Performance optimization method and device of injection molding composite material, electronic equipment and medium

Abstract

The invention relates to a performance optimization method and device for an injection molding composite material, electronic equipment and a medium. The method comprises the following steps: based on preset mold flow process analysis parameters, performing mold flow injection molding process analysis on a target mold flow injection molding analysis object for multiple times to obtain a fiber orientation distribution file and a weld line position file; the files are mapped to finite element models of the files, and stress distribution and structural rigidity of the composite material structure are calculated; calculating a durability damage value based on the stress distribution, and generating a first preset relation curve and a second preset relation curve in combination with preset mold flow process analysis parameters, structural rigidity and the durability damage value; and adjusting preset mold flow process analysis parameters according to the curve, and optimizing the durability and structural rigidity performance of the composite material structure of the target object. Therefore, the problem that in the prior art, the rigidity and durability of a chopped fiber reinforced composite material structure are unstable due to the fact that the fiber orientation and the weld line position are uncertain in the injection molding process is solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of injection molding, in particular to a performance optimization method and device for injection molding composite materials, an electronic device and a medium. BACKGROUND

[0002] With the increasing demand for product performance, short fiber reinforced resin-based composite materials gradually become an important material in the field of injection molding due to their excellent mechanical properties and lightweight characteristics. By adding short fibers to the resin matrix, the strength and stiffness of the product are significantly improved, and the weight is reduced, meeting the demand for high-performance and lightweight materials in modern industry. In the injection molding process, mold flow analysis is an important technical means for predicting the flow behavior of plastic melt in the mold, optimizing injection molding process parameters, and thus improving product quality and production efficiency.

[0003] In related technologies, mold flow analysis technology usually relies on professional simulation software such as Moldflow to perform mesh division and flow simulation on injection molds, determine the best gate location and runner design through simulation, and optimize injection molding process parameters (such as injection time, injection pressure, melt temperature, etc.).

[0004] However, this method mainly focuses on the filling behavior of the melt and the prediction of molding defects, but the analysis of fiber orientation distribution and weld line position is not accurate enough, resulting in unstable stiffness and durability of short fiber reinforced resin-based injection molding composite structures, which needs to be solved urgently. SUMMARY

[0005] The present application provides a performance optimization method and device for injection molding composite materials, an electronic device and a medium to solve the problem of unstable stiffness and durability of short fiber reinforced composite material structure in the injection molding process due to uncertain fiber orientation and weld line position in the prior art.

[0006] To achieve the above-mentioned purpose, the first aspect of the present application proposes a performance optimization method for injection molding composite materials, comprising the following steps: Based on the preset mold flow process analysis parameters, the target mold flow injection molding analysis object is sequentially subjected to multiple mold flow injection molding process analyses, and the fiber orientation distribution file and the weld line position file corresponding to each mold flow injection molding process analysis are obtained; The fiber orientation distribution file and the weld line position file corresponding to each mold flow injection molding process analysis are mapped to the finite element model of the target mold flow injection molding analysis object, and the stress distribution and structural stiffness of the composite material structure of the target mold flow injection molding analysis object are calculated. based on the stress distribution, calculate a durability damage value of the composite material structure of the target mold flow injection molding analysis object, and based on the preset mold flow process analysis parameters, the structural stiffness, and the durability damage value, generate a first preset relationship curve and a second preset relationship curve; According to the first preset relationship curve and the second preset relationship curve, adjust the preset mold flow process analysis parameters to optimize the durability performance and structural stiffness performance of the composite material structure of the target mold flow injection molding analysis object.

[0007] According to an embodiment of the present application, the mapping of the fiber orientation distribution file and the weld line position file corresponding to each of the mold flow injection molding process analysis processes to the finite element model of the target mold flow injection molding analysis object, the calculation of the stress distribution and the structural stiffness of the composite material structure of the target mold flow injection molding analysis object, comprises: constructing a finite element model of the target mold flow injection molding analysis object and assigning target composite material attributes to the finite element model sequentially mapping the fiber orientation distribution file and the weld line position file corresponding to each of the mold flow injection molding process analysis processes to the finite element model of the target mold flow injection molding analysis object, calculating the structural deformation and the stress distribution corresponding to each of the mold flow injection molding process analysis processes, and based on the structural deformation, calculating the structural stiffness.

[0008] According to an embodiment of the present application, before sequentially performing multiple mold flow injection molding process analysis on the target mold flow injection molding analysis object based on the preset mold flow process analysis parameters, further comprising: performing mesh division operation, mesh inspection operation and mesh repair operation on the target mold flow injection molding analysis object in sequence; calculating a target gate location of the target mold flow injection molding analysis object, and establishing a target gate and a target runner according to the target gate location; selecting materials for mold flow injection molding process analysis from a first preset composite material database, and determining the preset mold flow process analysis parameters.

[0009] According to an embodiment of the present application, the preset mold flow process analysis parameters include at least one of injection time, injection pressure, melt temperature, mold temperature, water distribution, and holding pressure strategy.

[0010] According to an embodiment of the present application, the first preset relationship curve takes the injection time as the abscissa and the structural stiffness as the ordinate; The second preset relationship curve takes the injection time as the abscissa and the durability damage value as the ordinate.

[0011] The performance optimization method of the injection molding composite material provided in the embodiments of the present application comprises the following steps: performing multiple times of mold flow injection molding process analysis on a target mold flow injection molding analysis object based on preset mold flow process analysis parameters, obtaining fiber orientation distribution files and weld line position files, mapping the files to a finite element model thereof, calculating stress distribution and structural stiffness of a composite material structure, calculating a durability damage value based on the stress distribution, generating first and second preset relationship curves in combination with the preset mold flow process analysis parameters, the structural stiffness and the durability damage value, and adjusting the preset mold flow process analysis parameters according to the curves to optimize the durability and structural stiffness performance of the composite material structure of the target object. Thus, the problem of unstable stiffness and durability performance of a short-cut fiber reinforced composite material structure in an injection molding process due to uncertain fiber orientation and weld line position is solved.

