process, microstructure & tooling - wilde analysis · process, microstructure & tooling dr...
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improving manufacturing by simulation:
Process, Microstructure & Tooling
Dr Brian Miller
Sales & Marketing Director
WildeAnalysis.co.uk
WildeAnalysis.co.uk
• Formed in 1980 as Finite Elements Ltd
• 1000+ clients
• Member of Wilde Group of 70+ employees and £10m
+ turnover
• Value Added Reseller for ANSYS, Autodesk Moldflow,
DEFORM & ReliaSoft
• ISO 9001:2008 Approved Quality Management
System
• On UK-steering committee for NAFEMS and
involvement with many industry associations.
Overview
WildeAnalysis.co.uk
Wilde Analysis
FEA
CFD
0 P
robabili
ty
Value S L
Reliability WildeAnalysis.co.uk
• In Design
– Improved product performance – optimised
– Less R&D lead time, costs and prototypes
– Lighter – reduced material and energy costs
– More reliable, less requirement for replacement
– Enables ‘design for manufacture’
• In Manufacture
– Less shop trials
– Reduced scrap rates
– Less material waste (flash, swarf, runners)
– Improved quality & material performance
Benef its of Simulation
WildeAnalysis.co.uk
Applications in all Engineering Fields
WildeAnalysis.co.uk
Manufacturing Simulation Topics
Plastic Injection Moulding (Unfilled + Fibre Filled)
Shape & tooling optimisation
+ initial property determination for structural analysis
Blow Moulding, Extrusion & Other Polymer Processes
Shape & tooling optimisation
+ initial property determination for structural analysis
(POLYFLOW)
Metal Forming + Heat Treatment + Microstructure
Shape & tooling optimisation
+ initial property determination for structural analysis
+ multiple process chain
WildeAnalysis.co.uk
• Design for Manufacture
• Example: Plastics Design
– Assess design
– Non-uniform thickness
– Poor draft angles / undercuts
– Complex and expensive
– Assess manufacturability
– Areas difficult/impractical to
manufacture
Process Modelling
Courtesy: Autodesk WildeAnalysis.co.uk
• Provides detailed
information about the
microstructure during
thermo-mechanical
processing .
• Opportunities to
improve process design
through understanding
impact on material
Microstructural Modelling
Courtesy: SFTC WildeAnalysis.co.uk
Tooling Analysis
• A carbide insert failed
consistently in a high volume
steel automotive part.
• DEFORM was used in 1996
to isolate the root cause - an
axial tensile stress at the
fracture initiation point.
• After redesign, the life was
increased more that ten-fold
for the first three stations in
the progression.
WildeAnalysis.co.uk
Virtual Prototyping of Blow Moulding
CAD Design
modify CAD
Process Simulation /
Manufacturing
Part Testing (Implicit / Explicit
structural analysis)
Fail
modify
process
PASS
Courtesy: ANSYS WildeAnalysis.co.uk
Blow Moulding Process Simulation
Courtesy: ANSYS WildeAnalysis.co.uk
Location of Minimum Thickness
Identification of location with smallest
thickness. Would this virtual product
satisfyingly pass the tests and behave
properly under services?
