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SIMULATION OF COMBINED FORMING AND INJECTION MOLDING PROCESSES

Injection and compression molding of fiber reinforced thermoplastic materials are proven and efficient processes to produce lightweight parts for automotive applications. By adding continuous fiber reinforced composites or sheet metal, the possible range of applications can be greatly increased while retaining the advantages of the molding processes, cost efficiency and design flexibility. So called hybrids parts are used for more and more applications, especially in the automotive industry. The reinforcements are formed by the closing motion of the mold and the flow of the molding material. A novel approach is suggested using Abaqus/Explicit coupled eulerian lagrangian simulation to model combined forming and molding processes.

Customer Papers

SIMULATION OF COMBINED FORMING AND INJECTION MOLDING PROCESSES
Prediction of compressive characteristic of hat section high-strength steel frame taking the Bauschinger effect into account

In recent years, the usage of high-strength steel is increasing in order to improve the rate of body weight reduction and the safety performance of a vehicle from crash. The Bauschinger effect is generally strong in high-strength steel sheets. Material properties used in crash analysis is conventionally treated as isotropic hardening material. However, the analysis results such as average loading and buckling wavelength from analysis deviates with those from tests, which is observed in some axial collapse problems of hat section frame that is composed of high-strength steel sheet. When axial collapse occurs in the hat cross section frame, buckling occurs along with a frame ridge rolling.

Customer Papers

Prediction of compressive characteristic of hat section high-strength steel frame taking the Bauschinger effect into account
Application of Predictive Engineering Tool to Determine Optimize Rubber Door Harness Grommet Design

A cable grommet is a tube ring through which an electric cable passes. They are usually made of rubber or metal. The cable grommet is used to protect, improve friction or seal cables passing through it, from a possible mechanical or chemical attack and for aesthetic look. It becomes very important to determine the optimum length of the grommet used for particular application. Bigger length will have results into folding of grommet and lesser length will yield into stretching of rubber grommet. Finite element simulation technique presented in this paper can be used to determine the optimum geometry of the grommet. Component used for this study is an automotive door harness rubber grommet.

Customer Papers

Application of Predictive Engineering Tool to Determine Optimize Rubber Door Harness Grommet Design
Strength Assessment of Injection Molded ShortFiber-Reinforced Plastic Components

Components made of short-fiber-reinforced plastics (SFRP) are stressed highly both mechanically and thermally. Therefore an intelligent component design is required in order to fully exploit the potential of these materials. Hence, the design of such components must be based on a reliable strength assessment. For this purpose models for the description of the anisotropic and elasto-plastic failure behavior of SFRP are required. In contrast to the widespread use of SFRP, methods for a reliable strength assessment based on FE analyses for components made of these materials have not been sufficiently developed yet. This paper presents an approach for the strength assessment of SFRP components based on FE analyses. In the scope of this appropriate failure limits and failure criteria for these materials are presented.

Customer Papers

Strength Assessment of Injection Molded ShortFiber-Reinforced Plastic Components
Topology optimization of a motorcycle swing arm under service loads using Abaqus and Tosca

In research and development environment and concept design, people involved in new projects often need to design a completely new shape for the structure target of the analysis. The loading conditions and constraints are usually known but the designer hardly knows how to create the geometry of the structure that meets the requirements of the project and that can be manufactured at the same time respecting the target costs. In this paper is presented the topology optimization of a motorcycle swing arm, starting from a design space which takes into account the overall dimensions, and trying to minimize the mass while maximizing stiffness. The use of Tosca Structure, that drives the FEM simulation of the swing arm performed with Abaqus, allowed to obtain a shape that can be manufactured in compliance with the requirements of the project.

Customer Papers

Topology optimization of a motorcycle swing arm under service loads using Abaqus and Tosca
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