PREDICTION OF WARPAGE IN WELDED ASSEMBLIES Amin Sedighiamiri *, Dave Brands *, Tim Dassen§

* GApT – Reinforced Plastics Center

§ CODE Product Solutions, Geleen, The Netherlands

No. 1

OUTLINE

• SABIC, who are we?

• Long glass fiber polypropylene (STAMAX™).

• What is Warpage?

• Secondary operations: factors influencing warpage.

• Welding process.

• Welding simulation methodology.

• Implementation in Hyperworks.

• Application: “air duct – IP carrier” welded assembly.

• Conclusions

No. 2

WE ARE SABIC

Chemicals, polymers, fertilizers, metals

1976, our beginning

37 years of growth

2nd largest global diversified chemical company*

88th largest public company in the world*

62 world-class plants worldwide

8,000 global patents

* Forbes 2012

No. 3

OUR GLOBAL OPERATIONS

SABIC Global Headquarters (1)

Technology Centers (13)

Application Centers (4)

SABIC Corporate Research

and Innovation Center (1)

Distribution, Storage Facilities

and Logical Hubs (51)

International Subsidiaries and

Sales Offices (84)

Manufacturing and Compounding

Companies (62)

40,000 employees

40 countries

1 Corporate Research & Innovation Center

17 Technology and Application Centers

150 new products each year

No. 4

SABIC INNOVATIVE PLASTICS

Base materials:

PE, PP, PC, PBT, ABS, PEI, etc. and numerous blends. Automotive materials:

• LEXAN™ - Glazing

• NORYL™ - Fenders

• PP Compounds - Bumpers

• etc.

• VERTON™ Long Glass Reinforced Polyamide 6,6

• STAMAX™ Long Glass Reinforced Polypropylene

No. 5

TYPICAL STAMAX™ PP-LGF APPLICATIONS

instrument panel carrier

door module

front-end module

Tail gate

No. 6

WHAT IS WARPAGE?

Fiber reinforced materials

- anisotropic shrinkages

High thickness shrinkage

Low in-plane shrinkage

Injection molding fiber orientation

Low fiber alignment

High fiber alignment

1

2 3

No. 7

PRODUCTION OF IP CARRIERS

1

2

3

4

™

No. 8

5 mm

4 mm

1

2

SECONDARY OPERATIONS: FACTORS INFLUENCING WARPAGE

™

No. 9

Warpage after assembly New SABIC unique differentiator Warpage prediction of PP-LGF parts

SECONDARY OPERATIONS: FACTORS INFLUENCING WARPAGE

™

No. 10

air duct

IP carrier

Press: welding tools close

Joining: Parts heated

Release: welding tools open

Example: Instrument panel carrier

Part positioning in tools

Warped parts to be welded

WELDING PROCESS

No. 11

WELDING SIMULATION METHODOLOGY

airduct

IP carrier

Press analysis Anisotropic mechanical simulation

Joining analysis Applying boundary conditions at weld

locations to connect parts

Tool release analysis Spring back analysis using predicted

stiffness and stress from press analysis

Warpage analysis Warped shape of individual parts and fiber orientation dependent stiffness

graphical user interface • Import Moldflow files • Pressing individual parts • Define welding locations • Apply boundary conditions

No. 12

IMPLEMENTATION IN HYPERWORKS

No. 13

IMPLEMENTATION IN HYPERWORKS

No. 14

APPLICATION: “AIR DUCT – IP CARRIER” ASSEMBLY

Air duct Material: SABIC™STAMAX™ 20YK270 5 drops Injection time: 2.6 s

IP carrier Material: SABIC™STAMAX™ 30YK270 7 drops Injection time: 5.9 s

No. 15

APPLICATION: “AIR DUCT – IP CARRIER” ASSEMBLY

-5.0

8.0

4.75

1.5

-1.75

0.3

2.5 0.2

mm

No. 16

NEXT STEP …

Method validation

3D laser scan measurements Moldflow z-deflection Measured normal deflection

No. 17

CONCLUSIONS

• Warpage of assembled part could significantly differ from that of the individual parts.

• We developed a predictive engineering method to predict warpage in welded

assemblies.

• The whole procedure is implemented and automatized in Altair Hyperworks

software:

• Graphical User Interface.

• Reduce the chance of user errors.

• Fast and easy: implementation time within 2 hours

• Feasible for application in engineering projects.

• Further validation is ongoing.

No. 18

Thank you for your attention!

No. 19

DISCLAIMER

THE MATERIALS, PRODUCTS AND SERVICES OF SABIC INNOVATIVE PLASTICS HOLDING BV, ITS SUBSIDIARIES AND AFFILIATES

(“SELLER”), ARE SOLD SUBJECT TO SELLER’S STANDARD CONDITIONS OF SALE, WHICH CAN BE FOUND AT http://www.sabic-ip.com .

AND ARE AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION OR RECOMMENDATION CONTAINED HEREIN IS GIVEN IN

GOOD FAITH, SELLER MAKES NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (i) THAT THE RESULTS DESCRIBED HEREIN

WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN

INCORPORATING SELLER’S PRODUCTS, SERVICES OR RECOMMENDATIONS. EXCEPT AS PROVIDED IN SELLER’S STANDARD

CONDITIONS OF SALE, SELLER SHALL NOT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS PRODUCTS OR

SERVICES DESCRIBED HEREIN.

Each user is responsible for making its own determination as to the suitability of Seller’s products, services or recommendations for the user’s

particular use through appropriate end-use testing and analysis. Nothing in any document or oral statement shall be deemed to alter or waive any

provision of Seller’s Standard Conditions of Sale or this Disclaimer, unless it is specifically agreed to in a writing signed by Seller. No statement

by Seller concerning a possible use of any product, service or design is intended, or should be construed, to grant any license under any patent or

other intellectual property right of Seller or as a recommendation for the use of such product, service or design in a manner that infringes any

patent or other intellectual property right.

SABIC and brands marked with ™ are trademarks of SABIC or affiliates