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MSC Software Confidential MSC Software Confidential
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
MSC Software Confidential
• Product lifecycle management of injection-molded part
• Integration of injection molding & structure analysis CAE
• Case of fiber-reinforced product
• Molding-induced variation
• Conclusion
Outline
2
MSC Software Confidential
Product Lifecycle Management (PLM)
of Injection-Molded Part
3
MSC Software Confidential
Product Lifecycle Management (PLM)
of Injection-Molded Part
4
Plastic
MSC Software Confidential
PLM – Injection Molding Process
Screw Screw simulation
Marc structural analysis
Performance
Mold Filling simulation
MSC Software Confidential
• Injection molding is a manufacturing technique for making parts
from thermoplastic material in production.
Plastics Injection Molding Process
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Polymer Rheology
7
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
MSC Software Confidential
Plastics Injection Molding Applications
8
Computers
Automotive
Consumer electronics Communication Consumer products
Lens
Micro-component
Semiconductor Aerospace
Others
MSC Software Confidential
• 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
MSC Software Confidential
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
MSC Software Confidential
• 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
11
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Integration of Injection Molding &
Structure Analysis CAE
12
MSC Software Confidential
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
MSC Software Confidential
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.
MSC Software Confidential
Better Procedure for Structure Analysis
Correct
Initial Condition
Correct
Material Properties
Proper
Mesh
Correct
Boundary Condition
Structure
Analysis
Solver
Accurate
Results
MSC Software Confidential
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?
MSC Software Confidential
Fiber-Reinforced Product Example
17
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• Slot-loading CD-ROM drive bearing fastener
• Size: 50.5 × 5.1 × 44.6 mm
Product Case
18 18
Fixed
Up force
Spring
force
Fixed
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• Minimize height difference under loading.
Product Quality
19
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
20
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• PA66 \ Ultramid A3WG10
Material Properties
21
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• Melt front time
Moldex3D Results
22
MSC Software Confidential
Moldex3D Results
• 10X warp (mm)
23
MSC Software Confidential
Moldex3D Results
• Fiber orientation
24
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Integration of Injection Molding & Structure
Analysis CAE via Moldex3D-FEA
MSC Software Confidential
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
MSC Software Confidential
Molding-induced variation
How to estimate?
29
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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
MSC Software Confidential
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)
MSC Software Confidential
• 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
33
MSC Software Confidential 34