1、Introduction of Successful Cases of Moldex3D Plastic Mold Flow Simulation in Autoliv Copyright Autoliv Inc., All Rights ReservedMoldex3D Simulation Cases in AutolivMarch 24, 2017Autoliv General Presentation 20172Copyright Autoliv Inc., All Rights ReservedMoldex3D Simulation Cases in AutolivCopyright
2、 Autoliv Inc., All Rights ReservedMoldex3D Simulation Cases in AutolivCopyright Autoliv Inc., All Rights ReservedMoldex3D Simulation Cases in AutolivMarch 24, 2017Autoliv General Presentation 20175Copyright Autoliv Inc., All Rights ReservedMoldex3D Simulation Cases in Autoliv Sink mark displacement
3、thinMarch 24, 2017Autoliv General Presentation 201760.5 mm R0.1Sensor node15, 22.5, 30, 37.5, 45, 60, 90, 120Copyright Autoliv Inc., All Rights ReservedOutline What kind of plastic products are usually developed in ALV? What kind of plastic materials are usually applied in ALV plastic products? Why
4、we do mold flow simulations? How we do mold flow simulations? Successful cases in CTC CAE. PU Foaming Correlation Q/AMarch 24, 2017Autoliv General Presentation 20177Copyright Autoliv Inc., All Rights ReservedWhat kind of plastic products are usually developed in ALV? Product specification1.2 Driver
5、Air Bag (DAB)1.3 Passenger Air Bag (PAB)1.4 Inflated Cushion (IC)1.5 Side airbag (SAB/KAB)1.6 Steering wheeling (SW)1.7 Active Safety (AS)March 24, 2017Autoliv General Presentation 20178Webbing guide Pillar loopTongue PLP coverPLP sleeveCopyright Autoliv Inc., All Rights ReservedWhat kind of plastic
6、 products are usually developed in ALV? Product specification1.1 Seat Belt (SB)1.3 Passenger Air Bag (PAB)1.4 Inflated Cushion (IC)1.5 Side airbag (SAB/KAB)1.6 Steering wheeling (SW)1.7 Active Safety (AS)March 24, 2017Autoliv General Presentation 20179DAB CoverDAB HousingDAB emblem Copyright Autoliv
7、 Inc., All Rights ReservedWhat kind of plastic products are usually developed in ALV? Product specification1.1 Seat Belt (SB)1.2 Driver Air Bag (DAB)1.4 Inflated Cushion (IC)1.5 Side airbag (SAB/KAB)1.6 Steering wheeling (SW)1.7 Active Safety (AS)March 24, 2017Autoliv General Presentation 201710PAB
8、HousingNew concept PAB HousingCopyright Autoliv Inc., All Rights ReservedWhat kind of plastic products are usually developed in ALV? Product specification1.1 Seat Belt (SB)1.2 Driver Air Bag (DAB)1.3 Passenger Air Bag (PAB)1.5 Side airbag (SAB/KAB)1.6 Steering wheeling (SW)1.7 Active Safety (AS)Marc
9、h 24, 2017Autoliv General Presentation 201711IC frameB-pillarRAMPCopyright Autoliv Inc., All Rights ReservedWhat kind of plastic products are usually developed in ALV? Product specification1.1 Seat Belt (SB)1.2 Driver Air Bag (DAB)1.3 Passenger Air Bag (PAB)1.4 Inflated Cushion (IC)SAB/KAB1.6 Steeri
10、ng wheeling (SW)1.7 Active Safety (AS)March 24, 2017Autoliv General Presentation 201712SAB CoverKAB CoverCopyright Autoliv Inc., All Rights ReservedWhat kind of plastic products are usually developed in ALV? Product specification1.1 Seat Belt (SB)1.2 Driver Air Bag (DAB)1.3 Passenger Air Bag (PAB)1.
