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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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Page 1: 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

© 2013 Autodesk© 2017 Autodesk

Autodesk Moldflow

Moldflow Research & Development

Dr Franco Costa

Senior Research Leader

Page 2: 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

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

Page 3: 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

Slide 3 of 67

Solver Features in Recent Moldflow Releases

Solver & Mesh Features under development

Research Collaborations

Outline

Page 4: 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

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

Page 5: 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

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)

Page 6: 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

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

Page 7: 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

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

Page 8: 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

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

Page 9: 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

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

Page 10: 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

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

Page 11: 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

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

Page 12: 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

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

Page 13: 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

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

Page 14: 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

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

Page 15: 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

Research

Page 16: 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

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.

Page 17: 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

Slide 17 of 67

Extracting Center Lines of CAD Cooling System

Centerline Extraction for CAD Cooling System

Page 18: 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

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

Page 19: 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

Slide 19 of 67

“Underflow severity” as a result

Underflow Diagnostic Plot

Underflow regionviewmold.com

Page 20: 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

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

0.4

0.5

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)

Page 21: 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

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)

Page 22: 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

Slide 22 of 67

Warp Accuracy: Thickness Shrinkage for Warpage

MF 2×4mm corner mold (MAT5322 PP)

0

1

2

3

4

5

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

-8

-6

-4

-2

0

2

4

6

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Corn

er A

ngle

Cycle

F. van der Veen Corner PP

Experiments AMI2017 Generic shrinkage TP2017 Residual Stress

with thickness shrinkage

Page 23: 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

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

Page 24: 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

Slide 24 of 67

0

0.2

0.4

0.6

0.8

1

-40.0

-30.0

-20.0

-10.0

0.0

10.0

20.0

30.0

40.0

-0.5

-0.4

-0.3

-0.2

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

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

Page 25: 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

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

Page 26: 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

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

Page 27: 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

Slide 27 of 67

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

New results: K factor, & Friction factor

Cooling Network Only Analysis

Page 28: 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

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

Page 29: 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

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

Page 30: 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

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

Page 31: 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

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

Page 32: 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

Slide 32 of 67

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

Filler Effect on Viscosity - RMIT

Page 33: 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

Slide 33 of 67

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

Composite Overmolding

320mm

Page 34: 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

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)

Page 35: 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

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

Page 36: 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

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

Page 37: 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

Slide 37 of 67

Flow instability mechanism understood.

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

Surface Appearance (Tiger Stripes)

Page 38: 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

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

Page 39: 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

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

Page 40: 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

Autodesk and the Autodesk logo are registered trademarks or trademarks of Autodesk, Inc., and/or its subsidiaries and/or affiliates in the USA and/or other countries. All other brand names, product names, or trademarks belong to their respective holders. Autodesk reserves the right to alter product and services offerings, and specifications and pricing at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document.

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