process automation with hyperworks for blow moulding of plastic containers
TRANSCRIPT
Process Automation with HyperWorks for Blow Moulding of Plastic Containers
Claudius Oblasser, Alpla
European HTC 2011
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OUTLINE
Alpla
Introduction
Customisation example
Conclusions
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VISION
„We create plastic packaging solutions
to our customers’ complete satisfaction.
Our goal is to attain global market and
technology leadership“.
company's founder Alwin Lehner
1955 – Alpenplastik Lehner Alwin OHG was founded by Alwin and Helmuth Lehner, Cap production started for local mustard maker, Lustenauer
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FACTS 2010
Total sales 2010: 2.560 billion €
12000 employees
134 production sites in 37 different countries
One of the largest global rigid packaging manufacturer
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CORE TECHNOLOGIES
EBM
EXTRUSION BLOW MOULDING
SBM
STRETCH BLOW MOULDING
IM
INJECTION MOULDING
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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!
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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
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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
Work
flow
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Enter node coordinates by HM/Geom/nodes
Create line
Rotate line
Mesh surface
CUSTOMISATION EXAMPLE
Bottle CAD model
Create parison with assumptions (geometry/mesh)
Work
flow
Steps through an EBM to Top Load Simulation - Parison
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GUI for EBM Simulation
CUSTIOMISATION EXAMPLE
Bottle CAD model
Create parison with assumptions (geometry/mesh)
Work
flow
Steps through an EBM to Top Load Simulation - Parison
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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 > 10.000
CUSTIOMISATION EXAMPLE
Bottle CAD model
Create parison with assumptions (thickness)
Work
flow
Steps through an EBM to Top Load Simulation - Parison
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Thickness on each element
By calculation of thickness = f(x, y, z) + “empirically modelled relations” from 3rd party (Alpla internal) products and individual parameters
CUSTIOMISATION EXAMPLE
Bottle CAD model
Create parison with assumptions (thickness)
Work
flow
Steps through an EBM to Top Load Simulation - Parison
Par A
Par B
Par C
Par D Par E Par F
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CUSTIOMISATION EXAMPLE
Bottle CAD model
Create parison with assumptions
Extrusion Blow Molding simulation to Estimate the wall thickness
Work
flow
Steps through an EBM to Top Load Simulation
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)
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CUSTIOMISATION EXAMPLE
Steps through an EBM to Top Load Simulation - mapping
Mapping the thickness to the bottle
Check of the weight and distribution
Work
flow
Result from EBM simulation
Thickness for Top Load simulation
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)
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CUSTOMISATION EXAMPLE
Steps through an EBM to Top Load Simulation - mapping
Mapping the thickness to the bottle
Check of the weight and distribution
Work
flow
Result from EBM simulation
Thickness for Top Load simulation
Commands
Commands
Run Hyperview in
background (-b) Run tcl script Result file
Run Hypermesh in
background Run tcl script
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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
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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
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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
http://www.tcl.tk/
../hw11.0/help/hwdref/hwdref.htm
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
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THANK YOU FOR
YOUR ATTENTION!
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