[0012] To achieve the above object, the second aspect of the present application provides a performance optimization device of an injection molding composite material, comprising: An analysis module is configured to perform multiple times of mold flow injection molding process analysis on a target mold flow injection molding analysis object in sequence based on preset mold flow process analysis parameters, and obtain fiber orientation distribution files and weld line position files corresponding to each mold flow injection molding process analysis process. A calculation module is configured to map the fiber orientation distribution files and the weld line position files corresponding to each mold flow injection molding process analysis process to a finite element model of the target mold flow injection molding analysis object, and calculate stress distribution and structural stiffness of a composite material structure of the target mold flow injection molding analysis object. A generation module is configured to calculate a durability damage value of the composite material structure of the target mold flow injection molding analysis object based on the stress distribution, and generate first and second preset relationship curves based on the preset mold flow process analysis parameters, the structural stiffness and the durability damage value. An adjustment module is configured to adjust the preset mold flow process analysis parameters according to the first and second preset relationship curves, so as to optimize the durability performance and structural stiffness performance of the composite material structure of the target mold flow injection molding analysis object.

[0013] According to one embodiment of the present application, the calculation module is specifically configured to: construct a finite element model of the target mold flow injection molding analysis object, and assign target composite material attributes to the finite element model map the fiber orientation distribution files and the weld line position files corresponding to each mold flow injection molding process analysis process to the finite element model of the target mold flow injection molding analysis object in sequence, calculate structural deformation and stress distribution corresponding to each mold flow injection molding process analysis process, and calculate the structural stiffness based on the structural deformation.

[0014] According to one embodiment of the present application, before the target mold flow injection analysis object is sequentially subjected to multiple mold flow injection process analysis based on the preset mold flow process analysis parameters, the analysis module is further configured to: performing grid division operation, grid inspection operation and grid repair operation on the target mold flow injection analysis object in sequence; calculating the target gate location of the target mold flow injection analysis object, and establishing a target gate and a target runner according to the target gate location; selecting materials for mold flow injection process analysis from a first preset composite material database, and determining the preset mold flow process analysis parameters.

[0015] According to one embodiment of the present application, the preset mold flow process analysis parameters include at least one of injection time, injection pressure, melt temperature, mold temperature, water distribution and pressure holding strategy.

[0016] According to one embodiment of the present application, the first preset relationship curve takes the injection time as the abscissa and the structural stiffness as the ordinate; The second preset relationship curve takes the injection time as the abscissa and the durability damage value as the ordinate.

[0017] The performance optimization device for injection molded composite material according to the embodiments of the present application performs multiple mold flow injection process analysis on the target mold flow injection analysis object based on the preset mold flow process analysis parameters, obtains fiber orientation distribution files and weld line position files, maps these files to the finite element model thereof, calculates the stress distribution and structural stiffness of the composite material structure, calculates the durability damage value based on the stress distribution, generates first and second preset relationship curves based on the preset mold flow process analysis parameters, structural stiffness and durability damage value, and adjusts the preset mold flow process analysis parameters according to the curves to optimize the durability and structural stiffness performance of the target object composite material structure. Thus, the problem of unstable stiffness and durability performance of short-cut fiber reinforced composite material structure caused by uncertain fiber orientation and weld line position during the injection molding process is solved.

[0018] To achieve the above-mentioned purpose, the third aspect embodiment of the present application proposes an electronic device, which comprises a memory, a processor and a computer program stored on the memory and executable on the processor, and the processor executes the program to implement the performance optimization method for injection molded composite material as described in the above embodiments.

[0019] To achieve the above-mentioned purpose, the fourth aspect embodiment of the present application proposes a computer readable storage medium having a computer program stored thereon, which is executed by a processor to implement the performance optimization method for injection molded composite material as described in the above embodiments.

[0020] Additional aspects and advantages of the present application will be apparent from the following description, taken in conjunction with the accompanying drawings, wherein: BRIEF DESCRIPTION OF DRAWINGS

[0021] The above and / or additional aspects and advantages of the present application will become apparent and be more fully understood from the following description, taken in conjunction with the accompanying drawings, wherein: Figure 1 A flow chart of a method for optimizing performance of an injection molded composite material according to an embodiment of the present application; Figure 2 A flow chart of another method for optimizing performance of an injection molded composite material according to an embodiment of the present application; Figure 3 A schematic diagram of a geometric model of a powertrain support assembly structure according to an embodiment of the present application; Figure 4 A schematic diagram of a target gate location, water line arrangement and mold flow injection molding process simulation according to an embodiment of the present application; Figure 5 A schematic diagram of mapping fiber orientation distribution results to a structural finite element model according to an embodiment of the present application; Figure 6 A schematic diagram of mapping weld line location distribution results to a structural finite element model according to an embodiment of the present application; Figure 7 A schematic diagram of a relationship curve of a process parameter injection time and structural stiffness according to an embodiment of the present application; Figure 8 A schematic diagram of a relationship curve of a process parameter injection time and structural durability damage value according to an embodiment of the present application; Figure 9 A block schematic diagram of a device for optimizing performance of an injection molded composite material according to an embodiment of the present application; Figure 10 A structural schematic diagram of an electronic device according to an embodiment of the present application. DETAILED DESCRIPTION

[0022] Embodiments of the present application are described in detail below with reference to the attached drawing figures, wherein the embodiments of the application are shown as examples. The embodiments of the application described below are intended to explain the principles of the application and to enable a person skilled in the art to implement and use the application. The application is not limited to the embodiments described below.

