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Improved Quality Prediction of Injection Molded Fiber Reinforced
Components by Considering Fiber Orientations
Sascha Pazour
PART Engineering GmbH
0049 2204 30677 26
© PART Engineering GmbH, www.part-gmbh.de
Plastics
CAE Services & Software
Technical Simulation Contract Simulation Services
in FEA
CAE Staffing Resident Engineers at
customers‘ sites
CAE Software - Process-Structure-Interaction
- Strength & Fatigue Assessment
Metals
S-Life
Elastomers
Mechanical Solver Injection Moulding
Solver
- Moldflow
- Cadmould
- Sigma
- Moldex
- Fluent
- Simpoe
- 3D Timon
- Abaqus
- Ansys
- Radioss
- Nastran
- Marc
- FEMFat
- Ncode
Orientations
Pressures
Temperatures
Wall Thicknesses
Residual Stresses
Shrinkage & Warpage
Fig. 2
material:
PA6+GF30
perpendicular
parallel
Influence of Fiber Orientation onto Material Properties Fig. 3
Fiber Orientations in Short-Fiber-Reinforced Plastics
S1 Shear layer: Fibers oriented parallel to flow direction
S2 Mid layer: Fibers oriented perpendicular to flow direction
Fig. 4
Flow Direction X
X
Cut View X
Flow Direction
S1
S2
S1
Isotropic and Orthotropic Material Models
for Multiaxial Loading
s11
s33
s22
t32
t13
t12
t23 t21
t31
Isotropic Material Model
Orthotropic Material Model
Fig. 5
2*
3* 1*
local system
(orthotropic system)
needs 2 material properties: Tensile Modulus E and Poisson ratio
needs 9 material properties:
Tensile modulii the 3 orthotropic axes E1, E2, E3
Shear modulii the 3 orthotropic planes G12, G13, G23
Poisson ratios 12, 13, 23
Further the position of the orthotropic axes (local element coordinate sytem)
with reference to the global coordinate system is needed
1
3 2 global system
(part coordinate system)
Influence of Weld Lines
weld line
isotropic orthotropic
injection molding simulation simulated fiber directions in
the weld area
radial
displacement
Fig. 6
Fiber Orientation and Anisotropic Material
Fig. 7
Orientations and Degree of Orientations
from Injection Molding Simulation
shear layer mid layer
Fig. 8
Mesh Topology Fig. 9
Converse IM solver mechanical solver
shell (mid-plane/surface) => shell (tria, quad)
shell (mid-plane/surface) => solid (tet, hex)
solid => solid (tet, hex)
unequal meshes
possible
Material Dialog Fig.10
0
200
400
600
800
1000
1200
1400
0 1 2 3 4 5 6
Kra
ft [N
]
Verschiebung [mm]
Messung 1
Messung 2
isotrop
orthotrop
Rotary Valve
material: Grivory HTV 3H1
forc
e [N
]
displacement [mm]
test 1
test 2
FEA isotropic
FEA anisotropic
Fig. 11
Example: Air Intake Manifold
material: Ultramid A3WG6
shear layer mid layer
Fig. 12
Comparison of Eigenfrequencies and Eigenmodes
for Isotropic and Orthotropic Analysis
0
100
200
300
400
500
600
700
800
900
1000
250,00 270,00 290,00 310,00 330,00 350,00 370,00 390,00
eff
ektive M
asse
[g]
Frequenz [Hz]
x-Richtung - isotrop y-Richtung - isotrop z-Richtung - isotrop
x-Richtung - orthotrop y-Richtung - orthotrop z-Richtung - orthotrop
x-direction-isotropic
x-direction-anisotropic
y-direction-isotropic
y-direction-anisotropic
z-direction-isotropic
z-direction-anisotropic
frequency [Hz]
effe
ctive
ma
ss [kg
]
Fig. 13
Benefit of Anisotropic lin.-elast. FEA
• determination of initial part stiffnesses Stiffness
• application in the scope of strength assessments Strength
• unrestricted application in the scope of eigenfrequency extraction and response behavior analyses (due to linearization and small displacements/ amplitudes)
Frequency
• Significantly improved estimation of design limits Design
Fig. 14
Fig. 15
www.part-gmbh.de What´s New?
consider the real part properties
get better predictions of
strength & deformation
by using data already
available
integrates smoothly into
your day-to-day CAE routines
straigthforward easy-to-use
Fig. 16