Increase in Warpage Prediction Accuracy for Glass Filled Polyamide Material (PA66) through Integrative Simulation Approach

The warpage prediction accuracy of the simulation software depends on part geometry, material model and methodology. However, the material model in the existing simulation software’s does not consider factors such as nonlinear mechanical properties, temperature dependent behaviour, viscoelastic behaviour and transient description of warpage leading to less accuracy. Using an integrative simulation approach, BASF has developed Ultrasim® tool to overcome limitations in the material model of existing simulation software. In the new material model thermomechanical properties, stress relaxation behaviour and nonlinear mechanical properties were considered and this new material model is added to Ultrasim® tool. The model also considers time dependent descriptions of the warpage starting from packing phase of the moulding process, followed by actual ejection and cooling. In this paper warpage results predicted through new integrative simulation approach and existing simulation approach are compared with actual experimental results for 50% glass filled polyamide material (Ultramid®A3WG10). The results revealed that warpage values predicted by integrative simulation based Ultrasim® tool are closer to actual experimental results compared to values predicted by existing simulation technologies. Therefore an integrative simulation approach can be used prior to making real parts to reduce manufacturing cost.