[0023] With reference to the accompanying drawings, a method for optimizing performance of an injection molded composite material, an apparatus, an electronic device, and a medium are described below according to embodiments of the present application. First, a method for optimizing performance of an injection molded composite material according to an embodiment of the present application is described with reference to the accompanying drawings.

[0024] Figure 1 is a flowchart of a method for optimizing performance of an injection molded composite material according to an embodiment of the present application.

[0025] Before introducing the method for optimizing performance of an injection molded composite material according to embodiments of the present application, a brief introduction to the related technical background is given.

[0026] At the present stage, there are the following problems in the pros and cons of the durability of a short-cut fiber (such as glass fiber or carbon fiber) reinforced resin-based injection molded composite material structure: (1) injection molding time and other process parameters will affect the arrangement of short-cut fibers in the injection molded structure, thereby affecting the structural durability, and it is not clear at present how the fine tuning of the injection molding time process parameter affects the structural durability; (2) injection molding time and other process parameters will affect the position of the weld line formed by the intersection of the mold flow, and the material performance at the weld line position is relatively weak, thereby affecting the overall durability of the composite material structure, and it is not clear at present how the fine tuning of the injection molding time process parameter affects the distribution of the weld line, thereby affecting the structural durability.

[0027] Based on the above problems, a method for optimizing performance of an injection molded composite material is proposed in embodiments of the present application, which predicts the influence of injection time process parameters on the durability and stiffness performance of a short-cut fiber reinforced resin-based injection molded composite material structure through simulation, guides the effective adjustment of the mold flow process parameters, and thereby improves the structural durability and stiffness performance of the injection molded composite material.

[0028] The method for optimizing performance of an injection molded composite material according to embodiments of the present application will be described in detail below.

[0029] For example, as shown in Figure 1 The method for optimizing performance of an injection molded composite material includes the following steps: In step S101, based on the preset mold flow process analysis parameters, the target mold flow injection molding analysis object is sequentially subjected to multiple mold flow injection molding process analyses, and fiber orientation distribution files and weld line position files corresponding to each mold flow injection molding process analysis are obtained.

[0030] It can be understood that the preset mold flow process analysis parameters are process parameters used for mold flow injection molding process analysis, which can directly affect the flow behavior of the material in the injection molding process and the performance of the final product. The target mold flow injection analysis object refers to the geometric model of the plastic product that needs to be injection molded. In this application, it specifically refers to a short-cut fiber reinforced resin-based injection composite material structure, for example, a new energy vehicle chassis power assembly suspension bracket structure. The fiber orientation distribution file records the orientation distribution of the fibers in the mold cavity during the injection molding process. The orientation of the fibers has a significant impact on the mechanical properties of the composite material. For example, when the fibers are arranged in a certain direction, the strength and stiffness of the material in that direction will increase. The weld line position file records the position of the weld line in the mold cavity. The weld line is the place where the melt of different directions meets and fuses during the injection molding process. These positions are usually weak in material performance and are prone to become weak points of the structure.

[0031] In order to comprehensively evaluate the influence of different process parameters on the performance of injection composite materials, the Moldflow software (a plastic injection molding simulation software) can be used to perform multiple mold flow injection molding process analyses on the target mold flow injection analysis object by adjusting the preset mold flow process analysis parameters. After each analysis, a file formed by the fiber orientation distribution information of the current analysis process (i.e., the fiber orientation distribution information file Fiber_tensor_n.xml, n represents the nth mold flow injection molding process analysis) and a file formed by the weld line position (i.e., the weld line position file Weldline_1.xml, n represents the nth mold flow injection molding process analysis) can be extracted. After obtaining the fiber orientation distribution file and the weld line position file, the data in these files can be analyzed in detail. By comparing the differences in fiber orientation distribution under different preset mold flow process analysis parameters, it can be determined which parameters have a greater impact on the orientation of the fibers in the mold cavity, and how this change in orientation changes the mechanical properties of the composite material, such as the degree of influence on the strength and stiffness of the material in different directions. For the weld line position file, the position changes of the weld line under different process parameters are analyzed to find out the areas where the weld line is prone to occur and the material performance is weak, as well as the relationship between these areas and the process parameters. Based on the analysis results of the fiber orientation distribution file and the weld line position file, the specific influence mode and degree of influence of different process parameters on the performance of injection composite materials can be accurately determined, thereby providing strong data support for optimizing the performance of injection composite materials.

[0032] Optionally, in some embodiments, the preset mold flow process analysis parameters include at least one of injection time, injection pressure, melt temperature, mold temperature, water channel arrangement, and holding pressure strategy.

[0033] It can be understood that in the embodiments of the present application, the preset mold flow process analysis parameters include but are not limited to injection time, injection pressure, melt temperature, mold temperature, waterway arrangement and holding pressure strategy. Among them, the injection time refers to the time required for the melt to be injected into the mold cavity from the gate during the injection molding process, and the length of the injection time will affect the fiber orientation distribution and the position of the weld line. The injection pressure refers to the pressure for pushing the melt to fill the mold cavity, and the size of the injection pressure will affect the flow speed and filling effect of the melt. The high and low of the melt temperature can affect the viscosity and flowability of the melt. The mold temperature can affect the cooling speed and forming quality of the melt. The waterway arrangement refers to the design and layout of the cooling waterway in the mold, and the waterway arrangement can affect the temperature distribution and cooling efficiency of the mold. The holding pressure strategy refers to the strategy of maintaining a certain pressure after filling during the injection molding process, including holding pressure and holding time, etc. The holding pressure refers to the size of the pressure used in the holding stage, which is usually lower than the injection pressure, and the holding time is the duration of applying the holding pressure. The holding pressure strategy can affect the density and surface quality of the product.

