Modelling and Diagnostics in Boucherville

At IMI, the Modelling and Diagnostics section is investing major R&D efforts into developing process simulation and modelling tools, as well as diagnostic techniques using sensors that permit real-time monitoring of the processes. The goal: to increase the efficiency and speed of the forming processes, and to optimize parts design.

Work conducted in the area of process modelling targets the development of computerized models and analysis software programs that allow us to predict and better understand thermomechanical phenomena, and the microstructural evolution of materials as they are being formed. Thanks to these tools, it is possible to optimize the design of parts and improve control over the manufacturing processes. Applications targeted involve derivative processes of forming and moulding:

• Blow moulding
• Thermoforming
• Injection moulding
• Metal die casting

Work pertaining to process instrumentation deals with the development of diagnostic techniques (sensors) used to establish the physical properties and behaviour and evolution of the microstructure of materials during the forming process in a non-invasive manner, and to control the forming processes and the quality of the product obtained. This also permits the non-destructive evaluation of components and structures. The section favours techniques based on ultrasound and optical technology, including infrared technology.

The rapid advancement in computer and process modelling techniques also opens the door to developing intelligent control techniques, making use of control algorithms and sensors based on real-time operational models. These systems offer industry the advantage of maintaining high levels of quality, even in spite of the complexity of the microstructures to be produced and the inevitable parametric variations of the base materials and processes.

Interest in this type of control is also due to the fact that it enables an equilibrium regime to be quickly attained, especially during a change in grade or at the start of a new work shift, as well as maintaining or increasing productivity and reducing the amount of wastage. Thus, the section devotes a lot of energy to integrate sensors in intelligent control systems.

The section's activities are grouped under four major categories:

Characterisation and Ultrasonic Sensors deals with ultrasounds for the monitoring of polymers during their forming process, acoustic waveguides to monitor processes, and the use of ultrasound-laser techniques to characterize the microstructure of metals and their development during heat treatment, both in the laboratory and on the production line.

• In-Line Ultrasonic Measurements: A Powerful Tool for Process Diagnostics of Extrusion and Injection Moulding
• On-line Ultrasonic Technology for Monitoring of Polymer Processing
• Laser Ultrasonic Inspection of Materials and Structures
• Real-Time Diagnostics of Foam Extrusion Process Using Non-intrusive and Non-destructive Ultrasonic Techniques
• Real-Time Diagnostics of Polymer Processes Using Non-intrusive and Non-destructive Ultrasonic Techniques

Numerical Modelling of Processes involves the simulation models and tools for the behaviour of materials during the forming process. They deal with the casting of metal alloys and polymers, and predicting and optimizing the performance of materials, as well as optimizing parts design.

• Injection moulding
• Metal die casting
• Optimisation of moulding processes

Optical Techniques involves the optical generation and detection of ultrasounds (ultrasound-lasers) and the applications linked to the inspection of materials and control of processes: optical sensors for metrology and plasma laser spectroscopy applications, and thermal and thermographic analyses of processes.

• Laser-Induced Breakdown Spectroscopy (LIBS)
• Laser ultrasonics
• Forms and profiles measurement
• Pyrometry and thermography

Intelligent Forming Technologies is the prediction and optimization of the quality of formed parts and the forming processes themselves, as well as the development of intelligent software tools to improve parts design and process control:

• Blow moulding
• Thermoforming and stamping
• Optimisation and control of forming processes

Work is also conducted in conjunction with industry partners, the Special Interest Group in Blow Moulding (SIGBLOW) and the Special Interest Group in Thermoforming (SIGFORM).

To learn more, please consult our fact sheets:

• Biomedical Polymers Laboratories
• Intelligent forming technologies
• Laser Ultrasonic Inspection of Materials and Structures
• Numerical Modelling of Processes
• Optical Sensor Development for the Industry
• Software Technologies for Surgical Simulation
• Special Interest Group in Blow Moulding
• Special Interest Group in Thermoforming

Related Information

Institutes:

• NRC Industrial Materials Institute