MANUFACTURING PROCESS OPTIMIZATION

Transcription

1 MANUFACTURING PROCESS OPTIMIZATION BY MEANS OF SIMULATION For your Technical & Sport Equipment LAURENCE VILLE

2 OUTLINE TRANSVALOR COMPANY INDUSTRIAL NEEDS & SIMULATION GOALS SIMULATE TO OPTIMIZE YOUR PROCESS CONCLUSION

3 WHO ARE WE? TRANSVALOR S.A. IS A TECHNOLOGY TRANSFER COMPANY FOUNDED IN 1984 WITH HEAD OFFICE IN SOPHIA ANTIPOLIS, SOUTH OF FRANCE, WITH TODAY A DISTRIBUTION NETWORK WITH CERTIFIED LOCAL SUPPORT THROUGHOUT THE WORLD. CLOSE PARTNERSHIP WITH CEMEF MINES PARISTECH LAB. MAIN FOCUS IS DEVELOPMENT AND SALES OF MATERIAL FORMING PROCESS SIMULATION SOFTWARE ORIGINATED FROM VARIOUS INSTITUTES.

4 OUR DNA HIGHLY ROOTED IN RESEARCH RESEARCH LAB 170 SCIENTISTS DRIVEN BY INNOVATION TRANSITION FROM RESEARCH PROJECTS TO INDUSTRIAL SOFTWARE FOR THE INDUSTRIES WE SERVE DESIGNED FOR RESULTS INDUSTRY RELEVANCE SIMULATION INTELLIGENCE 4 TRANSVALOR COMPANY PROFILE

5 TRANSVALOR SOFTWARE SOLUTIONS THE COMPLETE SOFTWARE SOLUTION FOR METAL FORMING PROCESSES THE DEDICATED SOFTWARE SOLUTION FOR COLD FORMING THE SOFTWARE SOLUTION FOR CASTING PROCESSES THE SOFTWARE SOLUTION FOR POLYMER PROCESSING THE SOFTWARE SOLUTION DEDICATED TO WELDING PROCESSES THE SOFTWARE SOLUTION FOR MICROSTRUCTURAL EVOLUTION 5 TRANSVALOR COMPANY PROFILE

6 INDUSTRIAL NEEDS & SIMULATION GOALS

7 INDUSTRIAL NEEDS COST & TIME & WEIGHT SAVINGS! 7 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

8 SIMULATION GOALS ANALYZE & DETERMINE OPTIMUM PROCESS PARAMETERS TO ENSURE FINAL PART HIGH QUALITY SIMULATION ALLOWS TO SEE WHAT HAPPENED INSIDE THE MOLD & ANALYZE THE REASONS OF FINAL PROPERTIES. WITH SIMULATION ANALYSIS YOU CAN OPTIMIZE FINAL QUALITY PART BY DETERMINING OPTIMUM SETTINGS PARAMETERS. ADVANCED PLOTTING, ANIMATION, ISO-VOLUME ARE REAL HELPFUL TOOLS TO REDUCE R&D TIME. 8 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

9 SIMULATION GOALS SOFTWARE SOLUTION FOR POLYMER PROCESSING 9 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION REM3D OFFERS EASY & EFFICIENT CASE SETTING AND RESULTS ANALYSIS FOR INJECTION MOLDING: POLYMER FLOW EVOLUTION FILLING - PACKING - COOLING, SHRINKAGE & WARPAGE THERMOPLASTICS & THERMOSETS OVERMOLDING, INSERT MOLDING, GAS ASSISTED INJECTION MOLDING (GAIM) MOLD REGULATION, HOT RUNNER

10 SIMULATE TO OPTIMIZE YOUR PROCESS Foam Sole & Foam Roller examples

11 SIMULATION PARAMETERS ARE THE KEY TO ENSURE PREDICTIVE RESULTS YOU MUST HAVE THE BEST MATERIAL CHARACTERIZATION Isocyanate Polyol 11 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

