simulation services for injection molded plastic components€¦ · simulation services for...

Simulation Services for

Injection MoldedPlastic Components

Who we are:The Plastics Engineering Group is supplier of engineering services for the development of plastics products and the simulation of plastic part manufacturing processes.

Advantages for our Customers: • improved product quality • reduction of development time • optimized manufacturing processes • cost savings • increase of customer satisfaction

What we offer:Our scope of activity ist the optimization of injection molded parts, theassociated molds and the injection molding process using leadingfinite element based simulation tools (MOLDFLOW, ANSYS, ...).

• Moldflow analyses • meshing services (midplane modelling, shell meshes, solid meshes) • CFD modelling • structural analyses • design of experiments (DOE) • consulting service for the development of plastic parts • training • anisotropic structural analysis

Facts: • MOLDFLOW users since 1989 • proven record: > 11,000 projects • MOLDFLOW experience > 180 years • access to all MOLDFLOW applications

Our philosophy:Our daily mission on behalf of our customers is shaped by our commitment to best service and highest quality standards. We develop secured and practice-relevant solutions considering the technical goals and economic interests of our customers.

Contact: Sven Theissen (Dipl.-Ing.)Phone: +49 (0)6151 / 8504 020Email: [email protected]

Thomas Wittmann (Dipl.-Ing.)Phone: +49 (0)6151 / 8504 010Email: [email protected]

PEG GmbH • Robert-Bosch-Str. 7 • D-64293 Darmstadt • GermanyPhone: +49 (0)6151 / 8504-0 • Fax: +49 (0)6151 / 8504-099

[email protected] • www.pe-group.de

hybrid model

Generation of High Quality

Finite Element Models

Models for all Application Areas:• midplane models• shell meshes for

Moldflow, Ansys, Abaqus, LS-Dyna, Nastran, ...

• solid meshes forMoldflow analysesstructural analysesacoustics analyses CFD applications



detailed hexahedron model

complex midplane model

Our Strengths - Your Advantages:• day to day service• guaranteed intime delivery• flexible capacities• fixed rates• avoid waste of expensive expert resources

Our Modelling and Meshing Tools:• ANSA• CATIA• IDEAS / UG / NX• ICEM• HYPERMESH

Contact: Sven Theissen (Dipl.-Ing.)Phone: +49 (0)6151 / 8504 020Email: [email protected]

Thomas Wittmann (Dipl.-Ing.)Phone: +49 (0)6151 / 8504 010Email: [email protected]

thermal mold design

Full Analysis ServiceAnalyses and Optimization of

Injection Molded Plastic Components

Structural Analyses:• thermal expansion analyses• linear/nonlinear statics and dynamics

with contact• structural optimization• modal- and frequency response analyses• buckling analyses



stress distributionunder applied load

filling analyses

Moldflow Analyses:• MPI, Midplane, Fusion, 3D• Fibre, Warp, Cool, Gas,

Sequential Filling, Overmolding,Dynamic Feed, Co-Injection, MuCell,Injection Compression, Reactive Molding

The Plastics Engineering Group:• experienced Moldflow users since 1989• proven record of more than 11000

projects• individual and multilingual reporting• up to date software applications• multifaceted CAD data import

MOLDFLOW analyses

Mold design and process optimization

l l lPEG GmbH Robert-Bosch-Str. 7 D-64293 Darmstadt Germany

Phone: +49 (0)6151 / 8504-0Fax: +49 (0)6151 / 8504-099

[email protected] www.pe-group.de

Plastics Engineering Group

Moldflow applications:® ®l Autodesk Moldflow Insight (AMI) used

l Midplane, Fusion and 3D meshing technologyl Filling simulationl Runner design and runner balancing

- Sequential gating®- Dynamic Feed

l Cooling channel design and optimizationl Shrinkage and warpage prediction

- Including fiber orientation effectsl Special processes

- In-mold decoration (film, wood, metal)

- Overmolding of part inserts (hybrid)

- 2K injection molding

- Gas injection molding

- Injection compression molding (ICM)

- Reactive injection molding (RIM)

- Co-Injection®- Mucell process (microcellular foam)

