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Insert Molding 通过模流分析结果判断产品应力开裂问题

Insert Molding 通过模流分析结果判断产品应力开裂问题

Customer challenge

随着 Insert Molding 在塑胶制品中广泛应用,嵌件产品所产生的缺陷也日益显现,例如塑胶与金属嵌件结合力不足问题、熔接线问题、变形问题以及产品开裂问题等。困气会对产品结合力问题产生影响,模流分析可以通过评估气穴问题对结合力进行评估和改善;充填和熔接线结果可以对熔接线问题进行评估和优化;变形结果可以直观的评估产品变形,并验证优化方案。唯独产品开裂问题,客户在以往的分析中没有模流分析结果对其进行评估和优化,产品开裂主要原因是由于残余应力导致的,这种开裂具有时效性,往往是产品放置或者使用一段时间后,才会发生开裂,从而影响产品的品质、影响品牌口碑甚至影响产品的安全。而且再发现产品开裂问题出现后,再进行问题评估和改善,需要从产品结构、模具方案、注塑工艺方面进行全面的检讨,对于可能引起开裂的原因逐一进行验证排查,要花费很高的成本才能解决问题,同时改善周期较长,也会影响产品的生命周期。客户急需寻找一种在前期进行评估和分析时有效的方法或者模流分析结果,对产品的应力开裂进行评估,以便在前期进行问题的风险评估和有效改善。

Project goals

通过使用 Autodesk moldflow 软件,对 Insert Molding 产品进行建模分析,通过"最大剪切应力"结果评估产品是否存在开裂风险。并将"最大剪切应力"结果中最大应力区域的数值与实际产品开裂区域进行对比,制定应力开裂的判定标准,即针对特定材料分析结果中"最大剪切应力"数值超过制定的标准值时,可以判定实际产品会出现开裂风险。

Solution

一、软件操作演示; 二、关键结果说明; 三、结果显示设置; 四、模流分析结果与实际问题对比,形成判定标准; 五、线上、线下的技术支持。

Business outcome

技术支持文件,内容包括: 一、在工艺设置向导-翘曲设置中取消“使用网格聚合”; 二、查看"最大剪切应力结果",将结果属性中的比例,最小值指定为材料建议的剪切应力值,最大值设置合适数值,在看结果中最大剪切应力的分布; 三、通过该方法将以前开裂案例进行模流分析验证,对比最大应力分布区域与实际产品开裂区域是否一致,从而指定特定材料的判定标准。

Conclusion

通过使用 Autodesk moldflow 中的"最大剪切应力"结果,对 Insert Molding 产品的开裂问题进行前期评估有了一个可参考的结果,并且该结果可以通过数据定量评估,使得前期对开裂评估有了数据支持。并且随着分析结果与实际产品进行对比,制定了判定标准,不断提高评估的准确性。为产品结构优化、模具方案优化提供了有效的数据支持。-------David 模具部经理

Project summary

    Duration & delivery

  • 90
  • 2021-06-02

    Autodesk solutions

  • Moldflow Insight

    Services provided

  • Technical Support
  • Product Activation & Onboarding
  • Product Training
  • Solution Adoption Services
  • Simulation

    Customer industry

  • Additive Manufacturing
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