2008 International ANSYS Conference
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1 2008 International ANSYS Conference Plastic Injection Molding Using ANSYS Sarah Luo Ph.D. Senior. Mechanical Engineer Aurora Optical Inc. Daniel Robinson Senior Consulting Engineer PADT Inc ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 1 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
2 OUTLINE Introduction Issue Assumption Approach Simulation Results Conclusions and Future Work 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 2 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
3 Aurora Optical Inc. Introduction A Quality Picture Worth a Thousand Words AO produces a wide range of camera modules, including FPC or socket based, Ultrathin, Macro, and Auto-Focus - custom module design is our business! Camera Module Applications: Personal Security Systems Embedded PC Cameras Mobile Phones VoIP Phone Systems Wireless Devices Consumer Electronics Medical Applications Automotive Optical Systems 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 3 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
4 PADT Intro - We Bring Dimension to Your Ideas PADT is an Engineering Services Company Mechanical Engineering Design Simulation Manufacturing 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 4 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
5 Issue: A plastic part has larger shrinkage rate than steel parts during manufacturing. This is a major issue for our precision plastic parts. An example of a plastic part with shrinkage over 7~10 µm during cooling 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 5 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
6 Factors Plastic Part Shrinkage varies depending on: Geometries Material Properties Process Parameters 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 6 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
7 Advantages Plastic injection molding process simulation provides: Shrinkage prediction for tooling compensations to produce parts with best precision Information for optimization, which can produce parts with minimum shrinkage and shortest cycle time 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 7 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
8 Simulation Modeling The simulation models a completed plastic injection molding cycle: Packing and Holding Mold Cooling Air Cooling T( C) / P(MPa) Closing Mold Injection Gate Freeze-off Ejection Temperature/ pressure vs. Time during a cycle t (s) Packing Pressure (Given) Part Pressure Gate Temperature (Given) Part Temperature 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 8 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
9 Approach Plastic Injection Molding Simulation Resin Material Properties Plastic Injection Molding Process Parameters 3D Model Solid Material Properties Boundary Conditions CFX-Mesh Workbench Mesh CFX P (x,y,z,t) Volume Fraction (t) T (x,y,z,t) CFX Convection Load Thermal Transient Analysis Delta x, y, z Static Analysis T(x,y,z,t) Shrinkage Profile Multiphysics 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 9 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
10 Assumptions Polymers: 1. Amorphous 2. Non-fiber reinforced Known Input: 1. Process parameters 2. Gate temperature vs. time measurement data 3. Material properties 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 10 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
11 PVT Diagram for Amorphous Polymer Modeling Five stages at PVT diagram: 1 Injection phase: A-B 0.95 Polycarbonate 0 MPa A Packing/Holding phase: B-C Gate Freeze-off and in-mold cooling phase: C-D Ejection parts: D Specific Volume (cm 3 /g) E D T g T g C 100 MPa Outside mold cooling phase: D-E Temperature ( C) 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 11 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
12 Injection Phase CFX Simulation Results: Injection flow Temperature Pressure 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 12 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
13 Packing/Holding Phase CFX Simulation Results: Volume Fraction Temperature Pressure 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 13 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
14 Gate Freeze Phase CFX Simulation Results: Temperature Pressure 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 14 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
15 Transient Results of the In-mold (Cured) Cycle Transient Temperature at the part center Transient Pressure at the part center 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 15 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
16 Cooling after Ejection Thermal transient analysis shrinkage results 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 16 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
17 Shrinkage Data in Multiphysics The shrinkage data are exported to Excel for shrinkage contour plots 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 17 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
18 ANSYS results vs. Measurement Results Shrinkage Predicted by ANSYS Measured Shrinkage* * The data were provided by Process Engineer Rick Culler 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 18 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
19 An Example of a Finished part using ANSYS Shrinkage Compensation Dimension Deviation actual-nonimal < 1µm! Measurement data after tooling compensation predicted by ANSYS* * The data were provided by Process Engineer Rick Culler 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 19 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
20 Process Optimization ANSYS Design Explorer Six-Sigma tools Design of Experiments performed to optimize mold temperature, deformation, stress 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 20 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
21 Design for Six-Sigma Input Parameters - Inlet temperature - Mold wall convective film coefficient 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 21 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
22 Six-Sigma Analysis - Distributions Output Parameters - Temperature - Directional deformation - Von Mises Stress 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 22 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
23 Design Points 3X3 DOE Parameters varied block factorial design, in order to characterize the design space 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 23 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
24 Response Charts Design Space Response Parameters - Maximum deformation - Maximum Von Mises stress 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 24 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
25 Min/ Max Values Output Parameters 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 25 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
26 DFSS Study Summary Parameters varied were mold inlet temperature, mold to Lexan convective film coefficient for cooling Design of Experiments performed to examine effect of these parameters on cooled solid part deformation, maximum stress. Results show for inlet temperature = 240F (design point) h f = Btu/hr-ft 2 -F maximum residual stress = 61.6 psi 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 26 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
27 Conclusions and Future Work ANSYS results provide accurate shrinkage compensation for tooling. Future work includes non-amorphous, fiber-reinforced polymer injection molding simulation, gate/runner optimization etc ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 27 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
28 Acknowledgements A special thank to Arnie Sen, Raymond Hsiao, George Kelly, and Dave Fredley for their consistent support of the project. Also thanks Rick Culler for providing shrinkage measurement data ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 28 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
29 Questions and Answers Thank you! 2008 ANSYS, Inc. and AURORA OPTICAL Inc. All rights reserved. 29 AURORA OPTICAL Inc. and ANSYS, Inc. Proprietary
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