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© 2013 Autodesk© 2017 Autodesk
Autodesk Moldflow
Moldflow Research & Development
Dr Franco Costa
Senior Research Leader
Slide 2 of 67
Research In-house24 PhD employees in Moldflow development
A Lab with state-of-the-art equipmentFour modern injection molding machines for test & validation
Establishing a network of third-party Labs
Academic Research CollaborationSix Universities with seven PhD students
Industrial Research PartnershipsOver 20 companies and institutions
Research & Development
Slide 3 of 67
Solver Features in Recent Moldflow Releases
Solver & Mesh Features under development
Research Collaborations
Outline
Slide 4 of 67
FeaturesApply properties of a dry fiber mat where needed.
Anisotropic permeability follows the shape of the product.
Detect areas where resin cannot penetrate.
Includes Vacuum Infusion & Gravity effect.
ResultsDegree of Cure, Volumetric shrinkage, Mat orientation, etc.
RTM and SRIM in 3D
Fiber Mat Orientation
Resin Penetration
Slide 5 of 67
Improved 3D Fiber Orientation
Measured data provided by BASFBASF PA 30%GF
Implementation of a New ModelMRD (Moldflow Rotational Diffusion)
0 0.5 1 1.5 2 2.5 3 3.5
Fib
er
ori
en
tati
on
Through thickness, mm
Position C3, orientation A11
Experiment 2017 FCS 2017 R2 (MRD)
Slide 6 of 67
AMI release Constitutive model BASF Bradford Delphi DSM EMS Mechanical Plaque
Number of cases 1 2 23 1 1 1
Number of locations for each case 9 3 3 6 1 1
2017FCSF-T 0.16 0.20 0.14 0.11 0.23 0.17
RSC 0.11 0.12 0.11 0.089 0.16 0.14
2017 R2
F-T 0.091 0.16 0.11 0.079 0.16 0.13
RSC 0.076 0.11 0.10 0.077 0.14 0.10
MRD 0.071 0.11 0.08 0.054 0.12 0.085
Improved 3D Fiber OrientationAverage error of predictions for different releases and constitutive models.Results for the default models are in bold
2017 R2 halves the average error of fiber orientation predictions
Slide 7 of 67
σxx
σyy
-9
-7
-5
-3
-1
1
3
5
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
Measurement (literature) Generic shrinkage model Residual stress model
-8
-6
-4
-2
0
2
4
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
Measurement (literature) Generic shrinkage model Residual stress model
3D Residual Stress PredictionMolded-in residual stress prediction
Experimental data using layer removal method from W.F.Zoetelief, L.F.Douven, and A.J. Ingen Housz. Polymer Engineering and Science, 36(14), 1886-1896
Slide 8 of 67
3D Warp using Residual Stress
Ultramid B3WG6 BK0056,BASF
Since AMI 2017.3:• Residual Stress is the default 3D Warp model• Extended to Thermoset materials• Mesh Aggregation option enabled
Slide 9 of 67
Powder Injection Molding (PIM )
9
Mold filling simulation of Metal Injection Molding (MIM) and
Ceramic Injection Molding (CIM) materials
Predict the powder concentration
Material characterization for PIM is available
Powder concentration
Slide 10 of 67
Including Wall Slip for PIM
Failed to predict initial jetting without Wall Slip
With Wall Slip, predicted initial jetting in PIM simulation, which matched reality better
𝛕𝐜 Critical shear stress 0.01 MPa
m Slip exponent 1
a Constant sip coefficient 1.0e-05
b Temperature dependency 0
c Pressure dependency 0
Slide 11 of 67
Multi-barrel Injection Molding SimulationMaster Barrel with 4 sub-barrel
Delay time 0.25 s and 0.5 s for sub3 and sub 4, respectively
Slide 12 of 67
Use numerical simulation to calculate temperature and cure changes during preconditioning stage
Either use contact conditions to automatically apply temperature boundary conditions or input value specified on elements for the thermal boundary conditions
Result: Temperature and cure distribution at the end of preconditioning stage
Preconditioning – Reactive Compression Molding
Temperature and cure distribution at the end of preconditioning. Initial melt temperature: 50 C
Mold temperature: 175 C
Delay time: 10 sec
Slide 13 of 67
You can now consider cooling rate and pressure effects on Solidification
Solver API - Solidification
van der Beek et. al. Inter. Polymer Processing, 20, 111-120, (2005).
