Process Automation with HyperWorks for Blow Moulding of Plastic Containers

Transcription

1 Process Automation with HyperWorks for Blow Moulding of Plastic Containers Claudius Oblasser, Alpla European HTC 2011

2 OUTLINE Alpla Introduction Customisation example Conclusions 2 of 20

3 VISION We create plastic packaging solutions to our customers complete satisfaction. Our goal is to attain global market and technology leadership Alpenplastik Lehner Alwin OHG was founded by Alwin and Helmuth Lehner, Cap production started for local mustard maker, Lustenauer company's founder Alwin Lehner

4 FACTS 2010 Total sales 2010: billion employees 134 production sites in 37 different countries One of the largest global rigid packaging manufacturer 4 of 20

5 CORE TECHNOLOGIES EBM EXTRUSION BLOW MOULDING SBM STRETCH BLOW MOULDING IM INJECTION MOULDING 5 of 20

6 INTRODUCTION Alpla started FEA with Altair products in 2010 Save costs Reduce development time Reduce number of prototypes Generate Know-How Keep it simple Identification of significant parameters Information on process Software evaluation What are our topics? Comparison of leading FEA-Tools depend on Flexibility (open source, interface, customisation) Pre-, Post processor (modelling time, ease of learning) Solver performance (elapse time, precision) Help system and support! 6 of 20

7 INTRODUCTION Focus on flexibility (open source, interface, customisation) Process manager Customised GUI s For our core technologies we currently use customised GUI s Example of EBM simulation 7 of 20

8 Workflow CUSTOMISATION EXAMPLE Steps through an EBM to Top Load Simulation - Overview Bottle CAD model Create parison with assumptions Extrusion Blow Molding simulation to estimate the wall thickness Mapping the thickness to the bottle Check of the weight and distribution Top load simulation Results comparison with hardware bottle if avalible 8 of 20

9 Workflow CUSTOMISATION EXAMPLE Steps through an EBM to Top Load Simulation - Parison Bottle CAD model Create parison with assumptions (geometry/mesh) Enter node coordinates by HM/Geom/nodes Create line Rotate line Mesh surface 9 of 20

10 Workflow CUSTIOMISATION EXAMPLE Steps through an EBM to Top Load Simulation - Parison Bottle CAD model Create parison with assumptions (geometry/mesh) GUI for EBM Simulation 10 of 20

11 Workflow CUSTIOMISATION EXAMPLE Steps through an EBM to Top Load Simulation - Parison Bottle CAD model Create parison with assumptions (thickness) Thickness by Components/Property To many components for discrete field! Thickness on element by using Mesh/Card edit/element A lot of work for no. of Elements > of 20

12 Workflow CUSTIOMISATION EXAMPLE Steps through an EBM to Top Load Simulation - Parison Bottle CAD model Create parison with assumptions (thickness) Thickness on each element By calculation of thickness = f(x, y, z) + empirically modelled relations from 3 rd party (Alpla internal) products and individual parameters Par A Par B Par C Par D Par E Par F 12 of 20

13 Workflow CUSTIOMISATION EXAMPLE Steps through an EBM to Top Load Simulation Bottle CAD model Create parison with assumptions Extrusion Blow Molding simulation to Estimate the wall thickness Same procedure for other tasks like Boundary conditions Import models (forms) Create contact / Rigid bodies Check mass / Update mass Export model file Create batch files for closed loop applications (EBM > mapping on Top Load) 13 of 20

14 Workflow CUSTIOMISATION EXAMPLE Steps through an EBM to Top Load Simulation - mapping Result from EBM simulation Thickness for Top Load simulation Mapping the thickness to the bottle Check of the weight and distribution Currently Results Mapper does not support Radioss A00* files Solution Automatic export of nodal coordinates, element connectivity and element thickness values from Hyperview into *.csv file Import of *.csv files into Hyperworks Mapping of thickness Interactive with GUI In batch mode (5 times faster) 14 of 20

15 Workflow CUSTOMISATION EXAMPLE Steps through an EBM to Top Load Simulation - mapping Result from EBM simulation Thickness for Top Load simulation Mapping the thickness to the bottle Check of the weight and distribution Commands Run Hyperview in background (-b) Run tcl script Result file Commands Run Hypermesh in background Run tcl script 15 of 20

16 CONCLUSION What s behind all this - TCL Simple and programmable syntax Can be used as standalone application or embedded in programs Open source Interpreted language New TCL commands can be implemented using C language 16 of 20

17 CONCLUSION What s behind all this - Tk Graphical user interface (GUI) toolkit Tk adds about 35 TCL commands Create and manipulate widgets Widget is a window in GUI with particular appearance and behavior 17 of 20

18 CONCLUSION Customisation of Hyperworks is not as difficult as it seems to be Huge time savings in modelling repeating tasks can be measured Consistence of simulation models from different users is given New team members will be guided to defined tasks They become more familiar with simulation processes within a shorter time period Help can be found at Review your command.cmf Every mouse click in Hypermesh is written into this file Use macro to convert these lines into TCL language for Hypermesh Copy paste into new file 18 of 20

19 THANK YOU FOR YOUR ATTENTION! 19 of 20