Moldex3D在奧托立夫中國區(qū)技術中心流體仿真中的成功應用案例介紹

IntroductionofSuccessfulCasesofMoldex3DPlasticMoldFlowSimulationinAutolivMoldex3DSimulationCasesinAutolivMarch24,2017AutolivGeneralPresentation20172Moldex3DSimulationCasesinAutolivMoldex3DSimulationCasesinAutolivMoldex3DSimulationCasesinAutolivMarch24,2017AutolivGeneralPresentation20175Moldex3DSimulationCasesinAutolivSinkmarkdisplacement@thinMarch24,2017AutolivGeneralPresentation201760.5mm

R0.1Sensornode15,22.5,30,37.5,45,60,90,120OutlineWhatkindofplasticproductsareusuallydevelopedinALV?WhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?Whywedomoldflowsimulations?Howwedomoldflowsimulations?SuccessfulcasesinCTCCAE.PUFoamingCorrelationQ/AMarch24,2017AutolivGeneralPresentation20177WhatkindofplasticproductsareusuallydevelopedinALV?Productspecification1.1SeatBelt(SB)1.2DriverAirBag(DAB)1.3PassengerAirBag(PAB)1.4InflatedCushion(IC)1.5Sideairbag(SAB/KAB)1.6Steeringwheeling(SW)1.7ActiveSafety(AS)March24,2017AutolivGeneralPresentation20178WebbingguidePillarloopTonguePLPcoverPLPsleeveWhatkindofplasticproductsareusuallydevelopedinALV?Productspecification1.1SeatBelt(SB)1.2DriverAirBag(DAB)1.3PassengerAirBag(PAB)1.4InflatedCushion(IC)1.5Sideairbag(SAB/KAB)1.6Steeringwheeling(SW)1.7ActiveSafety(AS)March24,2017AutolivGeneralPresentation20179DABCoverDABHousingDABemblemWhatkindofplasticproductsareusuallydevelopedinALV?Productspecification1.1SeatBelt(SB)1.2DriverAirBag(DAB)1.3PassengerAirBag(PAB)1.4InflatedCushion(IC)1.5Sideairbag(SAB/KAB)1.6Steeringwheeling(SW)1.7ActiveSafety(AS)March24,2017AutolivGeneralPresentation201710PABHousingNewconceptPABHousingWhatkindofplasticproductsareusuallydevelopedinALV?Productspecification1.1SeatBelt(SB)1.2DriverAirBag(DAB)1.3PassengerAirBag(PAB)1.4InflatedCushion(IC)1.5Sideairbag(SAB/KAB)1.6Steeringwheeling(SW)1.7ActiveSafety(AS)March24,2017AutolivGeneralPresentation201711ICframeB-pillarRAMPWhatkindofplasticproductsareusuallydevelopedinALV?Productspecification1.1SeatBelt(SB)1.2DriverAirBag(DAB)1.3PassengerAirBag(PAB)1.4InflatedCushion(IC)1.5Sideairbag(SAB/KAB)1.6Steeringwheeling(SW)1.7ActiveSafety(AS)March24,2017AutolivGeneralPresentation201712SABCoverKABCoverWhatkindofplasticproductsareusuallydevelopedinALV?Productspecification1.1SeatBelt(SB)1.2DriverAirBag(DAB)1.3PassengerAirBag(PAB)1.4InflatedCushion(IC)1.5Sideairbag(SAB/KAB)1.6Steeringwheeling(SW)1.7ActiveSafety(AS)March24,2017AutolivGeneralPresentation201713BackshellPURfoamingGarnishWhatkindofplasticproductsareusuallydevelopedinALV?Productspecification1.1SeatBelt(SB)1.2DriverAirBag(DAB)1.3PassengerAirBag(PAB)1.4InflatedCushion(IC)1.5Sideairbag(SAB/KAB)1.6Steeringwheeling(SW)1.7ActiveSafety(AS)March24,2017AutolivGeneralPresentation201714ECUCoverOutlineWhatkindofplasticproductsareusuallydevelopedinALV?WhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?Whywedomoldflowsimulations?Howwedomoldflowsimulations?SuccessfulcasesinCTCCAE.PUFoamingCorrelationQ/AMarch24,2017AutolivGeneralPresentation201715WhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?March24,2017AutolivGeneralPresentation201716Global

ResinTeamwebsiteWhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?March24,2017AutolivGeneralPresentation201717GuidebyPropertiesPurpose:Thepurposeofthis

guideistoenabledevelopmentanddesignteamstoselecttherightthermoplasticmaterialfortheirparts.WhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?March24,2017AutolivGeneralPresentation201718GuidebyPolymerClassMarch24,2017AutolivGeneralPresentation201719GuidebyApplicationSeatbeltResinListWhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?WhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?March24,2017AutolivGeneralPresentation201720GuidebyApplicationAirbagHousing

ResinListWhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?March24,2017AutolivGeneralPresentation201721GuidebyApplicationAirbagCover

ResinListWhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?March24,2017AutolivGeneralPresentation201722GuidebyApplicationSteeringWheel

ResinListOutlineWhatkindofplasticproductsareusuallydevelopedinALV?WhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?Whywedomoldflowsimulations?Howwedomoldflowsimulations?SuccessfulcasesinCTCCAE.PUFoamingCorrelationQ/AMarch24,2017AutolivGeneralPresentation201723Whywedomoldflowsimulations?Earlierstageofdevelopment(Beforemoldtooldesign/manufacture)1.Predictfillpattern(shortshot,airtraps,thicknessdistribution,…)2.Predictinjectionpressure(injectionmachine,hot/coldrunner,…)3.Determineclamptonnage(injectionmachine/ton)4.Locateweld(knit)lines(surfacequality,strength,…)5.Determinefiberorientation(strength,…)6.Findhotspots(coolingchannellayout…)7.Determinecooling(andreduce)cycletime8.Predictwarpage(ifitisacceptable)March24,2017AutolivGeneralPresentation201724Changepartgeometry/materialWhywedomoldflowsimulations?Laterstageofdevelopment(aftermoldtooldesign/manufacture)1.Optimizegating/Optimizerunnersystem(refertoissue)2.Optimizethecoolinglayout(refertoissue)3.Optimizeinjectionspeed/pressure(refertoissue)4.Defineoptimumpackingprofile(refertoissue)Changepartgeometry/processparameters/coolingchannellayoutMarch24,2017AutolivGeneralPresentation201725OutlineWhatkindofplasticproductsareusuallydevelopedinALV?WhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?Whywedomoldflowsimulations?Howwedomoldflowsimulations?SuccessfulcasesinCTCCAE.PUFoamingCorrelationQ/AMarch24,2017AutolivGeneralPresentation201726Howwedomoldflowsimulations?March24,2017AutolivGeneralPresentation201727.stepformat.CATPARTformatPart3DMeshfile.stlformatMoldflowModelfilePre-ProcessingCoolingchannelsRunnerEarlystageLaterstageRunnerCoolingNoneedProvideHowwedomoldflowsimulations?ProcesssettingFilling/PackingsettingFillingrateprofileFillingpressureprofileHowwedomoldflowsimulations?ProcesssettingInjectionmachineinformationCoolingsettingsPackingpressureprofileHowwedomoldflowsimulations?ProcesssettingAnalysissequencesettingHowwedomoldflowsimulations?Post-ProcessingFillinganimationHowwedomoldflowsimulations?Post-ProcessingOutlineWhatkindofplasticproductsareusuallydevelopedinALV?WhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?Whywedomoldflowsimulations?Howwedomoldflowsimulations?SuccessfulcasesinCTCCAE.PUFoamingCorrelationHowtorequestamoldflowsimulationtask?Q/AMarch24,2017AutolivGeneralPresentation201733SuccessfulcasesinCTCCAECase1XXX

PillarLoopMarch24,2017AutolivGeneralPresentation201734ProblemSimulationSolutionTestResultsaddrib

andincreasethicknessWeldlinevisibleCRACKSuccessfulcasesinCTCCAECase2XXXDABHousingMarch24,2017AutolivGeneralPresentation201735ProblemSimulationSolutionTestResultsCrackinLTdeploymentWeldlineWeldlineaddthickness

andincreaseradiusBadFiberOrientationSuccessfulcasesinCTCCAECase3XXXDABCoverMarch24,2017AutolivGeneralPresentation201736ProblemSimulationSolutionTestResults12HCrackindeploymentOK,NoCrackSuccessfulcasesinCTCCAECase4XXX