[0034] It is crucial to set reasonable preset mold flow process analysis parameters for optimizing the injection molding process and improving the performance of the product.

[0035] In step S102, the fiber orientation distribution file and the weld line position file corresponding to each mold flow injection molding process analysis are mapped to the finite element model of the target mold flow injection molding analysis object, and the stress distribution and structural stiffness of the composite material structure of the target mold flow injection molding analysis object are calculated.

[0036] Specifically, based on the Digimat software platform (a composite material multi-scale modeling and simulation platform), a special database containing the performance parameters of chopped fiber composite materials is first established, and the corresponding mechanical property parameters are assigned to the structural materials on this basis. Subsequently, using the data mapping function of the Digimat software, the fiber orientation distribution file and the weld line position file obtained by each mold flow injection molding process analysis are respectively mapped to the finite element model of the target mold flow injection molding analysis object. Then, using a finite element analysis software (such as ABAQUS), the composite material structure of the target mold flow injection molding analysis object is numerically simulated and calculated, the stress distribution characteristics of the composite material structure of the target mold flow injection molding analysis object under load are analyzed, and the result data is saved as a standard *.odb format output file after the stress field simulation calculation. On this basis, the displacement deformation data of the key parts of the composite material structure are further extracted, the overall deformation characteristics of the composite material structure are obtained through post-processing analysis, and the equivalent stiffness parameters (i.e. structural stiffness) of the composite material structure are calculated based on the force-displacement relationship curve, which provides data support for subsequent structural performance evaluation and optimization design.

[0037] This process achieves seamless connection from process analysis to structural performance evaluation, providing accurate material property basis for subsequent structural strength analysis and performance prediction. Through this integrated analysis method, the impact of manufacturing process on the final performance of composite materials can be more comprehensively considered, thereby improving the reliability and accuracy of structural design.

[0038] The following will explain in detail how to calculate the stress distribution and structural stiffness of the composite structure of the target mold flow injection analysis object.

[0039] As a possible implementation, in some embodiments, the fiber orientation distribution file and weld line position file corresponding to each mold flow injection process analysis process are mapped to the finite element model of the target mold flow injection analysis object, and the stress distribution and structural stiffness of the composite structure of the target mold flow injection analysis object are calculated, including: constructing a finite element model of the target mold flow injection analysis object, and assigning target composite material properties to the finite element model; sequentially map the fiber orientation distribution file and weld line position file corresponding to each mold flow injection process analysis process to the finite element model of the target mold flow injection analysis object, calculate the structural deformation and stress distribution corresponding to each mold flow injection process analysis process, and calculate the structural stiffness based on the structural deformation.

[0040] Specifically, first, a finite element model of the target mold flow injection molding analysis object can be constructed, which is created based on the geometry and size of the target mold flow injection molding analysis object, usually using finite element analysis software (such as ABAQUS). That is, the three-dimensional geometric model of the target mold flow injection molding analysis object (usually generated by CAD software) is imported into the finite element analysis software, the geometric model is divided into a plurality of small units (meshes), which can be tetrahedrons, hexahedrons or other shapes, and then the boundary conditions (such as fixed constraints, symmetric boundaries, etc.) and load conditions (such as pressure, force, temperature, etc.) of the model are defined, which will be used to simulate the working conditions in actual use. In addition, in the finite element model, each unit needs to be assigned with corresponding material properties (such as matrix material properties (elastic modulus, Poisson's ratio, density, etc. of the resin), fiber material properties (elastic modulus, Poisson's ratio, density, etc. of the resin), etc.), which can be obtained from a material database or determined by experiment. In the finite element model, these properties will be used to calculate the mechanical behavior of the structure. After the finite element model is constructed, the fiber orientation distribution file and the weld line position file generated by each mold flow injection molding process analysis can be imported into the finite element analysis software, and the finite element analysis software can map the information in the fiber orientation distribution file and the weld line position file to each unit of the finite element model, and the mapping process ensures that the fiber orientation and weld line position information of each unit are consistent with the mold flow analysis results. After the information is imported, the displacement, strain and stress of each unit can be calculated by solving the mechanical equation, and then the calculation results, including the deformation of the structure (such as displacement, deformation shape) and stress distribution (such as stress contour, showing the stress size at different positions in the structure), can be extracted. Then, according to the deformation of the structure, the stiffness of the structure can be further calculated.

[0041] In step S103, based on the stress distribution, the durability damage value of the composite material structure of the target mold flow injection molding analysis object is calculated, and based on the preset mold flow process analysis parameters, the structure stiffness and the durability damage value, the first preset relationship curve and the second preset relationship curve are generated.

[0042] Optionally, in some embodiments, the first preset relationship curve takes injection time as the abscissa and structure stiffness as the ordinate; the second preset relationship curve takes injection time as the abscissa and durability damage value as the ordinate.

[0043] Specifically, the *.odb format output file (i.e. stress distribution) obtained in step S102 is imported into a fatigue life analysis software (such as FEMFAT), the FEMFAT software includes a material database, which stores fatigue life characteristics of various materials, such as S-N curve (stress-cycle number curve) and fatigue parameters of the material, etc. In the FEMFAT software, a material model corresponding to the material used by the target mold flow injection molding analysis object is selected, a fatigue life model of the chopped fiber composite material is constructed according to the parameters in the material database, based on the fatigue life model of the chopped fiber composite material, the stress distribution and the fatigue life characteristics of the material, the durability damage value of the composite material structure is calculated, and a result file of the durability damage value is output, which usually contains the durability damage value distribution of each element.

