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Peter Wentzel, 24 th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6 TH Edition, Eindhoven (NL)

Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

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Page 1: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Peter Wentzel, 24th June 2016

Induction Heating Simulation

with Autodesk® Moldflow®

Benelux Autodesk® Moldflow® User Meeting

6TH Edition, Eindhoven (NL)

Page 3: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

- Creation of the Company: 2000

- Technology Provider for Plastic

Injection and Compression

- Most advanced Heat and Cool

technology in the industry

- Engineering Team 100% focused

on Heat & Cool solutions

- Facilities in Europe,

Asia and North America

Page 4: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

FranceHeadquarters &

Demo Center

TaiwanOffice &

Demo Center

USARocTool Inc.

Office &

Demo Centers

JapanOffice &

Demo Center

GermanyRocTool GmbH

Office &

Demo Center

ItalyDemo Center

RocTool Offices

Page 5: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Markets

Aerospace Consumer

Products

Electronics Automotive Sport and

Leisure

Energy Cosmetics

Page 6: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

3iTech® – Overview- High speed heating of the tool surface

with integrated induction network

- Cooling with water lines

- Complete mold temperature control

with easy interface (thermocouples)

- Process designed for standard steels

- Full automatic mode compatible with

all press machines

Page 7: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

3iTech® – Primary Technology

Molding Surface

Mold in Magnetic Steel- Example 1.2343 (H11)

- Electric resistivity ρr:40 Ω.m

- Relative permeability μr:55

- Thermal conductivity k:27W/m.K

Insulating Layers (1 or 2)

Inductor (copper)

Thermal Diffusion

Induced Currents

Magnetic Fields

Injected Currents

Close up of the inductor cavity:

Page 8: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

A complete process integration

Patents and License Generator

PackagesDevelopment &

Production Support

Engineering

and FEA

Tool Design

Support

Complete Induction Heat & Cool Package includes:

- Engineering / Simulation & Full Analysis

- Generator Package with Peripherals

- License and know how transfer

- Installation, Start Up & Complete Training

Page 9: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Performance

Benchmark

Induction Heating

Flow Processes*(Steam; Pressurized water)

Electric Heater*

Heating Speed

Up to 25°C/sec

Up to 10°C/sec

Up to 5°C/sec

Temperature

Up to 400°C

Up to 180°C

Up to 300°C

Energy Cost

Low to Medium

Medium High

Very High

Process

Performance

Extended

Limited

Limited

MATERIAL AND DESIGN (2010) 382–395

Research of thermal response simulation and mold structure optimization for

rapid heat cycle molding processes, respectively, with steam heating and

electric heating - Guilong Wang, Guoqun Zhao , Huiping Li, Yanjin Guan

Page 10: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

RocTool EngineeringAn Overall Control of the Process

Electromagnetic

Analysis

Thermal

Analysis

Thermomechanical

AnalysisFlow Analysis

Page 13: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Surface QualityElimination of Visible

Weld Lines

Page 14: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Surface Quality

Combination of

High and Low Gloss

Possible

Page 15: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Flow ImprovementFlow Improvement and Thin Wall Capabilities

BT ADSL Hub

with thin wall

for LED

Page 16: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

BMW 1 Serie – Air Vents Trim

Peugeot 208 – Decoration Trim and Air vents

Audi A8 – Centrale Console

BMW 3 Series – Air Vents Trim

Application Examples: Interior Automotive

Page 17: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

BMW 7 Series – Rear Entertainment System

Mercedes –Benz S-Class – Rear Entertainment System

Application Examples: Interior Automotive

Citroen C4 Cactus – Interior Trim

Renault Zoe – Central Cluster

Page 18: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Application Examples: Electronics

Electronic AccessoriesLapTop A and D covers

Electronic devices

Smartphones Battery

covers and Body parts

Page 19: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

High Definition Plastics Evolution

Injection Molding- Design Functionality

- Productivity

Induction Heat- Top Surface Quality

- Defect Reduction or Elimination

- Thinner Walls

Surface Oriented Resins- Color / Particels

- Durability

- Scratch Resistance

- Chemical Resistance

- Additional Features (haptics)

Laser Texturing- Eliminate Secondary Operation

- Unique Design Possibilities

- New Aesthetics

- Brand Recognition (patterns)

Page 20: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Conventional

Process

RocTool

Technology

Case 1

VDI* Ra (µm)

22 1.43

17 56%

Mold

Plastic Part

Material: PC

Mold Temperature:

80°C/176°F*VDI 3400 (CH)

Case 2

VDI* Ra (µm)

24 1.85

19

Case 3

VDI* Ra (µm)

27 2.47

22

Case 1

VDI* Ra (µm)

22 1.43

21

Mold

Plastic Part

Material: PC

Mold Temperature:

160°C/320°F*VDI 3400 (CH)

Case 2

VDI* Ra (µm)

24 1.85

23

Case 3

VDI* Ra (µm)

