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Dynamic Simulation of an Injection Molding Machine

Dynamic Simulation of an Injection Molding Machine. GAMM2005 Mehrkörpersysteme und Kinematik 29. März - 01. April 2005, Luxemburg. C . Hostert H. Kollmeier S. Maas R. Nordmann A. Zürbes. Université du Luxembourg. Index. Project Project QUADLOC Software Models MBS Flexible Bodies

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Dynamic Simulation of an Injection Molding Machine

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  1. Dynamic Simulation of anInjection Molding Machine GAMM2005 Mehrkörpersysteme und Kinematik 29. März - 01. April 2005, Luxemburg C. Hostert H. Kollmeier S. Maas R. Nordmann A. Zürbes Université du Luxembourg

  2. Index • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects • Project • Description of project • QUADLOC™ clamp unit • Simulation tools • Models • Multi-Body Simulation model • Integration of flexible bodies in MBS • Hydraulic model • Controls model • Simulation • Results / Comparison with measurements • Prospects

  3. Project • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects • 3 partners: • HUSKY Injection Molding Systems • TU-Darmstadt • Université du Luxembourg dynamic simulation of a QUADLOC clamp unit integration of mechanical, hydraulic and controls systems combination of commercial software

  4. QUADLOC™ clamp unit • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects 2-platen design 2 stroke cylinders stationary platen 4 tie bars 4 integrated clamp pistons moving platen

  5. Unigraphics geometries for models DSHplus hydraulics ADAMS Multi-Body ANSYS Finite Element flexibility of components co-simulation of mechatronic systems data for stress analysis Simulink controls measurements validation Software • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects combination of commercial simulation programs

  6. revolute joint with friction sperical joint flexible body rigid body sperical joint with joint motion hydraulic force MBS model of clamp locking • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects 1 rigid-body DOF + 57 flexible-body DOFs

  7. hydraulic force contact forces rigid body flexible body bushings rigid body MBS model of moving platen stroke • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects 6 rigid-body DOFs + 150 flexible-body DOFs

  8. FE-model for moving platen stroke • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects SOLID 187 BEAM 188 SHELL 63 COMBIN 14 : connecting substructures BEAM 4 : interface nodes

  9. Flexible bodies in MBS • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects 1st step: Component Mode Synthesis called Craig-Bampton approach: constraint modes & fixed normal modes i  interior b  boundary C  constraint N  normal siehe auch R.Gasch, Strukturdynamik – Band 2 gemischte statische und modale Kondensation

  10. Flexible bodies in MBS • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects 2ndstep: Mathematical Transformation Craig-Bampton modal basis difficult to implement in MBS code solving the following eigenvalue problem: thus so that • synthesized from fixednormal and constraint modes are: • 6 rigid body modes; can now be disabled in MBS, • free normal modes, • mode shapes of the boundary, • modes with no apparent physical meaning.

  11. P B G Flexible bodies in MBS • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects 3rd step: Integration in ADAMS position: where orientation: 3-1-3 Euler Angles ( transformation matrix A) angular velocity: linear velocity: generalized coordinate set

  12. Theory of Flexible Bodies • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects 3rd step: Integration in ADAMS Lagrange's equations for a flexible body: kinetic energy: potential energy: dissipative energy:

  13. Parasolid 2. ANSYS/Workbench automatic meshing 3. ANSYS/Classic SOLID 187 manual generation of BEAM elements BEAM 4 interface node for MBS model FE-model of a connecting bar • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects 1. CAD model

  14. Integration of ANSYS-models in ADAMS • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects ADAMS-interface available in ANSYS • generation of FE-model • ADAMS-interface: • selection of interface nodes • reduction of FE-model • transfer of reduced matrices (mnf-File)  assembly of flexible body into MBS-model

  15. z y x Verification of reduced model • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects modal analysis of assembled connecting bar

  16. Moving platen and tie bar sliding • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects modelled in ADAMS with IMPACT statement non-linear spring-damper maintains continuous contact between 2 geometries

  17. moving platen shoe d1 d2 d3 d4 DZ DY,VY node clamp base 1 0 d1 d2 d3 d4 Moving platen and tie bar sliding • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects own-programmed statement using IMPACT contact force permanently calculated only applied to node when necessary through a weighting function

  18. Moving platen and tie bar sliding • Project • Project • QUADLOC • Software • Models • MBS • Flexible Body • Hydraulics • Controls • Simulation • Results • Prospects disadvantges: - huge number of DOFs - discontinuous contact forces  use of slave nodes for sliding

  19. Hydraulic model • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects DSHplus by FLUIDON GmbH Spin-off of IFAS, RWTH-Aachen differential cylinder modeling of cylinder cushion hoses pilot operated 43 proportional valve pipes and hoses pump and pressure-reducing valve

  20. model of components: • pipe • valve RH LH CH RH Hydraulic model • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects formulas based on - one-dimensional flow theory - supplemented by empirical considerations Resistance : Capacitance : Inductance :

  21. Co-simulation • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects ADAMS Mechanics DSHplus Hydraulics SIMULINK Controls • cylinder force • moving platen position • position of cylinder • velocity of cylinder • input voltage valve • input voltage valve

  22. Comparison with measurements • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects

  23. Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects

  24. Simulation of Mechatronic Systems • Project • Project • QUADLOC • Software • Models • MBS • Flexible Bodies • Hydraulics • Controls • Simulation • Results • Prospects interest of integrated simulations : • get full understanding of dynamics of complete system, difficult to assess with simple calculations • analyse influence of one parameter on behaviour of complete system • analyse interactions between sub-systems, e.g. hydraulics and mechanics • work-out improvements • replace costly prototypes

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