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Faculté des Sciences, de la Technologie et de la Communication
Dynamic Simulation of an
Injection Molding Machine
GAMM2005
Mehrkörpersysteme und Kinematik
29. März - 01. April 2005, Luxemburg
C. HostertH. KollmeierS. MaasR. NordmannA. Zürbes Université du
Luxembourg
Faculté des Sciences, de la Technologie et de la Communication
Index
1. Projecta) Description of project
b) QUADLOC™ clamp unit
c) Simulation tools
2. Modelsa) Multi-Body Simulation model
b) Integration of flexible bodies in MBS
c) Hydraulic model
d) Controls model
3. Simulationa) Results / Comparison with measurements
b) Prospects
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Project
dynamic simulation of a QUADLOC clamp unit
integration of mechanical, hydraulic and controls systems
combination of commercial software
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
3 partners: HUSKY Injection Molding Systems TU-Darmstadt Université du Luxembourg
Faculté des Sciences, de la Technologie et de la Communication
QUADLOC™ clamp unit
2-platen design
moving platen
stationary platen
4 tie bars
4 integratedclamp pistons
2 stroke cylinders
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Software
combination of commercial simulation programs
ADAMSADAMSMulti-Body
SimulinkSimulinkcontrols
UnigraphicsUnigraphicsgeometries for models
DSHDSHplusplus
hydraulics
measurememeasurementsnts
validation
flexibility of components
co-simulationof mechatronic
systems
data for stress analysis
ANSYSANSYSFinite Element
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
MBS model of clamp locking
1 rigid-body DOF + 57 flexible-body DOFs
revolute jointwith friction
sperical joint
sperical jointwith joint motion
hydraulic force
flexible body
rigid body
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
MBS model of moving platen stroke
6 rigid-body DOFs + 150 flexible-body DOFs
rigid body
contact forces
flexible body
hydraulic force
bushings
rigid body
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
FE-model for moving platen stroke
SOLID 187
BEAM 188
SHELL 63
COMBIN 14 : connecting substructures
BEAM 4 : interface nodes
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
1st step: Component Mode Synthesis
i interiorb boundaryC constraintN normal
q0I
u
uu
N
C
NCi
b
called Craig-Bampton approach:
constraint modes &
fixed normal modes
NN
CCT
K0
0KkK
NNNC
CNCCT
MM
MMmM
siehe auch R.Gasch, Strukturdynamik – Band 2gemischte statische und modale Kondensation
Flexible bodies in MBS1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Craig-Bampton modal basis difficult to implement in MBS code
MqKq qqN ˆ qqu ˆ̂
synthesized from fixed normal and constraint modes are:
6 rigid body modes; can now be disabled in MBS,
free normal modes,
mode shapes of the boundary,
modes with no apparent physical meaning.
solving the following eigenvalue problem:
so that thus
2ndstep: Mathematical Transformation
Flexible bodies in MBS1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
G
PB
Ps Pu
r
position: where
orientation: 3-1-3 Euler Angles ( transformation matrix A)
angular velocity:
linear velocity:
PPP usArr qu ˆˆPP
T~ AA
qAqsArv ˆˆˆ~ˆ~
PPPP
n,1i,q̂
z
y
x
i
q
p
ˆ
PPPP
ˆˆ~ˆ~ ABqsAIvgeneralized
coordinate set
3rd step: Integration in ADAMS
Flexible bodies in MBS1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Theory of Flexible Bodies
3rd step: Integration in ADAMS
0QFLL T
dt
dLagrange's equations for a flexible body:
V P
TP dVvvT
2
1
V PPP
TTP
TT
PPT dVˆABq̂
~ˆs~AI
Aˆ
Aq̂~ˆs~B
I
MT T
2
1
T2
1
q̂Dq̂F T 2
1
kinetic energy:
potential energy: dissipative energy:
q̂Kq̂VV Tg 2
1
QDV
KM
MM
TG
T
2
1
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
automatic meshing
2. ANSYS/Workbench
Parasolid
FE-model of a connecting bar
1. CAD model
SOLID 187
BEAM 4
interface nodefor MBS model
3. ANSYS/Classicmanual generationof BEAM elements
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Integration of ANSYS-models in ADAMS
ADAMS-interface available in ANSYS
assembly of flexible body into MBS-model
1. generation of FE-model
2. ADAMS-interface:
selection of interface nodes
reduction of FE-model
transfer of reduced matrices (mnf-File)
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Verification of reduced model
modal analysis of assembled connecting bar
ANSYS(25000 DOF)
ADAMS(25 DOF)
MeasureMode shape
26.8 Hz 5.9 % 26.7 Hz 5.5 % 25.3 Hz 1. z
39.5 Hz 0.0 % 39.5 Hz 0.0 % 39.5 Hz 1. x
106.5 Hz 9.8 % 106.5 Hz 9.8 % 97.0 Hz 2. z
151.1 Hz 1.8 % 151.2 Hz 1.8 % 148.5 Hz 2. x
244.8 Hz 244.7 Hz ? 3. z
331.4 Hz 3.4 % 331.4 Hz 3.4 % 320.5 Hz 3. x
y
z
x
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Moving platen and tie bar sliding
modelled in ADAMS with IMPACT statement
non-linear spring-damper
maintains continuous contact between 2
geometries
1
1e
1contact
xx0
xxxcxxkF
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Moving platen and tie bar sliding
1
1e
contactxDY0
xDYVYcDY1xkF
own-programmed statement using IMPACT
clamp base
moving platen shoe
node
d1 d2
d3 d4
DY,VYDZ
contact force permanently calculated
only applied to node when necessarythrough a weighting function
d1 d2
d3 d4
1
0
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Moving platen and tie bar sliding
disadvantges: - huge number of DOFs
- discontinuous contact forces
use of slave nodesfor sliding
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Body
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Hydraulic model
DSHplus by FLUIDON GmbH
differential cylinder
modeling of cylinder cushion
hoses
pilot operated43 proportional valve
pipes and hoses
pump andpressure-reducing valve
Spin-off of IFAS, RWTH-Aachen
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
2H QRp
dtQC
1p
H
dt
dQLp H Inductance :
Capacitance :
Resistance :
iQ Up
model of components:
pipe
valve
LH RH
CH
RH
Hydraulic model
formulas based on
- one-dimensional flow theory
- supplemented by empirical considerations
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Co-simulation
SIMULINK
Controls
ADAMS
Mechanics
DSHplus
Hydraulics
position of cylinder velocity of cylinder input voltage valve
cylinder force moving platen position
input voltage valve
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
Comparison with measurements1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects
Faculté des Sciences, de la Technologie et de la Communication
interest of integrated simulations :
get full understanding of dynamics of complete system, difficult to assess with simple calculations
analyse influence of one parameter on behaviour of complete system
analyse interactions between sub-systems, e.g. hydraulics and mechanics
work-out improvements
replace costly prototypes
Simulation of Mechatronic Systems1.Project
a)Project
b)QUADLOC
c)Software
2.Models
a)MBS
b)Flexible Bodies
c)Hydraulics
d)Controls
3.Simulation
a)Results
b)Prospects