11、4 Inflated Cushion (IC)1.5 Side airbag (SAB/KAB)1.7 Active Safety (AS)March 24, 2017Autoliv General Presentation 201713BackshellPUR foamingGarnish Copyright Autoliv Inc., All Rights ReservedWhat kind of plastic products are usually developed in ALV? Product specification1.1 Seat Belt (SB)1.2 Driver
12、Air Bag (DAB)1.3 Passenger Air Bag (PAB)1.4 Inflated Cushion (IC)1.5 Side airbag (SAB/KAB)1.6 Steering wheeling (SW)March 24, 2017Autoliv General Presentation 201714ECU CoverCopyright Autoliv Inc., All Rights ReservedOutline What kind of plastic products are usually developed in ALV? What kind of pl
13、astic materials are usually applied in ALV plastic products? Why we do mold flow simulations? How we do mold flow simulations? Successful cases in CTC CAE. PU Foaming Correlation Q/AMarch 24, 2017Autoliv General Presentation 201715Copyright Autoliv Inc., All Rights ReservedWhat kind of plastic mater
14、ials are usually applied in ALV plastic products?March 24, 2017Autoliv General Presentation 201716Global Resin Team websiteCopyright Autoliv Inc., All Rights ReservedWhat kind of plastic materials are usually applied in ALV plastic products?March 24, 2017Autoliv General Presentation 201717 Guide by
15、PropertiesPurpose: The purpose of this guide is to enable development and design teams to select the right thermoplastic material for their parts.Copyright Autoliv Inc., All Rights ReservedWhat kind of plastic materials are usually applied in ALV plastic products?March 24, 2017Autoliv General Presen
16、tation 201718 Guide by Polymer ClassCopyright Autoliv Inc., All Rights ReservedMarch 24, 2017Autoliv General Presentation 201719 Guide by ApplicationSeatbelt Resin ListWhat kind of plastic materials are usually applied in ALV plastic products?Copyright Autoliv Inc., All Rights ReservedWhat kind of p
17、lastic materials are usually applied in ALV plastic products?March 24, 2017Autoliv General Presentation 201720 Guide by ApplicationAirbag Housing Resin ListCopyright Autoliv Inc., All Rights ReservedWhat kind of plastic materials are usually applied in ALV plastic products?March 24, 2017Autoliv Gene
18、ral Presentation 201721 Guide by ApplicationAirbag Cover Resin ListCopyright Autoliv Inc., All Rights ReservedWhat kind of plastic materials are usually applied in ALV plastic products?March 24, 2017Autoliv General Presentation 201722 Guide by ApplicationSteering Wheel Resin ListCopyright Autoliv In
19、c., All Rights ReservedOutline What kind of plastic products are usually developed in ALV? What kind of plastic materials are usually applied in ALV plastic products? Why we do mold flow simulations? How we do mold flow simulations? Successful cases in CTC CAE. PU Foaming Correlation Q/AMarch 24, 20
20、17Autoliv General Presentation 201723Copyright Autoliv Inc., All Rights ReservedWhy we do mold flow simulations? Earlier stage of development (Before mold tool design/manufacture) 1. Predict fill pattern (short shot, air traps, thickness distribution,) 2. Predict injection pressure (injection machin
21、e, hot/cold runner,) 3. Determine clamp tonnage (injection machine /ton) 4. Locate weld (knit) lines (surface quality, strength,) 5. Determine fiber orientation (strength,) 6. Find hot spots (cooling channel layout) 7. Determine cooling (and reduce) cycle time 8. Predict warpage (if it is acceptable
22、)March 24, 2017Autoliv General Presentation 201724Change part geometry/material Copyright Autoliv Inc., All Rights ReservedWhy we do mold flow simulations? Later stage of development (after mold tool design/manufacture) 1. Optimize gating/ Optimize runner system (refer to issue) 2. Optimize the cool
23、ing layout (refer to issue) 3. Optimize injection speed/pressure (refer to issue) 4. Define optimum packing profile (refer to issue)Change part geometry/ process parameters /cooling channel layoutMarch 24, 2017Autoliv General Presentation 201725Copyright Autoliv Inc., All Rights ReservedOutline What
