cae organization in toray - 3d timon · s total applications 150 parts ... cae software &...

CAE Organization in TORAYs CAE support for resin customers since 1986

s CAE group of Plastic Technology Dept.

Material Testing, Compounding, Process ...

s CAE Software＆Solution Business Dept.

Software Development, Marketing...

CAE Software & Solution Business Dept., Toray Ind.Inc.

CAE Support in 1997

s Customer field Automotive,E&E,Construction,etc.

s Total Applications 150 parts

s Structural Analysis 50 %

s Molding Simulation 50 %

s Intake Manifold 10 %(include prototyping )


CAE for Air Intake Manifold

s Molding Simulation

s Vibration Welding Analysis

s Structural Analysis

s Modal Analysis

s Fluid flow Analysis

s Acoustic Analysis


Molding Simulation

s Software : TIMON ( by TORAY )

Since 1985

s Data link with 3D CADUG, Pro/E, I-Deas, CATIA, SolidWorks...

s 3D Solid analysis from filling to warpage

s Automatic hexahedron mesh generator




s Modal Analysis


s Acoustic Analysis


Auto Meshing from 3D CAD3D CAD Stereo Lithography

(STL) File TIMON-MESH 3D TIMONSolidMesh


Improvement of Warpage

Effect of Stiffening by RibEffect of Gate Layout-1.5

-1

-0.5

0

0.5

1

1.5

2

2.5

3

3.5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

War

page

[mm

]

-2

-1.5

-1

-0.5

0

0.5

1

1.5

2

2.5

3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

4 Points Gate

Measured

2 Points Gate

Rib-A

Rib-B

Original

1 ５９１３

２４

Rib - A Rib - B

Resin： CM1016G30（PA6）


Melt Core Deformation

Cavity Pressure

Core Deformation

Core Deformation

Mold FillingAnalysis

Cavity Pressure

StructuralAnalysis

Deformation


Vibration Welding Analysis

s Software : VWELD ( by TORAY )

s Residual stress by warpage

s Simulation of welding process

s Estimation of welding time & melting region




s Modal Analysis


s Acoustic Analysis


Residual Stress by Warpage

Residual Stress When Compulsive Joining(High Tensile Stress at Red Section)

1 Point Gate

Max Stress 22.7 MPa Warpage Analysis

Structural Analysis

Residual Stress

Warped Shape


Thermal analysis in welding

0

50

100

150

200

250

300

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6

0.5sec 1.0 1.5 2.0 2.5Temperature [C]

Change of temperature distribution in welding process

Distribution of Welding EnergyDistance from initial surface [mm]


Modal Analysis

s Software : ABAQUS

s Natural frequencies & modes

s Dynamic response to base excitation

s Dynamic response to inner air pressure




s Modal Analysis


s Acoustic Analysis


Natural Frequencies & ModesMode 1 94.5Hz

Mode 2 194.8Hz


Response to Base Excitation

10G

Highly Stressed

Displacement

s Attached Mass, Moments Viscous Damping


Fluid flow analysis

s Software : Star/CD

s Air flow velocity & Pressure loss

s Transient air pressureStructural coupling between surface vibration and air pressure

s Turbulent flow energyEvaluation of acoustic source




s Modal Analysis


s Acoustic Analysis


Turbulent flow analysisPressure

Velocity

Deformation byPressure


Acoustic Analysis

s Software : ABAQUS/SYSNOIZE

s Resonance frequencies

s Sound transmission through wall

s Radiated sound by surface vibration includingcoupling effect with structure

s Air flow induced noise radiation (Future)




s Modal Analysis


s Acoustic Analysis


Sound radiation analysis

ABAQUS SYSNOISE

Natural Frequencies & Mode Vectors

Sound PressureSound Intensity

Inside Sound Source

Transmission

ABAQUS SYSNOISE

Dynamic Displacement Sound PressureSound IntensityBase Excitation

Sound by Structural Vibration


Air flow induced noise

Inside Sound Source

ABAQUS SYSNOISE

Dynamic DisplacementSound PressureSound IntensityAir Pressure

Sound by Air Caused Vibration

Star/CD

ABAQUS SYSNOISE

Dynamic DisplacementSound PressureSound Intensity

Star/CD

Sound by Turbulent flow (Future)


Vibration by Sound Pressure

15th natural vibration mode

15th mode

Mode Number

Mode Participation Function


Sound Transmission Analysis

Vibration by sound pressure Measuring plane definition


Sound Transmission Analysis

Sound Pressure at 850Hz Frequency Response

S.P[db]

[Hz]


Experimental Facility

s Injection Molding Machine

s Vibration Welding Machine

s Mechanical, Thermal & Chemical Testing

s Modal Analysis

s Acoustic Pressure & Intensity


Modal ExperimentFrequency Response Function

Cal. Exp. [Hz]1st 95 1162nd 195 204

Natural Frequency


Acoustic Experiment

s Sound SourceInside SpeakerInner Air Blow

s MeasurementRadiated Sound PressureRadiated Sound Intensity

Surface Acceleration

ＦＦＴ


Acoustic Experiment

Intensity Measurement

Sound Pressure


cae organization in toray - 3d timon · s total applications 150 parts ... cae software &...

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