Moldflow analyses offer you:l Increased part and mold qualityl Shorter cycle timesl Reduced efforts during molding trialsl Stable molding processesl Better understanding of the complex rheolo-

gical and thermal phenomena during molding

Runner system design / Pressure distribution

Co-injection / Distributionndof 2 component

Our offer contains:l Short response timesl Timely delivery of our servicesl Analysis fee communicated in advance

Cooling channel design

Leading by Simulation

Analysis goals & problemdefinitions

Part / cavity:l Gate placement, general ability to fill the part, position of weld lines and air traps,

pressure and clamp force requirements, shrinkage holes, thermal and mechanical

loading on the melt, cooling time, part deflection (shrinkage and warpage)l Process window and process capabilitiesl Part deflection: Tolerance compliance, part flatness, part roundness, position of holes,

screw bosses and other functional featuresl Part inserts taken into acountl Core deflectionl Identification of jetting phenomena


Cooling channel layout:l Determination and optimization of the cycle timel Detecting thermal vulnerabilities like hot spots and other non-uniform cooling issuesl Cooling channel layout, channel dimensioning and process settings like flow rates

and temperaturesl Optimizing the cooling system with mold inserts (Ampcoloy, copper, BeCu, heatpipes, ...)l Part deflection due to thermal influences

Hot and cold runner systems:l Number and positions of the injection pointsl Runner balancing, minimizing the clamp force requirement, avoiding flashl Dimensioning of the gates for most effective packingl Hot runner layout and valve gate timing for sequential gating

®l Hot runner layout and pressure profils (Dynamic Feed )

for single cavity, multi cavity, family and stack molds...

Special processes:l In-mold decoration (IMD): Assessment of thermal and mechanical loading on the filml Part inserts: Thermal and mechanical effectsl Overmolding: Thermal effects of A-component on B-component,

vice versa shrinkage and warpage analysis of A- and

B-component coupledl Gas injection molding: Placement of gas needles and overflow cavities, gas channel

penetration, final polymer wall thickness, fingering processing

parameters like gas delay time, gas pressure profile, ...l ICM: Clarify advantages of ICM over conventional molding,

compression forces, thermal and mechanical loading of the melt,

processing: Volume to be filled, press-open distance,

closing profile, ...l Co-injection: Determining (thickness) distribution of skin and core

components penetration of core component®

l Mucell : Weight savings, sink marks, bubble distribution

Processing: Initial volume to be filled, gas concentration, ...


Phone: +49 (0)6151 / 8504-0Fax: +49 (0)6151 / 8504-099



Meshing ServicesMOLDFLOW analyses

Low Pressure Molding



Phone: +49 (0)6151 / 8504-0Fax: +49 (0)6151 / 8504-099



Hotmelt technology:l Ability to fill the partl Filling animationsl Position of weld linesl Position of air trapsl Ventingl Pressure and clamp forcel Overmolding and bondingl Runner and gate dimensioningl Freeze timel Shear rates and shear stressesl Shrinkage & warpagel Process optimizationl Gravity, inertia & jetting

Reactive technology:l Reactive molding

- Epoxy, EMC, LSR, rubber, ...

- Conversion

- Curing kinetics

- Venting and air pressurel Microchip encapsulation

- Paddle shift

- Wire sweep

Freezing of gate area (left),Shear stress (right)

Filling animation(Microchip Encapsulation)

Chip Encapsulation: Wiresweep during filling process

Reactive moldingCuring of the material

Time

Your advantages:l Less development timel Higher quality standardl Optimized production processesl Cost savingsl Less claims and complaints

= CUSTOMER SATISFACTION

FEM - Structural analyses

Structural mechanicsand strength analysis



Scope of tasks:• Structural analysis of plastic-, metal- and

composite parts• Pressure load cases• Thermal load cases• Crash- and droptests

• Tool dimensioning• Process coupled structural mechanics

Benefits:• Prediction and evaluation of stresses,

strains and deformations• Evaluation of strength and deformation

requirements• Prediction of functionality, reliability and

safety reserves• Reduced test effort• Close-to-production prototype• Better understanding of the general

mechanical behavior

Our offer contains:• Short response times• Timely delivery of our services• Analysis fee communicated in advance

