Plastic Part Design Optimisation using Digital Prototyping Tools

Eric Henry
Manufacturing, Northern Europe

Autodesk Ltd

2006 Autodesk

Autodesk
Customers use our technologies to create digital models and workflows that help p them visualise, , simulate, , and analyse their designs. This enables them to experience their ideas before they are real and improve the real world performance of their projects.

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 2006 Autodesk

The Injection Moulding Process

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Part Defects
Incomplete Surface finish B bbles Bubbles Shape Dimensions Fail in service Many causes!

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Implications of Producing Bad Parts

Extended E tended mould mo ld development de elopment time High production costs C Cannot t deliver d li parts t on ti time Blame culture develops L t to Late t market k t Product failures & recalls Unhappy customer

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The Injection Moulding Process

Pi Primary P Problem bl - Islands I l d of f Automation A t ti

Production Mould Design Part Design

Islands of Automation adds cost and creates quality and process efficiency problems

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Challenges in Plastics Part Design

Complex manufacturing process Thousands of material candidates Part defects discovered in manufacturing Trial & error approach to fix Production and shipping delays Demands of today:
- reduce costs - reduce time to market - increase quality

..Requires Requires Risk Management

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Technology Solutions
Autodesk Inventor Tooling

Integrated Moldflow analysis

Autodesk Moldflow Advisers

Design Manufacturing g Advanced

Autodesk Moldflow Insight

Basic Performance Ad Advanced d

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Key Philosophy
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 thick and thin sections as well as holes PBT material

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Filling Analysis

An air trap is formed in the recessed area area.

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Filling Analysis

An air trap is formed in the recessed area.

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Melt Temperature

An air trap is formed in the recessed area area.

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Confidence of Fill

An air trap is formed in the recessed area area.

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Air Trap Defects

Last areas to fill should be in natural venting positions

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Part Design Change

The depth of the recess in the base is reduced.

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Filling Analysis Modified Design

An air trap is formed in the recessed area area.

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Improved Part Fill

Before

After

The air trap in the recess is eliminated.

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Modified Design

Melt Temperature

Confidence of Fill

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PartDistortion (Warpage)

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Twin Headlamp Carrier

Original design & gate position

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

Mould Temperature

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 atte Analysis a ys s

Moldflow prediction for flow pattern near end of fill

Short shots to show actual flow pattern near end of fill

Short shot digital photos to match above

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Moldflow Results

Mitutoyo Vision Pro Inspection Results

BAG16 SAMPLE 1
0.08 0.06 0.04 0 02 0.02 0 1 -0.02 -0.04 POINTS 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 DEVIATION

The maximum deviation is correct to within 2 microns and the shape of the deflection curve shows a similar trend.

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DEVIA ATION

HDPE Bin Lid Warpage Centre Gated

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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

Without With t Moldflow

With Moldflow

Shrink & Warp

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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Moldflow Export to Showcase

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PartPerformance & ProductFailure

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Product Failure

INDUSTRY: Office Equipment PRODUCT: High Volume Finisher

Broken pivot boss

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INDUSTRY: Office Equipment PRODUCT: High Volume Finisher

Original Design

Cause of failure = High shrinkage in pivot boss

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INDUSTRY: Office Equipment PRODUCT: High Volume Finisher

Modified Design

Acceptable shrinkage in pivot boss

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Product Failure
Crack/failure Parts were observed to crack in the hinge region of predicted maximum shear stress. High stress

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XBox Original Design

An air trap is formed in the recessed area area.

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XBox Original Design Quality

An air trap is formed in the recessed area area.

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XBox Modified Design Quality

An air trap is formed in the recessed area area.

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Weld Line Positions

Actual

Predicted
IP Substrate Moulded part v Moldflow model
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Moldflow to FEA

Primary stiffening cover cover, essential for the entire phone stiffness

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Moldflow to FEA
Following model is used in following structural analyses
Restraints Force

at screw tower locations restraints

to cause bending g and torsion deformation to the cover

Vertical force

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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

Gate location

Fiber orientation

Poor orientation in this area

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Moldflow to FEA

Gate location

Fiber orientation

Good orientation in this area

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Moldflow to FEA
Summary of deflections Gate location Bottom Mid Top Isotropic material Fiber orientation Good Good Poor Max. deflection 4.95mm 4.27mm 5.29mm 3.45mm

Conclusions to gate location with fiber filled material: Influence of gate location is significant 23% on deflection Expected higher influence on fiber orientation Effects of fiber orientations can be quantified Isotropic, homogenous material definition Results differs significantly from models with fiber orientation
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Stress Comparison
Fully integrated analysis:
vonmises=35.9 MPa

