Presentation EBM New

8/11/2019 Presentation EBM New

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BLOWVIEW DEMO

Introduction to Dazztech

Introduction to Blowview DeveloperIntroduction to Blowview and itsadvantages

Physical models

How to start a simulationIntroduction to solver

Introduction to post processer

Validations/case study

Conclusions

Contact us


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Dazztech About UsBased in Kelana Jaya, Petaling JayaPrimary focus in providing cutting-edge Computer-Aided Engineering(CAE) & Optimization solutions

Companys vision is to becomes a leading technology enabler inMalaysia and regionally with the provision of a comprehensive leadingedge technology tools for the industry of its focus.Companys mission is to help customers to enhance their designs andproducts through What -if and explore design space via Multi -Disciplinary Design Optimization and Structural / Topology Optimization.Our market coverage include Education, Maritime, C&S, Electronics,

Automotive, Manufacturing, Aerospace sectors in Malaysia & SouthEast Asia.Existing customers include NTU, G&P Water, JMTI, Kolej KemahiranTinggi MARA, Singapore Polytechnic, STP, Dialog, Thermahygro, SunHigh Tech, Canon, Panasonic, Golden Deem, IIUM, Universiti MalaysiaPahang, Universiti Sains Malaysia, Juken EngineeringTechnology, etc.


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Blowview Developer

Blowview is process simulation and modelling tools technology, developed by theIndustrial Material Institute (IMI) of National Research Council of Canada (NRC):

Canadian governments leading R&D organization 30 employees in the IMI R&D (over 3400 employees in NRC) Over $40M invested in software development since 1990

RheoWare (Rheology Software) Inc is a spin-off of NRC for commercialization ofBlowview.


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Blowview is finite element analysis tool capable of predicting parison / preformdeformation in extrusion blow moulding & stretch blow moulding applications.

In addition to the simulation, there is also an optimization module for extrusion

blow moulding.

Software is useful for engineers, technicians, mould makers and resinsmanufacturers etc.

What is Blowview ???


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Blowview Competitive Advantage

Finite element solver specifically for plastic industryPrecise, fast, 10x faster than other commercial softwareSolves day-to-day problems in industrial manufacturingDigital moulding and optimization through the consideration of materialcharacterizationDeveloped by an innovative and advanced R&D institute (IMI) for morethan 18 yearsUsed and validated by more than 50 industry leaders in Europe, North

American and Asia


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Benefits from Simulation

Conception and fabrication of a mould & part adapted to the clients need and to the market. The manufactures willhave to produce more and more complex parts with specific characteristics. The simulation will allow customers toquickly make those parts.

Guide in the design of moulds by identifying troubled area and minimize design problem before production. Helpdiagnostic various manufacturing defects (warping, webs and folds). These problems can be avoided right away inthe simulation stage.

Guide the choice of equipment to produce new parts. A part can be simulated with different types of die in order tofind the optimal way to produce it.

Reduction in the product development cycle. By using process simulation, the customer can proceed tomodifications and improvements at the design time and develop a better part faster by identifying problems earlieron. It can avoid costly trial and error in the mould fabrication stage.

Help in diagnostic various manufacturing defects (warping, webs and folds) to improve the part quality. Theseproblems can be avoided right away in the simulation stage.

Eliminate trial and error method by simulating those different possibility virtually , reduce the development costs.

By reducing the number of trials and error, thus reducing the number of prototype, the customer can reduce itscost of mold rework, material and labor.

Production processes optimization. The optimization module allows the customer to optimize the existing processto find the optimal processing conditions of the machine for the desired parts.