[0044] In order to intuitively reflect the law of structural stiffness and durability damage value changing with process parameters, the injection time process parameter can be taken as the horizontal coordinate, and the structural stiffness of the first to nth structure can be taken as the vertical coordinate to draw a relationship curve (i.e. first preset relationship curve), through which the influence of injection time on structural stiffness can be intuitively seen. The injection time process parameter can also be taken as the horizontal coordinate, and the durability damage value of the first to nth structure can be taken as the vertical coordinate to draw a relationship curve (i.e. second preset relationship curve), through which the influence of injection time on structural durability damage performance can be intuitively seen.

[0045] In step S104, the preset mold flow process analysis parameters are adjusted according to the first preset relationship curve and the second preset relationship curve, so as to optimize the durability performance and structural stiffness performance of the composite material structure of the target mold flow injection molding analysis object.

[0046] Specifically, after obtaining the first preset relationship curve and the second preset relationship curve, the variation law of structural stiffness value with injection time can be analyzed through the first preset relationship curve, thereby guiding effective adjustment of the injection time process parameter. For example, if the curve shows that the structural stiffness reaches the maximum value when the injection time is 1.0 second, it is recommended to adjust the injection time to 1.0 second, so that the structural stiffness performance is improved. Through the second preset relationship curve, the variation law of structural durability damage value with injection time can be analyzed, thereby guiding effective adjustment of the injection time process parameter. For example, if the curve shows that the durability damage value reaches the minimum value when the injection time is 1.0 second, it is recommended to adjust the injection time to 1.0 second, so that the durability performance of the composite material structure is improved.

[0047] It should be noted that in actual application, the rigidity and durability of the structure need to be considered at the same time, therefore, a balance point needs to be found between the first preset relationship curve and the second preset relationship curve. For example, if the structure rigidity and durability are both good when the injection time is 1.0 second, 1.0 second is selected as the optimal injection time. In addition to the injection time, other mold flow process parameters can also be combined for comprehensive optimization, for example, adjusting the injection pressure and melt temperature to further improve the structure performance.

[0048] Further, in some embodiments, before sequentially performing multiple mold flow injection molding process analyses on the target mold flow injection molding analysis object based on the preset mold flow process analysis parameters, further comprising: sequentially performing a mesh division operation, a mesh inspection operation and a mesh repair operation on the target mold flow injection molding analysis object; calculating the target gate location of the target mold flow injection molding analysis object, and establishing a target gate and a target runner according to the target gate location; selecting the material used for mold flow injection molding process analysis from the first preset composite material database, and determining the preset mold flow process analysis parameters.

[0049] It can be understood that before performing mold flow injection molding process analysis, a series of preparation work can also be performed on the target mold flow injection molding analysis object. Mesh division is to decompose the geometric model of the target mold flow injection molding analysis object into many small units (meshes) for numerical simulation. Through mesh division, the continuous geometric model can be discretized so that it can be numerically calculated by computer. Mesh inspection is a process of evaluating the quality of generated meshes to ensure that the meshes have no obvious defects. High-quality meshes can improve the accuracy and reliability of simulation results and avoid calculation errors or result deviations caused by mesh quality problems. Mesh repair is a process of correcting mesh quality problems found in the inspection process. The purpose of repair is to improve the quality of meshes to meet the requirements of simulation analysis.

[0050] Specifically, the geometric model of the target mold flow injection molding analysis object (usually generated by CAD software) is imported into Moldflow software. Moldflow is then used to mesh the geometric model, setting appropriate mesh size and type to generate an initial network. Next, the shape quality of the initial network is checked to ensure each element has a regular shape, and the mesh size is checked to ensure it meets analysis requirements. Excessively large elements can lead to insufficient accuracy, while excessively small elements can cause computational inefficiency. Mesh connectivity is also checked to ensure correct connections between elements and the absence of isolated elements. Mesh quality issues can be repaired, such as adjusting element size and shape, repairing irregular elements, and, if necessary, re-meshing to ensure the mesh quality meets requirements. Then, Moldflow is used to analyze the gate location (the entrance point where the melt enters the mold cavity) of the target mold flow injection molding analysis object. Based on the analysis results, the optimal gate location (i.e., the target gate location) is determined. Based on the determined target gate location, the target gate and target runner can be established in the mold design to ensure smooth melt flow and reduce pressure loss and filling time. Using the material database in Moldflow software, suitable composite materials are selected according to the requirements of the target mold flow injection molding analysis object, and the properties of the selected materials (such as viscosity, elastic modulus, Poisson's ratio, etc.) are confirmed. Based on the properties of the selected materials, process parameters such as injection time, injection pressure, and melt temperature are set, which provides a foundation for subsequent mold flow injection molding process analysis.

[0051] To facilitate those skilled in the art to further understand the performance optimization method of injection-molded composite materials in the embodiments of this application, the following is combined with... Figures 2-8 To elaborate further.

[0052] like Figure 2 As shown, the performance optimization method for this injection-molded composite material may further include the following steps: Step S201: Perform geometric cleanup, mesh generation, and mesh repair on the geometric model using Moldflow software.

[0053] Step S202: Determine whether the mesh quality check meets the requirements. If yes, proceed to step S203; otherwise, proceed to step S201.

[0054] Step S203: Based on Moldflow software, determine the gate location, set process parameters, and conduct the first simulation of the mold flow injection molding process.

[0055] Step S204: Extract the fiber arrangement, weld line position, and mold flow analysis model file from the simulation results of the first mold flow injection molding process.

[0056] Step S205: Adjust the injection time process parameters, conduct the nth mold flow injection process simulation, and extract information such as fiber arrangement and weld line position.

[0057] Step S206: Establish a structural finite element model based on ABAQUS software.

[0058] Step S207: Based on Digimat software, process document information (fiber arrangement, weld line position) is mapped onto the structure, and ABAQUS software is used to calculate the first structural deformation and stress.