12 DEDICATED MODULE FOR FOAMING PROCESSES CONTROL & OPTIMIZE YOUR FOAMING PROCESS DETERMINE MINIMUM MASS FOR FULL FILLING DETERMINE OPTIMUM MOLD BALANCING CONTROL THE POURING PATH EFFECTS ANALYZE GRAVITY & TILT MOLD IMPACT OPTIMIZE MOLD TEMPERATURE OPTIMIZE MOBILE MOLD & OVERMOLDING OPTIMIZE VENTS POSITIONS ANALYZE FINAL DENSITY THROUGH THE THICKNESS ANALYZE FINAL DENSITY IN VOLUMIC SAMPLING STEERING WHEEL CAR SEAT IN ORDER TO GET THE BEST FINAL PROPERTIES OF THE PARTS: MECHANICAL, THERMAL, INSULATION 12 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

13 DEDICATED MODULE FOR FOAMING PROCESS DETERMINED THE MASS FOR FULL FILLING # FOAM ROLLER EXAMPLE SIMULATION OF THE FULL FILLING WITH 130G: AT THE END OF THE INJECTION PHASE: o MASS ~130 G AND 53% OF THE MOLD IS FILLED AT THE END OF THE EXPANSION PHASE: 100% FILLING OF THE MOLD FOAM FLOW EVOLUTION FillingRate Melt1Mass FILLING TIME AT THE END OF THE FULL FILLING 20 FOAM FLOW EVOLUTION & MASS FILLING VARIATION REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

14 DEDICATED MODULE FOR FOAMING PROCESS DETERMINED THE OPTIMUM MASS FOR FULL FILLING 120 # FOAM ROLLER EXAMPLE INJECTION OF 72G: AT THE END OF THE INJECTION PHASE: o MASS ~72 G AND 6% OF THE MOLD IS FILLED AT THE END OF THE EXPANSION PHASE: 85% FILLING OF THE MOLD Time s FOAM FLOW EVOLUTION & MASS FILLING VARIATION FillingRate Melt1Mass INJECTION OF 108G: AT THE END OF THE INJECTION PHASE: o MASS ~108 G AND 6% OF THE MOLD IS FILLED AT THE END OF THE EXPANSION PHASE: 100% FILLING OF THE MOLD Time s FillingRate Melt1Mass 14 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

15 DEDICATED MODULE FOR FOAMING PROCESS DETERMINED THE OPTIMUM MASS FOR FULL FILLING # FOAM ROLLER EXAMPLE INJECTION OF 130G: AT THE END OF THE INJECTION PHASE: o MASS ~130 G AND 53% OF THE MOLD IS FILLED AT THE END OF THE EXPANSION PHASE: 100% FILLING OF THE MOLD FINAL DENSITY IN THE PART INJECTION OF 108G: AT THE END OF THE INJECTION PHASE: o MASS ~108 G AND 6% OF THE MOLD IS FILLED AT THE END OF THE EXPANSION PHASE: 100% FILLING OF THE MOLD 15 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

16 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE MOLD THERMAL IMPACT # FOAM ROLLER EXAMPLE WITH THE SIMULATION TOOL: ANALYZE THE MOLD THERMAL IMPACT WITH THE FULL COUPLED MECHANICAL-THERMAL-KINETICAL RESOLUTION OF THE FOAM REACTION 16 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

17 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE THE FINAL PART PROPERTIES # FOAM ROLLER EXAMPLE AND FINALLY: ANALYZE THE DENSITY ON EACH POINT OF THE PART THROUGH THE THICKNESS ANALYZE THE DENSITY IN A VOLUMIC SAMPLE DURING THE SIMULATION Density kg.m Sensor1 FullFillingCase Sensor2 FullFillingCase Sensor3 FullFillingCase Sensor1 ShortShotCase Sensor2 ShortShotCase -200 Time s 17 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

18 DEDICATED MODULE FOR FOAMING PROCESS # FOAM SOLE EXAMPLE FOAM FLOW EVOLUTION 18 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

19 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE GRAVITY IMPACT # FOAM SOLE EXAMPLE INFLUENCE OF THE MOLD ORIENTATION ON THE FILLING & THE FINAL PART QUALITY REFERENCE -10 C -45 C +45 C FOAM FLOW EVOLUTION AT 1 S 19 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

20 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE GRAVITY IMPACT # FOAM SOLE EXAMPLE INFLUENCE OF THE MOLD ORIENTATION ON THE FILLING & THE FINAL PART QUALITY REFERENCE -10 C -45 C +45 C FOAM FLOW EVOLUTION AT 2 S 20 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

