Linking mould filling and structural simulations

Abstract

Computer Aided Engineering (CAE) is common standard in the development process within the automotive industry. For thermoplastic components, for example, the manufacturing process is commonly simulated with injection moulding simulation software and passive safety with explicit crash software. Currently both disciplines are only linked within the simulation of fibre reinforced thermoplastics to take into account the fibre orientation from injection moulding simulation within crash simulation due to the significant influence of the fibre orientation on mechanical part properties. This work proposes a methodology that allows consideration of moulding conditions on the mechanical behaviour of unreinforced injection moulded components by coupling injection moulding simulation (Moldflow) and crash simulation (LS-DYNA (R)/RADIOSS (R)). A newly developed dedicated computer application allows to directly consider results from injection simulation within crash simulations. The manufacturing boundary conditions that most influence the mechanical behaviour are combined within the thermomechanical indices (TMI) methodology, and mapped onto each finite element within the crash simulation. Mathematical functions have been used to correlate the TMI to important mechanical properties of the moulded polymer. A user defined material model can read those indices and translate them to local mechanical properties.