[0059] Step S208: Based on Digimat software, process document information (fiber arrangement, weld line position) is mapped onto the structure, and ABAQUS software is used to calculate the nth structural deformation and stress.

[0060] Step S209: Based on the structural deformation calculation results from the first to the nth time, calculate the structural stiffness and plot the curve of the relationship between injection time and structural stiffness.

[0061] Step S210: Calculate the structural durability damage from the first to the nth time using FEMFAT software.

[0062] Step S211: Based on the structural durability damage calculation results from the first to the nth time, plot the curve of the relationship between injection time and structural damage.

[0063] Step S212: Based on the relationship curves between injection time and structural damage and between injection time and structural stiffness, determine how to adjust the injection time to improve structural stiffness and durability.

[0064] The following explanation uses the chassis powertrain suspension bracket structure (short-cut fiber composite material structure) of a certain new energy vehicle as an example.

[0065] Explanation of the vehicle coordinate system: The positive X-axis (direction 1) is from the front to the rear of the vehicle, and the positive Z-axis (direction 3) is vertically upward. The positive Y-axis of the vehicle coordinate system is governed by the right-hand screw rule, and the rotation directions around the X, Y, and Z axes represent directions 4, 5, and 6, respectively.

[0066] The first step is to import the powertrain bracket assembly structural geometric model into Moldflow software, such as... Figure 3 As shown. After geometric processing of the model, mesh generation is performed. The mesh size can be 2mm, and the mesh type is triangular elements. If the mesh quality does not meet the requirements, geometric cleanup or mesh management can be performed again until the mesh quality meets the requirements.

[0067] The second step involves using Moldflow software to select the corresponding material file from the Moldflow material database, determine the gate location, and then set process parameters such as injection time, injection pressure, melt temperature, mold temperature, water channel dimensions and layout, and holding pressure control. The first mold flow injection molding process simulation is then conducted. Figure 4 As shown.

[0068] The third step is to extract the corresponding fiber orientation distribution result Fiber_tensor_1.xml file and the corresponding weld line position distribution result Weldline_1.xml file based on the first mold flow injection simulation results of Moldflow software, and export the model file model_1.udm file for mold flow analysis. Save the above three types of files for later use.

[0069] Fourth, using Moldflow software, after adjusting the injection time process parameters, perform mold flow process simulation again, extract the corresponding fiber orientation distribution result (Fiber_tensor_2.xml file), extract the corresponding weld line position distribution result (Weldline_2.xml file), and export the mold flow analysis model file (model_2.udm file). Save these three types of files for later use. Similarly, extract the corresponding fiber orientation distribution result (Fiber_tensor_n.xml file), extract the corresponding weld line position distribution result (Weldline_n.xml file), and export the mold flow analysis model file (model_n.udm file). Save these three types of files for later use.

[0070] The fifth step involves establishing a mesh model of the composite material suspension support structure based on the ABAQUS user template in Hypermesh software. At the same time, isotropic material properties are assigned, constraints and load conditions are established, and the finite element calculation model Fem.inp is exported.

[0071] Step 6: Using Digimat software, import the finite element calculation model Fem.inp, the first mold flow injection molding simulation model model_1.udm file, and then import the fiber orientation distribution results Fiber_tensor_1.xml file and the weld line position distribution results Weldline_1.xml file extracted after the first mold flow simulation analysis. Map the fiber orientation distribution results and weld line position distribution results obtained from mold flow injection molding onto the finite element calculation model, such as... Figure 5 and Figure 6 As shown, Digimat, in conjunction with ABAQUS, conducted the first simulation of structural displacement and stress results, obtaining the DigimatCoupledABAQUS_1.odb file.

[0072] Step 7: Based on Digimat software, import the finite element calculation model Fem.inp, the nth mold flow injection molding simulation model model_n.udm file, and the fiber orientation distribution results extracted from the first mold flow simulation analysis Fiber_tensor_n.xml file and the weld line position distribution results Weldline_n.xml file. Map the fiber orientation distribution results and weld line position distribution results obtained from mold flow injection molding onto the finite element calculation model. Digimat, in conjunction with ABAQUS, conducts the first structural displacement and stress result simulation to obtain the DigimatCoupledABAQUS_n.odb file.

[0073] Step 8: For the calculated structural displacement results from the first to the nth time, divide the applied load by the vertical displacement of the structure to obtain the structural stiffness results from the first to the nth time. Plot the relationship curve with the injection time as the abscissa (in this application example, the injection times are 0.75s, 0.9s, 1.0s, 1.1s, 1.25s, and 1.5s respectively) and the structural stiffness as the ordinate. Figure 7 As shown, the structural stiffness reaches its maximum value when the injection time is around 1 second. Within the range allowed by the process, it is recommended to adjust the injection time to around 1 second.

[0074] Step 9: Using FEMFAT software, import the result file of the first finite element analysis (igimatCoupledABAQUS_1.odb), input the number of iterations (400,000), establish the properties of the chopped fiber composite material based on the FEMFAT material library, import the first mold flow injection molding process file (Fiber_tensor_1.xml), and calculate the durability damage of the structure after the first mold flow simulation. Import the result file of the nth finite element analysis (igimatCoupledABAQUS_n.odb), input the number of iterations (400,000), establish the properties of the chopped fiber composite material based on the FEMFAT material library, import the mold flow injection molding process file (Fiber_tensor_n.xml), and calculate the durability damage of the structure after the nth mold flow simulation. Plot the relationship curve with injection time as the x-axis (in this example, injection times are set to 0.75s, 0.9s, 1.0s, 1.1s, 1.25s, and 1.5s) and structural durability damage as the y-axis. Figure 8 As shown, when the injection time is around 1 second, the structural durability damage reaches a minimum. Within the range allowed by the process, it is recommended to adjust the injection time to around 1 second.

