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Computer Aided Engineering (CAE) Filling olmuloUon
Or. Mahesh Olvekar
BASF India Lid.
Performance Materials - South Asia
Contact: +91-9930574643
CAD-.gn
-
Performance,evaluation by local failura
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a•BASF
We create chemistry
Computer Aided Engineering (CAE) FIiiing slmulatlon
Dr. Mahesh Divekar
BASF India Ltd.
Performance Materials - South Asia
Contact: +91-9930574643
CAD design
a
Performance evaluation by local failure
criterion
mmcm
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Glass fiber orientation
FEA with Ultrasim®
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Contents
• What is CAE and How its Work...!
• Application Development support through
CAE
• Injection Process Simulations
• Structural Simulations
• Design Optimizations
• CAE Support for All Industries
00:12:0IS ii V1tw
2
Cl•BASF

Tool Development Cycle
- - - - -
Idea
------
~ ~ - --;--
,11
[ CAD Modelling 1
---~--~.
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t
I..!:",-:-J
[ Final Design 1
•
LMan8
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--.
Actual Experimental
Testing D•BASF
• - " , . I

Tool Development Cycle
Idea
CADMoclelNng
~
[ Prototype
J
e
[ Lab Test
~
• "'
[ ,.....,..... )
~
•
L Sample J
Manufacturing
lf
~ • • E11perlmental
Testing
6
PDC Approach
without Simulation
I
C•BASF
- ~ , ,- . . I

ool Development Cycle
Idea
CAD Modelling
r Prototype ]
,e.
[ LabTest 111
• •
rFinal Design7 -A
•
Sample
Manufacturing
Dr. Mahesh Divekar's screen
PDC Approach
without Simulation
• • • • • • • • • D•BASF

ool Development Cycle
Idea -
•
CAD Modelling
~
[ Prototype
7
C
C Lab Test
J.-
.. J'
[ Final DNlgn
..
L Sample
Manufacturing
..· - ■
Dr. Mahesh Divekar's screen
PDC Approach
without Simulation
• • • • •
- - - - - -
Idea
( CAD Modelling
~
lCAE Simulation
~
[ Final Design
..
Sample
Manufacturing
•
Actual Experimental
• •
Testing D•BASF

AE Simulation Example
Actual Experimental
Testing
Dr. Mahesh Divekar's screen
• • • • • • • • •
CAE Simulation

Advantages- Accurate and well in advance simu1
lation CCAE)
•
• Eliminate/Minimize physical prototype testing efforts
• Saves time and Money
• Design decisions can be made in earlier
• Can provide performance insights earlier in the development process.
• Made design evaluation easier.
• Reduce the costs associated with the product lifecycle.
C•BASF
- ~ " • ~ I
10

mm AiiiHH,IM 1111
How It Works...!
Autodesk Moldflow
•
• Processing
- F:lling/ Warpage
- Runner balance
- Weld line prediction
- Gate optimization
- Flber orientation
- PU Foam Simulation
- CFD
Leave

M ,-- M'M·l·I··l:iA 1111...
How nWorks...!
Autodesk Moldflow Abaqus Implicit Abaqus explicit/ LS Dyna
Altair Optistruct
•
~
Ultraslme
Processing
~ • Basic structure • Shape
• Processing - Liner static strength - Pedestrian protection - Bead
- F1ll1
ng/ Warpage - Burst analysis - Drop test - Frequency
- Runner balance - Modal frequency - High speed burst
- Weld line prediction - V1
brat1on study
- Gate optimization - Seaflng and Creep
- Fiber orientation . Thannal analysis
- PU Foam Simulation
- CFO
Leave

I •• s 11sss ez s ,,.,.. ME·ii,H:IM
CAE Support For Application Development
Simulation Capabilities - - - - - - - - - - - - - - - - - - - - - - - - - - - -
ULTRASIM®
The Solution
CAE Competence for
Your Innovative
Components
InJection Process
CAE
I I
Structural Simulation Design Optimization

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Plastic Processing Methods
Rotational Mold:ng

OCHl55
Injection Process Simulations
• Key Requirements
• Process results validation
• Gate and process optimization for new tool development
• Process Troubleshoot
• Warpage control and mold shrinkage for tool
• Type of Injection Process Simulations
• Injection process simulation for process validation
• Gate and Process parameter opt1mizat1on
• Runner balance analysis for family and multicavity molds
• Core shift analysis
• Sequential gating analysis
• Cooling system analysis
• Process trouble shooting by rnoldflow analysis
• Warpage prediction, Control guidelines
• Mold shrinkage prediction for tool cutting*
Leave
Unmuh: '.:1,ir! '/ :1~·~

Injection Process Simulations
Process Analysis Steps
30 CAD Data
Customer
Pre-processing
BASF
+
Moldflow Input
BASF/Customer
Moldflow Process Parameters :
• Gate Location
• Filling time
• Temperature etc
• Results
'
Ill
• Filling Pattern
• Weld lines, Air Voids
• Warpages
• Shrinkage, etc.

