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Plastic CAE (Computer Aided Engineering) is used as indispensable technology in the plastic prod-
uct design today. However, by integrating CAE technology and the CAO (Computer Aided Optimization)
technology in which utilization has started, the automatic optimal design of a plastic product is attained
and much more shortening the period of a product design, reducing development cost, and improving
the quality and the performance of a product can be expected. Moreover, it becomes the powerful sup-
port technology of material development. In this paper, the outline of the integrated technology of the
plastics CAE and CAO that we have developed, some application examples, and the integrated design
optimization system for the plastic products of our company are described.
This paper is translated from R&D Report, “SUMITOMO KAGAKU”, vol. 2004-II.
developed for use with conventional metal materials method, which is now the main current for optimal
and various types of molding CAE developed especially design and investigations, and other methods and opti-
for polymers. Mechanical CAE has technology for mization software was in investigations for reducing
structural analysis, impact analysis, vibration analysis the weight of automobiles in the 1980s.9) In the more
and the like for evaluating static and dynamic mechani- than 20 years since then, there has been progress in
cal characteristics, but there is a need to develop the both optimization analysis technology and optimization
technology for use with polymer materials. On the software, and optimal design technology using CAO
other hand, in molding process CAE, specialized soft- has made a great deal of progress.
ware has been developed for injection molding, blow CAO technology is technology for allowing computer
molding, extrusion molding and various other types on software instead of people to carry out CAE analysis,
molding processes. Using these, it is possible to simu- make judgments on the results and automatically per-
late the behavior and history of the changes in state for form optimization work until the target performance is
melting, cooling and hardening of polymer materials obtained, performing the design optimization work that
during the molding process, and further, the appear- was, in conventional product development, done
ance, quality and performance of the product after through a repetition of human judgments and manual
molding based on the dilution history, and this can be corrections, analysis and evaluation of analytical mod-
used in analysis and evaluation. els until the target performance was obtained using
Sumitomo Chemical has been developing plastic CAE technology for virtual prototyping, carrying out
CAE technology for more than 20 years as one of the virtual tests and evaluating the results. Furthermore,
basic technologies for molding processes, and it has by integrating various types of CAE, optimization of
been applied in (1) supporting customer product and multiple combined areas necessary when there is inte-
mold design, supporting clarification and measures for grated optimization of performance in actual products
bad molding phenomena and the like, (2) supporting is possible.10) Fig. 2 shows a this concept.
Sumitomo Chemical’s materials development and (3)
supporting the development of plastic products at Sum-
Optimization by Trial and Error
itomo Chemical and related companies. 5)– 8) Fig. 1
Virtual Experiment (CAE)
shows the Sumitomo Chemical plastic CAE system.
Design Analysis Estimation Production
Virtual Model is Modified by Man
Modal Analysis Characteristics of vibration Stress and deformation
Vibration and sound analysis simulation(BBA) analysis
Environmental vibration testing Automatic Optimization By Computer
Heat transfer
Impact Testing Virtual Experiment (CAE)
analysis
Crash Testing io n Prod
lu a t uct
eva l analy
sis de Design Analysis Estimation Production
t e n ta Impact analysis
sig
m
Ex c
i
per
du
Development of
n
Since 1981
CAO; Computer Aided Optimization
Development of the materials
Injection Molding
Extrusion Molding old analysis
n
M
analysis des N u m e ric al a n aly sis ti o Fig. 2 Comparison of CAE Approach and CAO
ig n, n di
O p ti m e s s i n g Co Mold cooling Approach in a Product Design
SP mold analysis iz a ti o n of P r o c
→
Objective function : f ( x ) → min (1) straints and design variables that make up optimal
→
Constraints : g j ( x ) < 0 ( j = 1~m) (2) design problems are given in Table 1.
→
hk ( x ) = 0 ( k = 1~m’ ) (3)
→
x L < x→ < x→U (4) 2. Types of Optimization Methods13), 14)
→
Design variable : x = {x1, x2 …, xn}T (5) When optimization is carried out, the characteristics
of the target of optimization, the type of design vari-
In this instance, the problem is defined as determin- ables and objective function and time required for opti-
ing the design variable in equation (5) such that the mization must be considered. Specifically, when, for
objective function in equation (1) is minimized while example, (1) there is a nonlinear solution space in the
satisfying the constraints in equations (2) – (4). n is the optimization, we can bring up questions such as: does
number of design variables; m is the number of it have multiple peaks or a single peak? (2) Are the
inequality equations for the constraints, and m’ is the design variables handled as being continuous or as dis-
number of integrated constraint equations. The prob- crete values or handled as symbols? (3) What kinds of
lem above becomes a maximization problem if the constraints will be set? (4) Is there a single or multiple
objective function is multiplied by (–), and it can be target performances? (5) Are quality engineering con-
thought of as reversing the orientation of the inequali- cepts reflected in the target performance? (6) How
ties if the constraint inequalities are multiplied by (–). much time will be needed to run each analysis?
