DESIGN CAE ACTIVITY Montecarlo June 7 9 2000

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 First Southern European Technology Conference CAE Design approach to develop applicative solutions in automotive polymer based systems M. Chiara Ferrari, Filippo Gallieri Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 DESIGN & CAE Business Support Tool to develop applicative solutions in automotive polymer based systems

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 Design & CAE: a powerful tool in the Business Support Computer Aided Engineering Design Testing & validation

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 CAE TOOLS Product actual service conditions Simulation main variables/part performances computer calculation replacing qualitative/empirical approach Process tools and conditions process influence on part

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 New material/processes Design solutions CAE ADVANTAGES Production Process Tests (homologation. . . )

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 CAE ADVANTAGES • New material/processes: - no process tool building during the preliminary evaluation phase - critical issues investigated by simulation • Design solutions: - no prototype building up - several solutions evaluated and compared in short time: - materials - mechanical constraints - geometry

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 CAE ADVANTAGES • Tests (homologation. . . ): - the number is dramatically reduced; - main tests are focused on the final solution; - possible flops are predicted and solved on the computer • Production Process: - avoiding tools judged inadequate once already set up - part quality: - part performances foreseen in the design phase are respected - controlled defects due to process - time/costs are optimised

DESIGN & CAE ACTIVITY CAE & MONTELL Montecarlo, June 7 -9 2000 • Supporting to Montell product development - property profile for specific applications - directions for improvement • Driving the customer to Montell materials - advanced properties - best material/design system • Establishing Montell as a leading supplier to the technical industry: - differentiated offering (product and service)

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 R&D • Internal: new material/application development CAE: A KEY FACTOR FOR Business • External: penetration into the market

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 Car dashboards: from new concepts to first applicative projects

DESIGN & CAE ACTIVITY New concepts on dashboards Montecarlo, June 7 -9 2000 OBJECTIVE: cost reduction Dashboard system complexity causes a big influence of design (shape, assembly solutions) on final performances. Computer simulation in the early feasibility stage to compare solutions (materials, design, thickness)

DESIGN & CAE ACTIVITY New concepts on dashboards: creep as a key issue Montecarlo, June 7 -9 2000 Cycle: heating to 85°C, 22 hours creep, cooling to 23°C Example of Z displacement distribution after 22 hours creep at 85°C and cooling to room temperature example: Renault X 76 customer: Allibert

DESIGN & CAE ACTIVITY New concepts on dashboards: creep as a key issue Montecarlo, June 7 -9 2000 Cycle: heating to 85°C, 22 hours creep, cooling to 23°C Displacement comparison of selected points Material Density Thickness of the dashboard BR 131 G CR 250 F CR 1152 F 1. 14 1. 04 0. 97 2. 8 2. 4 2. 8 Upper right corner of central console 0. 85 0. 79 1. 25 2. 25 Top of instrument cover (“visière”) 1. 21 1. 08 1. 27 1. 73 Bottom of glove box 2. 35 2. 43 2. 45 Local relative displacement in right horizontal area 0. 70 0. 90 0. 36 0. 56

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 STRATEGY: concurrent engineering and simulation based design offered to selected partners

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 • Montell Design Support: - Static behaviour - Long term thermal stability (thermal/creep simulations) - Head impact simulation (ECE R 21 Standard) - Dynamic behaviour (Vibration) - Moldfilling simulation for all dashboard components • Applicative project for dashboard development grades

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 Part performances (static, thermal/creep, head impact, vibration) main phases : • Preliminary feasibility calculation with simplified assumptions: highlight of general behaviour, does it work? • Detailed calculation: - problem solving and optimisation on single components - evaluation of different material solutions • Rework of design according to CAE guidelines (customer) • Possible last calculation on final design

DESIGN & CAE ACTIVITY Dashboard: Head impact ECE R 21 IMPACT POSITIONS Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY Dashboard: Head impact ECE R 21 Fig 18 Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY Dashboard: Thermal cycle AF Montecarlo, June 7 -9 2000 6 H 85 C 16 H 40 C 3 H

DESIGN & CAE ACTIVITY Dashboard: Thermal cycle AF Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY Dashboard: Thermal cycle AF Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY Montecarlo, June 7 -9 2000 Dashboard Component: Manufacturing process design