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Blowview in Product Development

Product Specifications

Production

Pre-ProductionValidation

Optimization on tooling andoperating conditions:

production cost part quality

Simulations to determine initialDesign:

mould part material

Corrections


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Extrusion Blow Moulding (EBM)

Simulation


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Process simulation:Flow in extrusion diesParison sagMould clampingParison inflation

Part coolingPart shrinkage and warpage

Additional options:Coupled effect of sag and swell in parison extrusionEffect of die geometry (Possibility of simulating different types of die)

Monolayer, multilayer and 3D blow mouldingExtrusions at non-uniform gapDesign advisor for multi-objective part developmentNon-isothermal effectsPrediction of forming defects (webs and folds)

EBM Process Simulation


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EBM Parts Simulation

Old and new Booster Seat comparison: 25% Weight Reduction 10% Cycle Reduction Quality Improvement


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Parison Extrusion and Stretching

Mould Displacement

Parison Blowing

Final PartThickness

JERRY CAN EBM Process Simulation

Integrated phases
http://localhost/var/www/apps/conversion/Simulations%20PACE/Local%20Settings/Industrial%20Marketing/Presentations/Animation_blowAVI/Jerrycan_Wedco.avi


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Parison Mould Displacement

Parison Blowing

Final Part Thickness

Air Duct EBM Process Simulation

Integrated phases
http://localhost/var/www/apps/conversion/Simulations%20PACE/Local%20Settings/Industrial%20Marketing/Presentations/Animation_blowAVI/AirDuct_Wedco.avi


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Parison Extrusion Parison ClampingParison Stretching

Mould Displacement and Blowing

Final Part Thickness

Optimization Simulation of Die ShapingProfile During Moulding Process

FUEL TANK
http://localhost/var/www/apps/conversion/Simulations%20PACE/Local%20Settings/Industrial%20Marketing/Presentations/Animation_blowAVI/Die_Shaping_Optimization.avi


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How To Run SimulationExtrusion Blow Moulding


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BlowView

2. Die / Parison /Preform Geometry

1. CAD Mould Files

3.Machine ProcessingConditions

4. Material Propertiesfrom Database

Conversion( if necessary)

BlowView

DeformationResults

TemperatureResults

Results forStructural

Analysis

Simulation Process

Pre-simulation Post-simulation


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Mould Design

Mould & part design by one offollowing CAD Systems:UnigraphicsCatiaProEngineerIdeas

Amira Ansys AutoCADSolidedgeSolidWorksCimatronOther domestic software

o Requiremento Design a preliminary mould

containing just the cavityo All other equipments (pinch plates,

rod) must also be drawn in CADo Moulds must not have any holes

Moulds and parts


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CAD Files Conversion

Amira (.am), Ansys (.ans, cdv), AutoCAD (.dfx),Unigraphics (.inp), Catia (.stl), Proengineer (.stl), Ideas(.unv)

Output files of all parts and moulds from CAD SystemImport these files in BlowViewConvert these files into .pat (Patran) format in BlowViewMeshing must be in triangular element format

*.stl

*.inp*.am

*.ans

*.cdb

*.dfx

*.unv

Files Conversion to

*.pat (Patran)BlowView format

Mesh of Mould


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Die Geometry for EBM

VWDS

SFDR

PWDS

DSM

Gap opening vs time

Die gap vs angular position

Stroke positions vs time

Slide position vs time

Determine type of die


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EBM equipment

MandrelDie


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Parison Shape

Die Opening & Parison Example

Parison Geometry for Extrusion Blow Moulding Input extrusion profile specification

5

8

10

6

4

3

2

7

9

1 2.5 mm

9.4 mm

Thickness


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Machine Processing Conditions

Determine each processing conditions time (blowing, clamping, etc.)

Time Line Sequence of Events

Stage (For a total of 7 STAGES) Intermediate steps (For a total of 30 LOAD STEPS)

11 4 1 4 143

Gas Tank Processing Conditions


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Material Characterization

Verify if the chosen material exists in the database or get the resin sample fromthe customer for characterization.

WLF Model Fit - HDPE 4261AK-BKZ Model Fit on RMS Data - HDPE 4261A

Material model


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Simulation

Input all the information in BlowViewRun the simulation


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Coarse Simulation

Determine and enter all the stages(extrusion, pinching, clamping,blowing & inflation, cooling andwarpage) and the level ofimportance of each step inBlowView

Run a coarse simulations(reduced number of elements) ofthe part

To save timeTo correct diagnostic errors

The number of load step defines the

viewing steps. The number of sub step defines thelevel of precision.