[0075] According to the performance optimization method for injection-molded composite materials proposed in this application, the target injection molding analysis object is subjected to multiple injection molding process analyses based on preset mold flow analysis parameters to obtain fiber orientation distribution files and weld line location files. These files are then mapped to its finite element model to calculate the stress distribution and structural stiffness of the composite material structure. Based on the stress distribution, durability damage values ​​are calculated. Combining the preset mold flow analysis parameters, structural stiffness, and durability damage values, first and second preset relationship curves are generated. The preset mold flow analysis parameters are adjusted according to the curves to optimize the durability and structural stiffness performance of the target composite material structure. This solves the problem of unstable stiffness and durability performance of short-cut fiber reinforced composite materials during injection molding due to uncertain fiber orientation and weld line location in existing technologies.

[0076] Next, the performance optimization apparatus for injection-molded composite materials proposed according to the embodiments of this application is described with reference to the accompanying drawings.

[0077] Figure 9 This is a block diagram of a performance optimization device for injection-molded composite materials according to an embodiment of this application.

[0078] like Figure 9 As shown, the performance optimization device 10 for injection molded composite materials includes: an analysis module 100, a calculation module 200, a generation module 300, and an adjustment module 400.

[0079] The analysis module 100 is used to perform multiple mold flow injection molding process analyses on the target mold flow injection molding analysis object based on preset mold flow process analysis parameters, and obtain fiber orientation distribution files and weld line position files corresponding to each mold flow injection molding process analysis process. The calculation module 200 is used to map the fiber orientation distribution file and weld line position file corresponding to each mold flow injection molding process analysis to the finite element model of the target mold flow injection molding analysis object, and calculate the stress distribution and structural stiffness of the composite material structure of the target mold flow injection molding analysis object; The generation module 300 is used to calculate the durability damage value of the composite material structure of the target mold flow injection molding analysis object based on stress distribution, and to generate a first preset relationship curve and a second preset relationship curve based on preset mold flow process analysis parameters, structural stiffness and durability damage value. The adjustment module 300 is used to adjust the preset mold flow process analysis parameters according to the first preset relationship curve and the second preset relationship curve, so as to optimize the durability and structural stiffness of the composite material structure of the target mold flow injection molding analysis object.

[0080] Optionally, in some embodiments, the calculation module 200 is specifically used for: Construct a finite element model of the target mold flow injection molding analysis object, and assign the target composite material properties to the finite element model. The fiber orientation distribution file and weld line location file corresponding to each mold flow injection molding process analysis are sequentially mapped to the finite element model of the target mold flow injection molding analysis object. The structural deformation and stress distribution corresponding to each mold flow injection molding process analysis are calculated, and the structural stiffness is calculated based on the structural deformation.

[0081] Optionally, in some embodiments, before performing multiple mold flow injection molding process analyses on the target mold flow injection molding analysis object based on preset mold flow process analysis parameters, the analysis module 100 is further configured to: The target mold flow injection molding analysis object is subjected to mesh generation, mesh checking, and mesh repair operations in sequence. Calculate the target gate location for the target mold flow injection molding analysis object, and establish the target gate and target runner based on the target gate location; Select the material to be used for mold flow injection molding process analysis from the first preset composite material database, and determine the preset mold flow process analysis parameters.

[0082] Optionally, in some embodiments, the preset mold flow process analysis parameters include at least one of injection time, injection pressure, melt temperature, mold temperature, water channel layout, and pressure holding strategy.

[0083] Optionally, in some embodiments, the first preset relationship curve is plotted with injection time on the horizontal axis and structural stiffness on the vertical axis; The second preset relationship curve uses injection time as the horizontal axis and durability damage value as the vertical axis.

[0084] It should be noted that the foregoing explanation of the performance optimization method embodiment for injection-molded composite materials also applies to the performance optimization device for injection-molded composite materials in this embodiment, and will not be repeated here.

[0085] According to the performance optimization device for injection-molded composite materials proposed in this application, the device performs multiple injection molding process analyses on the target injection molding analysis object based on preset mold flow process analysis parameters to obtain fiber orientation distribution files and weld line location files. These files are then mapped to its finite element model to calculate the stress distribution and structural stiffness of the composite material structure. Based on the stress distribution, durability damage values ​​are calculated. Combining the preset mold flow process analysis parameters, structural stiffness, and durability damage values, first and second preset relationship curves are generated. The preset mold flow process analysis parameters are adjusted according to the curves to optimize the durability and structural stiffness performance of the target composite material structure. This solves the problem of unstable stiffness and durability performance of short-cut fiber reinforced composite materials during injection molding due to uncertain fiber orientation and weld line location in existing technologies.

[0086] Figure 10 A schematic diagram of the structure of an electronic device provided in an embodiment of this application. The electronic device may include: The memory 1001, the processor 1002, and the computer program stored on the memory 1001 and capable of running on the processor 1002.

[0087] When the processor 1002 executes the program, it implements the performance optimization method for injection-molded composite materials provided in the above embodiments.

[0088] Furthermore, electronic devices also include: Communication interface 1003 is used for communication between memory 1001 and processor 1002.

[0089] The memory 1001 is used to store computer programs that can run on the processor 1002.

[0090] The memory 1001 may include high-speed RAM (Random Access Memory) memory, and may also include non-volatile memory, such as at least one disk storage.

[0091] If the memory 1001, processor 1002, and communication interface 1003 are implemented independently, then the communication interface 1003, memory 1001, and processor 1002 can be interconnected via a bus to complete communication between them. The bus can be an ISA (Industry Standard Architecture) bus, a PCI (Peripheral Component Interconnect) bus, or an EISA (Extended Industry Standard Architecture) bus, etc. The bus can be divided into address bus, data bus, control bus, etc. For ease of representation, Figure 10 The bus is represented by a single thick line, but this does not mean that there is only one bus or one type of bus.

