pps proceeding - Abstract Preview
pps proceeding
Symposium: S04 - Injection Molding and Molds
Poster Presentation
 
 

Deformation analysis of an Automotive Part by Injection Molding Simulation: Influence of Material data and Mold Modelling on Prediction Quality.

Luger Hans-Jürgen (1)*, Berger Gerald (1), Müller Florian (1), Friesenbichler Walter (1), Beythollahi Irmgard (2), Filz Paul (3)

(1) Montanuniversitaet Leoben, Department of Polymer Engineering and Science - Leoben - Austria, (2) Magna Auteca AG - Krottendorf - Austria, (3) simcon kunststofftechnische Software GmbH - Würselen - Germany

Injection molding simulation is nowadays commonly used in the development process of plastic parts. As a “front-loading” tool it supports engineers finding and solving problems occurring in early states of part design. Lately, simulation tools are additionally used for the calculation of process windows enabling feasibility studies and further virtual process optimization. One of the most demanding sectors in terms of part quality as well as accuracy is the automotive industry. The virtual calculation of the final part deformation is crucial for reducing development costs. However, accurate simulation results not only depend on good calculation models, but also on proper mold modelling and precisely measured material data under correct process conditions. In this paper, the deformation of a round shaped automotive part was simulated with Cadmould® 3D-F 6.0 and compared with experimental obtained results. A detailed model of the mold was created, which includes hot runner and cooling systems. Moreover, sufficient mesh density was ensured. The used material was a fiber reinforced thermoplastic polyethylene-terephthalate and its material data for first simulations was provided by the producer. In order to increase accuracy of the shrinkage and warpage simulation thermal conductivity and specific heat capacity were measured temperature dependent. Furthermore, pvT-data was remeasured indicating large differences in comparison to the producer`s data. Special attention had been drawn to the transition temperature. By implementing the new material data the maximum deviation in shrinkage and warpage results between simulation and experimental measurements could be reduced from 1 % to 0.25 %.