Realistic Simulation solutions for Design, Optimization, and fabrication of Plastics
0 likes318 views
The document discusses realistic simulation solutions for the design, optimization, and fabrication of plastic products, highlighting VIA's capabilities in engineering consultancy and simulation technologies. It details the advantages of realistic simulations in improving design efficiency, sustainability, and reducing costs associated with physical prototyping and testing. Additionally, it covers specific applications such as injection molding simulation, optimization strategies, and the benefits of utilizing the 3DExperience platform for collaborative innovation.
Realistic Simulation solutions for Design, Optimization, and fabrication of Plastics
- 1. REALISTIC SIMULATION SOLUTIONS FOR DESIGN, OPTIMIZATION, AND FABRICATION OF PLASTICS Arindam Chakraborty, PhD, PE VP of Advanced Engineering, VIAS Houston, TX www.viascorp.com achakraborty@viascorp.com May 10, 2018
- 2. © 2018 Virtual Integrated Analytics Solutions Inc. Agenda • VIAS Overview • Realistic Simulation & Optimization • Collaborative Innovation • Examples- ✓ Simulation for Injection Molding ✓ Injection Molding Demo ✓ Simulation based Optimization • Concluding Remarks 2
- 3. WHO WE ARE
- 4. © 2018 Virtual Integrated Analytics Solutions Inc. Who We Are Engineering Consultancy Training Automation &Customization Software • Multiple Industry Experience • Oil & Gas, • Machinery & Equipment • Petrochemical & Process • Consumer Goods • Aerospace • Medical Devices • Automotive • Presence in Houston, Chicago, Cincinnati, San Francisco, Portland • Provides Engineering Consultancy, Automation and Customization, Training • Team consists of PhD’s and MSc’s in Solid Mechanics, Fluid Mechanics, Materials & Corrosion, Numerical Analyses, Optimization & Reliability, Data Analytics • Solution partner of Dassault Systèmes SIMULIA – Abaqus, Isight, fe-safe, Tosca, CATIA, DELMIA, 3DEXPEREINCE • Provide AM Simulation and 3D Printing Services 4
- 5. © 2018 Virtual Integrated Analytics Solutions Inc. VIAS Capabilities Design Analysis and Validation using Simulation FEA based Fracture / Damage Mechanics Fluid Structure Interaction (FSI) Multi-physics Simulations (CFD, Thermal Analysis) Additive Manufacturing Simulation Material Modeling and Process Simulation S-N and e-N based Fatigue Analysis (varying temperatures) Simulation Automation CATIA Design and Analysis Product Lifecycle Management (PLM) 5
- 7. © 2018 Virtual Integrated Analytics Solutions Inc. What is Realistic Simulation? “Realistic Simulation” is a simulation that is physically realistic and “life like” in every way • Enables engineers to create life like models that will behave similarly to the real part / product. • Typically, start with simple models and increase the complexity, model size and the physics as confidence in simulation results increase their • Enables building up expertise and most importantly find value in simulation 7
- 8. © 2018 Virtual Integrated Analytics Solutions Inc. Why Realistic Simulation? • Designers often create innovative concepts, but retreat to conventional shapes due to limited time and resources for physical prototyping and testing • Simulation enables designers to virtually test new innovative concepts ▪ Reduces design time and the expensive cost of physical testing ▪ Lowers material cost and improves sustainability by light-weighting ▪ Reduces damage cost during production and transport by eliminating bad designs quickly Courtesy Mechanical Design and Analysis Corporation, 2010 SCC 8
- 9. © 2018 Virtual Integrated Analytics Solutions Inc. Challenges in Modelling Plastics and Polymers • Polymeric materials are complex in their mechanical behavior • Exhibit large strain, anisotropic and irreversible response; often accompanied by stable localized necking behavior • Modelling failure and fracture a challenge • Simulation models must deal with severe non-linearities Blow Molding (Plastic Bottle) Necking (ASTM D638 Hyperelastic) Viscoelastic Rubber Seal Insertion Fracture / Delamination Crimping
- 10. © 2018 Virtual Integrated Analytics Solutions Inc. Optimization – Deterministic and Probabilistic 10 Flexible automated design exploration strategies combining DOE, surrogate models, multi-objective optimization and stochastics. Y1 Constraint Boundary Y2 Initial Design Search for solution Optimization Robust/Reliability Design (Quality Engineering) Feasible Infeasible (safe) (failed) X2 X1 DOE: Critical Factors And Initial Design
