杜邦-热塑材料和各向异性材料的仿真
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Test samples
Tensile Testing
Properties Prediction
Numerical Modeling If necessary
Virtual Testing
Material / Microstructure Modeling
9/13/2012
Copyright© 2012 DuPont. All rights reserved
9/13/2012
Autodesk® and Moldflow® are registered trademarks of Autodesk, Inc.
10
Copyright© 2012 DuPont. All rights reserved
Workflow
Rheological Simulation Material Modeling / Mapping
9/13/2012
Copyright© 2012 DuPont. All rights reserved
12
Digimat® Material Properties
9/13/2012
Copyright© 2012 DuPont. All rights reserved
13
Material Model Validation
7
Anisotropy in Glass Reinforced Plastics
Anisotropy produced by: Reinforcements Glass Fibers
Orientation affected by: Injection Molding Process Part / Gate Dimensions
16
3 points bending beam – Moldflow model
Two injection configurations:
Standard: 4 gates opened at same time
Sequential: 1 gate delayed opening
Changes in:
5
Copyright© 2012 DuPont. All rights reserved
Mechanical Properties of Plastic Materials
σ [MPa]
F
ε [%]
9/13/2012
Copyright© 2012 DuPont. All rights reserved
Moldflow® mesh
Ansys® mesh
Mapping OT for Anisotropic analysis with Digimat®
Filling Simulation
9/13/2012
Copyright© 2012 DuPont. All rights reserved
Extract Fiber Orientation Tensor for Structural Analysis
Structural Analysis
11
9/13/2012
Copyright© e-Xstream engineering SA - Image extracted from Digimat® manual
Digimat® Material Properties
Microscopic approach based on mean-field homogenization technique.
Contact defined between the different components Pilot node For CC case: nodes clamped
9/13/2012
Copyright© 2012 DuPont. All rights reserved
19
3 points bending beam – Results 4 gates
18
3 points bending beam – FEA model
Element type: Shell 181 Ansys® Classical V14 No Failure Criteria Multiple Real Constant for different thicknesses Rigid body
CADFEM Forum 2012
Thermoplastic materials and anisotropy in plastic part components
Sulmoni Mattia – DuPont ETC – mattia.sulmoni@che.dupont.com
Summary
Overview DuPont company and DPP products Mechanical properties of GR Thermoplastic materials FEA Approach to simulate anisotropic behavior Practical Study Conclusion / Future Works Q&A
Calculated from constituent phases (polymer and reinforcements) and microstructure morphology.
User defined material specified in Ansys®; Digimat® called for material properties at each load step and for each integration point.
9/13/2012
Copyright© 2012 DuPont. All rights reserved
4
DuPont Performance Polymers Applications
9/13/2012
http://www2.dupont.com/Plastics/en_US/index.html
9/13/2012
Copyright© 2012 DuPont. All rights reserved
9
Anisotropic Approach
Manufacturing
Loading
Ansys® is a registered trademark of Ansys, Inc. Digimat® is a registered trademark of e-Xstream engineering SA.
in general: unreinforced materials ANISOTRPIC
when they DO depend from the X,Y,Z axis direction.
in general: reinforced materials
9/13/2012
Copyright© 2012 DuPont. All rights reserved
9/13/2012
Copyright© 2012 DuPont. All rights reserved
8
How to Simulate GR materials?
Standard Isotropic Method: Knock-down Factor:
σ (mean) = 80 % * σ (flow) = 100 [MPa] E-modulus (mean) = 80 % * E-modulus (flow)
14
3 points bending beam - Equipment
Material: Zytel®70G30HSLR Two set of boundary conditions: free-free and clamped-clamped Testing: multiple T – low / high speed – Aramis system Two injection configurations: 4 gates and sequential 3+1 gates
9/13/2012
Copyright© 2012 DuPont. All rights reserved
2
DuPont Origins – founded in Safety in DuPont: 200 + years story!
