The Relationship between Ribs Layout on a Body Exterior “Belly Pan” Part, and Its Prediction of Moldflow´s Warping

This presentation was made at the NAFEMS Americas Seminar - Confidence in Engineering Simulation: The Next 10 Years of CAE in Mexico.

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Resource Abstract

One of main goals in the automotive industry is bring products that achieve and exceed the high quality levels to the final costumer as well to the internal one in the supply chain. The plastic parts play a critical role in this chain, as they are present in an important proportion inside a car.

In an assembly process, it is quite common not to reach the range of geometrical and dimensional tolerances, due to the warpage present in the parts. One possible solution is to investigate the warpage in the parts to be assembled and compare their dimensions with the tolerance of the design.

Sometimes, the design proposals do not consider the relationship of the molding process conditions, the geometrical attributes and the warpage trend. Therefore, in this work is studied the influence of the four different rib layouts in the warpage trend, as well its magnitude. Other variable analysed was the thickness of the ribs. The part used in this study was a body exterior “Belly pan” part.

For this analysis, the material considered for the belly pan was a thermoplastic olefine (TPO). The study of the four different geometries was made using a Computer-aided Engineering (CAE) software Autodesk Moldflow Insight. In this case, the software allows to the designer improve and optimize the part and tool design considering the warpage as an output. The molding process conditions and the tool design (feeding and cooling system) were constant in all the simulations. A Design of Experiments (DOE) and the analysis of variance (ANOVA) were develop to find the lower warpage values produced by the rib layouts and rib thickness configurations.

The different results in warpage shown the importance of a good selection of rib layout, as well its thickness on a “Belly Pan” part, to avoid overdesigned parts, as well late engineering changes in the product development cycle time.

Document Details

AuthorErnesto Hernández Álvarez. V
Date 8th November 2018
OrganisationFord Motor Company


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