Polycarbonate: Infino EH-1050; Cheil Industries
Tt(P)
Tt(P) = b5 + b6 P
Slide 14 of 67
Autodesk Moldflow Simulation 2017 R21. Wall Slip
2. Resin transfer molding
3. Thermocouple-controlled cooling
4. Heater wattage specification for heater element
Autodesk Moldflow Simulation 2017 R35. CAD meshing support for Linux
6. Synergy Support for Delete CAD bodies
7. Synergy Support for Copy of CAD bodies
8. Support the exporting of STEP files
9. Powder injection molding support
Autodesk Moldflow Simulation 2018.010. Multi-step large vector deformation support (modelling)
11. Multistage support for normal deformations (modelling)
12. User defined initial strain support for Anisotropic inserts (Warp)
13. Preconditioning analysis for reactive compression molding
14. Injection compression overmolding (3D)
New Features for Recent Releases
Research
Slide 16 of 67
Disclaimer
We may make statements regarding planned or future development efforts for our existing or new products and services. These statements are not intended to be a promise or guarantee of future delivery of products, services or features but merely reflect our current plans, which may change. Purchasing decisions should not be made based upon reliance on these statements.
The Company assumes no obligation to update these forward-looking statements to reflect events that occur or circumstances that exist or change after the date on which they were made.
Slide 17 of 67
Extracting Center Lines of CAD Cooling System
Centerline Extraction for CAD Cooling System
Slide 18 of 67
Supports Linux, & Parallelization
Use the Autodesk “Flow Design” Voxel CFD Solver
Faster Conformal (3D) Coolant Flow Solver
Cross section
Voxel mesh
Voxel solve
Voxel results
Moldflow 3D Channel mesh Moldflow results
Pressure
Velocity
Slide 19 of 67
“Underflow severity” as a result
Underflow Diagnostic Plot
Underflow regionviewmold.com
Slide 20 of 67
Core Shell
SkinShell
Skin Skin Orientation
Believed to be due to fountain flow
Adaptive Fiber Model Orientation Prediction
Shell OrientationStrong alignment in flow direction
Alignment controlled by fiber interactions, CI, ARD bi, MRD Di
Core OrientationTransverse or random orientation dependent on flow near gate
Width Controlled RSC factor κ
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Fib
er o
rien
tati
on
ten
sor
com
po
nen
ts
Normalized thickness
A11 (Data) A11 (2018) A11 (Dev) A22 (Data) A22 (2018) A22 (Dev)
Slide 21 of 67
Fiber Concentration
Higher concentration at core while lower concentration at shear region.
Fiber concentration, orientation, & breakage affect mechanical properties.
Measured data: G.M. Vélez-García, Compos. Part A-Appl. Vol 43: 104-113 (2012)
Slide 22 of 67
Warp Accuracy: Thickness Shrinkage for Warpage
MF 2×4mm corner mold (MAT5322 PP)
0
1
2
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Co
rner
an
gle
Cycle
MF 2x4mm Corner Mold with unfilled PP
Experiment Generic shrinkage RS with thickness shrinkage
F. van der Veen corner mold (CM1160 PP)
Wrong bending direction
-12
-10
-8
-6
-4
-2
0
2
4
6
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Corn
er A
ngle
Cycle
F. van der Veen Corner PP
Experiments AMI2017 Generic shrinkage TP2017 Residual Stress
with thickness shrinkage
Slide 23 of 67
Warp Accuracy - Shrinkage Correction by Machine Learning
0.00%
0.10%
0.20%
0.30%
0.40%
0.50%
0.60%
0.70%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Parallel shrinkage
Experiment No CRIMS
Machine Learning CRIMS
• Use Machine Learning to estimate moldedshrinkage
• Provide CRIMS correction for non-shrinkage characterized grades
Slide 24 of 67
0
0.2
0.4
0.6
0.8
1
-40.0
-30.0
-20.0
-10.0
0.0
10.0
20.0
30.0
40.0
-0.5
-0.4
-0.3
-0.2
-0.1
0.0
0.1
0.2
0.3
0.4
0.5
DISTANCE FROM GATE, x/L
ST
RE
SS
_2
2 (M
Pa
)
DIMENSIONLESS THICKNESS, z/h
Stress relaxation (viscoelastic)Long cooling time effectIn-mold shrinkageLiquid portion at ejection Solidification sequence effect
Warp Accuracy - Anisotropic Thermo-Viscoelastic Stress Model
Slide 25 of 67
Ejection Force
Automatic Detecting based on ejectors movement
direction
User check, add or remove surface
elements manually
Final contact surface
Von Mises Stress During Ejection
Slide 26 of 67
Calculate the mold life and approximated range of cycles.
