CONNTECT! Moldflow® User Meeting 2011 - Tuesday, 17. 05. - Wednesday, 18. 05. 2011 Frankfurt

 

CONNECT! - Refreshing Ideas

 

9. CONNECT! European Moldflow® User Meeting

 

5th - 6th June 2018, Frankfurt/Main

 

Only 3 weeks to CONNECT! 2018.

Please remember to register!

The following programme items await you:

 

Lectures, Hands-On-Labs and Round Table

LectureLectures from industry and research, hands-on labs and round tables are waiting for you. All lectures will be translated from English into German and vice versa by simultaneous interpreters.

 

 

 

 

 

 

 

User Experience Team

Moe ZunThis year the User Experience Team will be represented by Moe Zun, who is available for individual meetings to record her experiences with Moldflow and in particular to talk about the following topics:

  • New concepts for a generative design tool that supports the design of cooling channels for injection molds.
  • Mold fatigue - in which typical scenarios do you commonly experience this problem and how is it currently solved?
  • "First Time Right" Molding - a new workflow should make it possible to define upfront dimensional requirements which will drive changes to the part geometry. This uses local win,dage corrections.
  • New ways to transfer material data to Autodesk, use and search for material data in Moldflow.

Appointments can be arranged directly via the following link MeetMe.so - Moldflow-Connect-2018

 

 

Hot Runners

HotRunnerBring your running shoes!

The traditional Hot Runner course takes place on the morning of the second day. Employees of MF SOFTWARE, PEG and Autodesk look forward to starting the day with you during a pleasurable run.

 

 

 

 

 

 

 

NEW IN 2018: Training Day

On 07.06.2018 trainings on different topics will take place. The following topics are offered:

 

  • API Introductory Training
  • Introduction to Anisotropic Mechanics
  • Update Training AMI 2019
  • Associate Certification Exam

 

Please register in advance for these trainings.

 

 

 

Lectures

 

Simulation of foam injection moulding - from research to product implementation

When injection molding visible parts in the interior of an automobile, the foam injection moulding process offers various advantages such as weight savings, less warpage, less sink marks, lower injection pressure and shorter cycle times. This process can also be represented in Moldflow.

A sample tool was developed at the Ford Research & Innovation Center Aachen to evaluate the simulation results. The production with different polymers, chemical blowing agents and different blowing agent concentrations was simulated and verified in the experiment with the sample components.

The resulting sink marks could be predicted qualitatively well, but the quantitative calculation result was usually too high. The influence of the blowing agent concentration on the sink marks could also not always be calculated correctly.

The simulation results to a large extent depend on the foaming parameters, which were adapted on the basis of the sample components in the second step and which significantly improved the result.

In the last step, the real and simulated injection moulding process was analysed on a tailgate cover, both compact and with core-back CFA. With the parameters determined using the sample tool, the material savings and sink marks could be predicted very precisely. The described procedure is currently used in the development of various foamed interior trims at Ford.

 

Dr. Thomas Baranowski, Ford-Werke GmbH (D)

Thomas Baranowski studied Mechanical Engineering at RWTH Aachen University from 2001 to 2006 with the focus on Plastics and Textile Technology.

After his Master degree he joined in 2006 the Institute of Plastics Processing (IKV) at RWTH Aachen University as team leader in the group „Injection Molding Simulation / Material Properties / CAE”. In 2012 he completed his PhD with the title “Crystallization Simulation of Polypropylene in Injection Molded Parts”.

Since 2011 he is responsible for research activities regarding Injection Molding, Injection Molding Simulation and Additive Manufacturing within the Vehicle Interior Technologies team at Ford Research & Innovation Center Aachen.

 

Norbert Klar, Ford-Werke GmbH (D)

Norbert Klar studied Mechanical Engineering at RWTH Aachen University from 1990 to 1998 with the focus on Polymer Technology. Furthermore, he joined the MBA program at the Rhein-Ahr Campus in Koblenz in 2004 which he successfully completed in 2006.

After his Master degree, he worked from 1998 until 2000 as CAD/CAE engineer for Bertrand on the development and simulation of vehicle components. From 2000 to 2004, he joined Visteon as development-engineer for automotive HVAC-systems.

