Numerical Modelling of Processes

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Research activities in the field of modelling and simulation for moulding processes conducted by the Industrial Materials Institute (IMI) of the National Research Council of Canada (NRC) are designed to provide industry with the latest manufacturing technologies they need to remain competitive in the global economic market. Research is centred on the development of numerical simulation tools for processes. Results of this work means that we can offer companies the necessary support to develop and optimize manufacturing processes and products.

Expertise

The research group on numerical modelling of processes is composed of researchers and technical advisors who have multidisciplinary expertise in fluid mechanics, applied mathematics and computer and materials engineering and rheology.

Objective

The group's objective is to develop and provide the simulation tools that will enable industry to:

• predict the quality of pieces produced by various moulding processes
• integrate simulation tools in a process optimization and control environment

R & D Activities

Research and development activities target a better understanding of the moulding processes, and are designed around the following four scientific axes:

• modelling of the behaviour of materials during the forming process
• high-performance scientific computing
• mathematical optimization of moulding processes
• characterization of materials and experimental techniques for validation

Industrial Processes

Simulation models developed at IMI enable a wide range of industrial materials forming processes, such as:

• Polymer: injection moulding, including gas-assisted injection moulding and co-injection;
• Light Alloys: pressure die casting of metals; semi-solid casting;
• Metal Powder: injection moulding.

Other related procedures also form part of research activities, such as the study of flow of molten zinc in galvanization bath for steel sheets.

Research Topics

Numerical Modelling and Simulation of Injection Moulding

IMI has developed different finite element software that enables the simulation of various injection moulding processes to be simulated: conventional moulding, gas-assisted injection moulding and co-injection moulding. Among these tools, a state of the art fully three-dimensional simulation tool is available to simulate the most demanding applications. IMI simulation tools allow us to:

• simulate polymer behaviour during the mould filling, compression and cooling stages
• predict the distribution of residual constraints in the injected piece and the deformations caused by warpage

	Polymer face at time of gas injection
Position of the gas bubble

Simulation of the progression of the bubble during gas-assisted injection moulding of a car handle

Simulation of injection moulding of metallic powder gels (experimental data courtesy of Honeywell).

Face of the second injected polymer
	Prediction of weld lines

Simulation of the progression of a second polymer within a piece of variable thickness moulded by co-injection.

Modelling and Simulation of Light Metals and their Composites

IMI conducts research work in the field of pressure die casting and gravity die casting of aluminium and magnesium alloys and their composites. This work has resulted in the development of finite element software capable of modelling the filling of the mould, solidification and development of residual stresses for die casting, permanent die casting, semi-solid and sand die casting processes. Projects have been conducted on a wide variety of parts, such as piston heads, valve covers, axles, motor heads, wheels, differentials, struts, seat frames, alternator housings, lawnmower bodies, high-voltage line struts and other electromechanical components.

Numerical modelling of the filling of a mould (colours represent the various temperatures).

Optimization of the Injection Moulding Process

Based on sensitivity methods, the group is also conducting work on the optimization of injection moulding processes. The tools developed enable us to:

• optimize operating conditions to strict and efficient standards;
• predict the optimal conditions for injection process parameters;
• reduce development time and costs for new products, while improving their end properties.

Equipment Available

The equipment at the Centre on Virtual Processing enables large-scale projects to be successfully conducted. Among the equipment available are:

High-performance Computers

• Intel/Myrinet Cluster- 64 processor
• SGI Origin 2000 - 16 and 14 processors
• PowerPC/FastEthernet Cluster- 28 processor
• Servers - IBM - 4 processor

Stereoscopic Viewing Centre

• ImmersaDesk R2
• Graphic Server - SGI Onyx2 - 4 processor

Work Stations

• HP, Linux/Intel, IBM, SGI, Sun

Collaborating with Industry

Thanks to the simulation tools developed by IMI, several projects have been successfully completed with industry partners in the automotive, packaging, aerospace, and sports and leisure sectors, affording them many benefits, such as:

• a reduction in design time
• a reduction in or complete elimination of the number of changes made to the mould
• optimal manufacturing conditions
• better product quality and production cost savings

IMI develops solutions adapted to the needs of companies, and helps them adopt technologies on an on-going basis. The Institute, while assuming a portion of the technological risk inherent to any innovation, offers various forms of partnerships and collaborative agreements, in complete confidentiality.

Information

For more information about these technologies, and to take advantage of the NRC's R & D resources, thus ensuring a competitive technological edge for your company, please contact IMI's representatives.

Dr. Jean-François Hétu Group Leader Numerical Modelling of Processes Modelling and Diagnostics Section Tel.: (450) 641-5082 Fax: (450) 641-5106 E-mail: Jean-Francois.Hetu@cnrc-nrc.gc.ca
Ngoc Huynh, Eng., M.A.Sc., M.B.A. Business Development Officer Modelling and Diagnostics Section Tel.: (450) 641-5135 Fax: (450) 641-5106 E-mail: Ngoc.Huynh@cnrc-nrc.gc.ca

Related Information

Institutes:

• NRC Industrial Materials Institute