New Developments for the Optimisation of High Performance Elastomers Using 3D Simulation Tools

摘要

During the development of injection moulded rubber and plastic components simulation is used frequently to optimise the performance of new products. Using new 3D simulation techniques the die fill, the curing process and the subsequent cooling of the parts is calculated to optimise the process before any die steel has been cut. Rubber components such as sealings or anti-vibration parts for the automotive industry show three dimensional geometries with varying wall thickness and complex metal inserts. The paper will present a new simulation program which was especially developed for the optimisation of 3D injection mouldings. The program works on the basis of 3D volume elements and is 3-dimensional, in-transient and non-isothermal. Thixotropic effects can be calculated. The fluid flow algorithms are based upon Navier-Stokes' equations: kinetic effects such as jetting into the mould are calculated. Results are depicted in 3D colour graphics. The program is used to predict gate position, runner balancing, flow fronts, local curing, die temperatures, cycle times, etc. The paper will discuss the application of this new tool on real life production parts. A new module allows the calculation of fibre orientation in 3D.