During on-road tests, while performing an alternating temperature test, a sliding roof frame suffers from warping and goes out of shape (thermal expansion problem); the sun roof cannot be closed any more.
Key points: Thermal expansion, alternating temperature test, filling simulation/moldflow analysis, fibre orientation, cooling simulation, transfer of fibre orientation to finite element analysis
Challenge / task
- Analysis of the situation and identification of possible ways to reduce component warpage while maintaining component geometry
- Investigation of how the moldflow process influences the materials' characteristics
Objectives / goal
- Analyse component warpage using a filling simulation/moldflow analysis to determine fibre orientation
- Transfer fibre orientation results to ABAQUS simulation software in order to perform a cooling simulation
- Change fibre orientation within the component by changing the gate position
- Review results by re-using filling simulation and cooling simulation
Results & benefits
- The material's strength along the fibre is much higher than across the fibre. Changing the gate position led to a different fibre orientation (see image) that strenghtened the component's resistance at the right spot against alternating temperatures.
- By changing the fibre orientation, the component's deformation was reduced substantially and the component's functionality was restored.
- The component's geometry remained completely unchanged