ADVANCED COMPOSITE MATERIALS FOR … · Design & simulation Processes & tools Smart Hybrids Recycling. Ce do ument et les informations qu’il ontient sont la propriété d’IPC

Ce document et les informations qu’il contient sont la propriété d’IPC. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite d’IPC

ADVANCED COMPOSITE MATERIALS FOR INDUSTRIAL USE: MODELLING CHALLENGES AND TRANSLATION EXPERIENCE

Ronan Le Goff, PhDR&D Programme Manager


IPC AT A GLANCE


INNOVATION PLASTURGIE COMPOSITES

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IPC, established December 1st 2015, is theFrench Technical Centre for Innovation andExpertise in support of Industry.

Opened to industrials, IPC takes part in thesetup of partnerships and helps to createsynergies between actors of the plastics andcomposites branches.

OUR OBJECTIVESImproving the competitiveness of the industrythrough innovationGiving access to latest technological means forindustrials.

EXPERTISERESEARCH &DEVELOPMENT

Our activities

■ R&D■ Services■ Collective actions■ Training

Our competencies

■ Materials■ Design & simulation■ Processes & tools■ Smart Hybrids■ Recycling


120 employees (researchers, engineers, technicians): multi-competencies teams

Annual sales

INNOVATION PLASTURGIE COMPOSITES

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Our certifications

CIRAgréé CréditImpôt Recherche (CIR)

SGSCertifié ISO 9001v2008

COFRACISO 17025

Research & Development(private R&D or collaborative projects )

Services for companies

40 % 60 %

20162010 2011 2012 2013 2014 2015 2017

5.9M€

6.3M€

6.7M€

8.2M€

8.2M€

9M€

10M€

12M€

Collective actions setting-up

22%VARIOUS

5%ELECTRONICS

8%PACKAGING

25%AUTOMOTIVE

25%AEROSPACEDEFENSE

15%MEDICAL

Market share


ADVANCED COMPOSITES CHALLENGES


Product & Technology Evolution

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From high-performance

Structural ApplicationTo Smart Systems

From single polymer

composite

To multi-material product and hybrid manufacturing

To high production rates

applications

Functionalization


Applications and target markets

• Lightweight

• Structure health monitoring

• Active aerodynamics

• Interface – sensors integration

• Optical properties

• Touch feel

• Traceability

• Integration of functions

• Prostheses

• Antimicrobial systems

• Medicine packaging

• Multifunctional

• Smart windows

• Lightweight and smart structures

• Lightweight packaging

• Smart packaging

• Actives and antimicrobial packaging

• Biobased packaging

• Solar

• H2 Storage/ Fuel cell

• Batteries packaging

• Wind

• Interfaces

Market needs for advanced functionalities

Energy

Buildings and Infrastructures

Medical and Health

Packaging

Transport

Consumer goods


TRANSLATION EXPERIENCE1-HYBRID OVERMOULDING


Hybrid Overmoulding

Project description The objective is to improve and validate a modelling workflow for

manufacturing of a structural composite thermoplastic product

By improving modelling accuracy

By comparison with a demonstration tools

The product is made by hybrid overmoulding. It is a combination of :

Continuous Fibre Reinforced Thermoplastic composite (CFRTP)

Short Fiber Reinforced Thermoplastic (SFRTP)

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Continuous FRTP

Short FRTP


Hybrid Overmoulding

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StampingHeating

Modelling

Material output• Fiber orientation• Warpage• Polymer Flow• Internal stresses

Material input• CFRTP• SFRTP

Overmoulding

1-Picking 2-Heating 3-Stamping 4-Overmoulding 5-Ejection

Continuous FRTPShort FRTP

Several steps Many material parameters into account (number of plies, thicknesses, woven structure…)

Process Workflow

Dedicated Commercial Software

Link to chain models

Modelling Workflow


Hybrid Overmoulding

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Translation challenges Identify the steps of the modelling where we can increase

simulation accuracy

To keep thermal history of material on the whole workflow

To take into account anisotropy on mechanical results

To handle with commercial software

SpecificationDefinition Implementation Final Restitution

Project Manager (Modelling expert with scripting skills)

Sales

Heat Transfer Expert

Validation

Process Engineer

Software Editor

ClientClient

Translation Strategy


Hybrid Overmoulding

Validation

Tightening area

Fiber orientation

wrinkle

Compression area


Hybrid Overmoulding

Economic impact Investment :

Technical cost of invest (Material + equipment) : €5,000

IPC Modelling cost of invest:

Staff cost : €8,000

Software cost : Hyperworks +Moldflow = €80,000 (Cost of the software licences)

Computing cost : €2,000

Client ROI

A better definition of the process sequence

Shorten the cycle time

Increase robustness

Reduce trial and experiments

A improvement in product design Crash engineers

• To get fiber directions due to forming history

Product engineers

• To study formability

• To optimize the initial flat ply shape to avoid wrinkles

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TRANSLATION EXPERIENCE2-COOLING CIRCUIT MOLD DESIGN

With the agreement of


Cooling circuit mold design

Project description and general outcome The objective is to improve manufacturing performance of a Body actuator

plastic product

By re-designing the production tool

By improving quality

by increasing productivity

Modelling outcome Modelling helps in

designing a new cooling system in injection molding mold

identifying the best location for cooling channels

understanding heat transfer in metal during in-service behavior

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The product is made by injection molding and the actual mold lifetime is over



Global Product Development workflow

Modelling worflow

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Heat transfercalculation

Best coolingtime

estimation

Heat transferoptimization

Coolingchanneldesign

Modelling

Validation

QuotationProduct and

Process Design

Manufacturingtools

building

TuningDiagnostics

Manufacturing



Modelling results Model 1 : 1D energy equation

Model 2 : 3D heat transfer + optimization engine

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Conformal Cooling Channels design

Heat and mass transfer modeling

Isotherms for cooling channel design

Temperature

distribution on cooling

surface

Isotherm and heat flux

Heat transfer calculation App for cooling time estimation in injection molding



Numerical and Experimental Validation

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Drilled cooling channelsConformal cooling

channelsOutcome

Production Numerical Production Numerical Production

Productivity

Cycle time[s] 66 64 42 42 -36%

Cooling time [s] (Packing

included)

50 50 32 32 -35%

Quality[mm] 0.48 0.13 0.25 0.13 - 48%

[mm] 0.30 0.32 0.18 0.29 - 40%



Economic impact Investment :

Client Technical cost of invest (mold overcost+staff) : €10,000

IPC Modelling cost of invest:

Staff cost : €1,500 (weighted on the project)

Software cost : €25,000 (Cost of the software licence)

Computing cost : €2,000

Client ROI

Total (actual or expected) value of financial returns : €60,000

Better productivity -36% on cycle time : €48000

Accelerated production preparation and tuning : €12000

ROI = (60,000-10,000)/10,000 = 500 %

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Efficient Translation

1. Well understanding of the need

2. Definition of a modelling strategy according :

• Deadlines and Budget

• Result Accuracy

• Different scenario in mind

3. Explain the approach in the “client’s language”

4. Availability of material data

5. Right expert facing the right problem

6. Interpretation of results with the benefit of hindsight

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DefinitionSpecification

Implementation

Restitution


THANKS FOR YOUR ATTENTION !

Documents

ADVANCED COMPOSITE MATERIALS FOR … · Design & simulation Processes & tools Smart Hybrids Recycling. Ce do ument et les informations qu’il ontient sont la propriété d’IPC