The classifications for the objective functions, con- Optimization methods can be generally classified
into numerical optimization techniques and exploratory
techniques. Table 2 gives optimization methods classi-
Table 1 Classification of Optimization
fied according to application. Moreover, among the
Objective Number Uni-Objective Multi-Objective optimization methods in Table 2, simulated annealing
Function Type Functional Numerical and the genetic algorithm are exploratory techniques,
Constraint Existence Constraint Unconstraint
and the others are numerical optimization techniques.
Condition Type Functional Numerical
Design The gradient method, which is a numerical optimiza-
Type Continuous Discrete Mixed
Variable tion technique, can be visualized from Fig. 3.
Start
Numerical optimization techniques are ones that
determine the optimal direction from the slope (sensi- Analyses of
Sample Points
tivity) in the vicinity of the design variable currently
being focused on and successively change the design
Creation of
variable. Numerical optimization techniques give well Response Surface Model
organized optimization solutions when there is an opti-
mization space with a single peak, but when optimizing Optimization using
Response Surface Model
a multi-peak solution space it often gets trapped locally
and cannot give a comprehensive optimization. There- Analysis of Optimization
Point on R.S.M.
fore, when it is predicted that the target of optimization
will have multiple peaks, an exploratory technique is
Large Difference
used. Simulated annealing, which is an exploratory of Analysis and
R.S.M.
technique, can be visualized from Fig. 4. Small
End
the material, the product design and the molding currently developing the Sumika Integrated Design
process.6) The factor of the material includes mechani- Optimization System for Plastic Products (SIDOS)
cal properties, thermal properties and rheological prop- where optimization work can be done on a graphical
erties. The factor of the product design includes the user interface (GUI) without specialized CAO knowl-
shape and structure of product. The factor of the mold- edge.
ing process includes the mold structure and the mold- Fig. 6 shows a schematic of SIDOS.
ing conditions. At designing products, these three ele-
ments must be considered while optimizing the prod- Examples of Applying CAO Technology to
uct design. In other words, designing plastic products Plastic Product Design
is a optimization problem with a combination of areas
where optimization is carried out while simultaneously The application of CAO techniques to plastic product
considering each of these elements. Conventionally, design is roughly divided into cases of application to
Sumitomo Chemical used the CAE system in Fig. 1, the structural aspects of products to obtain the optimal
repeating the processes of analyzing, evaluating and performance for the functions (rigidity, impact absorp-
correcting. tion characteristics, vibration characteristics, etc.)
The commercial CAO support software “iSIGHT” required for the plastic product and cases of application
(Engineous Software, Inc., U.S.A.), which has an opti- to the optimization of mold structure design and mold-
mization function for combined areas was developed in ing conditions so that the necessary quality is achieved
the United States in 1994, and it entered the Japanese in molding aspects and constraints (clamping force,
market at the end of 1998.3) Sumitomo Chemical con- cycle time, etc.) for molding for plastic products having
firmed that this software would be effective for plastic designs defined in terms of the structural aspects.
product optimal design problems in early testing and The following two points can be raised as important
introduced it in 2000. After that, investigations into points for application of CAO techniques in actual prod-
integration technology for conventionally constructed uct design. One is how to extract the design variables
CAE technology and CAO technology were carried out for design items in the target of optimization and the
for making progress toward a second generation plas- other is how to digitalize the performance for the target
tic CAE technology. of optimization and set the objective function. In the fol-
At present, automated optimization technology has lowing we will introduce applications to plastic product
been established for the principle CAE technologies, design with regard to these two points in examples.
and in addition, automatic optimization technology for The various solvers shown in Fig. 6 are used in the
integrating these CAE technologies with combinations CAE analysis in these examples.
of areas has been established. To further increase the
efficiency and simplify this optimization work, we are 1. Application of Optimization Techniques to the
Design of Parts for Automobile Interiors
(1) Impact absorption performance required for interi-
GUI or parts for automobiles.