Mesh Size

Mesh Size of 1 Mesh Size of 5

Stage Loadsteps

Substeps

1. Parison Extrusion 10 5

2. Stretch Pinching 5 5

3. Mould clamping 5 54. Blowing & Inflation 6 5

5. Cooling 1 5

6. Warpage 3 5

Processing Conditions


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Calculation Precision

Determine calculation precision foreach step of the processRefine the part mesh for the finalizedsimulation

Stage Loadsteps

Substeps

1. Parison Extrusion 10 5

2. Stretch Pinching 5 5 1

3. Mould clamping 5 5 84. Blowing & Inflation 6 5 8

5. Cooling 1 5 20

6. Warpage 3 5 40

Processing Conditions

Changes

Mesh Size

Mesh Size of 1 Mesh Size of 5


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Scenario simulation

Run the whole simulation fordifferent possible processscenario

Scenario 1 Uniform Thickness Parison

Scenario 2 Die Gap Programming

Scenario 3 Die Gap Programming andDie Shaping

Etc

Scenarios Examples


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Optimal Simulation Result Choice

1st scenario has blue and green, the thickness is not uniform across the part.2nd scenarios thickness is much more uniform, but too much material in the middle showed bygray, the materials thickness in the middle is higher than 5 mm, the material was wasted.3rd scenarios wall thickness is much more uniform across the part showed in green. The handlehas a little bit more material, but can been minimized if necessary.

Three Scenarios


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Simulation Results

Extrusion Blow Moulding Parison temperature and thickness distributions during extrusion Part thickness, temperature and strain distributions during forming Part deformation and residual stresses after solidification

Temperature during forming Maximum True Stress Final Part Thickness

Extrusion Blow Moulding Results from BlowView


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Optimization for EBM

Why do you need to optimize?

Make the part according to the clients need

Improve your part performance

Reduce the amount of material use

Optimization Capabilities of BlowView

Part weight

Parison length

Parison weight

Parison length target

Parison thickness standard deviation


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Optimization of Gas tank

In this example, the objective is to minimize the parison weight.

Parameters to manipulate: Programming profile Extrusion time Die gap

Parameters to keep fixed Parison length Extrusion time Minimum thickness


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Optimal Simulation ResultParison Weight

Non-optimizedParison Weight

21.73 kgs

OptimizedParison Weight

18.05 kgs

Optimization of parison weight

After the optimization, the weight of the parison have been reduced.


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Optimal Simulation ResultPart Thickness

By reducing the weight of the parison, the weight of the part has alsobeen reduced as you can see in the mapped results.


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Mould Final Design

Decision on the moulds based onthe chosen simulation scenarioModeling and assembly of all thecomponents of the mould in CADsoftware

Finalize mould CAD files in CADsoftwareMould Fabrication

Mould CAD Files


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Mould & Experimental Part Fabrication

Make the mould and experimental part according to the simulation

Mould and Part


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Production

Make the partVerify the part for defects and warpage

Assemble small components to part Assembled part


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lowView Software

Simulation ase Studies

Optimization ase Studies onclusion

Out l ine


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1. Parison Extrus io n

2. Parison St retchin g

3. Mou ld Travel ing & Clam ping

4. Part Infl at ion

6. PartWarpage

5. Part Coo l ing

Blo w View Sof tware EBM Process Simulation Integrated phases


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Blow View Sof tw are(PWDS + SFDR)

0

5

10

15

20

25

0.00

22.50

45.00

67.50

90.00

112.50

135.00

157.50

180.00

202.50

225.00

247.50

270.00

292.50

315.00

337.50

w/o PWDS

with PWDS

-2.5-2

-1.5-1

-0.50

0.51

1.5

22.5

0 90 180 270 360

PWDS

C h a n g e s

i n t h e

G a p

( m m

)


