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

 

sponsors:


Autodesk Financing

Stream Engeneering

HRS Flow

Volume Graphics GmbH

Contura

Contura

DYNAmore
mensch+maschine


2017 - CONNECT! - The Moldflow Universe - Final Call

 

8. CONNECT! European Moldflow® User Meeting

 

on May 3rd and 4th, 2017 in Frankfurt/Main

 


Training Sessions Look forward to lectures from industrie and research, training sessions to bordering software and round tables. Simultaneous translators (German – English and vice versa) attend the event.
Runners The second day of the event traditionally begins with the Hot Runner race before breakfast. Employees of PEG, MF SOFTWARE and Autodesk are looking forward to accompanying you.

We place special attention on the possibility to arrange individual meetings with Caroline Dorin and Dr. Shishir Ray both from Autodesk.

Dr. Shishir Ray Shishir (Research Manager Solver) offers to discuss with him about special technical topics. Individual meetings can be arranged directly with him via e-mail: shishir.ray@autodesk.com.
Caroline Dorin Caroline (Principal User Experience (UX) Designer) will be attending the Connect! European Moldflow User Group meeting in order to gather your feedback on a number of prototype developments that are not yet released.

 

The topics that Caroline will be discussing include:

 

  • SimStudio Tools
  • New methods to supply material data
  • Advanced Material Exchange assembly pairing
  • Advanced Material Exchange temperature dependent material model
  • Centerline extraction for channels
  • Flatness and roundness warp post-processing tools
  • Valve gate enhancements
  • Updated ejection force workflows

 

If you would like to try a prototype or discuss your requirements for any of the above topics, please book an appointment with Caroline using her booking page.

 

 

More Lectures:

simulations of mircro injection molding of TPE micro rings – digital experiments for process/product optimization

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 are a powerful tool for the optimization of the design of mould, parts and process. However, the miniaturized scale of the micro products introduces relevant challenges in terms of both validation and accuracy of the simulations.

In this presentation, a case study based on the micro injection moulding process of thermoplastic elastomer micro rings for sensors application is treated. Optical measurements of real parts were used to validate the simulations results.

Process simulations were successfully utilized for accurately predicting the defects (i.e. weld lines and air traps) affecting the part quality. Moreover, the effects of the process parameters on the geometries of the moulded micro parts were correctly captured by the utilized model, opening the door to future micro injection moulding virtual experiments.

 

tl_files/connect_template/bilder/Referenten/2017/Federico_Baruffi.jpg

Federico Baruffi, Technical University of Denmark (DK)

Federico Baruffi holds a master degree of mechanical engineering from the Politecnico di Milano which he received in April 2016. The master thesis was written at LEGO in cooperation with TU Denmark. After that he started to work at the Technical University of Denmark in the department of mechanical engineering, section of materials and manufacturing and he is currently writing his doctoral thesis on the subject of „Integrated micro Product/process quality assurance in micro injection moulding production“

 

fibre dispersion and breakage in long glass fibre reinforced injection moulding

Short (up to 250 µm) and long (up to 30 mm in pellet form) glass fibre reinforced commodity polymers continue to be used as routes to replacements for traditional metallic components in a number of global industries. However, the fibre orientation, fibre dispersion and fibre lengths that arise during the injection moulding process can significantly affect the mechanical performance of the injection moulded composite components. For short glass fibres the dispersion and orientation has been shown to be mostly dependent on mould geometry and processing conditions. In the case of long fibre reinforcement, the fibre orientation, fibre dispersion and fibre length distributions can be more closely linked to the geometry of the processing machine, with the majority of fibre breakage occurring within the screw section of the process.

In this presentation, we provide an update on the AutoDesk funded PhD into fibre breakage within the screw region of the injection moulding process. Fibre length distributions are presented, along with microCT data showing how pellets deform and fibres break along the screw section. Some data of flow within the nozzle and sprue is also shown, to demonstrate the historical effects stored within composite injection moulded components. The Materials under investigation include 20, 30 and 40% reinforced PP provided by Sabic. Initial investigations have been conducted with the assistance of Prof F Desplentere of KU Leuven.