Multi-Disciplinary Level
Plastic products for the interior parts in automobiles
Integrated Analysis Software require freedom of shape and have be multipurpose in
Optimization
(iSIGHT)
terms of weight and cost on the one hand, and must
Uni- Disciplinary Level maintain a sufficient shock absorption performance for
Injection Structural Impact secondary impact (impact inside of the car) with the
Molding
Analysis Analysis
Analysis
(ABAQUS) (LS-DYNA)
heads of passengers during accidents. For example, in
(Moldflow)
the standards in Federal Motor Vehicle Safety Stan-
Optimization Optimization Optimization dard (FMVSS) 201U provided by the National Highway
Traffic Safety Administration (NHTSA), the head part
Design Design Design
Variables Variables Variables in the parts shown in Fig. 7, must have sufficient shock
absorption performance so that no injury will be caused
Fig. 6 SUMIKA Integrated Design Optimization even with secondary impact to the head.15)
System for Plastic Product (SIDOS) In evaluations of shock absorption performance for
Free Motion Headform (FMH) 3: Creating 1 Pitch of Vertical Rib at Next Position
Pillar Garnish
No
Number of Vertical Ribs?
Table 3 Material Properties the vertical rib and the angle (Th) with the y axis for
Materials A B C the yz plane that includes the vertical rib, and two vari-
Young's Modulus [MPa] 863 2420 863 ables for the design that prescribes the horizontal ribs,
Specific Gravity [–] 0.90 1.08 0.90 the distance (R1) in the x direction between the stan-
Poison Ratio [–] 0.40 0.40 0.40 dard position for the horizontal rib and the part parallel
Static Yield Stress [MPa] 19.6 23.9 19.6
to the yz plane in the design range and the distance
Failure Plastic Strain [%] 40.0 8.0 8.0
Cowper-Symonds Parameter (R2) between horizontal ribs. (Fig. 11)
C [1/s] 2.80 170 2.80 In addition, the objective function is HIC (d) calculat-
P [–] 9.87 4.56 9.87 ed using equation (1), equation (2) and the accelera-
tion at the FMH center of gravity for the analysis
1
σ y = σ y0 × [1 + ( ε̇ ) P ] (8) model. A combination of the response surface model
C
and modified method of feasible directions was used
σy : yield stress, σ y0 : static yield stress, for the optimization method.
ε̇ : strain rate, C, P : parameters As results in this example, it was found that interior
parts with the rib shape optimized using material B
The vertical rib positions (vertically oriented ribs in with a large Young’s Modulus and yield stress and a
Fig. 10) and horizontal rib positions (horizontally ori- small failure plastic strain exhibited the most superior
ented ribs in Fig. 10) and rib pitch for the rib parts shock absorption performance. The initial shape for
were selected as the design targets. Therefore, there the material B interior parts had a HIC (d) that exceed-
were a total of five design variables, three variables for ed 1000, but as a result of optimizing the rib shape,
the design prescribing the vertical ribs, the y coordi- with the pitch of the horizontal ribs being reduced and
nates (T1 and T2) for the starting point and end point the position of the vertical rib brought closer to the
for the line segment in the design range on a line FMH impact position, HIC (d) was reduced to under
formed in the xy plane which is the plane that includes 600, and the performance was improved. (Fig. 12)
Interior Part
Material A Material B Material C
6.7m/s
4.54kg
In this example, the side gate is moved approximately increase the cooling time, but on the other hand, this
70mm toward the right side with almost no change in increases the molding cycle time and reduces produc-
the dimensions of the center gate, and by increasing tivity. Here, we will introduce an example where CAO
each of the dimensions for the side gate, results where techniques are applied to optimization of molding con-
it was possible to have no welds occur outside of areas ditions for these kinds of diametrically opposed
10 and 20 and to reduce the clamping force to 60% or requirements.
less of the initial value were obtained. (Fig. 16, Table 4) The shape model for the plastic part in this exam-
ple is shown in Fig. 17 and the mold cooling tubes
in Fig. 18.