DESIGN & CAE ACTIVITY Dashboard : Manufacturing process design Montecarlo, June 7 -9 2000 Process simulation: main phases • Preliminary calculation: - choice of best manufacturing process (injection molding? , traditional? sequential? ) - evaluation of different materials - evaluation of different gating solutions • Final calculation: - runner system balancing - investigation on process parameters influence (packing) • Special calculations for critical parts (injection molding): - cooling - warpage

DESIGN & CAE ACTIVITY Dashboard: Manufacturing process design Coiffe & runner system finite element model 1 Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY Dashboard: Manufacturing process design Montecarlo, June 7 -9 2000 Runner system dimensions [mm] Cold sprues G 1 , G 3 , G 4 , G 5 , G 6 Ø= 6 to 10 Cold runners G 1 , G 3 , G 4 , G 5 , G 6 Ø= 10 G 5 G 4 Ø= 24 -8 Ø= 20 G 6 G 1 G 3 G 2 Ø= 24 -8 Ø= 20 -8 i) Ø= 16 ii) Ø= 20 G 1 , G 2 , G 3 , G 5 , G 6 Gates (width x length x tk) thin area 20 x 2 x 1. 8 thick area 20 -0 x 8 Ø= 20 i) Ø= 14 -6 ii) Ø= 22 -8 G 4 Gate (width x length x tk) thin area 120 x 2 x 1. 8 thick area 120 x 8 Ø= 20 -8 G 2 , Cold sprue Ø= 5 to 8 G 2 , Cold runner Ø= 8 This is the only difference between type i) and type ii)

DESIGN & CAE ACTIVITY Ddashboard: Manufacturing process design Montecarlo, June 7 -9 2000 Molding machine parameters & Variable limits for PP Mold temperature 40 deg. C Variable limits for PP: Max. Pressure Max shear stress Max. shear rate Clamp force 1300 Tonne Max. Pressure No Restraints = 90 100 MPa = 0. 25 MPa = 100000 1/s Melt temperature 250 deg. C Fill time 6 -8 sec

DESIGN & CAE ACTIVITY Ddashboard: Manufacturing process design Fill time [s] & Weld lines Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY Dashboard: Manufacturing process design Pressure at end of filling [MPa] Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY Dashboard: Manufacturing process design Clamp force trend [Tonne] Max value = 740 Tonne Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY Dashboard: Manufacturing process design Montecarlo, June 7 -9 2000

DESIGN & CAE ACTIVITY HSBM Thin wall bumper concept Montecarlo, June 7 -9 2000 CAE support to concept development Evaluation of thickness reduction feasibility and design optimization Structural performances Molding technology e. g. thermal/creep behaviour e. g. sequential injection CAE simulations as a key issue

DESIGN & CAE ACTIVITY Thermal/creep cycle simulation on bumpers Montecarlo, June 7 -9 2000 High temperature effect • Temporary dilatation due to CLTE • Possible permanent deformations due to dilatation and weight To allow evaluation of material behaviour and design changes effect: • Simulation of the whole cycle (heating, creep, cooling) • Material nonlinearities considered (CLTE vs. temperature, stress/strain vs. temperature, creep vs. time, temp. , stress) • Temperature distribution: constant (e. g. oven) or variable along the surface and across thickness (e. g. sunload effect)

DESIGN & CAE ACTIVITY Thermal/creep cycle simulation on bumpers Montecarlo, June 7 -9 2000 Local temporary deformation during high temperature cycle

DESIGN & CAE ACTIVITY Thermal/creep cycle simulation on bumpers Montecarlo, June 7 -9 2000 Local final deformation after high temperature cycle and cooling

DESIGN & CAE ACTIVITY CAE: A KEY FACTOR FOR MONTELL Montecarlo, June 7 -9 2000 CUSTOMER WORLD IN Design Idea Preliminary Design Static MONTELL DESIGN & CAE WORLD Impact Thermal ! Prototype MATERIAL CHOICE DEVELOPMENT Flops Creep Fatigue Vibration PRODUCTION PROBLEM SOLVING IMPROVEMENTS OUT Injection molding New material FINAL DESIGN Extrusion Gas-assisted inj. Molding Thermoforming Blow molding