27 2.47

2654% 54% 85% 92% 93%

RocTool Combined with Laser Etchingwith RocTool Technology: Better Replication of Mold and Low Gloss Improvement

Page 21: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

- RocTool Heat & Cool Technology

- Top Surface Quality

- Combined with Laser Texturing

- OEM Proprietary Pattern

Page 22: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

MuCell® and RocTool CombinationMuCell® For:

- Lightweighting

- Material savings

- Dimensional Stability

RocTool For:

- Top Surface Quality

- Process Improvement

- Part Overall Improvement

MuCell® RocTool + MuCell®

l

Page 23: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Unique Aesthetic

Light diffraction textures: Replication of 3D textures

Page 24: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Induction Heating Simulation with Autodesk® Moldflow® Insight

Real induction simulation developed by Autodesk®

Moldflow® on top of the Cool (FEM) module in the

Moldflow Insight 2016 release

• Dual Domain and 3D mesh models

• Available in Moldflow Insight Premium and Ultimate

• The analysis demonstrates the impact on the final product

Page 25: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Model Components

Induction

Coil

Part

Air gap

Cooling

channels

Page 26: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Model Components

Induction

Coil

Part

Air gap

Cooling

channels

Page 27: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Process parameters

Apply High/Low potential terminal conditions to the

induction coils

Page 28: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Electro-magnetic results

Induced

current

Magnetic flux

density

Joule

heating

Page 29: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Joule Heating over time

Page 30: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Transient Mold Temperature

Page 31: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Transient Mold Temperature Cavity Side

Page 32: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Transient Part Mold Temperature Cavity Side

Page 33: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Transient Mold Temperature Core Side

Page 34: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Transient Part Mold Temperature Core Side

Page 35: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Temperature vs time at 3 points

Induction heating starts at 36s

Page 36: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Filling

Page 37: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Welding lines

Because the mold temperature is hot

and above the glass transition

temperature, the welding line will not

be visible.

In the same way the aspect in front of

the 2 nozzles is satisfying

Page 38: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Packing

Compared to CIM,

packing lasts for a

longer time because

the cooling rate is

slower

High

temperature

Good pressure

transmission

no freezing

Page 39: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Warpage

Page 40: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Performed an Induction Heating Simulation and use results

as injection trials input

Compare simulation to experimental data

Tool equipped with RJG sensors : temperature and pressure

Plastic part : 150x80x1.8 mm

Resin : PC Makrolon® AL2447 from Covestro

Induction Heating Simulation : INNOTOOL-A

EDM grain

Glass polish

Chemical grain

Page 41: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Tool equipped with 2 surface pressure sensors, 1 temperature (RJG) & 1

RocTool Thermocouple to control process

Tool equipment

RJG software – Machine interface

Surface sensor

pressure (RJG)

Thermocouple RocTool (to control process)

mounted in an insert Surface sensor temperature (RJG)

mounted in an insert

Surface sensor temperature

mounted in an insert

Page 42: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

CAD model

Cavity and Core side

Mold block

Induction coil

Air gap

Coolant circuit

Part

Tool design

Moldflow model CAD import

Assign properties & materials

Meshing mold & part

Implement boundary conditions

Implement process settings :

Cool FEM input

Induction input

Injection input

Run Induction simulation

PartAir gap

Coolant

circuit

Core

side

Cavity

side

Induction

coil

Page 43: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Process parameters

Assign Property & Material Process cycle description

Electrical & Thermal data are essential for each component

13s: ready to fill

20s: end of packing

48s: end of cooling 7s:

End of heating

Mold open Cooling stageFilling+Packing stage

Heating

48s/0s 7s 35s35s 42s

Time = 0s to 7s : 3itech heating (during previous part extraction)

Time = 11s : mold closing

Time = 13s : part filling

Time = 48s : mold opening + part ejection - end on the thermal cycle

0s:

46s

Closed

Diffusion

11s:

cycle time implemented directly in

process setting & on induction coil

for Heating control

Name Property Material

Mold block Mold Block (3D) Steel

Cavity & Core Mold insert (3D) Steel

Air gap Mold insert (3D) Air

Induction coil Induction coil (3D) Copper

Page 44: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Cavity side

Insert-cavity interface Temperature, Transient

Core side

GIF animation

Page 45: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Temperature, mold-cavity interface

Page 46: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Correlation

0

25

50

75

100

125

150

175

200

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54

Cav

ity

inte

rfac

e te

mp

erat

ue

(°C

)

Time cycle (second)

Cavity interface temperature evolution during cycle process

Trial data Simu_STEEL GAP_48KHz_425amp

Page 47: Induction Heating Simulation with Autodesk® Moldflow® Wentzel, 24th June 2016 Induction Heating Simulation with Autodesk® Moldflow® Benelux Autodesk® Moldflow® User Meeting 6TH

Thank you for your attention.

Please visit our website

RocTool.com