Traditional stress analysis:

vonmises=14.4 MPa

Fully F ll i integrated d analysis: l i

vonmises=80.1 MPa

Traditional stress analysis:

vonmises=17.2 17 2 MP MPa

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Fibre Orientation & Mechanical Properties p

Fibre

Modulus

Side Injection
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End Injection

Data Export, Moldflow to FEA

Unfilled Materials

Elastic modulus, Shear modulus & Poissons ratio from Material database Coefficient of thermal expansion (CTE) from Material database Layer-wise (through the thickness of each element) Residual stresses Layer-wise y Elastic modulus, , Shear modulus & Poissons ratio Layer-wise CTE Layer-wise Residual stresses Layer-wise Fiber orientation angle

Fiber-filled Materials

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Algor FEA - Moldflow Interchange

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Enhanced Structural Simulation of Plastic Parts

Enhance accuracy of structural simulations
Import models from FEA Simulation software Map fiber orientation results to FEA Simulation software Moldflow Material database included with Algor FEA Simulation software

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MaterialSelection & Optimisation

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Materials Database

8 400+ Material Grades 8,400+ Evaluate materials options while also considering g the environmental impact of the material

Energy Usage Indicator Resin Identification

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Which Material for the Application ?

Material A = Best Material B = OK Material C = No processing window

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Moulding Window Analysis Automated Design Of Experiments

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Valve Device

Top face flatness tolerance of 0.15mm 3 Material Candidates

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Valve Device
Unfilled POM

Top face deflects 0.64 mm

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Valve Device
30% Glass Filled PET Rynite

Top face deflects 0.19 mm

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Valve Device
33% Glass Filled PPS Ryton

Top face deflects 0.08 mm

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Casestudy - Arad Ltd

Based in Israel Israel, Arad specializes in the design, development p and manufacture of top quality precision water meters for applications li ti such h as domestic, waterworks, irrigation and water irrigation, management throughout the world.

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Water Meter Measuring Chamber

A fundamental and important element of a water meter Original weight of the measuring chamber was g 46g Single cavity mold tool Cycle time of 40 seconds

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Design Change

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Injection Location Change

1 2 3 or 4 injection locations 1,2,3 Compromise

Quality Cycle time Dimensional accuracy Material selection

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Two Cavity Mould

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Conclusions

Original design Weight: 46 g Cycle time: 40 sec Quantity: 420,000/year

Revised design Weight: 30 g Cycle time: 28 sec Quantity: 600,000/year

Saving g of 9600kg g of material p per y year

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Design Innovation (with Moldflow)

f Fuel Flange

Creative design with significant cost savings

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CAD System Design Indicators

3 Indicators

Manufacturability Cost Efficiency Plastic Material Impact (Sustainability)

Instantaneous feedback with

Alerts Model highlighting Design advice

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CAD System Design Indicators

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Feed System Design Optimisation

Easily model and balance all types of hot and cold runner feed systems y and g gating g configurations
Unbalanced

Balanced

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Avenue Mould Solutions

INDUSTRY: Pharmaceutical PRODUCT: Inhaler

30% less part weight 50% less clamp tonnage Mould ran first time

25 000 savings on material in one year 25,000

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Mould Cooling
Optimise mould cooling systems to improve surface appearance, minimise warpage p g & reduce cycle times

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Autodesk Inventor Tooling Suite

g Process Automated Mould Design 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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Additional Applications

2-Shot Overmoulding Sequential Valve Gates Synventive Moulding Design of Experiments Gas Assist Injection Compression Co-Injection Micromoulding Birefringence Thermosets & Rubbers
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Evolving Development Process

Old

Fix

Validate

Optimise

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Plastic Part Product Development

Slo er time to market Slower market, more expensive, lower quality parts, longer cycles times, more scrap, Prototype Tool Trials Modifications more part weight weight, possible part Manufacture defects. X3

Component Design

Tool Design

Process Trials

Manufacture

Time / Money C tti M Cutting Metal t l Slow / Expensive

Manufacture

Component Design

Moldflow Tool Tool and process Trials/ optimised part Analysis FullyDesign Manufacture Verification - faster to market, better parts, reduced cost. Digital Prototyping / Optimisation

Timescale
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Strong ROI
Siemens saved 11k in production costs on 1 tool

Jaguar 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 resulting in early to market & ~18k savings on each design. design

Samsung saved $169K in production costs on 1 design in 1 year year. ROI in less than 12 months

Legrand saved 180k in material costs & reduced cycle times on average between 20-40%. 20 40%

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Digital Prototyping with Autodesk Moldflow Technology

Focus on manufacturability Ensure good parts produced first time Spend less time troubleshooting & more time innovating & optimising Create fewer physical prototypes g different departments/cos p Integrates Get to market faster

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Thank You
Stand 182 Win latest version of Xbox & Guitar Hero
eric henry@autodesk com eric.henry@autodesk.com

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