7. CONNECT! European Moldflow® User Meeting
on June 21st and 22nd, 2016 in Frankfurt/Main
Dear Moldflow community,
once again we cordially invite you to this year's Moldflow User Meeting on 21 and 22 June 2016 in Frankfurt.
For more information on the venue, program, registration, accommodation etc. please visit the event's website www.connect.moldflow.eu.
Besides the professional part the CONNECT! offers the possibility for personal interaction with other Moldfow users or Autodesk staff during the breaks as well as during the evening event.
The conference will be complemented with a sporting program point, the "Hot Runners” who meet in the morning of the second day for a 30 minutes run. Pack your running shoes and join us. Employees of MF SOFTWARE and Autodesk will welcome you.
Please remember to register in time!
We look forward to many interesting lectures and tutorials, a varied social program and not least many participants.
In the following please find the presentation of some additional lectures. All lectures will be translated by simultaneous interpreters (English – German and vice versa).
An integrative simulation approach for injection-molded short fiber-reinforced plastics enables the consideration of process-induced morphologies like locally varying fiber orientations. The knowledge of these process-induced micromechanical characteristics is gained by conducting injection molding simulations and transferring them into structural Finite Element (FE) analyses in combination with corresponding mechanical material parameters. This combined approach is essential in order to obtain high quality FE analysis results.
Commonly, early stages of product development processes are characterized by a high degree of uncertainty. Often, detailed information about the injection molding process or about mechanical material parameters required for a comprehensive application of an integrative simulation chain are only partially or even not available. In this contribution, these uncertainties are focused by analyzing the impact of different parameter variations on the final structural simulation results.
Dr.-Ing. Jan-Martin Kaiser, Robert Bosch GmbH (D)
After graduating in production technology and mechatronics at the University of Saarland Jan-Martin Kaiser remained at the University as a research assistant.
In 2013 he received his doctorate on the subject of "contribution to the micromechanical calculation of short fiber reinforced plastics - deformation and failure" and with it he started his career at Robert Bosch GmbH as a research engineer in the Corporate Sector Research and Advance Engineering: Polymer Technology.
The decorative, dimensional and functional demands on plastic components are steadily increasing while the required time for the development and industrialization of the products is decreasing.
This results in less time for any optimization loops of the components.
In conclusion, a greater attention must be paid in the product development phase for an optimum degree of plastics-oriented design of the components. In order to evaluate which part geometry is the "better" one the simulation can be a great support.
Furthermore the simulation offers the possibility to estimate the impact of the tool on the product quality and the process.
The simulation tries to illustrate accurately reality by mathematical models etc. But because of material and process influences the results of simulation results cannot be transferred 1: 1 to reality.
How accurate simulation results are can be determined by comparison with real parts. This will be explained in the presentation on the example "air flow heat pump dryer".
Dipl. –Ing. Thomas Homsma, Miele & Cie. KG (D)
Thomas Homsma graduated in plastics engineering at the University of Darmstadt in 2006, before that he gained practical experience as a qualified injection moulding technician.
After the thesis he started his career as a supervisor for plastic items at an automotive supplier in the field of lighting technology. Amongst others he was responsible for the qualification of injection molding tools.
Since seven years Thomas Homsma is working for Miele & Cie. KG in the equipment production and he is engaged in the industrialization of resources and as well in the simulation of injection molding tools.
Overmoulding of thermoplastic composites is a technology in which a thermoplastic composite is thermoformed and subsequently injection overmoulded. The near-net-shape manufacturing process is well suited for automated large series production of complex 3D structures with excellent structural performance and a high level of function integration. Although the feasibility of the process is increasingly demonstrated, it is acknowledged that there is a lack of proper design tools that can be used for a right-the-first-time design strategy. The COMPeTE project was established with the aim to create (numerical) design tools based on the basic mechanisms that underlay the overmoulding of thermoplastic composites using commercially available software packages. The work was carried out by the TPRC and funded by industrial partners from both the aerospace and automotive industry.
Establishing a bond between the resin and the insert requires intimate contact and healing of the two materials. Although intimate contact is a prerequisite for healing, the actual bond strength develops during the healing process in which polymer chains diffuse across the interface. The part, however, cools down rapidly during overmoulding to achieve short cycle times. This limits the available time for bonding and therefore makes the process more difficult. A test method was developed to characterise the bond strength under tensile and shear loading conditions. The characterized bond strength was used to develop numerical tools that predict the interface strength as a function of the injection moulding process characteristics.
An experimental method was developed for the analysis of warpage and spring-forward in single curved, overmoulded geometries. A thermo-elastic model was experimentally validated and subsequently implemented in a FE simulation, taking into account the fibre stresses and fibre reorientation resulting from the draping process. The methodology will finally be demonstrated using a three-dimensional, doubly curved C/PEEK part that was manufactured using the covermoulding process.
TPRC acknowledge Safran, Boeing, Victrex, Johnson Controls, SMP, Harper Engineering, KraussMaffei and Autodesk for the funding of the project.
Thijs Donderwinkel, ThermoPlastic Composites Research Center (NL)
Thijs Donderwinkel studied mechanical engineering at the University of Twente in Enschede. During this period, he participated in the solar car racing team, where his interest for composite materials started. Further experiences with composite materials were obtained during his internship at Audi AG in Neckarsulm and his graduation project at the ThermoPlastic composite Research Center. Currently, he is a researcher at the ThermoPlastic composite Research Center. Together with industrial partners, a software tool is being developed to predict shape distortions during the overmolding process.
Injection molded plastic parts are widely used in industrial applications due to their fast processing times and their ability to conform to a variety of geometries. Fiber reinforced plastics offer further benefits by offering enhanced stiffness-to-weight and strength-to-weight ratios. Injection molding simulation software packages can be used to predict the warped shape of the ejected, room-temperature part, as well as the distribution of fiber orientation for filled materials. Both results can have effects on the mechanical properties of the part. Autodesk Helius PFA has been developed to leverage manufacturing data in standard structural FEA tools by mapping manufacturing data from Autodesk Moldflow simulations to structural meshes of varying element types and mesh densities. Please join us for a discussion on leveraging Autodesk Helius PFA for as-manufactured structural simulation of fiber reinforced plastics, including mapping manufacturing data from Moldflow to structural FEA, predicting orthotropic plasticity and rupture in tension and compression and predicting the strength of weld lines.
Doug Kenik, Autodesk® Inc. (USA)
Doug Kenik ist Produktmanager für Composite Simulation Produkte bei Autodesk, Inc.
Doug Kenik is a product line manager for composite simulation products within Autodesk, Inc. He holds both an MS and a BS in mechanical engineering from the University of Wyoming, where he spent his graduate career developing high-fidelity micromechanics models for composite material simulation. Prior to working at Autodesk, Doug spent 5 years as a developer and application engineer at Firehole Composites, where he helped implement new technologies for composite simulation and define next-generation enhancements for use within existing products.
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