[0092] Optionally, in a specific implementation, if the memory 1001, processor 1002, and communication interface 1003 are integrated on a single chip, then the memory 1001, processor 1002, and communication interface 1003 can communicate with each other through an internal interface.

[0093] The processor 1002 may be a CPU (Central Processing Unit), an ASIC (Application Specific Integrated Circuit), or one or more integrated circuits configured to implement the embodiments of this application.

[0094] This application also provides a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements the above-described method for optimizing the performance of injection-molded composite materials.

[0095] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0096] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0097] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A method for optimizing the performance of injection-molded composite materials, characterized in that, Includes the following steps: Based on preset mold flow process analysis parameters, the target mold flow injection molding analysis object is subjected to multiple mold flow injection molding process analyses in sequence to obtain fiber orientation distribution files and weld line position files corresponding to each mold flow injection molding process analysis process; The fiber orientation distribution file and weld line location file corresponding to each mold flow injection molding process analysis are mapped to the finite element model of the target mold flow injection molding analysis object, and the stress distribution and structural stiffness of the composite material structure of the target mold flow injection molding analysis object are calculated. Based on the stress distribution, the durability damage value of the composite material structure of the target mold flow injection molding analysis object is calculated, and based on the preset mold flow process analysis parameters, the structural stiffness and the durability damage value, a first preset relationship curve and a second preset relationship curve are generated. Based on the first preset relationship curve and the second preset relationship curve, the preset mold flow process analysis parameters are adjusted to optimize the durability and structural stiffness of the composite material structure of the target mold flow injection molding analysis object.

2. The method according to claim 1, characterized in that, The step of mapping the fiber orientation distribution file and weld line location file corresponding to each mold flow injection molding process analysis to the finite element model of the target mold flow injection molding analysis object, and calculating the stress distribution and structural stiffness of the composite material structure of the target mold flow injection molding analysis object, includes: Construct a finite element model of the target mold flow injection molding analysis object, and assign the target composite material properties to the finite element model. The fiber orientation distribution file and weld line location file corresponding to each mold flow injection molding process analysis are sequentially mapped to the finite element model of the target mold flow injection molding analysis object. The structural deformation and stress distribution corresponding to each mold flow injection molding process analysis are calculated, and the structural stiffness is calculated based on the structural deformation.

3. The method according to claim 1, characterized in that, Before performing multiple mold flow injection molding process analyses on the target mold flow injection molding analysis object based on the preset mold flow process analysis parameters, the method further includes: The target mold flow injection molding analysis object is subjected to mesh generation, mesh checking, and mesh repair operations in sequence; Calculate the target gate location of the target mold flow injection molding analysis object, and establish the target gate and target runner based on the target gate location; Select the material to be used for mold flow injection molding process analysis from the first preset composite material database, and determine the preset mold flow process analysis parameters.

4. The method according to claim 1, characterized in that, The preset mold flow process analysis parameters include at least one of injection time, injection pressure, melt temperature, mold temperature, water channel layout, and pressure holding strategy.

5. The method according to claim 4, characterized in that, The first preset relationship curve uses the injection time as the horizontal axis and the structural stiffness as the vertical axis; The second preset relationship curve has the injection time as the horizontal axis and the durability damage value as the vertical axis.

6. A performance optimization device for injection-molded composite materials, characterized in that, include: The analysis module is used to perform multiple mold flow injection molding process analyses on the target mold flow injection molding analysis object based on preset mold flow process analysis parameters, and obtain fiber orientation distribution files and weld line position files corresponding to each mold flow injection molding process analysis process; The calculation module is used to map the fiber orientation distribution file and the weld line position file corresponding to each of the mold flow injection molding process analysis processes to the finite element model of the target mold flow injection molding analysis object, and to calculate the stress distribution and structural stiffness of the composite material structure of the target mold flow injection molding analysis object; The generation module is used to calculate the durability damage value of the composite material structure of the target mold flow injection molding analysis object based on the stress distribution, and generate a first preset relationship curve and a second preset relationship curve based on the preset mold flow process analysis parameters, the structural stiffness and the durability damage value. The adjustment module is used to adjust the preset mold flow process analysis parameters according to the first preset relationship curve and the second preset relationship curve, so as to optimize the durability and structural stiffness of the composite material structure of the target mold flow injection molding analysis object.

7. The apparatus according to claim 6, characterized in that, The computing module is specifically used for: Construct a finite element model of the target mold flow injection molding analysis object, and assign the target composite material properties to the finite element model. The fiber orientation distribution file and weld line location file corresponding to each mold flow injection molding process analysis are sequentially mapped to the finite element model of the target mold flow injection molding analysis object. The structural deformation and stress distribution corresponding to each mold flow injection molding process analysis are calculated, and the structural stiffness is calculated based on the structural deformation.

8. The apparatus according to claim 6, characterized in that, Before performing multiple mold flow injection molding process analyses on the target mold flow injection molding analysis object based on the preset mold flow process analysis parameters, the analysis module is further used for: The target mold flow injection molding analysis object is subjected to mesh generation, mesh checking, and mesh repair operations in sequence; Calculate the target gate location of the target mold flow injection molding analysis object, and establish the target gate and target runner based on the target gate location; Select the material to be used for mold flow injection molding process analysis from the first preset composite material database, and determine the preset mold flow process analysis parameters.

9. An electronic device, characterized in that, include: A memory, a processor, and a computer program stored in the memory and executable on the processor, the processor executing the program to implement the performance optimization method for injection-molded composite materials as described in any one of claims 1-5.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, The program is executed by the processor to implement the performance optimization method for injection-molded composite materials as described in any one of claims 1-5.

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