24、 kind of plastic products are usually developed in ALV? What kind of plastic materials are usually applied in ALV plastic products? Why we do mold flow simulations? How we do mold flow simulations? Successful cases in CTC CAE. PU Foaming Correlation Q/AMarch 24, 2017Autoliv General Presentation 2017
25、26Copyright Autoliv Inc., All Rights ReservedHow we do mold flow simulations? March 24, 2017Autoliv General Presentation 201727 .step format .CATPART formatPart 3DMesh file .stl formatMold flow Model file Pre-ProcessingCooling channels Runner Early stageLater stageRunnerCooling No needProvide Copyri
26、ght Autoliv Inc., All Rights ReservedHow we do mold flow simulations? Process settingFilling/Packing settingFilling rate profileFilling pressure profileCopyright Autoliv Inc., All Rights ReservedHow we do mold flow simulations? Process settingInjection machine informationCooling settingsPacking pres
27、sure profileCopyright Autoliv Inc., All Rights ReservedHow we do mold flow simulations? Process settingAnalysis sequence settingCopyright Autoliv Inc., All Rights ReservedHow we do mold flow simulations? Post-ProcessingFilling animationCopyright Autoliv Inc., All Rights ReservedHow we do mold flow s
28、imulations? Post-ProcessingCopyright Autoliv Inc., All Rights ReservedOutline What kind of plastic products are usually developed in ALV? What kind of plastic materials are usually applied in ALV plastic products? Why we do mold flow simulations? How we do mold flow simulations? Successful cases in
29、CTC CAE. PU Foaming Correlation How to request a mold flow simulation task? Q/AMarch 24, 2017Autoliv General Presentation 201733Copyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 1 XXX Pillar LoopMarch 24, 2017Autoliv General Presentation 201734ProblemSimulationSolutionTest
30、Resultsadd rib and increase thicknessWeld line visibleCopyright Autoliv Inc., All Rights ReservedCRACK Successful cases in CTC CAE Case 2 XXX DAB HousingMarch 24, 2017Autoliv General Presentation 201735ProblemSimulationSolutionTest ResultsCrack in LT deploymentWeld lineWeld lineadd thickness and inc
31、rease radiusBad Fiber Orientation Copyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 3 XXX DAB CoverMarch 24, 2017Autoliv General Presentation 201736ProblemSimulationSolutionTest Results12H Crack in deploymentOK, No CrackCopyright Autoliv Inc., All Rights ReservedSuccessful
32、cases in CTC CAE Case 4 XXX PAB HousingMarch 24, 2017Autoliv General Presentation 201737ProblemSimulationSolution 1Test Results 1Crack in deploymentCrack againCopyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 4 XXX PAB HousingAutoliv General Presentation 2017Solution 2Test
33、Results 2No crackCopyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 5 XXX TongueMarch 24, 2017Autoliv General Presentation 201739ProblemSimulationSolutionTest ResultsCrack in high-low(-35100 degree) temperature during testOK, No CrackCopyright Autoliv Inc., All Rights Reserv
34、edSuccessful cases in CTC CAE Case 6 XXX PAB CoverMarch 24, 2017Autoliv General Presentation 201740ProblemSimulationSolutionTest ResultsWarpage larger than tolerance Approved by CustomerAdd a cool lineCopyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 7 XXX EmblemMarch 24, 2
35、017Autoliv General Presentation 201741ProblemSimulationSolutionTest ResultsLack of material at this pinWhen hot air handle关于热风焊塌料的问题根本原因在于： 进胶点位置的料剪切应力较大，导致进胶点位置胶料密度不够，热风熔化塌陷产品进浇口由潜热熔柱改成潜胶片，对应浇口位置增加胶片OKCopyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 8 XXX Pillar LoopMarch
36、 24, 2017Autoliv General Presentation 201742ProblemSimulationSolutionTest ResultsCrack at sled test Shear Stress = 20.8665 MPaAllowed stress is 0.5 MPa.Supplier change injection machine and not inform ALV ! 1.Use before machine2.Use low injection speed NCM is not closed yetCopyright Autoliv Inc., Al