Tool calculation / Analysis of the deformation

Internal pressure load with consideration of the fibre orientation

Stability analysis incl. buckling analysis

filling simulation coupled with

structural mechanics

Application:l Specific part designl Weight optimizationl Analysis of weld line quality

Benefits:l More accurate and realistic resultsl Consideration of fiber orientationl Taking the microstructure into account

Consulting Services:l Material testing & validationl Moldflow fiber solver adjustmentl Analyses & optimisationl Evaluation projects

Technology:l Non-linear non-isotropic approachl “MAPPING”: ideal numerical models for

process simulation and structural analysesl Virtual material laboratoryl Definition of any material model with

different base polymers and fillers

Plastics Engineering GroupLeading by Simulation

l l lPEG GmbH Robert-Bosch-Str. 7 D-64293 Darmstadt GermanylPhone: +49 (0)6151 / 8504-131

[email protected] www.pe-group.deFax: +49 (0)6151 / 8504-099

Coupling process simulationresults with the structure mechanical model

Material Data:non linear anisotropicStress-strain curves

Our offer:l Coordination of medium-term development

projectsl Possible cooperation with leading „Plastics

Institutes“ in Darmstadt, Germanyl First certified German Digimat service

provider

Strain distribution:considering anisotropicmaterial properties

Meshing ServicesRecord of projects /

Experience 1/2



Phone: +49 (0)6151 / 8504-0 Fax: +49 (0)6151 / 8504-099



automotive exterieur

2K spray nozzle2-parts bumper2-parts wheel housingadaptive lighting housingair duct air duct instrument panelback housingback light housingback light lensbaffle cover ASDbezel headlightbezel tailgatebumperbumper center grillbumper reinforcementbumper side grillcar roofcaravan roof top car-jack supportcarrier instrument panelchrome-plated front grillchrome-plated trimchrome-plated trim stripcontrol panelcover back lightcover brake linecover mirrorcover side plate frontcover side plate rearcover tailgatecrash safety bardecoration ringdecoration stripdiffuser lensdoor framedoor handledoor leafdoor paneldoor trim panelemblem housingengine bay coverengine coverexhaust silencerfin grillfront bezelfront bumperfront bumper fasciafront bumper protection stripfront bumper reinforcementfront bumper with integrated emblem front bumper with integrated grillefront fenderfront grillfront housingfront spoilergas-assisted air ductgas-assisted door handlegas-assisted mirror housingglas wiperglass roof framegrillground plate mirrorgutterhand railhandle tailgateheadlight housingheadlight lensheadlight mounting plateheat protection platehoneycomb grillehybrid front endinner wheel coverlenslens 2Kmirror mirror bezelmirror bracketmirror bracket covermirror bracket framemirror housingmirror shellmirror shell (bus)mirror supportmounting rocker panelmulti colour lensouter wheel coverplanking coverradiator grillerear bezelrear bumperrear bumper fasciarear bumper protection striprear bumper reinforcementrear fenderrear spoilerreflector

reflector housingrocker panelrocker panel lowerrocker panel upperroofroof frameroof galeryroof rackroof rack bracketroof rack closurescreen (injection compression molding)screen (injection molding)side protection strip fenderside protection strip frontside protection strip rearside spoilersliding roof framespare wheel mountingspoiler spoiler libstep board (truck)sunrooftroughtruck mirror shelltruck spoilertruck wheel housingtruck windshieldunderbody skidplatewheel housingwheel housing with fleece insertwindow framewindshield panelwiper bar