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0o

270 90

Normal Die Gap

Die Slide

Motion

Increased Die Gapdue to SlideMotion at acertain extrusiontime and die angle

PartingLine

180

o o

o

Blow View Sof tware(Die Slide Motio n: DSM)


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Blo w View Softw are(Interm it tent extrus ion )

w 1

t 1

w 2

t 2

w 3

t 3

w 4

t 4

w 5

t5

w 6

t 6

w 7

t 7

w 8

t 8

w 9

t 9

w 10

t 10

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

0.0 2.0 4.0 6.0 8.0 10.0 12.0

Time (s)

M a s s

f l o w r a

t e ( w / t )

L = 550

mm

Flow rate evolu t ion p rof i le can b e used as in

p u t to th e sof tware


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Prediction of Parison Formation


Optimization ase Studies

onclusion

Out l ine


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Fuel Tank

HDPE 4261

u = 6 s

0 = 330 kPa.s

Flow rate = 270 g/s

WE No . = 1 30

Length = 1700 mm

MaterialProperties

OperatingConditionsCase StudyPart

Simulation

22

0

0

0

ii

ii

S uG

G J

l

l h h l

0 = Zero-shear v isco s i ty h A diedieQ

WE l


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E E t i t i


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Error Es t imat ion(Exper im ental vs . Simu lat ion )

Variable PhysicalPrototype

SimulationPrototype

% Error

Flow Rate (Kg/hr) 888.6 872.5 1.8

Cycle Time (s) 57.1 56.1 1.7

Shot Weight (kg) 13.81 13.91 0.7

Part Weight (Kg) 9.995 9.91 0.8

Flash Weight (kg) 3.82 4.00 4.7

Minimum Thickness (mm) 3.04 3.06 0.6

Physical and virtual EBM comparison shows over 95% accuracy.


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Prediction of Parison Formation


Optimization ase Studies onclusion

Out l ine

Par ison Program m ing


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% Gap Opening ( q)

Programming Pointsor Ext ru s ion Time (sec)

1 2 3 4 5 6 7 8

20%

0%

40%

60%

80%

100%

0% open 100% openDie

Mandrel

Par ison Program m ing(Vert ical Wall Dis t r ib ut io n System )

Programmedparisonshowingheavier

wallthickness

for greatestexpansion

area

1

2

3

4

5

6

7

8

VWDS:


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10

6 5 4 3 2

1

7 8 9

Axial Programming Profile

Programming Points

Radial Die Programming Profile

0 45315

Die Points

Parison Length Optimization

Die Shaping Optimization

VWDS Optimization+

PWDS or DSM Optimization

Fully Automatic

No

Yes

SFDR ?

Yes

VWDS ? No

Stop

BlowDesign Software(Optimization Flowchart)

SFDR:

VWDS:

Bl D i S f


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Blo wDesign Sof tware(Opt im ization Strategy)

text

, q

Q

12

3 4 5 6789

1011121314

1516

S 1 S 2

Design Objective Function:

n

T T Min et t ithickness part

2arg )(

By manipulating

Gap opening limits

Uniform part thickness

Constant parison length

Subject to constraints Ti = Ttarget

P length = P L

q min < q < q max

Parison Programming (t ext , q )Radial Die Gap ( G)Stroke Positions (S 1, S 2 )Flowrate (Q)

SFDR:


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Mandrel Opening ( %)

E x t r u s

i o n

T i m e

( t )

1

2

3

4

5

6

#Prog

Q (kg/m 3)T (C)

D

L1

L2

L3

L4

L5

L6

L

ti,Open i

Inflation

k

k

t T

BR

k T

k t

Algorithm:

Update no dal ext rud ed par iso nth ickness

)Target(1 nk nk

nk

un

k n

k t t T

T T

NProg1,i,1n

iT

Com pu te the average ext rudedpar i son th ickness segments

)(11 n

ini

i

n

nni

ni T T

T

Update d ie gap open ings

Optimization Strategy(Integrating Swell)


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Part Case Study OptimizationStrategy Material

VWDS,

VWDS + PWDS ,

VWDS + SFDR ,

VWDS + SFDR + PWDS

PP Pro -Fax S V152(Montel l)