I •• s II n az , ,,... MM·i#:H:IA
Injection Process Simulations
Process Analysis Steps
30 CAD Data
Customer
Actual part manufacturing
Customer
Pre-processing
BASF
IOpti~ization
I
+
:--~-~
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v ~ =----
Moldflow Input
BASF/Customer
Moldflow Process Parameters :
• Gate Location
• Filling time
• Temperature etc
• Results
'
II
• Filling Pattern
• Weld lines, Air Voids
• Warpages
• Shrinkage, etc.
Cl•BASF
00:~9;45
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Injection Process Simulations
Moldflow
-
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Gate Optimization Sequential Gates Runner Balance
Cooling System Advanced Simulations Shrinkage Recommendation

e
Gate Optimization
Adjusting Lever
Adjusting Lever
IFIii Pattern I
Original
IFiber Orientation Tensor I
....
Modified
IWeld-Lines I
• Proposed design shows significant warpage improvement.
• Maintained circularity and reduced injection pressure.
21
Internal
am
Proposal
IPart Warpage J
D•BASF
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Sequential!Gates
Roof Rail
Adjusting Lever Option 1 Option 2 Option 3
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Ultramld 8267GHS
IResults: FIii Pattern IResults : Warpage In All Direction I
t 7
~
Warpage in All direction is 0.262mm to 7.945mm
• Proposed option 1 sequential gating design shows significant warpage improvement.
• Option 1 is better considering warpages, pressure, clamp force and cost point of view. D•BASF
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23
Internal

II e
Runner Balance
Multicavity runner balance
Ultramid 83WG7
Optimized runner dimensions : Balanced flow
,.,_ ..,.......,.,... MM+i:ii,IM
Uniform runner dimensions : Unbalanced flow
• Uniform runner and gate dimensions results
into unbalanced flow causing into high
pressure and clamp force in the cavity.
• Optimized runner and gate dimensions gives
balanced flow in the cavity.
C•BASF
Leave

e
Cooling System
SuccessfuJ case ot Office Chair Lifter Module
Original
I
-
• Form latches directly during mo
lding process.
Positive mold trial feedback from customer
Warpage: improve obviously.
Cycle time: 155s ➔ 47s.
28
Internal
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■ Improve Assembly Efficiency
■ Reduce Cycle Time & Warpage
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• Proposed design shows significant warpage improvement.
• The cycle time is predicted to have 57% reduction.
D•BASF
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8
Structural Simulation
Structural Analysis Steps
3D CAD Data
Customer
Pre-processing
BASF
◄-------1
37
Actual part manufacturing
Customer
I
IOpti~ization
I
I
I
X
V
Internal
•
Structural Input
BASF/Customer
Loading and Fixed locations
•
-
-
Load
e Fix
• Results
• Displacement
• Stress
• Pressure
• Life, etc.
D•BASF
A.-' l>dl<o~')-,T <!,

8
Stati·c simulation
I· What is static simulations? I
• Analysis to evaluate the progressive failure of the component under the static
loads
• Burst pressure analysis
• Weld bead strength analysis
• Point load analysis
• Torque load analysis
I· Inputs from customer I
• Temperature condition of test
• Load : Pressure, Force, Torque
• Fixation Locations
I· BASF Output I
40
• Failure criteria
• Results:
• Displacement, Stress, Failure if any.
• Design suggestions
• Recommendations in design if failure occurs.
Internal
01:38:1~
D•BASF
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8
Advanced Simulations
I• Insert shift/ Core shift analysis I I• Mucell I
I• Conformal Cooling I • Transient Ultrasim• Warpage simulations
.i
D•BASF
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30
Internal

8
Non-Linear static simulation
PAIM: Bursi Pressure Analysis
PAIM: Model
' '
•
-
7 re r
.6. Fix Points
Recommendations
Flange shell
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Ultramlcte 8233GW PA8 + GF33%
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The maximum stress observed at nange shell on s~ffener/ribs. it is 121.32 MPa. This stress
is higher than allowable limit of the material (115 MPa)
Add round cross section as highlighted
In crease lhewith of lhe stiffener.; above atsharp section beads
D•BASF
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41
Internal