- 11. © 2018 Virtual Integrated Analytics Solutions Inc. Automation and Optimization - Isight 11 • Process Integration and Design Optimization • Integrate Disparate Simulation Tools without programming • Automate Simulation Process Flows
- 13. © 2018 Virtual Integrated Analytics Solutions Inc. Collaborative Innovation 13 Perfect Production Perfec t Lab Perfect Shelf Perfect Product Perfect Package Perfect Value Chain Local Teams 3DEXPERIENCE : Collaborative Innovation LAUNCHDEVELOP PRODUCE ADAPT / REPLICATEIDEATE Scientists Formulators Artwork Designers Production Transportation Sales Planning Stores Materials suppliers Agencies Management Local markets Digital Equipment Suppliers Packaging suppliers LAUNCHDEVELOP PRODUCE ADAPT / REPLICATEIDEATE FIRST MARKET Packaging Engineers Legal
- 14. © 2018 Virtual Integrated Analytics Solutions Inc. SIMULIA Product Portfolio Overview Access to Technology through multiple user interfaces facilitates migration • Transition to 3DEXPERIENCE as applications mature and customers are ready • Enable existing SIMULIA portfolio within 3DEXP platform 3DEXPERIENCE provides integration of applications and technology in an open and extensible environmentDelivering trusted, proven, robust, dependable technology on an open platform to connect 3rd party technologies 3DS Simulation Portfolio Multiphysics Simulation Applications delivering a comprehensive environment for multiphysics simulation Product Design Simulation Applications tailored to guide product design from concept through validation Simulation Process Integrate applications, disciplines and data to enable collaborative decision making through analytics Isight Automate and explore design alternatives and identify optimal performance parameters through simulation process flows Abaqus Solvers Abaqus Standard Abaqus Explicit Abaqus CFD Solidworks Simulation Simulation solutions providing seamless integration within the Solidworks V1 environment V5 Analysis Finite element simulation within the V5 environment providing seamless integration Tosca Simulate the right design more efficiently through design exploration and optimization fe-safe Accurately determine the fatigue life of components under complex cyclic loading Abaqus/CAE Finite element modeling, visualization and process automation for Abaqus 14
- 15. © 2018 Virtual Integrated Analytics Solutions Inc. Design Validation using Simulation 15 Design of the package • Design the package with the CATIA app: Structural package design • Apply material with rendering and simulation properties Model preparation• Meshing of the Model, • Preparation of the connection and properties Scenario definition • Visualization of the stresses, displacement • Validation of the structure • Optimization of the design• Application of forces, restraints • Definition of the scenario (dynamic, static) Results Analysis
- 17. © 2018 Virtual Integrated Analytics Solutions Inc. Injection Molding - Capabilities using FEA • Optimize design of parts and molds • Design complex shapes - get the best design without doing “trial and error” prototyping • Simulate filling and packing phases • Ascertain pressure requirements for uniform filling • Gain insights into the thermal gradient of the part cross-section • Develop cooling solution for solidification • Automatic report generation with HTML, PPT and Word Formats 17
- 18. © 2018 Virtual Integrated Analytics Solutions Inc. Simulation in Injection Molding - Filling • Different polymers have varying properties and process requirements • Plastics Simulation can answer the following questions: • Will my part fill completely? • Where are the parting lines? • Will there be air traps? • Where are the best gate locations? • Do all my cavities fill equally? • How much pressure and clamping force will I need? • What happens if I change materials? Sink marks and air traps Temperature growth Bulk temperature 18
- 19. © 2018 Virtual Integrated Analytics Solutions Inc. Filling Examples Will my part fill completely? Will there be short shots? Predict the weld lines, possible air traps and structural weakness Air Trap Locations 19 1. 2. 3.