DuPont gun powder mills
1802
9/13/2012
12000
TEST 4 gates - CC Digimat 4 gates - CC
10000
ISOTROPIC
Iso 80% reduction - CC Test 4 gates - FF Digimat 4 gates - FF
8000
Iso 80% reduction - FF
TEST ANISOTROPIC
6
Anisotropy iБайду номын сангаас Glass Reinforced Plastics
Material mechanical properties are ... ISOTROPIC
Z Y
ow ion l F ct re i d
X
when they DO NOT depend from the X,Y,Z axis direction.
Copyright© 2012 DuPont. All rights reserved
Early DuPont black powder mill along the Brandywine river, Wilmington, Delaware, US
3
Some key milestones in our history
• Can be good but conservative approach • Does not consider influence of injection process Anisotropic / Orthotropic Method: • Better correlation / accuracy • Increase complexity and CPU time • Need link between Injection Molding and Structural Analysis
TEST 3+1 gates
10000
TEST 3+1 gates - CC Digimat 3+1 gates - CC
8000
Iso 80% reduction - CC
FY [N]
6000
4000
TEST 4 gates
2000
0 0
9/13/2012
Copyright© 2012 DuPont. All rights reserved
9/13/2012
Copyright© 2012 DuPont. All rights reserved
15
3 points bending beam – Moldflow model
Moldflow Element Type: triangular
9/13/2012
Copyright© 2012 DuPont. All rights reserved
10
20
30
UY [mm]
40
50
60
21
3 points bending beam – Results S1
CC - 4 gates
CC – 3+1 gates
9/13/2012
Copyright© 2012 DuPont. All rights reserved
22
Summary
Isotropic Approach: Simple but effective approach with high productivity Scaling factor depends on manufacturing - load case No composite material data required
FY [N]
6000
4000
2000
0 0
9/13/2012
Copyright© 2012 DuPont. All rights reserved
5
10
15
20
UY [mm]
25
30
35
40
20
3 points bending beam - Results
12000
TEST 4 gates - CC Digimat 4 gates - CC
– –
Weld line locations Local fiber orientation
17
9/13/2012
Copyright© 2012 DuPont. All rights reserved
3 points bending beam – Mapping
Moldflow® Meshed Model
Tensile Testing
Properties Prediction
Numerical Modeling If necessary
Virtual Testing
Material / Microstructure Modeling
9/13/2012
Copyright© 2012 DuPont. All rights reserved
9/13/2012
Autodesk® and Moldflow® are registered trademarks of Autodesk, Inc.
10
Copyright© 2012 DuPont. All rights reserved
Workflow
Rheological Simulation Material Modeling / Mapping
9/13/2012
Copyright© 2012 DuPont. All rights reserved
12
Digimat® Material Properties
9/13/2012
Copyright© 2012 DuPont. All rights reserved
13
Material Model Validation
7
Anisotropy in Glass Reinforced Plastics
Anisotropy produced by: Reinforcements Glass Fibers
Orientation affected by: Injection Molding Process Part / Gate Dimensions
16
3 points bending beam – Moldflow model
Two injection configurations:
Standard: 4 gates opened at same time
Sequential: 1 gate delayed opening
Changes in:
5
Copyright© 2012 DuPont. All rights reserved
Mechanical Properties of Plastic Materials
σ [MPa]
F
ε [%]
9/13/2012
Copyright© 2012 DuPont. All rights reserved
Moldflow® mesh
Ansys® mesh
Mapping OT for Anisotropic analysis with Digimat®
Filling Simulation
9/13/2012
Copyright© 2012 DuPont. All rights reserved
Extract Fiber Orientation Tensor for Structural Analysis
Structural Analysis
11
9/13/2012
Copyright© e-Xstream engineering SA - Image extracted from Digimat® manual
Digimat® Material Properties
Microscopic approach based on mean-field homogenization technique.
