Process-Structure Interaction for Injection Molded Plastics Parts

© PART Engineering GmbH, www.part-gmbh.de

Altair ETHC

Bonn, 08.11.2011

Process-Structure Interaction

for Injection Molded Plastics Parts

Dr.-Ing. Wolfgang Korte

PART Engineering GmbH

Plastics

CAE Services & Software

Technical Simulation Contract Simulation Services

in FEA

CAE Staffing

Resident Engineers at

customers‘ sites

CAE Software - Process-Structure-Interaction

- Strength & Fatigue Assessment

Metals

S-Life

Elastomers

Influence of Injection Molding Process onto Part and Mold

properties (of the part)

- fiber orientation

- weldlines

- wall thicknesses

- shape

loads (on part and mold)

- pressure

- temperature

Fig. 2

Considering Process Data in Mechanical Simulation

Molding

Simulation

now

Mechanical

Simulation

Coupling

Software

improved

assessment of:

-strength

-deformation

- fiber orientation

- pressure

- temperature

- deformation

(shrinkage & warpage,

wall thicknesses)

- weldlines (indirectly)

past

Fig. 3

Overview

Considering Process-Induced Part Properties in FEA

• Influence of Fiber Orientation onto Mechanical Properties

• Obtaining Orientation and how to Handle them

• Example: Rotary Valve

Considering Process-Induced Loads in FEA

• Example: Pressure-Mapping for an Airintake Manifold

• Example: Pressure-Mapping for an Electronic Device

Fig. 4

Influence of Injection Molding Process onto Part and Mold

properties (of the part)

- fiber orientation

- weld lines

- wall thicknesses

- shape

loads (on part and mold)

- pressure

- temperature

Fig. 5

material:

PA6+GF30

perpendicular

parallel

Influence of Fiber Orientation onto Material Properties Fig. 6

Fiber Orientations in Injection Molded

Short-Fiber-Reinforced Components

S1

S2

S1

Flow Direction Wanddicke

S1 shear layer: fibers oriented parallel to flow direction

S2 mid layer: fibers oriented perpendicular to flow direction

Fig. 7

[DKI]

[BASF]

Example: Rotary Valve Fig. 8

material: Grivory HTV 3H1

force

test rig

Example: Rotary Valve – Mapping of Fibers Fig. 9

molding

simulation

mechanical

simulation

0

200

400

600

800

1000

1200

1400

0 1 2 3 4 5 6

forc

e [N

]

deflection [mm]

test sample #1

test sample #2

FEA w/o fibers (isotropic)

FEA w fibers (anisotropic)

Example: Rotary Valve - Stiffness Fig. 10

+60%

0

100

200

300

400

500

600

700

800

0 1 2 3 4 5 6

forc

e [N

]

deflection [mm]

test sample #1

test sample #2

FEA w fibers (anisotropic)

Example: Rotary Valve - Strength Assessment Fig. 11

Pos.1

Pos.1

precise

prediction

of failure

ma

trix

str

es

s [

MP

a]

strain [%]

Mapping of Fiber Orientations and Material Properties Fig.12

Consideration of Weldlines

weldline

isotropic anisotropic

molding

simulation

calculated fiber orientation

in the weld area

pressure

Fig.13

Influence of Injection Molding Process onto Part and Mold

properties (of the part)

- fiber orientation

- weld lines

- wall thicknesses

- shape

loads (on part and mold)

- pressure

- temperature

Fig. 14

Example: Core Shift of an Airintake Manifold Fig. 15

molding simulation pressure on core

mapping

of pressure

Example: Overmolding of an Electronic Device Fig. 16

calculated stresses in

electronic insert

molding simulation pressure on insert

mapping

of pressure

Mapping Temperatures and Pressures Fig.17

Add Value to Your Mechanical Simulation Fig. 18

consider the real part properties

get better predictions of strength

& deformation

at nearly no

additional costs

by using data

already available

integrates smoothly into your day-to-

day CAE routines

straigthforward easy-to-use

Moldflow

Cadmould

Sigma

Fluent

Abaqus

Ansys

Radioss

Marc

Interfaces

Thank you

Questions?