1. © 2011 Autodesk Digital Prototyping at FIAT Elena Bortolotti CRF (FIAT Research Center) – Moldflow team

2. © 2011 Autodesk Class Summary In this class you explore how Autodesk® Moldflow® and Autodesk® Showcase® software can visualize manufacturing defects in plastic parts and how Moldflow® results can improve SIMULIA® Abaqus® simulation of thermal load.

3. © 2011 Autodesk Learning Objectives At the end of this class, you will be able to:  Visualize part defects using Autodesk® Showcase® rendering capabilities with homemade graining database  Improve the thermal load simulation of plastic assemblies with injection molding residual stresses results

4. © 2011 Autodesk Visualization as an engineering communication tool Interior Sink Marks Visualization Dashboard Flush Gap Simulation under Thermal Load FIAT Punto Evo Alfa Romeo Giulietta

5. © 2011 Autodesk Interiors Sink Marks Visualization

6. © 2011 Autodesk  Dashboard upper cover - sink mark estimate  Glove box - comparison between simulated and real part  Door panel - comparison between simulated and real part Interiors Sink Marks Visualization

7. © 2011 Autodesk Interiors Sink Marks Visualization We have studied three interior parts… Door panel Glove box Dashboard upper cover

8. © 2011 Autodesk Interiors Sink Marks Visualization …and made a comparison with real parts

9. © 2011 Autodesk Visualization Material database Process conditions Interiors Sink Marks Visualization Design

10. © 2011 Autodesk Interiors Sink Marks Visualization Ø2Ø2 Ø4Ø4 Ø4.25

11. © 2011 Autodesk - + + - Sink mark estimate (through process simulation) Dashboard upper cover Real part Without graining Interiors Sink Marks Visualization

12. © 2011 Autodesk Glove box - Process Sink mark estimate [mm] Mid Pressure Sink mark estimate [mm] Low Pressure Interiors Sink Marks Visualization

13. © 2011 Autodesk Glove box - Low pressure - Visualization Glove box - Low pressure - Real part Part weight 362 g not ok with D21 graining Interiors Sink Marks Visualization

14. © 2011 Autodesk Glove box - Mid pressure - Visualization Glove box - Mid pressure - Real part Part weight 372 g ok with D21 graining Interiors Sink Marks Visualization

15. © 2011 Autodesk Interiors Sink Marks Visualization Glove box - Mid pressure Without graining Glove box - Mid pressure Lighter emboss than D21 not cover defects

16. © 2011 Autodesk 2 3 1 2 3 Real door panel Without graining Sink mark estimate (through process simulation) Interiors Sink Marks Visualization

17. © 2011 Autodesk Visualization Real door panel With graining Interiors Sink Marks Visualization OK! Graining and process have been tuned to cover defects!

18. © 2011 Autodesk Real door panel Without graining Interiors Sink Marks Visualization 2 3 1 4 2 3 1 4 Sink mark estimate (through process simulation)

19. © 2011 Autodesk Visualization Real door panel With graining Interiors Sink Marks Visualization Ok with D21 graining

20. © 2011 Autodesk Dashboard Flush Gap Simulation under Thermal Load

21. © 2011 Autodesk  Classical simulation  Process oriented simulation  Glove box: comparison of calculated and experimental data  Fuse box: comparison of calculated and experimental data Dashboard Flush Gap Simulation under Thermal Load

22. © 2011 Autodesk Dashboard Flush Gap Simulation under Thermal Load 3D CAD data FEM model for every component Dashboard assembly Thermal load (gravity) Flush gap Comparison with cockpit flush gap Classical Simulation

23. © 2011 Autodesk Injection molding simulation Dashboard Flush Gap Simulation under Thermal Load 3D CAD data FEM model for every component Dashboard assembly Thermal load (gravity) Flush gap Comparison with cockpit flush gap Process Oriented Simulation

24. © 2011 Autodesk Dashboard Flush Gap Simulation under Thermal Load  Thermoplastic parts modeled for accomplish both software programs mesh request  Parts fixed to the body in white

25. © 2011 Autodesk Dashboard Flush Gap Simulation under Thermal Load 10 11 12 1 2 3 54 6 7 8 9 13 14 15 16 17 Glove box flush gap points of measure Fuse box flush gap points of measure

26. © 2011 Autodesk Dashboard Flush Gap Simulation under Thermal Load

27. © 2011 Autodesk Dashboard Flush Gap Simulation under Thermal Load

28. © 2011 Autodesk Autodesk University Session Feedback Your feedback is very important to Autodesk. You can complete the session survey on your mobile device, PC, or at a survey station. Each completed session survey enters you in that day’s drawing for a free AU 2012 pass. You can help make AU 2012 better! Complete the AU Conference Survey at a survey station and receive an AU 2011 T-Shirt.

29. © 2011 Autodesk Autodesk, Moldflow, Showcase* [*if/when mentioned in the pertinent material, followed by an alphabetical list of all other trademarks mentioned in the material] are registered trademarks or trademarks of Autodesk, Inc., and/or its subsidiaries and/or affiliates in the USA and/or other countries. All other brand names, product names, or trademarks belong to their respective holders. Autodesk reserves the right to alter product and services offerings, and specifications and pricing at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document. © 2011 Autodesk, Inc. All rights reserved.