Courtesy: ANSYS WildeAnalysis.co.uk
Effect of Variable Thickness
Top load - total
deformation
uniform
thickness
variable
thickness
WildeAnalysis.co.uk
• Primary stiffening cover, essential for the entire phone stiffness
Moldf low to Structural Analysis
Courtesy: Autodesk WildeAnalysis.co.uk
• Material PA, Zytel HTN53G50HSLR (DuPont)
(50%Glass)
Moldf low to Structural Analysis
restraints
Vertical force
Courtesy: Autodesk WildeAnalysis.co.uk
• Gate Location: Top
Moldf low to Structural Analysis
Gate location Fiber orientation
Poor orientation in this area
Courtesy: Autodesk WildeAnalysis.co.uk
• Gate Location: Bottom
Moldf low to Structural Analysis
Gate location Fiber orientation
Good orientation in this area
Courtesy: Autodesk WildeAnalysis.co.uk
• Gate Location: Mid
Moldf low to Structural Analysis
Gate location Fiber orientation
Good orientation in this area
Courtesy: Autodesk WildeAnalysis.co.uk
Deflection Comparison
• Deflections predicted by Moldflow for
different fibre orientations compared to
isotropic material
Gate location Fiber orientation Max. deflection
Bottom Good 4.95mm
Mid Good 4.27mm
Top Poor 5.29mm
Isotropic material 3.45mm
Courtesy: Autodesk WildeAnalysis.co.uk
Stress Comparison
–Traditional stress analysis:
svonmises=14.4 MPa
–Fully integrated analysis:
svonmises=35.9 MPa
–Fully integrated analysis:
svonmises=80.1 MPa
–Traditional stress analysis:
svonmises=17.2 MPa
Courtesy: Autodesk WildeAnalysis.co.uk
Typical Metal Forming Applications
Hot forging Thread rolling
Cogging Machining Other applications
Mechanical joining
Courtesy: SFTC WildeAnalysis.co.uk
Typical Metal Forming Applications
Hot forging Thread rolling Mechanical joining
Cogging Machining Other applications
Courtesy: SFTC WildeAnalysis.co.uk
Typical Metal Forming Applications
Hot forging Thread rolling
Cogging Machining Other applications
Mechanical joining
Courtesy: SFTC WildeAnalysis.co.uk
Typical Metal Forming Applications
Hot forging Thread rolling Mechanical joining
Cogging Machining Other applications
Courtesy: SFTC WildeAnalysis.co.uk
Typical Metal Forming Applications
Hot forging Thread rolling
Cogging Machining Other applications
Mechanical joining
Courtesy: SFTC WildeAnalysis.co.uk
Typical Metal Forming Applications
Hot forging Thread rolling
Cogging Machining Other applications
Mechanical joining
Courtesy: SFTC WildeAnalysis.co.uk
Typical Metal Forming Applications
Hot forging Thread rolling
Cogging Machining Other applications
Mechanical joining
Courtesy: SFTC WildeAnalysis.co.uk
Integrated Process Modeling System
Cogging Forging Heat Treat Machining Spin
Alloy Composition Design
Properties
Geometry
Microstructure Anomalies
Residual Stress
Lifing
Cooling Rate Mission
Cycles
Machining
Sequences Shape
Ram Speed
Cogging
Sequence
DOE
Optimization
Courtesy: SFTC WildeAnalysis.co.uk
• A number of leading aero
engine OEMs and disk
manufacturers are managing
residual stress and machining
distortion on a production
basis.
• Three dimensional capabilities
are being developed as an
ongoing effort.
Machining Distortion
Courtesy: SFTC WildeAnalysis.co.uk
Machining Distortion
residual stress after heat treatment
residual stress after machining
machining distortion (magnif ied 20X)
slow
coo
l fa
st q
ue
nc
h
Courtesy: SFTC WildeAnalysis.co.uk
Machining Distortion
• 2D 3D conversion can
be used to sweep the
geometry and interpolate
the residual stress to a
three dimensional model.
• Heat treat & machining
distortion can be modeled in
2D as an axisymmetric
model.
• Broaching is simulated using
a 3D model.
WildeAnalysis.co.uk
Metal Forming Simulation – Future
Machining
Cogging
Casting
Spin
Testing
Heat Treatment Forging
Furnace
Heating
Induction
Heating
Extrusion
Sheet Forming
Spot Welding
Stir Welding
Milling
Machining
Distortion
Life
Rolling
Resistance
Heating
Cold Forming
Ring Rolling
Inertia Welding
Mechanical
Joining
Pull Test
Courtesy: SFTC WildeAnalysis.co.uk
• Engineering analysis increasingly applied to both
product design and also manufacture.
• In the most critical service applications, product
optimisation spans multiple dissimilar processes.
• Simulating geometry through the manufacturing
cycle is inadequate to accurately predict in-service
performance.
• Prediction of internal properties (microstructure/
residual stress / fibre orientation) is required to
simulate the part behaviour through a range of
processes.
Summary
WildeAnalysis.co.uk
Thank You
WildeAnalysis.co.uk
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