHARGED MATRIX : A DRILLING RISER APPLICATION A drilling riser is a conduit that provides a temporary extension of a subsea oil well to a surface drilling facility. These drilling riser are made of syntactic foam composed by a matrix charged with glass microspheres to reduced the weight and to ensure a good thermal insulation. Source : esyntactic.com Radial injection Source : Trelleborg.com Axial injection 11

12 DRILLING RISER : DETERMINE THE PARTICLES MIGRATION The influence of injection gate position on the final particle migration determine the final properties of the part. Radial injection Axial injection Volumic rate of glass microspheres 12

13 DRILLING RISER : INFLUENCE ON THE FINAL THERMAL PROPERTIES Thermal conductivity distribution Radial injection Axial injection Temperature distribution Extracted thermal flux Depending on injection point 13

14 FOAM INJECTION &EXPANSION PROCESS Determine optimum mass for full filling Initial Mass = 6 Kg Polyurethane Foam OPTIMUM Initial Mass = 6,4 Kg Fridge Optimization of mold thermal conditions 14

15 Density (kg/m3) FOAM: ACCURATE ANALYSIS OF THE DENSITY EVOLUTION Analysis of density evolution in critical area or area with specific density needs: ,41; 403, Density evolution within sensors Water heater ,22; 93,07 28,87; 59, Time (s) 15

16 FOAM: ACCURATE ANALYSIS OF THE FINAL DENSITY DISTRIBUTION Final density distribution through the thickness: Final density distribution Polyurethane foam 16

17 CONCLUSION: A DIFFERENTIATING & INNOVATIVE FRENCH PRODUCT!, a differentiating and innovative product: Designed to run any simulation, especially complex parts and innovative processes. Embedded unrivalled to simulate with unmatched accuracy within reduced computation time., a powerful assistant for decision making: Reduces risks level during design phase. Saves Engineering time and cost of design. Easily transfer to analysis of the final properties for the greatest benefits of manufacturing industry., a unique value proposition: Unlimited access to pre- and post-processors. Cost effective upgrade strategy. 17

18 CONTACT : sales@transvalor.com PLASTURGIE DU FUTUR September 2016 Paris 18