Mold Fatigue
Clamping-force-induced Stress
Thermal Stress
Pressure-induced Stress
Mold Fatigue
Slide 27 of 67
Features: Minor Loss, Friction formula, Simulate energy equation, & Simulate gravity
New results: K factor, & Friction factor
Cooling Network Only Analysis
Slide 28 of 67
Completed Projects
Long Carbon Fiber Orientation and Breakage - PNNL
Ongoing Projects
Composites Injection Overmodling – TPRC
Microcellular Foaming – Univ of Toronto
Fiber Effect on Viscosity – RMIT (Melbourne)
Composites Compression Overmolding – HUST
Fiber breakage in Barrel – Univ of Bradford
SMC Compression Molding – Ford
Long Carbon Fiber Orientation and Breakage – GM
Yokoi Injection Molding Consoritum – Univ of Tokyo
Overview of Moldflow External Research Collaborations
Slide 29 of 67
Prediction of fiber orientation and breakage during injection molding of “long” carbon fiber thermoplastics
Long Carbon Fiber Thermoplastic: Fiber Length
Comparison of measured and predicted fiber length distribution
Slide 30 of 67
Prediction of long fiber breakage during melting in injection barrel
Aim: Initial fiber length distribution for polymer at the sprue tip
Fiber Breakage in Barrel
Slide 31 of 67
Fiber breakage in barrel
Observing Fountain Flow Oscillation (Tiger Stripe)
Flow Imbalance (Race-Track)
Yokoi Injection Molding Consortium
Yokoi et al. PPS-31, 144-148 & 350-354
Slide 32 of 67
Model the change in viscosity due to filler migration, fiber orientation and fiber breakage
Filler Effect on Viscosity - RMIT
Slide 33 of 67
Model non-recoverable deformation and resistance of a continuous fiber composite (pre-preg) being compression overmolded
Composite Overmolding
320mm
Slide 34 of 67
Bubble effects on fiber orientation
Microcellular Injection Molding
Bubble nucleation or growth and the final foam structure(Microcellular Plastics Manufacturing Lab, Univ. Toronto)
Slide 35 of 67
Injection Overmolding on Continuous Fibers Composites
G/PA6 laminate + unfilled PA6
Interfaces AniForm draping solution to Moldflow Warp analysis of the combined structure
Models bond strength
Slide 36 of 67
US DOE funding to develop ICME for carbon fiber draped and compression molded parts (Automotive)
Autodesk Moldflow was invited to provide process modeling of
Compression molding, Fiber Orientation, & Local fiber volume fraction
Chopped Carbon Fiber Compression
Slide 37 of 67
Flow instability mechanism understood.
Potential collaboration to study appearance factors (aimed at Automotive parts)
Surface Appearance (Tiger Stripes)
Slide 38 of 67
University of Bradford (UK)Long Fiber Orientations, & Fiber breakage in barrel
Tokyo UniversityFiber breakage visualization, & Race track visualization
RMIT University (Australia)Effect of fiber and filler migration to change viscosity, & Thermal stresses in SLM 3D Printed parts
Huazhong University of Science and TechCompression Overmolding of Continuous Fiber Composites
University of TorontoMicrocellular bubble formation
University of WyomingProgressive failure of composites
Academic Research Collaborations
Slide 39 of 67
Long Carbon Fiber Thermoplastics (Injection Molded)Pacific Northwest National Labs, & GM
Chopped Carbon Fiber Thermoset (Compression Molded)Ford, Dow, Northwestern University
MicrocellularTrexel, University of Toronto, & Ford
Thermoplastic Composite OvermoldingTPRC (The Netherlands), Boeing, Fokker, Johnson Controls, Victrex
Industry Research Partnerships
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