PABHousingMarch24,2017AutolivGeneralPresentation201737ProblemSimulationSolution1TestResults1CrackindeploymentCrackagainIncrease10degreeofmelt/tooltemperatureSuccessfulcasesinCTCCAECase4XXX

PABHousingAutolivGeneralPresentation2017Solution2TestResults2NocrackSuccessfulcasesinCTCCAECase5XXX

TongueMarch24,2017AutolivGeneralPresentation201739ProblemSimulationSolutionTestResultsCrackinhigh-low(-35~100degree)temperatureduringtestOK,NoCrackSuccessfulcasesinCTCCAECase6XXX

PABCoverMarch24,2017AutolivGeneralPresentation201740ProblemSimulationSolutionTestResultsWarpagelargerthantoleranceApprovedbyCustomerAddacoollineSuccessfulcasesinCTCCAECase7

XXX

EmblemMarch24,2017AutolivGeneralPresentation201741ProblemSimulationSolutionTestResultsLackofmaterialatthispinWhenhotairhandle關于熱風焊塌料的問題根本原因在于：進膠點位置的料剪切應力較大，導致進膠點位置膠料密度不夠，熱風熔化塌陷產品進澆口由潛熱熔柱改成潛膠片，對應澆口位置增加膠片OKSuccessfulcasesinCTCCAECase8XXXPillarLoopMarch24,2017AutolivGeneralPresentation201742ProblemSimulationSolutionTestResultsCrackatsledtestShearStress=20.8665[MPa]Allowedstressis0.5MPa.SupplierchangeinjectionmachineandnotinformALV!1.Usebeforemachine2.UselowinjectionspeedNCMisnotclosedyetSuccessfulcasesinCTCCAECase9XXXDABCOVERProblemSimulationSolutionTestResultsThereare3placeswherebigcrackhappenduringdeployment@HT/LTCAEsuggestionWallthicknessIncreaseStraightTearseamchangetocurveSuccessfulcasesinCTCCAECase10XXXDABCOVERProblemShrinkageglossdifferenceSuccessfulcasesinCTCCAECase10XXXDABCOVERSimulationSolutionTestResultsOriginalupdatedSuccessfulcasesinCTCCAECase10XXXDABCOVERTestResultsOriginalUpdatedSuccessfulcasesinCTCCAECase11XXXTongueProblemSimulationSolutionTestResultsTonguegotcrackafter3cyclesthermalshocktest.(onecycle:30℃/3h100℃/3h).NextpagesTool1DateNameofpresentation48Injectionspeedislow

testSimulation射出圧力波形（実數(shù)値）射出速度波形（実數(shù)値）射出圧力波形（設定値）射出速度波形（設定値）75bar(91.5MPa)20%=26mm/sCase11XXXTongueTool2DateNameofpresentation49

testSimulation射出圧力波形（実數(shù)値）射出速度波形（実數(shù)値）射出圧力波形（設定値）射出速度波形（設定値）85bar(103.7MPa)25%=32mm/sCase11XXXTongueProblemintool3parameterTextDateNameofpresentation50Injectionpressureisnotenough!Setting80MPaInjectionspeedisveryslowly@crack112233441212Case11XXXTongueSuggestedparameterintool3DateNameofpresentation51CurrentSuggested

30mm/s120MPa3s40MPaCase11

XXXCLTTongueTool3-ProposalProcessresultDateNameofpresentation52

testSimulationCase11XXXTongueSuccessfulcasesinCTCCAECase11XXXTongueTestResultsOutlineWhatkindofplasticproductsareusuallydevelopedinALV?WhatkindofplasticmaterialsareusuallyappliedinALVplasticproducts?Whywedomoldflowsimulations?Howwedomoldflowsimulations?SuccessfulcasesinCTCCAE.PUFoamingCorrelationQ/AMarch24,2017AutolivGeneralPresentation201754R15.CAESETTINGSeptember19,2017Nameofpresentation55Runne