- 20. © 2018 Virtual Integrated Analytics Solutions Inc. Simulation in Injection Molding – Packing & Cooldown • Plastics Simulation can answer the following questions: • What is the time required for the part to cool down? • What is the effect of a packing pressure profile? • When do gates and other regions freeze? • What is my process cycle time? • Are there hot spots that delay ejection? • Where do residual stresses develop? • How much volumetric shrinkage do I have? 20
- 21. © 2018 Virtual Integrated Analytics Solutions Inc. Packing & Cooling Examples o Achieving uniform density o Uniform dimensional stability o Minimizing sink marks How long must I pack the part? Zeroing in on the gate will permit the user to identify the when the gate freezes off Temp at end of packingPressure after filling Pressure at end of packing Volume shrinkage 21 1. 2.
- 22. © 2018 Virtual Integrated Analytics Solutions Inc. SIMULIA Simpoe-Mold • SIMULIA provides a module to simulate the injection molding process “Simpoe-Mold also allows simulation of more advanced processes, such as gas-assisted injection, co-injection molding, bi-refringance, overmolding, multi-shots or multi- domain injection”. • Imports common CAD geometries • Large, customizable material database • Predicts process cycle time • Can be integrated with structural analysis using Abaqus 22
- 23. © 2018 Virtual Integrated Analytics Solutions Inc. Simpoe has been available since 1995 – first as a standalone now available on the 3DEXPEREINCE platform. The 3DEXPERIENCE platform is a business experience platform. It provides software solutions – from marketing to sales to engineering – that help in your value creation process. With a single, easy-to-use interface, it powers Industry Solution Experiences – based on 3D design, analysis, simulation, and intelligence software in a collaborative, interactive environment. Products Powered by SIMPOE Technology 3DEXPERIENCE Apps Plastic Part Filling (FPP) Plastic Part Injection (INK) Plastic Mold Injection (IME) 23
- 27. © 2018 Virtual Integrated Analytics Solutions Inc. Bottle Ideation •Capture the design ideas with CATIA Application: Natural Sketch •Define the material properties Configure the bottle with different sections •Based on Previous Results, configure the bottle with some market information. •Create and assemble several bottles. •With the SIMULIA Application Process composer Optimize the design of the bottle by changing parameters Optimize the volume (Minimize) and the reaction force (Maximize) Design Optimization Management of Parameters •With CATIA Knowledge Parameters, we can manage the parameters of each sections to adjust the size of the bottle Validation Simulation •With the SIMULIA Physical applications create a top compression test •Export Reaction Force (RF3) •Blow molding process Simulation compression •With the SIMULIA Physical applications create several validation simulation (caping, wrapping) •Test the consumer usage with handling tests. Rendering •Creation of realistic rendering Bottle Design With the 3DEXPERIENCE platform
- 28. © 2018 Virtual Integrated Analytics Solutions Inc. Case Study: Thickness Optimization for Blow Molded Bottle • Top Load (TL) thickness optimization • Vary thickness smoothly along bottle height ▪ Use 5 thickness values as optimization parameters • Constraints – minimum TL force > 100 N • Optimization target – minimize mass 2828
- 29. © 2018 Virtual Integrated Analytics Solutions Inc. 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 0 50 100 150 200 250 Target Thickness STH Case Study: Thickness Optimization for Blow Molded Bottle • Mass: 43% reduction • Meets target Top Loading Force 2929
- 31. © 2018 Virtual Integrated Analytics Solutions Inc. • For companies that design plastic parts or injection molds, INK or IME can help users: ➢ Predict and avoid manufacturing defects during the earliest stages of part and mold design ➢ Eliminate costly mold rework ➢ Improve part quality ➢ Decrease time to market • Business value ➢ More than 80% of plastic parts are injection molded ➢ Injection molding is a complex mix of time, temperature, pressure, material & tooling variables ➢ Injection molds range in cost from >$10K to $1M+ and mold rework is costly and time-consuming Plastic Injection Molding Simulation Value Proposition Avoiding Just One Round of Mold Rework can result in a Positive ROI 31
- 32. THANK YOU