Since 2004 he is working at Ford as a Design and Release engineer and is responsible for the development of plastic components for vehicle interior. Since 2009 his tasks comprise injection-molding simulations of interior components. Since 2016 he is coordinating the complete injection-molding simulation activities for Ford at the development center in Cologne.

 

 

Automation and standardization of simulation processes at P&G through the use of API

Procter & Gamble's process technology uses injection molding simulation throughout the entire process chain. After a short evaluation phase it was decided to use the software's programming interface to standardize and economize the reporting system for Moldflow simulations. This was used to develop an application that generates a configurable simulation report based on the company's corporate design specifications. Information and calculation results as well as result plots stored in Moldflow are read out automatically and reports are generated automatically.

 

Dominik_Frey,  P&G Braun GmbH (D)

Dominik_Frey, P&G Braun GmbH (D)

Dominik Frey studied plastics engineering at the university of applied sciences in Würzburg. Since 2013 he works as a process engineer for Procter and Gamble. Dominik went through several Oral-B projects from the first design draft till serial production. His main tasks are optimization of plastic parts and development of injection molding processes. Here Moldflow is used as a tool.

 

 

 

 

 

 

Investigation of factors influencing the weld line strength and their calculation in FE simulations

Weld lines are local weak zones in structural mechanical components. Accordingly, knowledge of their mechanical characteristics and simulative modelling is an important tool for making more valid statements in the early development phase.

Within the present study, wide-ranging investigations were carried out to what extent the mechanical parameters can be influenced by varying process parameters. For this purpose, test specimens were manufactured on a test specimen tool under different process conditions and using different materials. The subsequent quasi-static tensile and bending tests were used to identify the significance of individual process parameters.

Subsequently, the collected values were used to consider them as input parameters for the simulation. Within the injection molding simulation in Autodesk Moldflow, it was necessary to optimize the existing "weld line surface fromation" in advance, since an export of the natively calculated result did not meet the qualitative requirements. Accordingly, the result was optimized by API programming in Autodesk Moldflow.

In the following step, a mapping tool was used to transfer the calculated weld line position and the fiber orientation to the structural mechanics. Here it should be evaluated to what extent a weld liine breakage on the component can be better calculated by simulation.

 

Stefan Niedrig, Brose Fahrzeugteile GmbH & Co. KG (D)

 

 

 

 

 

 

 

 

 

Uwe Schilling, Brose Fahrzeugteile GmbH & Co. KG (D)

 

 

 

 

 

 

 

 

 

 

 

Micro components quality optimization using micro injection moulding process simulations

Micro injection moulding currently represents the best solution for manufacturing complex and net-shaped micro plastic parts. As in conventional injection moulding, process simulations of micro injection moulding can turn useful in designing mould, parts and process. However, the micro scale of micro products poses relevant challenges in terms of both validation and accuracy of the simulations.

In this presentation, two case studies are presented.

The first dealt with on micro injection moulding of thermoplastic elastomer micro rings for sensors application. In this case, process simulations were used with the aim of predicting the effects of process setting variations on the part dimensional accuracy. An experimental campaign was carried out to calibrate and validate the model within the selected process window. Optical measurements of real parts were used as term of comparison. Finally, a virtual optimization was carried out as conclusion of the study.

The second case study was based on micro injection moulding of an ultra-small POM component for medical applications. The aim was here to use process simulations to predict how the size of the flash affecting the part quality was influenced by the level of injection moulding process parameters. The comparison between numerical and experimental results proved that simulations could be used as optimization tool, even though an overestimation of the real flash size was observed.

 

Dario Loaldi, Technical University of Denmark (DK)

Dario Loaldi studied Mechanical engineering at Politecnico di Milano (IT). After completing a general Mechanical Engineering Bachelor degree, during his master he specialised in “Advance materials and manufacturing processes”. During this two years program he spent one semester at the RWTH University (DE) as part of Erasmus+ program and he concluded his master at the Technical University of Denmark, DTU (DK), where he write a thesis on the metrological characterisation of injection compression moulded micro polymer Fresnel surface. He is currently working on a PhD research project at DTU (DK) in the field of micro and nano structures replication. He focuses on the implementation and validation of process chains for the integration of micro/nano strucutres on consumer polymer products. He his using Moldflow to create a process digital twin for micro nano replication.