 

Dr. Fin Caton-Rose

Dr. Fin Caton-Rose, University of Bradford (GB)

Graduated in Engineering for Design and Manufacture (BEng) at Hull University in 1992 before starting work on the design, build and testing of a ceramic water pump for the Water Hydraulics Research Group at the same University. In 1995 Dr Caton-Rose registered for an industrially sponsored PhD into the computer modelling of large strain deformation for geogrid applications and graduated in January 2000. Dr Caton-Rose became a Lecturer in 2003 and was promoted to Senior Lecturer in Polymer Engineering in 2006.

He has taught across the Design and Engineering disciplines with specific interests in computer aided design, finite element analysis, digital prototyping and product design studio projects.

 

warpage minimization of structural component with glass fiber reinforced polymer by using HRS’s FlexFlow technology: a practical case

In this presentation, we provide an update on the AutoDesk funded PhD into fibre breakage within the screw region of the injection moulding process. Fibre length distributions are presented, along with microCT data showing how pellets deform and fibres break along the screw section. Some data of flow within the nozzle and sprue is also shown, to demonstrate the historical effects stored within composite injection moulded components. The Materials under investigation include 20, 30 and 40% reinforced PP provided by Sabic. Initial investigations have been conducted with the assistance of Prof F Desplentere of KU Leuven.

 

Nicola Pavan

Nicola Pavan, HRSflow/INglass S.p.A. (I)

Nicola Pavan has a Master Graduation in Mechanical Engineering from Padova University, Italy, and he holds also Autodesk Moldflow Professional Certification released on 2014.

He has large experience on simulations with a strong focus on plastic injection moulding processes and materials, and a deep know-how on automotive components. Currently CAE Manager in INglass, based in San Polo di Piave, Italy, he is responsible to manage regional CAE teams in Italy, India, China, Brasil and Canada for supporting customer, T1 and OEM in injection process definition, hot runner system concept and part quality assurance.

 

new insights into pressure dependent viscosity measurements of polycarbonates

The lecture presents how current pressure-dependent viscosity measurements are carried out at Autodesk and shows the influence on calculation results.

It is shown to what extent the pressure dependence of viscosity is important and how to use such material data in order to get a better understanding of the material and the process.

The results are compared with practice and a new developed method is presented in which the measurements are optimized in order to obtain better results.

 

Miguel Lopes

Miguel Lopes, Covestro Deutschland AG (D)

Miguel Venancio Lopes studied at the University of Minho (Portugal 2012) and after graduating as a Master of Polymer Engineering he gained some working experience as a production engineer at the company Simoldes (toolmaker / injection-maker). Since September 2013 he is working for the company Covestro (former Bayer MaterialScience) in the department for component development.

 

importance of a continuous simulation support from the first concept phase

In the automotive area a trend to shorter realization time for new products can be noticed since several years. It is driven by the OEMs because of faster replacement of vehicle generations to implement new technologies on the market. This has a drastically impact on the product development and tool construction processes due to much shorter available time. New strategies have to be implemented into the whole development process to speed up the realization of new components.

This presentation highlights the parallel collaboration between simulation, product development and tooling based on the real example of the new generation of integrated charge coupler box (ICCB). In this case it should be shown how the simulation can help to reach a product with high quality just in the first trial in a really short time.

 

Florian Schönenberg

Florian Schönenberg, Delphi Deutschland GmbH (D)

Having obtained a degree in mechanical engineering with the main focus on plastics engineering, Florian Schönenberg began his career in 2006 as an simulation expert with FCI Connectors Deutschland GmbH in Nürnberg and since 2012 he is working as a simulation expert for Delphi Deutschland GmbH in the department of Numerical Simulation. Florian Schönenberg is Silver Certified Analyst since 2008 and holds the Moldflow Expert Level Certification since 2014.

 

simulation of assemblies and subsequent welding

Moldflow simulation are used to predict an estimated warpage of injection-moulded parts. However, in most applications not only single parts are used, but welded assemblies consisting out of several parts.

This causes additional requirements regarding the warpage (the warped shape of each single part), as, for example, two half shells need to fit with the least absolute mismatch (of the welding contour) to reduce induced stresses by the welding process.

These requirements raise with a higher number of single parts.

BestFit enables the enigneer to run mismatch comparisons of single warped parts out of Moldflow simulations.

By searching for the best matching variant(s), production processes can be improved as ,e.g., the welding line quality can be improved by a better support with less part deformation during the welding process.

A higher quality, functionality and durability of the product will be the result of it.

