29-9-Lezing-5-Autodesk

7/28/2019 29-9-Lezing-5-Autodesk

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Plastic Part Design Optimisation using

Manufacturing, Northern Europe

Autodesk Ltd

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create digital models and workflowsthat hel them visualise, simulate,and analyse their designs.

This enables them to experience theirideas before they are real andimprove the real world performance

of their projects.

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Incomplete

Surface finish

u es

Shape

Dimensions

Fail in service

Many causes!

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Implications of Producing Bad Parts

x u v

High production costsanno e ver par s on me

Blame culture develops

a e o mar eProduct failures & recalls

Unhappy customer

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The Injection Moulding Process

rmary ro em - s an s o u oma on

Production

Part Design

Mould Design

Islands of Automation adds cost and creates qualityand process efficiency problems

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Complex manufacturing process

Thousands of material candidates

Part defects discovered inmanufacturing

Trial & error approach to fix

Production and shipping delays

- reduce costs

-

- increase quality

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Integrated Moldflowanalysis

Design

Manufacturing

Advanced

Autodesk Moldflow Insight

Basic

Performance

vance

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Design for manufacture

Right first time

Best part quality at minimum cost

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Cover Part

Approx 33 x 66 x 58 mm

General wall thickness approx

2.5 mm

Contains a combination of thickand thin sections as well as

holesPBT material

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An air trap is formed in the recessed area.


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Last areas to fi ll should be in natural venting positions

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The depth of the recess inthe base is reduced.

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Before After

The air trap in the recess is eliminated.

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Confidence of FillMelt Temperature

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PartDistortion(Warpage)

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Twin Headlamp Carrier

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Glass Filled Polypropylene


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Part Distortion Original Design

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Part Distortion Original Design

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Isolate Cause of Distortion

MouldTemperature

Thickness

Variation

Gate Position

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Warpage Solutions

End Gated PC/ABS, original gate position

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Twin Headlamp Carrier

With reinforcing rib

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Distortion with Reinforcing Rib

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Fill Pattern Anal sisMoldflow prediction forflow pattern near end of fill

Short shots to show actualflow pattern near end of fill

Short shot digital photos to match above

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Mitutoyo Vision Pro Inspection ResultsMoldflow Results

BAG16 SAMPLE 1

0.08

0.04

0.06

TIO

N

-0.02

0

.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

DEVI

-0.04

POINTS

The maximum deviation is correct towithin 2 microns and the shape of the

deflection curve shows a similar trend.

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SinkMarks&

InternalVoids

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Sink Marks & Voids

Figure 25.

Areasofpossiblevoidformation

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Example: Typical CAD Digital Prototype

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Components Internal Features (Ribs/Bosses)

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Internal Features Lead to Sink Marks

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Defect Visualisation

Sink marks

ouMoldflow

Moldflow

Shrink &Warp

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CAD Model in Showcase


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Fine Grain Surface Finish

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Coarse Grain Texture can hide defects

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PartPerformance&ProductFailure

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INDUSTRY: Office EquipmentINDUSTRY: Office Equipment

d il


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q p

PRODUCT: High Volume Finisher

q p

PRODUCT: High Volume FinisherProduct Failure

Broken pivot boss

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q p


q p


Original Design

Cause of failure =High shrinkage in

pivot boss

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PRODUCT: High Volume FinisherPRODUCT: High Volume Finisher

Modified Design Acceptable shrinkage in pivot boss

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Product Failure


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Product Failure

Crack/failureParts were observed tocrack in the hinge region of

predicted maximum shearstress.

High stress

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Weld Line Positions


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Weld Line Positions

Actual

Predicted

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IP Substrate Moulded part v Moldflow model

M l fl t FEA


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M l fl w t FEA ,for the entire phone stiffness

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Moldflow to FEA


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Moldflow to FEA

Following model is used in following

Restraints at screw tower locations

Force to cause bendin and torsiondeformation to the cover restraints

Vertical force

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Moldflow to FEA


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Moldflow to FEA

Material PA, Zytel HTN53G50HSLR (DuPont) (50%Glass))

Gate location Fiber orientation

Good orientation in this area

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Moldflow to FEA


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Moldflow to FEA


Poor orientation in this area

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Moldflow to FEA


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Moldflow to FEA


Good orientation in this area

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Moldflow to FEA


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Moldflow to FEA

Summary of deflections

Gate location Fiber orientation Max. deflection

Bottom Good 4.95mm

Mid Good 4.27mm

Top Poor 5.29mm

Isotropic material 3.45mm

Conclusions to gate location with fiber filled material: Influence of gate location is significant 23% on deflection