automotive interieur

2K button2K button set2K IMD button2K light duct2K pocket2K steering wheel2-part instrument panelac paneladjusting buttonair ductair jetair jet coverair jet housingairbag cover driver sideairbag cover driver side 2Kairbag cover passenger sideairbag cover passenger side 2Kairbag frameairbag housing driver sideairbag housing passenger sideairbag retainerairbag retainer driver sideairbag retainer passenger sidearm restarm rest bracketarm rest center consolearm rest coverbezel glove boxboot sillbracketbreak handlebus seatbutton guidebutton setbutton set 2Kcarrier center consolecarrier instrument panelcenter console ashtray center trimclipclock springcontrol panel with IMDcontrol panel with IMD 2Kcover A-pillarcover A-pillar 2Kcover audiocover B-pillarcover B-pillar 2Kcover CD entrycover CD/DVDcover C-pillarcover C-pillar 2Kcover D-pillarcover drawercover floor roomcover framecover highcover IHUcover loading edge car trunkcover lower cover spare wheel cover speakercover telematic

cover tuning screen air conditioncover venting channelcoverglass instrument areacup holder cup holder sliderdecoration ringdecoration ring airbag coverdecoration stip with foil IMDdecoration stip with wood IMDdecoration stripdefroster jetdirected lightingdoor bardoor coverdoor framedoor handledoor moduldoor paneldoor pocketdrawerDVD panelend capfinfish tailfont cover roof linerfoot restframe side windowfront framefront panelfront paneltractorgas pedalglove box glove box coverglove box frameglove box lidhandleheadlampheadresthead-up displayhousinghousing instrument panalhybrid barIMD buttoninstrument panelinstument frameknee airbaglight ductlight ringlock housinglock supportmanual traypusherradio coverrc panelrear seat arm rest housingrear seat housingrear trim trunkrear view camerarear view mirrorretainerrocker panel railroof arch convertibleroof handlesafety bar coversafety bar guidiancescreenscreen retainerseat seat channelseat front trimseat handleseat panseat side trimsecurity boardside airbagside panelside trimspeaker grillesteering column housingsteering wheelsteering wheel housingsteering wheel with insertssun visorsymbol paneltrim middle consoletrim side walltrim trunktrunk botttom plate window cover window-frame

automotive power train

2K radiator frameabsorberabsorber coverabsorber housingaccumulator consoleaccumulator support

air boxair collector air ductair filter housingair intake manifold (core fusion technology)air intake manifold (welding technology)air intake manifold V3air intake manifold V4air intake manifold V5air intake manifold V6air intake manifold V8air intake manifold V10assembly coveraxial radiatoraxial radiator with metal insertbearingbearing bracketbearing housingbearing supportcabel dict with living hingecarriercarrier radiator framecharcoal absorbercharge air coolercharge air manifoldcheck valvecheck valve housingclosureclutch actuator housingclutch housingclutch pedalcogwheelcollectorcompensation tankcompensation tank 2 shellscondensate tankconnecting flangecoolant compensation tankcyclonecylinder head cover 3cyl.cylinder head cover 4cyl.cylinder head cover 6cyl.deflection leverdraft tube housinge boxengine design cover V4engine design cover V5engine design cover V6engine design cover V8engine design cover V10engine hood railengine mountingexhauster exhauster hatches controlfan wheelfinger platefresh air manifoldfront endfront modulefuel absorberfuel feed linefuel linefuel railgasketgasket ringgear boxgear covergear element with spindlegear oil sumpgear rodgear rollergear segmentgear tooth systemgear wheel with housinghousing charcoal absorberhousing gear controlinlet manifoldladder framemanifoldmanifold shroudmanifold supportmulti absorbermulti twisteroil filteroil filter housingoil panoil pan truckoil separator cylinder head coveroil separator valve coveroil separatoroil panparking brakeperforated plateplatepneumatic suspension housingpower steering housingpressure compensation tankradial fan

automotive power train

radial fan with metal retainerradiatorradiator housingradiator shroud doubleradiator shroud singleresonatorretainersealing coversealing framesealing plateshift-forkshift-fork housingsingle radiator framesnorkelspindlespringspring bracketspring panelspring supportsteam partitiontanktank flangetank hutchtank inlet necktapped rodtooth wheeltransducer cylindertrim engine hoodtrottle body flangetruck cylinder head covertruck valve coverU-Boxvalvevalve cover 3 Zylvalve cover 4 Zylvalve cover 6 Zylvalve rollventilatorwater boxwater tank