: Gate Position
10 10
96
20 20 Weld
Control 40
Area
(10, 20)
I.C. Weld Line O.C. 400 150
40
10φ
(I.C.: Initial Condition, O.C.: Optimized Condition) 80
4φ
Fig. 16 Comparison of the Result Before and After
Optimization
116
120
Table 4 Comparison of the Result Before and After
Optimization Fig. 17 Simulation Model of Plastic Part
I.C. O.C.
sx [mm] 400 471 Cooling Channels of
sw [mm] 5.0 7.5 Top Side (10φ)
st [mm] 1.0 1.7
sd [mm] 8.0 11.0
cd [mm] 8.0 8.1
clamp [ton] 1532 857
weld [–] 10008 4
obj. [–] 11540 861
clamp : Value of Clamping Force Cooling Channels of
weld : Value of Weld Evaluation Bottom Side (10φ)
obj. : Value of Objective Function
Fig. 18 Cooling System of Injection Mold
I.C. : Initial Condition
O.C. : Optimized Condition
mold removal on the gate side surface and the opposite 3. Optimization Technique for Combined Perfor-
gate side surface and T was a cycle time (D0 and T0 mance of Structure and Molding for Injection
being the initial values). Moreover, to give the reduc- Molding
tion in warp priority in this example, this was carried The examples introduced up to this point have evalu-
out with the sum of the warp being given a weighting ated a single type of analysis (impact analysis or injec-
of 3 times that of the molding cycle. tion molding analysis) for the design target perfor-
mance, but with real products, the structure must be
determined by evaluating the integrated performance
Mold Dimension
of products for multiple types of analysis. Here, we will
HR2 HR3 introduce an example of optimal design for three types
(HL2) (HL3)
HR1 of performance, impact performance, product rigidity
(HL1) and molding characteristics for a pillar B interior auto-
Total Warpage : D = HR + H L mobile part. Impact performance is evaluated using
Gate Side : HR = HR1 + max(HR2, HR3) HIC (d) obtained from the impact analysis, and when a
Opposite Side of Gate : HL = HL1 + max(HL2, HL3)
negative load of 100N is applied at a midpoint in the
Fig. 19 Definition of Total Warpage attached part, the product rigidity is evaluated using
the values obtained from a structural analysis of the
Compared with the initial conditions, the resin tem- changes in position; the molding characteristics are
perature and fixed side cooling temperature were evaluated using the clamping force obtained from the
reduced, the cooling temperature on the mobile side injection molding analysis. Moreover, in terms of the
increased, the time pressure was maintained increased, precision of the analysis, the shape models for the
and the results obtained were an approximately 40% impact analysis and structural analysis use square ele-
reduction in warp and a 15% shortening of the molding ments and the shape model for the injection molding
cycle. (Fig. 20, Table 5) analysis uses triangular elements. (Fig. 21)
Black Part:
Fixed Region
100N
4.54kg
I.C. O.C.
a) Impact Analysis b) Structure Analysis
(I.C. : Initial Condition, O.C. : Optimized Condition)
I.C. O.C.
c) Injection Molding
MT [°C] 220 210 Analysis
WT1 [°C] 40 21
WT2 [°C] 40 49 Fig. 21 Simulation Models
PT [sec] 6.0 7.8
D [mm] 2.9 1.8
T [sec] 48.1 40.7
obj. [–] 4.0 2.7
For design variables in the present example, we used
the negative load was applied and the clamping force C GUI based on Excel
during injection molding.
Input File (Auto Setting)
Moreover, it was made dimensionless with H being
(Execution)
the critical value 1000, D being 1/10 of the pillar thick-
ness or 3mm, and C being the maximum clamping iSIGHT LS-DYNA
(Selection/
force for the presumed molding machine or 50 tons. Modification)
The results of optimization were that the rib pitch Input File
I/F
was narrowed, HIC (d) reduced, and the rigidity Output File
improved somewhat. (Table 6)
Fig. 22 Schematic Diagram of System
I.C. O.C.
Direct Input Selection of Operation
R1 [mm] 10.0 14.2
R2 [mm] 50.0 29.7
H [–] 956 737
D [mm] 1.59 1.25
C [ton] 28.4 28.2
obj. [–] 2.06 1.72
obj. : Value of Objective Function
I.C. : Initial Condition
O.C. : Optimized Condition
in the input iSIGHT file, and selecting the neces- ing progress in giving this technology more depth
sary I/F in the I/F part or modifying the standard and making it even more complete.
I/F. In addition, after the settings for optimization
and the I/F settings are complete, it is possible to References
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PROFILE
Tomoo H IROTA
Sumitomo Chemical Co., Ltd.
Petrochemicals Research Laboratory
Research Associate