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© 2013 Autodesk © 2017 Autodesk Autodesk Moldflow Moldflow Research & Development Dr Franco Costa Senior Research Leader

Autodesk Moldflow Moldflow Research & Development · Autodesk Moldflow Simulation 2017 R3 5. CAD meshing support for Linux 6. Synergy Support for Delete CAD bodies 7. Synergy Support

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Text of Autodesk Moldflow Moldflow Research & Development · Autodesk Moldflow Simulation 2017 R3 5. CAD...

  • © 2013 Autodesk© 2017 Autodesk

    Autodesk Moldflow

    Moldflow Research & Development

    Dr Franco Costa

    Senior Research Leader

  • Slide 2 of 67

    Research In-house24 PhD employees in Moldflow development

    A Lab with state-of-the-art equipmentFour modern injection molding machines for test & validation

    Establishing a network of third-party Labs

    Academic Research CollaborationSix Universities with seven PhD students

    Industrial Research PartnershipsOver 20 companies and institutions

    Research & Development

  • Slide 3 of 67

    Solver Features in Recent Moldflow Releases

    Solver & Mesh Features under development

    Research Collaborations

    Outline

  • Slide 4 of 67

    FeaturesApply properties of a dry fiber mat where needed.

    Anisotropic permeability follows the shape of the product.

    Detect areas where resin cannot penetrate.

    Includes Vacuum Infusion & Gravity effect.

    ResultsDegree of Cure, Volumetric shrinkage, Mat orientation, etc.

    RTM and SRIM in 3D

    Fiber Mat Orientation

    Resin Penetration

  • Slide 5 of 67

    Improved 3D Fiber Orientation

    Measured data provided by BASFBASF PA 30%GF

    Implementation of a New ModelMRD (Moldflow Rotational Diffusion)

    0 0.5 1 1.5 2 2.5 3 3.5

    Fib

    er

    ori

    en

    tati

    on

    Through thickness, mm

    Position C3, orientation A11

    Experiment 2017 FCS 2017 R2 (MRD)

  • Slide 6 of 67

    AMI release Constitutive model BASF Bradford Delphi DSM EMS Mechanical Plaque

    Number of cases 1 2 23 1 1 1

    Number of locations for each case 9 3 3 6 1 1

    2017FCSF-T 0.16 0.20 0.14 0.11 0.23 0.17

    RSC 0.11 0.12 0.11 0.089 0.16 0.14

    2017 R2

    F-T 0.091 0.16 0.11 0.079 0.16 0.13

    RSC 0.076 0.11 0.10 0.077 0.14 0.10

    MRD 0.071 0.11 0.08 0.054 0.12 0.085

    Improved 3D Fiber OrientationAverage error of predictions for different releases and constitutive models.Results for the default models are in bold

    2017 R2 halves the average error of fiber orientation predictions

  • Slide 7 of 67

    σxx

    σyy

    -9

    -7

    -5

    -3

    -1

    1

    3

    5

    -1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1

    Measurement (literature) Generic shrinkage model Residual stress model

    -8

    -6

    -4

    -2

    0

    2

    4

    -1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1

    Measurement (literature) Generic shrinkage model Residual stress model

    3D Residual Stress PredictionMolded-in residual stress prediction

    Experimental data using layer removal method from W.F.Zoetelief, L.F.Douven, and A.J. Ingen Housz. Polymer Engineering and Science, 36(14), 1886-1896

  • Slide 8 of 67

    3D Warp using Residual Stress

    Ultramid B3WG6 BK0056,BASF

    Since AMI 2017.3:• Residual Stress is the default 3D Warp model• Extended to Thermoset materials• Mesh Aggregation option enabled

  • Slide 9 of 67

    Powder Injection Molding (PIM )

    9

    Mold filling simulation of Metal Injection Molding (MIM) and

    Ceramic Injection Molding (CIM) materials

    Predict the powder concentration

    Material characterization for PIM is available

    Powder concentration

  • Slide 10 of 67

    Including Wall Slip for PIM

    Failed to predict initial jetting without Wall Slip

    With Wall Slip, predicted initial jetting in PIM simulation, which matched reality better

    𝛕𝐜 Critical shear stress 0.01 MPa

    m Slip exponent 1

    a Constant sip coefficient 1.0e-05

    b Temperature dependency 0

    c Pressure dependency 0

  • Slide 11 of 67

    Multi-barrel Injection Molding SimulationMaster Barrel with 4 sub-barrel

    Delay time 0.25 s and 0.5 s for sub3 and sub 4, respectively

  • Slide 12 of 67

    Use numerical simulation to calculate temperature and cure changes during preconditioning stage

    Either use contact conditions to automatically apply temperature boundary conditions or input value specified on elements for the thermal boundary conditions

    Result: Temperature and cure distribution at the end of preconditioning stage

    Preconditioning – Reactive Compression Molding

    Temperature and cure distribution at the end of preconditioning. Initial melt temperature: 50 C

    Mold temperature: 175 C

    Delay time: 10 sec

  • Slide 13 of 67

    You can now consider cooling rate and pressure effects on Solidification

    Solver API - Solidification

    van der Beek et. al. Inter. Polymer Processing, 20, 111-120, (2005).