Further numerical, fictive welding simulations reveal afterwards local hot spots of high material stressing caused by the production process. By this way designers are able to improve the part design regarding the production process.

 

Jeffrey van Delden

Jeffrey van Delden, MAHLE Filtersysteme GmbH (D)

Jeffrey van Delden studied aerospace technology with focus on statics and dynamics, aircraft construction and lightweight manufacturing at the university of Stuttgart. After his diploma in 2014 he started to work as a simulation engineer at MAHLE Filtersysteme GmbH.

 

predicting visual defects

The visual quality demands on held hand appliances like shavers are extremely high. Visual defects are the main cause for rejects in molding production at Philips Drachten and therefore predicting them is key. However, Moldflow has a limited set of outputs directly related to visual quality, which makes predicting visual defects a challenge. In this presentation, the quest for optimal injection molding process settings is reverse engineered and linked to Moldflow results.

 

Fokke J. van der Veen

Fokke J. van der Veen, Philips Consumer Lifestyle (NL)

Fokke J. van der Veen studied Mechanical Engineering at the University of Twente in Enschede, The Netherlands. During his master, he specialized in Designing in Plastics. After internship at Philips Drachten and graduation assignment for the same company, he joined in 1996. In his current position as Senior Engineer Plastics Processing, Fokke is responsible for the industrialization of new projects. His 21 years of experience was gained in pre-development and realization projects, process technology development and trouble shooting in production sites world wide for a broad range of consumer products. He started using C-MOLD in 1993 and Moldflow in 2000. Fokke is the owner of the Moldflow competence within Philips.

 

Digimat-AM: simulation of the additive manufacturing process

Since 2003, Digimat is the state-of-the-art software for multi-scale material modeling. Digimat provides solution to model accurately the material behavior of short fiber reinforced plastic by taking into account the effect of manufacturing process: compression and injection molding. New capabilities have been developed to capture all the physics of these materials: tension/compression behavior, strain rate dependency in both elastic and plastic domain, creep behavior, damping behavior… Thanks to these features, Digimat in combination with a Finite Element code is able to predict with high fidelity the performance of a part in NVH, Static and Dynamic and fatigue analysis.

Since few months, additive layer manufacturing of plastics is experiencing a paradigm shift. Following its initial development in rapid visual prototyping, the industry is now looking into the technology as a full production technique to achieve tailored design but also new lightweighting solutions which are not viable with other manufacturing methods. e-Xstream decided to follow this new trend and to release a dedicated solution for Additive Manufacturing : Digimat-AM. Digimat-AM has for goal to simulate the additive manufacturing process and to provide relevant information to predict the stiffness and strength of the component by taking into account the effect of the process : toolpath, printing speed, porosity,…

The first part of our presentation will be dedicated to the introduction of the latest capabilities of Digimat for the modeling of for short fiber reinforced plastic. This will be then followed by a detail presentation of our additive manufacturing solution.

 

Dr. Bernard Alsteens

Dr. Bernard Alsteens, e-Xstream engineering S.A. (LUX)

Dr. Bernard Alsteens joined e-Xstream engineering as a support engineer in 2007 and progressed to the position of Customer Services Manager since 2011.

He has global responsibility for the technical support functions for all Digimat customers. His role also includes training management and he also participates to the quality assurance of the Digimat software.

Prior to joining e-Xstream, Bernard worked for LMS International in the Virtual.Lab group (vibration and acoustic simulation) during 2.5 years. He holds an MSC in Mechanical engineering from the University of Louvain (Louvain-la-Neuve, Belgium). Afterwards he undertook a PhD on Mathematical modeling and simulation of dispersive mixing of carbon black agglomerate in rubber at University of Louvain (Louvain-la-Neuve, Belgium).

 

design and validation of highly stressed plastic motor components by integrative simulation

For injection molded parts, MANN + HUMMEL mainly uses glass fiber reinforced thermoplastics. In order to make optimum use of the material properties, accurate knowledge of the temperature- and time-dependent mechanical properties is necessary. The mechanical properties of the molded part are mainly determined by the material, component geometry and the manufacturing process. As a result of the glass fibers, direction-dependent properties occur in the component. In order to take into account these anisotropic properties in the design of the component the injection molding simulation and the FE simulation must be coupled (integrative simulation). Furthermore, the anisotropic material model parameters required for this must be determined. Commercial software programs already exist [1]. In order to meet the high demands to modern combustion engines all engine components must perform at their peak. The oil circuit is of central importance here, since only a clean engine oil can ensure permanently the same engine power. In the case of oil filter systems, under high temperatures and permanent pressure pulsations the stiffness of the plastic housing in the sealing region plays a decisive role in particular.