Uniform PartThickness

Uniform Par t Thickness


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Objective Targeted: Uniform part thickness = 3.0 mm

Design Variables: Gap openin g,Maxim um die gap,

f low rate,

s t roke mo t ions

Parison length: 430 m m

Extrusion time: 30 sec

No of prog. points: 10

Initial gap opening 60%

Uniform Par t Thickness


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2.5 mm

9.4 mm

2.6 mm

9.7 mm

2.4 mm

12.3 mm

2.8 mm

12.0 mm

0.5 5.0 mmTarget value 3.0 mm

6.8 mm

T

VWDS0.633.02

VWDS+PWDS0.513.03

VWDS+SFDR0.453.06

VWDS+SFDR+PWDS0.43.1

Initial Design0.833.38

Optim izat ion Resu l ts


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VWDS Generic HDPEMinimum Part

Thickness

Minim um Par t Thick ness


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Objective Targeted: Minimum part thickness = 3.4 mm (befo re sh rink age)

Design Variables: Gap openin g,f low ra te


Extrusion time: 120 sec


Initial gap opening 50%

Courtesy of Vitec

Minimum Par t Thick ness


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0

10

20

30

40

50

60

70

0 20 40 60 80 100 120Extrusion Time [s]

D i e G a p O p e n i n g [ % ]

Initial Design

Iter. #1

Iter. #5

Iter. #10

Iter #15

Final Design



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InitialDesign Iter #2 Iter #5 Iter #10

Iter #15 Iter #20 Iter #30

Tmin

3.52

21.99 mm

3.4

15.0 mm

3.4

15.0 mm



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VWDS Generic HDPEMinimum Part

Weight

Minimum Par t Weight


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Courtesy of Kautex

Objective Targeted: Minimum part weight (Minim um par t th ickn ess = 3.0 mm )

Design Variables: Gap op ening,

f low ra te


Extrusion time: 56.1 sec


Initial gap opening Slid e 21

Minim um Par t Weight

l


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0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60Extrusion Tim e [s]

D i e

O p e n

i n g

[ % ]

Initial Design

Iteration 1

Iteration 2


O ti i t i R l t


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13.1 kg 11.5 kg 10.2 kgInitial design Iteration #1 Iteration #2



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Conc lus ion

Swell p red ic t ion approach has a prom is ing p oten t ialin pred ic t ing sw ell a t a wid e rang e of op erat ingcond i t ions

Program po in ts f rom s im ula tions c an be readi lyused as a s ta r ting p oin t for m ach ine prof i le se t t ings .

Par t th ic kness & w eight o p t im iza tion e l imina tes th etr ia l-and-error appro ach resul t in g in low er labo r &faster del ivery


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Filler Panel

Warpage with asymmetric cooling(Lear)


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Warpage Characterization

Banana Effect

Carpet sideor

Cavity Side

Polymer sideor

Core side

DeflectionDeflection

PositionPosition

Bottom

Extrusion direction

Carpet sideor

Cavity Side

Polymer sideor

Core side

De flectionDeflection

PositionPosition

Bottom

Extrusion direction

How we measure warpage


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Warpage Prediction & Validation

Exp 1

T carpet = 14.5 C T polymer = 54.5 C

t c = 86 sec

Dexp = 15 mm)Dsim = 19 mm)

Exp 18

T carpet = 14.0 C T polymer = 38.0 C

t c = 46 sec

Dexp = 75 mm)Dsim = 76 mm)

Warpageprediction isprecise forboth smalland bigwarpage.


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Blowview User

BMPS

Plastique Micron

Q i ?


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Question ?

info@rheoware .com

http://www.rheoware.com
mailto:[email protected]:[email protected]


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For more information, a productdemonstration, or a samplesimulation please contact us at:

www.dazztech.com

[email protected]

www.flow3d.com

505-982-0088

Thank you

FLOW-3D and TruVOF are registeredtrademarks in the USA and other countries.

Presentation EBM New

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