21 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE GRAVITY IMPACT # FOAM SOLE EXAMPLE INFLUENCE OF THE MOLD ORIENTATION ON THE FILLING & THE FINAL PART QUALITY REFERENCE -10 C -45 C +45 C FOAM FLOW EVOLUTION AT 3 S 21 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

22 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE GRAVITY IMPACT # FOAM SOLE EXAMPLE INFLUENCE OF THE MOLD ORIENTATION ON THE FILLING & THE FINAL PART QUALITY REFERENCE -10 C -45 C +45 C FOAM FLOW EVOLUTION AT 4 S 22 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

23 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE GRAVITY IMPACT # FOAM SOLE EXAMPLE INFLUENCE OF THE MOLD ORIENTATION ON THE FILLING & THE FINAL PART QUALITY REFERENCE -10 C -45 C +45 C FOAM FLOW EVOLUTION AT 5 S 23 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

24 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE GRAVITY IMPACT # FOAM SOLE EXAMPLE INFLUENCE OF THE MOLD ORIENTATION ON THE FILLING & THE FINAL PART QUALITY REFERENCE -10 C -45 C +45 C FOAM FLOW EVOLUTION AT 6 S 24 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

25 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE GRAVITY IMPACT # FOAM SOLE EXAMPLE INFLUENCE OF THE MOLD ORIENTATION ON THE FILLING & THE FINAL PART QUALITY FILLING TIME HISTORY REFERENCE -10 C -45 C +45 C 25 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

26 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE GRAVITY IMPACT # FOAM SOLE EXAMPLE INFLUENCE OF THE MOLD ORIENTATION ON THE FILLING & THE FINAL PART QUALITY FILLING TIME HISTORY REFERENCE -10 C -45 C +45 C 26 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

27 DEDICATED MODULE FOR FOAMING PROCESS ANALYZE GRAVITY IMPACT # FOAM SOLE EXAMPLE INFLUENCE OF THE MOLD ORIENTATION ON THE FILLING & THE FINAL PART QUALITY FILLING TIME HISTORY REFERENCE -10 C -45 C +45 C 27 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

28 FULLY AUTOMATIC MESHING NO MORE INITIAL OR MANUAL MESHING STEPS! SIMPLIFIED SETUP NO INITIAL MESHING STEP NEED REDUCE SIGNIFICANTLY THE MESH SIZE REDUCE CPU TIME CO-INJECTION EXAMPLE HIGH PRECISION 3D RESULTS TO PREDICT THE TWO POLYMERS POSITIONS IN THE FINAL PART AND THUS THE GLOBAL MECHANICAL PROPERTIES AUTOMATIC RE-MESHING DURING THE COMPUTATION TO GET THE BEST ACCURACY WHEN IT IS NECESSARY 28 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

29 DEDICATED MODULE FOR FOAMING PROCESS FULLY AUTOMATIC MESHING # FOAM SOLE EXAMPLE MESH EVOLUTION DURING THE FILLING 29 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION

30 AND FOR ALL YOUR OTHER MOLDING APPLICATIONS ACCURATELY DESIGN YOUR PROCESSES TO ANALYSIS THE FINAL PROPERTIES (OF USE) CROSS SECTION: RED= MELT BLUE= GAS OR AIR GASASSISTED INJECTION MOLDING GAIM EXAMPLE 30 REM3D - TRANSVALOR POLYMER & COMPOSITE SOFTWARE SOLUTION EXPORT THE HOLLOWED FINAL SHAPE FOR MECHANICAL ANALYSIS

31 CONCLUSION SIMULATION CAN HELP YOU TO OPTIMIZE YOUR MOLDING PROCESSES. TRANSVALOR HAVE CREATED REM3D FRENCH SOFTWARE WHICH IS A COMPLETE SOLUTION FOR INNOVATIVE POLYMER ENGINEERING. DEVELOPED WITH THE SUPPORT OF INDUSTRIAL PARTNERS OUR SOFTWARE SOLUTION OFFERING HIGHEST ADDED VALUE FOR: ANALYZE & IMPROVE QUALITY PARTS OPTIMIZE YOUR PROCESSES ANSWER TO NEW TECHNICAL CHALLENGES FIRST TIME RIGHT!

32 ADDRESS: 694, av du Dr. Maurice Donat Parc de Haute Technologie Mougins cedex France