The paper describes the process of computational stiffness design of oil filter systems and the subsequent validation by experiments. The deformations on the sealing flange are measured very accurately with 3D optical methods (statically and dynamically). Starting from a calibrated fiber orientation model, the fiber orientation from the injection molding simulation is transferred to the structural mechanical mesh on the FE solver with a software for process-structure coupling and the anisotropic material model parameters required for the simulation are determined. By taking into account the anisotropy in the FE simulation a good match with real deformations is achieved - in contrast to the isotropic FE analysis. Since the sealing connection reacts very sensitively to changes in the sealing gap, the improvement in the accuracy of the stiffness prediction is decisive, shortens the development times and leads to more robust products.

 

Marco Woitoll

Marco Woitoll, MANN+HUMMEL GmbH (D)

Marco Woitoll studied plastic technology at the University of Applied Sciences Darmstadt. Since 2004 he is simulation engineer at Mann und Hummel GmbH in Ludwigsburg and is working in the fields of injection molding simulation and structural mechanics.

 

warpage simulation in contrast to real shape and assembling consequences

The HELLA Group develops and manufactures lighting and electronic components and systems for the automotive industry. This predominantly plastic components have to comply with multiple requirements, particularly warpage. Assembling forces, functions and required tolerances of final product are significantly affected by warpage. This warpage can be influenced with many structural and technological parameters. It is certainly possible to reduce warpage mechanically on assembling line, however this has defined limits by internal stress. More helpful seems to be warpage optimization during design development by Moldflow simulation, nevertheless this has defined limits by accuracy of many inputs. Therefore, absolute reducing of warpage in simulation by growing number of loops is not efficient. This presentation will focus on the compromise between high number of simulation loops and manageable warpage to fulfill requirements on assembly and functions.

 

Miroslav Michálek

Miroslav Michálek, Hella Autotechnik Nova s.r.o. (CZ)

Miroslav Michálek studied Applied Mechanics at the Czech Technical University in Prague. His primary focuses during his studies were numerical approaches to identify technical issues. In 2008 he changed to Mercedes Benz Technology, subsidiary of Daimler, where he firstly focused on durability optimization of engine machines, later on method development of fast and transient simulations. From 2012 he was in position of Technical leadership responsible for highly nonlinear simulations and crash tests in non-automotive. In 2015 he has started his position at HELLA in the field Injection Molding Simulation. The focus is on matching of produced plastic parts and Moldflow simulation results and using this knowledge to optimize development and manufacturing process.

 

advances in weld line strength predication and as-manufactured structural simulation for plastics

Weld lines are important to plastic part design as they produce areas that are aesthetically unappealing or have significantly reduced material properties compared to the bulk material. Historically “knock down” or strength reduction factors have been employed as best guess estimates to determine the structural impact of the localized strength losses. This method does not consider all the factors that affect the final product strength or if the location of the weld line moves beneath the initial formation skin layer. In this presentation, a better workflow will be presented in which as-manufactured results such as fiber orientation, weld line strength and residual strain/stress from injection molding simulation are mapped and considered for a nonlinear finite element analysis.

 

Matt Jaworski

Matt Jaworski, Autodesk Inc. (USA)

Matt Jaworski is a Senior Subject Matter Expert for Autodesk’s Moldflow Simulation Team. He has over 21 years’ experience in the injection molding CAE simulation field working for such companies as Erie Plastics, Hewlett Packard, Rubbermaid and Moldflow/Autodesk. He has dual BS degrees in Mechanical and Plastics Engineering Technology from Penn State, a MS in Plastics Engineering from UMass Lowell and is currently finishing his Ph. D. at UMass Lowell in Plastics Engineering on the research subject of weld line strength prediction. He is a member of the Society of Plastics Engineers and the American Society for Engineering Education. Matt is also active in education and has taught at the University of Massachusetts Lowell and Penn State Erie, The Behrend College as an adjunct professor.

 

We are looking forward to an interesting event with your participation.

 

Your conference chair

Thomas Wittmann / Sven Theissen

 

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