consumer + packaging

5 cavity preform mold8 cavity preform mold10 cavity preform mold24 cavity preform mold32 cavity preform mold48 cavity preform mold64 cavity preform mold72 cavity preform mold2K co-injected handle for screwdriverBeauty coverbit tool boxblade boxblisterbottlebottle bottombottle boxboxbrush headbucketcap nutcartridgecondensing dryer drumcondensing dryer rear panelcooker hoodcooker hood, gas-assisted creme jarcupdiaphragm dryer dryer dryer air ventdryer doordryer door inner platedryer front pnaneldryer housingdust panelectric toothbrush housinggarbage can 120 lgarbage can 140 lgarbage can 210 lgarbage can lidice boxmargarine tubnapkin boxplastic broompreformrubber broomsleevespray capstack boxsuds bowl (washing machine)suitcasetool boxtooth brushtransport box 40 l

tube capwashing machine bezelwashing machine frame washing machine lidwiper

E&E

2K leadframe2K sensorABS housingactuatorACV connectoradapter plateAGB housingAGR housingair condition housingair flow meterair flow sensorangle grinder housingaxial blowerbattery boxbattery housingbattery lidboardbusbarbuttonbutton setbutton sub-framecable channelcable conduitcable openingcamera bodycar antennacarriercell phone housingchainsaw handlechainsaw housingcircular saw housingcoffee machine housingcoffee machine water tankcomponent carrierconnectorconnector barconnector frameconnector housingconnector plateconnector sleeveconnerctor safety barcontact bridgecopier housingcordless screwdrivercurling iron handledrill housinge-boxelectric switchelectric tooth brush housingESL housingESL lidfanfeelerfridgefridge drawerfront wall dampingfront wall with air ductgrinder housinghair dryer housinghair dryer nozzlehand mixer housinghedge shears housinghousing protection switchinductorinductor carrierinductor housingISDN check housingISDN connectorjig saw housingjunction platekärcher handleKärcher housingkeyboardlead elementleadframe toollight switchlight switch framelong field lightningMID leadframemodul framemonitor housingmotor housing for wipermulti-cavity leadframemultipolar connectorphase sensorplaner housingpower drill housingpower window housingprotection switchpumppump housing

push-buttonradial fanrear view camera housingreflectorreflector housingrelais boxring sensorrotational speed sensorrotorscrap toolsensorsensor airbag coversensor casingsensor coversensor headsensor housingsensor premoldseparatorshaver base stationshaver head bridgeshaver head housingspiderstatorsteam iron apronsteam iron handlesteam iron housingsteam iron water tanksteering rate sensorstripstrip barsubwoofertelefon housingTFT housingthermostat housingTMPSTMPS antennatransformer coilTV front panelTV housingTV rear panelUEC boardvacuum cleaner housingVSC housingwashing machine bezelwire drive housing

medical technology

cap for insulin injectorchair wheel componentschair wheel foot lockdental housing front partdental housing back partdiagnosis systemdiagnostic platediskdispenser housinge-rackfilterinhaler housinginjectorlenslower test platemedical tackermikro test platepipette with disposal tiprack 24rack 96shower cushion (2K)syringetest stuff housingtray 12tray 24upper test plate

miscellaneous products

2K fitting2K palettebackrestboxbucketbucket handholdbullet jacketbushcastorcement mixer barrelchain linkchair with gas injection technologychar framecoat-hangercoin dispensercontainer cornercreme jarcurrugated tubecushiondeck chairdispenser box

door platedrain pipeface guard for weldingfilter frame with interfacefittingfitting with insertsfoam platefolding seatglass smoothing bladegutterhelmethingeice box 5 lice scraperLCD standlidmonitor rotary armnapkin dispenserpalettepen cappen housingpipepipe fittingpivot armroll chain rubber gaitershovelshower bonnetshower cabinstip barstoolsunbedtanktie wrapTV standtweetervisor wall holderwedge

Meshing ServicesRecord of projects /

Experience 2/2



Phone: +49 (0)6151 / 8504-0 Fax: +49 (0)6151 / 8504-099



simulation services for injection molded plastic components€¦ · simulation services for...

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