Contact defined between the different components Pilot node For CC case: nodes clamped
9/13/2012
Copyright© 2012 DuPont. All rights reserved
19
3 points bending beam – Results 4 gates
18
3 points bending beam – FEA model
Element type: Shell 181 Ansys® Classical V14 No Failure Criteria Multiple Real Constant for different thicknesses Rigid body
CADFEM Forum 2012
Thermoplastic materials and anisotropy in plastic part components
Sulmoni Mattia – DuPont ETC – mattia.sulmoni@che.dupont.com
Summary
Overview DuPont company and DPP products Mechanical properties of GR Thermoplastic materials FEA Approach to simulate anisotropic behavior Practical Study Conclusion / Future Works Q&A
Calculated from constituent phases (polymer and reinforcements) and microstructure morphology.
User defined material specified in Ansys®; Digimat® called for material properties at each load step and for each integration point.
9/13/2012
Copyright© 2012 DuPont. All rights reserved
4
DuPont Performance Polymers Applications
9/13/2012
http://www2.dupont.com/Plastics/en_US/index.html
9/13/2012
Copyright© 2012 DuPont. All rights reserved
9
Anisotropic Approach
Manufacturing
Loading
Ansys® is a registered trademark of Ansys, Inc. Digimat® is a registered trademark of e-Xstream engineering SA.
in general: unreinforced materials ANISOTRPIC
when they DO depend from the X,Y,Z axis direction.
in general: reinforced materials
9/13/2012
Copyright© 2012 DuPont. All rights reserved
9/13/2012
Copyright© 2012 DuPont. All rights reserved
8
How to Simulate GR materials?
Standard Isotropic Method: Knock-down Factor:
σ (mean) = 80 % * σ (flow) = 100 [MPa] E-modulus (mean) = 80 % * E-modulus (flow)
14
3 points bending beam - Equipment
Material: Zytel®70G30HSLR Two set of boundary conditions: free-free and clamped-clamped Testing: multiple T – low / high speed – Aramis system Two injection configurations: 4 gates and sequential 3+1 gates
9/13/2012
Copyright© 2012 DuPont. All rights reserved
2
DuPont Origins – founded in Safety in DuPont: 200 + years story!
DuPont gun powder mills
1802
9/13/2012
12000
TEST 4 gates - CC Digimat 4 gates - CC
10000
ISOTROPIC
Iso 80% reduction - CC Test 4 gates - FF Digimat 4 gates - FF
8000
Iso 80% reduction - FF
TEST ANISOTROPIC
6
Anisotropy iБайду номын сангаас Glass Reinforced Plastics
Material mechanical properties are ... ISOTROPIC
Z Y
ow ion l F ct re i d
X
when they DO NOT depend from the X,Y,Z axis direction.
Copyright© 2012 DuPont. All rights reserved
Early DuPont black powder mill along the Brandywine river, Wilmington, Delaware, US
3
Some key milestones in our history
• Can be good but conservative approach • Does not consider influence of injection process Anisotropic / Orthotropic Method: • Better correlation / accuracy • Increase complexity and CPU time • Need link between Injection Molding and Structural Analysis
TEST 3+1 gates
10000
TEST 3+1 gates - CC Digimat 3+1 gates - CC
8000
Iso 80% reduction - CC
FY [N]
6000
4000
TEST 4 gates
2000
0 0
9/13/2012
Copyright© 2012 DuPont. All rights reserved
9/13/2012
Copyright© 2012 DuPont. All rights reserved
15
3 points bending beam – Moldflow model
Moldflow Element Type: triangular
9/13/2012
Copyright© 2012 DuPont. All rights reserved
10
20
30
UY [mm]
40
50
60
21
3 points bending beam – Results S1
CC - 4 gates
CC – 3+1 gates
9/13/2012
Copyright© 2012 DuPont. All rights reserved
22
Summary
Isotropic Approach: Simple but effective approach with high productivity Scaling factor depends on manufacturing - load case No composite material data required
FY [N]
6000
4000
2000
0 0
9/13/2012
Copyright© 2012 DuPont. All rights reserved
5
10
15
20
UY [mm]
25
30
35
40
20
3 points bending beam - Results
12000
TEST 4 gates - CC Digimat 4 gates - CC
– –
Weld line locations Local fiber orientation
17
9/13/2012
Copyright© 2012 DuPont. All rights reserved
3 points bending beam – Mapping
Moldflow® Meshed Model