    Polycarbonate: Infino EH-1050; Cheil Industries

    Tt(P)

    Tt(P) = b5 + b6 P

  • Slide 14 of 67

    Autodesk Moldflow Simulation 2017 R21. Wall Slip

    2. Resin transfer molding

    3. Thermocouple-controlled cooling

    4. Heater wattage specification for heater element

    Autodesk Moldflow Simulation 2017 R35. CAD meshing support for Linux

    6. Synergy Support for Delete CAD bodies

    7. Synergy Support for Copy of CAD bodies

    8. Support the exporting of STEP files

    9. Powder injection molding support

    Autodesk Moldflow Simulation 2018.010. Multi-step large vector deformation support (modelling)

    11. Multistage support for normal deformations (modelling)

    12. User defined initial strain support for Anisotropic inserts (Warp)

    13. Preconditioning analysis for reactive compression molding

    14. Injection compression overmolding (3D)

    New Features for Recent Releases

  • Research

  • Slide 16 of 67

    Disclaimer

    We may make statements regarding planned or future development efforts for our existing or new products and services. These statements are not intended to be a promise or guarantee of future delivery of products, services or features but merely reflect our current plans, which may change. Purchasing decisions should not be made based upon reliance on these statements.

    The Company assumes no obligation to update these forward-looking statements to reflect events that occur or circumstances that exist or change after the date on which they were made.

  • Slide 17 of 67

    Extracting Center Lines of CAD Cooling System

    Centerline Extraction for CAD Cooling System

  • Slide 18 of 67

    Supports Linux, & Parallelization

    Use the Autodesk “Flow Design” Voxel CFD Solver

    Faster Conformal (3D) Coolant Flow Solver

    Cross section

    Voxel mesh

    Voxel solve

    Voxel results

    Moldflow 3D Channel mesh Moldflow results

    Pressure

    Velocity

  • Slide 19 of 67

    “Underflow severity” as a result

    Underflow Diagnostic Plot

    Underflow regionviewmold.com

  • Slide 20 of 67

    Core Shell

    SkinShell

    Skin Skin Orientation

    Believed to be due to fountain flow

    Adaptive Fiber Model Orientation Prediction

    Shell OrientationStrong alignment in flow direction

    Alignment controlled by fiber interactions, CI, ARD bi, MRD Di

    Core OrientationTransverse or random orientation dependent on flow near gate

    Width Controlled RSC factor κ

    0

    0.1

    0.2

    0.3

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    0.6

    0.7

    0.8

    0.9

    1

    0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

    Fib

    er o

    rien

    tati

    on

    ten

    sor

    com

    po

    nen

    ts

    Normalized thickness

    A11 (Data) A11 (2018) A11 (Dev) A22 (Data) A22 (2018) A22 (Dev)

  • Slide 21 of 67

    Fiber Concentration

    Higher concentration at core while lower concentration at shear region.

    Fiber concentration, orientation, & breakage affect mechanical properties.

    Measured data: G.M. Vélez-García, Compos. Part A-Appl. Vol 43: 104-113 (2012)

  • Slide 22 of 67

    Warp Accuracy: Thickness Shrinkage for Warpage

    MF 2×4mm corner mold (MAT5322 PP)

    0

    1

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    6

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

    Co

    rner

    an

    gle

    Cycle

    MF 2x4mm Corner Mold with unfilled PP

    Experiment Generic shrinkage RS with thickness shrinkage

    F. van der Veen corner mold (CM1160 PP)

    Wrong bending direction

    -12

    -10

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    -4

    -2

    0

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    Corn

    er A

    ngle

    Cycle

    F. van der Veen Corner PP

    Experiments AMI2017 Generic shrinkage TP2017 Residual Stress

    with thickness shrinkage

  • Slide 23 of 67

    Warp Accuracy - Shrinkage Correction by Machine Learning

    0.00%

    0.10%

    0.20%

    0.30%

    0.40%

    0.50%

    0.60%

    0.70%

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

    Parallel shrinkage

    Experiment No CRIMS

    Machine Learning CRIMS

    • Use Machine Learning to estimate moldedshrinkage

    • Provide CRIMS correction for non-shrinkage characterized grades

  • Slide 24 of 67

    0

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    1

    -40.0

    -30.0

    -20.0

    -10.0

    0.0

    10.0

    20.0

    30.0

    40.0

    -0.5

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    -0.2

    -0.1

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    DISTANCE FROM GATE, x/L

    ST

    RE

    SS

    _2

    2 (M

    Pa

    )

