improving manufacturing by simulation: processes, microstructure & tooling

34
improving manufacturing by simulation: Process, Microstructure & Tooling Dr Brian Miller Sales & Marketing Director WildeAnalysis.co.uk WildeAnalysis.co.uk

Upload: wilde-analysis-ltd

Post on 21-Dec-2014

1.866 views

Category:

Technology


4 download

DESCRIPTION

This presentation, made at the inaugural Virtual Engineering Centre Workshop on 25-26th October 2011, provides an overview of the application of simulation to optimise manufacturing processes and determine mechanical properties that can affect in-service performance. These properties can be imported into structural FEA programs such as ANSYS for subsequent analysis of the final product. Wilde Analysis believes that simulation techniques can play an important part in ensuring that parts are produced to a required standard and in an efficient way. Many of us are aware of simulation techniques such as finite element analysis (FEA) and computational fluid dynamics (CFD) being applied to product design. These techniques are now used extensively in product development for applications such as checks on structural integrity or pressure drops in fluid applications. However, fewer people are aware of the application of these and similar techniques to design and optimise the manufacturing processes and how they can deliver benefits in areas such as metal forging, machining, heat treatment and the injection moulding. The simulation of any one of these processes is technically demanding, but is now used extensively by many manufacturers, some of whom will not commit to making tools to produce a new part without first ‘proving’ the process using simulation. These simulations require advanced techniques including the modelling of non linear materials, large displacements, evolving contact surfaces and material removal in a multi-physics environment. Having mastered the modelling of a single process, the technology is now being applied to multi-stage modelling to simulate multiple operations and predict final properties that can affect in-service performance. This presents many new challenges and for some applications it’s still at the research stage. Nevertheless, current technologies are now being used to optimise manufacturing processes.

TRANSCRIPT

Page 1: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

improving manufacturing by simulation:

Process, Microstructure & Tooling

Dr Brian Miller

Sales & Marketing Director

WildeAnalysis.co.uk

WildeAnalysis.co.uk

Page 2: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• 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

Page 3: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Wilde Analysis

FEA

CFD

0 P

robabili

ty

Value S L

Reliability WildeAnalysis.co.uk

Page 4: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• 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

Page 5: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Applications in all Engineering Fields

WildeAnalysis.co.uk

Page 6: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 7: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• 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

Page 8: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• 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

Page 9: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 10: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 11: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Blow Moulding Process Simulation

Courtesy: ANSYS WildeAnalysis.co.uk

Page 12: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 13: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Effect of Variable Thickness

Top load - total

deformation

uniform

thickness

variable

thickness

WildeAnalysis.co.uk

Page 14: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• Primary stiffening cover, essential for the entire phone stiffness

Moldf low to Structural Analysis

Courtesy: Autodesk WildeAnalysis.co.uk

Page 15: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• Material PA, Zytel HTN53G50HSLR (DuPont)

(50%Glass)

Moldf low to Structural Analysis

restraints

Vertical force

Courtesy: Autodesk WildeAnalysis.co.uk

Page 16: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• Gate Location: Top

Moldf low to Structural Analysis

Gate location Fiber orientation

Poor orientation in this area

Courtesy: Autodesk WildeAnalysis.co.uk

Page 17: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• Gate Location: Bottom

Moldf low to Structural Analysis

Gate location Fiber orientation

Good orientation in this area

Courtesy: Autodesk WildeAnalysis.co.uk

Page 18: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• Gate Location: Mid

Moldf low to Structural Analysis

Gate location Fiber orientation

Good orientation in this area

Courtesy: Autodesk WildeAnalysis.co.uk

Page 19: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 20: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 21: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Typical Metal Forming Applications

Hot forging Thread rolling

Cogging Machining Other applications

Mechanical joining

Courtesy: SFTC WildeAnalysis.co.uk

Page 22: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Typical Metal Forming Applications

Hot forging Thread rolling Mechanical joining

Cogging Machining Other applications

Courtesy: SFTC WildeAnalysis.co.uk

Page 23: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Typical Metal Forming Applications

Hot forging Thread rolling

Cogging Machining Other applications

Mechanical joining

Courtesy: SFTC WildeAnalysis.co.uk

Page 24: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Typical Metal Forming Applications

Hot forging Thread rolling Mechanical joining

Cogging Machining Other applications

Courtesy: SFTC WildeAnalysis.co.uk

Page 25: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Typical Metal Forming Applications

Hot forging Thread rolling

Cogging Machining Other applications

Mechanical joining

Courtesy: SFTC WildeAnalysis.co.uk

Page 26: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Typical Metal Forming Applications

Hot forging Thread rolling

Cogging Machining Other applications

Mechanical joining

Courtesy: SFTC WildeAnalysis.co.uk

Page 27: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Typical Metal Forming Applications

Hot forging Thread rolling

Cogging Machining Other applications

Mechanical joining

Courtesy: SFTC WildeAnalysis.co.uk

Page 28: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 29: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• 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

Page 30: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 31: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 32: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

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

Page 33: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

• 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

Page 34: Improving Manufacturing by Simulation: Processes, Microstructure & Tooling

Thank You

WildeAnalysis.co.uk