Integration of Injection molding and structure analysis CAE with
Transcript of Integration of Injection molding and structure analysis CAE with
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Integration of Injection Molding and Structure Analysis
CAE with Considering Fiber Orientation Effects
2013 Regional User Conference
Presented By: Shih-Po Sun, Moldex3D
May 7, 2013
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• Product lifecycle management of injection-molded part
• Integration of injection molding & structure analysis CAE
• Case of fiber-reinforced product
• Molding-induced variation
• Conclusion
Outline
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Product Lifecycle Management (PLM)
of Injection-Molded Part
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Product Lifecycle Management (PLM)
of Injection-Molded Part
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Plastic
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PLM – Injection Molding Process
Screw Screw simulation
Marc structural analysis
Performance
Mold Filling simulation
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• Injection molding is a manufacturing technique for making parts
from thermoplastic material in production.
Plastics Injection Molding Process
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Polymer Rheology
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unoriented molecularchain before flow
oriented molecularchain after flow
velocityprofile
shear rateprofile
molecular chain orientation
decrease in orientation
Viscosity
Shear Rate
Lower Temp.
Higher Temp.
unoriented molecular chains
oriented molecular chains
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Plastics Injection Molding Applications
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Computers
Automotive
Consumer electronics Communication Consumer products
Lens
Micro-component
Semiconductor Aerospace
Others
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• Linear stress analysis
• Non-linear stress analysis
• Buckle analysis
• Heat treatment analysis
• Shock and response analysis
• Frequency response analysis
• Impact analysis
• Crack analysis
Common Plastic Structural Analysis
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Concept Design
PLM – without Considering Molding Effects
Production
Flow analysis Concept Design Concept Design Concept Design Concept Design Concept Design
Structural analysis Flow induced micro-structure ,e.g., fiber and weldline
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• Residual stress:
– From volume shrinkage difference
– From flow induced molecular orientation
• Material anisotropy:
– Molecular orientation
– Filler orientation distribution
• Material inhomogeneity
– Weldline
– Matrix density
– Filler concentration distribution
– Filler size distribution
Things we should consider in structural
analysis
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Integration of Injection Molding &
Structure Analysis CAE
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PLM – Considering Molding Effects
Concept Design
Production MARC
Structure Analysis
Moldex3D Injection molding
How to connect this
process from injection
molding analysis to
structure analysis?
Moldex3D-FEA
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To cover the process-induced variation during the processes
• Full Integration of injection molding analysis and structural analysis
• Cover polymer processing-induced properties for further structure
analysis
PLM – Injection Molding Process
Mesh,
Material,
Process…etc
Flow/Pack/Cool
Warp/Fiber
Simulation
Deformed geometry,
Fiber-reinforced
Material properties…etc
Structure analysis,
Drop test analysis,
Impact analysis…etc.
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Better Procedure for Structure Analysis
Correct
Initial Condition
Correct
Material Properties
Proper
Mesh
Correct
Boundary Condition
Structure
Analysis
Solver
Accurate
Results
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To cover the process-induced variation during the processes
• Fiber orientation output
• Optimized Material input reduction
• Map material properties between different meshes
• Thermal / Flow Residual stress output
• EOP Temperature output
• Initial strain output
• Multiple time step melt flow pressure output
• Moldbase related data output (pressure, temperature)
What Moldex3D-FEA can do?
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Fiber-Reinforced Product Example
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• Slot-loading CD-ROM drive bearing fastener
• Size: 50.5 × 5.1 × 44.6 mm
Product Case
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Fixed
Up force
Spring
force
Fixed
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• Minimize height difference under loading.
Product Quality
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Height
difference
B
A
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• Material: PA66 \ Ultramid A3WG10
• Processing conditions
– Filling time:
• 0.05 s, 0.2 s, 1 s
– Melt temperature:300 ℃
– Mold temperature:85 ℃
Moldex3D Injection Molding CAE analysis
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• PA66 \ Ultramid A3WG10
Material Properties
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• Melt front time
Moldex3D Results
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Moldex3D Results
• 10X warp (mm)
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Moldex3D Results
• Fiber orientation
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Integration of Injection Molding & Structure
Analysis CAE via Moldex3D-FEA
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Properties derivation
Element properties
Orientation information
Marc
Material parameters
Flow analysis
+
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Fiber Orientation Effect
Fiber-reinforced No fiber
5X
Warp (mm)
Fiber
orientation
1.04 mm 0.30 mm
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Fiber Orientation Effect
Material PA66
UltramidA3W
PA66
UltramidA3WG10
Fiber (%) 0 50
E modulus (dyne/cm2) 3.1e+010 1.96e+011 / 5.76e+010
Poisson's ratio 0.4 0.37(v12) / 0.56(v23)
CLTE (1/K) 8.5e-005 1.2e-005 / 5.5e-005
Warp (mm) 1.04 0.30
Fiber orientation warp (mm) X 0.13
Loading deformation (mm) 2.14 0.97
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Molding-induced variation
How to estimate?
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Molding-Induced Effects Different filling time
• Melt front time
0.05 sec 0.2 sec 1.0 sec
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Molding-Induced Effects
Filling time (sec) 0.05 0.2 1.0
Warp (mm) 0.27 0.30 0.31
Fiber-induced warp (mm) 0.14 0.13 0.12
0.05 sec 0.2 sec 1.0 sec
10X
Warp (mm)
Fiber
orientation
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Filling time (sec) 0.05 0.2 1.0
Loading Y-deformation (mm) 1.00 0.97 0.97
Von Mises stress (MPa) 98.0 74.5 86.6
Anisotropic Material Models
MARC Results – Loading Displacement
0.05 sec 0.2 sec 1.0 sec
Von Mises
stress (MPa)
Y-deformation
(mm)
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• An approach to study Marc structural analysis with molding
effects for injection-molded plastic parts is proposed.
• Through the link between mold-filling analysis and structural
analysis, the molding-induced anisotropic characteristics can be
taken into account.
• The results from several demonstrations show that structural
analyses of fiber-reinforced plastic parts depend heavily on
molding conditions.
• Part designers are recommended to use this approach evaluating
the part design and mold design for an injection-molded plastic
part .
Conclusion
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