    DIMENSIONLESS THICKNESS, z/h

    Stress relaxation (viscoelastic)Long cooling time effectIn-mold shrinkageLiquid portion at ejection Solidification sequence effect

    Warp Accuracy - Anisotropic Thermo-Viscoelastic Stress Model

  • Slide 25 of 67

    Ejection Force

    Automatic Detecting based on ejectors movement

    direction

    User check, add or remove surface

    elements manually

    Final contact surface

    Von Mises Stress During Ejection

  • Slide 26 of 67

    Calculate the mold life and approximated range of cycles.

    Mold Fatigue

    Clamping-force-induced Stress

    Thermal Stress

    Pressure-induced Stress

    Mold Fatigue

  • Slide 27 of 67

    Features: Minor Loss, Friction formula, Simulate energy equation, & Simulate gravity

    New results: K factor, & Friction factor

    Cooling Network Only Analysis

  • Slide 28 of 67

    Completed Projects

    Long Carbon Fiber Orientation and Breakage - PNNL

    Ongoing Projects

    Composites Injection Overmodling – TPRC

    Microcellular Foaming – Univ of Toronto

    Fiber Effect on Viscosity – RMIT (Melbourne)

    Composites Compression Overmolding – HUST

    Fiber breakage in Barrel – Univ of Bradford

    SMC Compression Molding – Ford

    Long Carbon Fiber Orientation and Breakage – GM

    Yokoi Injection Molding Consoritum – Univ of Tokyo

    Overview of Moldflow External Research Collaborations

  • Slide 29 of 67

    Prediction of fiber orientation and breakage during injection molding of “long” carbon fiber thermoplastics

    Long Carbon Fiber Thermoplastic: Fiber Length

    Comparison of measured and predicted fiber length distribution

  • Slide 30 of 67

    Prediction of long fiber breakage during melting in injection barrel

    Aim: Initial fiber length distribution for polymer at the sprue tip

    Fiber Breakage in Barrel

  • Slide 31 of 67

    Fiber breakage in barrel

    Observing Fountain Flow Oscillation (Tiger Stripe)

    Flow Imbalance (Race-Track)

    Yokoi Injection Molding Consortium

    Yokoi et al. PPS-31, 144-148 & 350-354

  • Slide 32 of 67

    Model the change in viscosity due to filler migration, fiber orientation and fiber breakage

    Filler Effect on Viscosity - RMIT

  • Slide 33 of 67

    Model non-recoverable deformation and resistance of a continuous fiber composite (pre-preg) being compression overmolded

    Composite Overmolding

    320mm

  • Slide 34 of 67

    Bubble effects on fiber orientation

    Microcellular Injection Molding

    Bubble nucleation or growth and the final foam structure(Microcellular Plastics Manufacturing Lab, Univ. Toronto)

  • Slide 35 of 67

    Injection Overmolding on Continuous Fibers Composites

    G/PA6 laminate + unfilled PA6

    Interfaces AniForm draping solution to Moldflow Warp analysis of the combined structure

    Models bond strength

  • Slide 36 of 67

    US DOE funding to develop ICME for carbon fiber draped and compression molded parts (Automotive)

    Autodesk Moldflow was invited to provide process modeling of

    Compression molding, Fiber Orientation, & Local fiber volume fraction

    Chopped Carbon Fiber Compression

  • Slide 37 of 67

    Flow instability mechanism understood.

    Potential collaboration to study appearance factors (aimed at Automotive parts)

    Surface Appearance (Tiger Stripes)

  • Slide 38 of 67

    University of Bradford (UK)Long Fiber Orientations, & Fiber breakage in barrel

    Tokyo UniversityFiber breakage visualization, & Race track visualization

    RMIT University (Australia)Effect of fiber and filler migration to change viscosity, & Thermal stresses in SLM 3D Printed parts

    Huazhong University of Science and TechCompression Overmolding of Continuous Fiber Composites

    University of TorontoMicrocellular bubble formation

    University of WyomingProgressive failure of composites

    Academic Research Collaborations

  • Slide 39 of 67

    Long Carbon Fiber Thermoplastics (Injection Molded)Pacific Northwest National Labs, & GM

    Chopped Carbon Fiber Thermoset (Compression Molded)Ford, Dow, Northwestern University

    MicrocellularTrexel, University of Toronto, & Ford

    Thermoplastic Composite OvermoldingTPRC (The Netherlands), Boeing, Fokker, Johnson Controls, Victrex

    Industry Research Partnerships

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    © 2017 Autodesk. All rights reserved.