 

 

Consideration of the Fiber Orientation of Form Elements in Structural Simulations

Due to the production process, short glass fibre reinforced thermoplastic injection moulded parts show locally different anisotropic part characteristics. Typical form elements such as ribs and screw bosses or significant areas, e.g. flat component sections, show completely different orientation distributions. For an adequate prediction of the part characteristics it is necessary to know the fibre orientation in these areas and to describe these with suitable modelling approaches in the structural simulation.

A new experimental tool enables the systematic investigation of the fibre orientation of the above-mentioned component sections. In addition to the variation of the form elements the characteristics of the form elements and also the angle of the flow can be examined in a specific manner. The knowledge gained is used for validation and calibration of the injection molding simulation and for subsequent material modeling in the structural simulation.

 

Markus Fornoff, Fraunhofer Institut LBF (D)

Markus Fornoff studied plastics engineering at the University of Applied Sciences in Darmstadt where he wrote his master thesis on the topic "Prediction of shrinkage and warpage as well as connection quality for organosheet-reinforced hybrid components".

During his studies he already worked part-time at the Fraunhofer Institute LBF where he is now employed as M. Eng. of Plastics Engineering research assistant in the field of plastics with a focus on calculation strategies for short glass fiber reinforced injection molded parts.

 

 

 

 

 

Integrative Simulation – Benefits through the joint use of Moldflow and Digimat

The use of short-fiber-reinforced materials to replace metallic materials for structural-mechanical and safety-relevant components, which are manufactured by injection molding, is constantly increasing. In order to meet these new challenges and to give the part designer safety in the design phase, integrative simulation is the ideal solution. The structural properties and process-specific features (fiber orientation, weld lines, etc.) arising in the injection molding process are transferred from the injection molding simulation to the FEM.

To illustrate the advantages of a coupled simulation strategy, the classical and integrative calculation approach is compared using a simple example component.

Accurate prediction of the performance of short fiber reinforced thermoplastic material requires dedicated modelling solutions. The main challenge is to accurately compute the dependency of stiffness and strength on various factors like fiber orientation, strain rate, temperature etc. In addition, the ultimate strength of materials is also not varying linearly with these factors. Important non-linear effects are observed and their intensity depends on the type of thermoplastic (polyamide, polypropylene, etc.).

Digimat offers a multi-scale material modelling strategy to account for the aforementioned dependencies of stiffness and strength and allows for an accurate prediction of failure. In order to simplify the usage of Digimat, we developed Digimat-RP to offer an easy to use solution for structural engineers who have no time to specialize in material science. Digimat-RP combines all Digimat technologies for accurately predicting the performance of structural parts in a user-friendly graphical interface.

It is shown how integrative simulation is implemented at PEG using Digimat, which strategies are used in material modeling and which assumptions can be made for time-critical projects. Finally, the results of the study are compared and evaluated.

 

Dr. Robert Wesenjak, e-Xstream engineering – MSC.Software GmbH (D)

Robert Wesenjak studied mechanical engineering at the TU München. Subsequently, he worked as a research assistant at the Institute of Materials Science and Mechanics of Materials at TUM on the mechanical behaviour and damage of dual-phase steels. After completing his doctorate, he worked at TWT-GmbH on issues in the field of chassis dynamics. Since August 2017 he has been working at e-Xstream engineering as an application engineer in the area of customer service and technical support for the software Digimat.

 

 

Dr. Sebastian Mönnich, PEG GmbH (D)

Sebastian Mönnich studied mechanical engineering at the TU Darmstadt until 2009.

From 2009 to 2012 he was a research associate at the German Plastics Institute and took over as head of the "Mechanics and Simulation" group at the Fraunhofer LBF in 2012.

December 2015 he received his doctorate at the Otto-von-Guericke University Magdeburg.

Since 2017 he is working for PEG Gmbh as the leader of the team for structural process simulations.

 

 

 

 

 

We look forward to meet you!

 

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