Effects of fiber orientations can be quantified

Isotropic, homogenous material definition

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Fully integrated analysis:

vonmises=35.9 MPa

vonmises=14.4 MPa

Fu y ntegrate anays s:

vonmises=80.1 MPa

Traditional stress analysis:

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vonmises= . a

Fibre Orientation & Mechanical Pro erties


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Fibre Orientation & Mechanical Pro erties

Fibre

Modulus

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Unfilled Materials

Elastic modulus, Shear modulus & Poissons ratio from Materialdatabase

Coefficient of thermal expansion (CTE) from Material database

Layer-wise (through the thickness of each element) Residual

Fiber-filled Materials La e -wise Elastic modulus, Shear modulus & Poissons ratio

Layer-wise CTE

Layer-wise Residual stresses

Layer-wise Fiber orientation angle

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Enhanced Structural Simulation of


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Plastic Parts

simulations

Import models from FEASimulation software

Map fiber orientation results to

FEA Simulation software

included with Algor FEASimulation software

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MaterialSelection

&

Optimisation

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,

Evaluate materials options

while also considerin theenvironmental impact of thematerial

Energy Usage Indicato

Resin Identification

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Which Material for the Application ?


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Material A = Best

Material B = OK

Material C = No

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processing windowMoulding Window Analysis

Automated Design Of Experiments

Valve Device


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Top face flatness tolerance of 0.15mm

3 Material Candidates

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Valve Device


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Unfilled POM

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Valve Device


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30% Glass

Filled PETRynite


Valve Device


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33% Glass

Filled PPSRyton


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,specializes in the design,

develo ment andmanufacture of top qualityprecision water meters forapp ca ons suc as

domestic, waterworks,,

management throughoutthe world.

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element of a water meter

measuring chamber was46g

Single cavity mold tool

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, ,

Compromise

Cycle time

Material selection

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Weight: 46 gCycle time: 40 sec

Weight: 30 gCycle time: 28 sec

Quantity: 420,000/year Quantity: 600,000/yea

Savin of 9600k of material er ear

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f Fuel Flange

Creative design with significant cost savings

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AD t mD i n In i t r


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3 Indicators

Manufacturability

Cost Efficiency

Plastic Material Impact (Sustainability)

Instantaneous feedback with

Alerts

Model highlighting

Design advice

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types of hot and cold runner

feed s stems and atinconfigurations

Unbalanced

Balanced

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Avenue Mould Solutions


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INDUSTRY: PharmaceuticalINDUSTRY: Pharmaceutical

PRODUCT: InhalerPRODUCT: Inhaler

30% less part weight

50% less clamp tonnage

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to improve surface appearance,

minimise war a e & reducecycle times

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Automated Mould Design Process

Integrated Moldflow Functionality

Best in Class simulation

Gate location, Filling, Shrinkage analysis

Process settings, Weld Lines, Air Traps

Comprehensive Material Library

Powered By

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Overmoulding

Synventive Moulding

Gas Assist

Co-Injection

Birefringence

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Old

Fix

Validate

Optimise

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Component Tool Prototype Tool Trials Modifications Process Manufacture

w ,expensive, lower quality parts,

longer cycles times, more scrap,

Design Design Manufacture Trials

X3Time / Money

,defects.

Moldflowuttng eta

Slow / Expensive

ComponentDesign

ToolDesign

ToolManufacture

Trials/Verification

ManufactureAnalysis Fully optimised part and process- faster to market, better parts,

reduced cost.

Digital Prototyping /Optimisation

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Siemens saved 11k in production costs on 1 tool

J aguar reduced scrap from 42% to 7%,saving 600k on 1 design.

Microsystems achieved a 6 weeks time to market reduction &reduced cycle times by ~35%.

5 weeks of development time removed from most project timelines.

Samsung saved $169K in production costs on 1

Legrand saved 180k in material costs & reduced cycle times

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Ensure good parts produced first time

Spend less time troubleshooting &more time innovating & optimising

Create fewer physical prototypes

Inte rates different de artments/cos

Get to market faster

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Thank You

Win latest version of

. .

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Documents

29-9-Lezing-5-Autodesk