37、l Rights ReservedSuccessful cases in CTC CAE Case 9 XXX DAB COVERProblemSimulationSolutionTest ResultsThere are 3 places where big crack happen during deploymentHT/LTCAE suggestionq Wall thickness Increaseq Straight Tear seam change to curveCopyright Autoliv Inc., All Rights ReservedSuccessful cases
38、 in CTC CAE Case 10 XXX DAB COVERProblemShrinkage gloss differenceCopyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 10 XXX DAB COVERSimulationSolutionTest ResultsOriginal updatedCopyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 10 XXX DAB COVERTest
39、 ResultsOriginal UpdatedCopyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 11 XXX TongueProblemSimulationSolutionTest Results Tongue got crack after 3 cycles thermal shock test. (one cycle: 30/3h100/3h). Next pagesCopyright Autoliv Inc., All Rights ReservedTool 1DateName of
40、presentation48 Injection speed is low testSimulation射出圧力波形（実数値）射出速度波形（実数値）射出圧力波形（設定値）射出速度波形（設定値）75 bar (91.5MPa)20%=26mm/s Case 11 XXX TongueCopyright Autoliv Inc., All Rights ReservedTool 2 DateName of presentation49 testSimulation射出圧力波形（実数値）射出速度波形（実数値）射出圧力波形（設定値）射出速度波形（設定値）85 bar(103.7MPa)25%=32mm
41、/s Case 11 XXX TongueCopyright Autoliv Inc., All Rights ReservedProblem in tool 3 parameter Text Injection pressure is not enough! Setting 80MPa Injection speed is very slowly crack112233441212 Case 11 XXX TongueCopyright Autoliv Inc., All Rights ReservedSuggested parameter in tool 3DateName of pres
42、entation51Current Suggested 30 mm/s120 MPa3 s40 MPa Case11 XXX CLT TongueCopyright Autoliv Inc., All Rights ReservedTool 3-Proposal Process result DateName of presentation52 testSimulation Case 11 XXX TongueCopyright Autoliv Inc., All Rights ReservedSuccessful cases in CTC CAE Case 11 XXX TongueTest
43、 ResultsCopyright Autoliv Inc., All Rights ReservedOutline What kind of plastic products are usually developed in ALV? What kind of plastic materials are usually applied in ALV plastic products? Why we do mold flow simulations? How we do mold flow simulations? Successful cases in CTC CAE. PU Foaming
44、 Correlation Q/AMarch 24, 2017Autoliv General Presentation 201754Copyright Autoliv Inc., All Rights ReservedR15. CAE SETTINGSeptember 19, 2017Name of presentation55 Runner Cavity Overflow Gate 40 degreePU Foaming CorrelationCopyright Autoliv Inc., All Rights ReservedSIMULATION TEST MATRIX (SHORT SHO
45、T)September 19, 2017Name of presentation56 Test 1=340 g Test 2=500 g Full=680 g完全填充 PU Foaming CorrelationCopyright Autoliv Inc., All Rights ReservedSeptember 19, 2017Name of presentation57340g/ 180 g/s=1.89 s injection pressure cooling settingsPU Foaming CorrelationCopyright Autoliv Inc., All Right
46、s ReservedCAE RESULTS and TEST RESULTSSeptember 19, 2017Name of presentation58PU Foaming CorrelationCopyright Autoliv Inc., All Rights ReservedCAE RESULTS and TEST RESULTSSeptember 19, 2017Name of presentation59Bubble Bubble PU Foaming CorrelationCopyright Autoliv Inc., All Rights ReservedSeptember
47、19, 2017Name of presentation60 Moldex3D Test CAE RESULTS and TEST RESULTSPU Foaming CorrelationCopyright Autoliv Inc., All Rights ReservedSeptember 19, 2017Name of presentation61CAE RESULTS and TEST RESULTSPU Foaming CorrelationCopyright Autoliv Inc., All Rights ReservedSeptember 19, 2017Name of pre
48、sentation62End of material front face is “radial” both in CAE and test PU Foaming CorrelationCopyright Autoliv Inc., All Rights ReservedCURRENT ISSUES Short shot got in actual tests are not reproduced in simulation Lack of material“ defects got in actual tests are properly reproduced in simulation “Bubble” defects got in actual tests are properly reproduced in simulation Short shot will be run using Moldex3D-R16.0 (PU expansion ratio 发泡倍率) September 19, 2017Name of presentation63PU Foaming Correlation
