Resin Molded Article Warpage Analysis Using Topology Optimization
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Solution Overview
Problem
Current methods for analyzing and mitigating warpage in resin molded articles are time-consuming and costly, requiring labor-intensive region division and optimization, with limited precision and reliance on engineer perception for determining effective countermeasures.
Innovation Solution
A deformation state analysis method using topology optimization, dividing the resin molded article into minute regions and optimizing a target function under constraint conditions to minimize rigidity, with a contribution ratio-based approach to identify and address deformation-causing areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional warpage analysis methods are used with detailed element division and optimization calculation, then analysis precision is improved, but analysis execution time and calculation cost are greatly increased
Solution Approach 1:
The patent segments the warpage analysis problem into two distinct phases: (1) a preliminary analysis phase using a coarse mesh model to identify the general warpage trend and critical regions, and (2) a detailed analysis phase using a fine mesh model only in the identified critical regions. This segmentation allows the system to achieve high precision where needed while minimizing overall calculation time and cost.
Solution Approach 2:
Instead of performing detailed fine-mesh analysis across the entire molded article, the patent applies partial action by concentrating computational resources only on the critical regions identified in the preliminary phase. This partial analysis approach achieves the necessary precision for warpage prediction while dramatically reducing the total number of elements and calculation time required.
2Measurement precision
If traditional warpage analysis methods are used with detailed element division and optimization calculation, then analysis precision is improved, but calculation cost is greatly increased
Solution Approach 1:
The patent segments the warpage analysis problem into two distinct phases: (1) a preliminary analysis phase using a coarse mesh model to identify the general warpage trend and critical regions, and (2) a detailed analysis phase using a fine mesh model only in the identified critical regions. This segmentation allows the system to achieve high precision where needed while minimizing overall calculation time and cost.
Solution Approach 2:
Instead of performing detailed fine-mesh analysis across the entire molded article, the patent applies partial action by concentrating computational resources only on the critical regions identified in the preliminary phase. This partial analysis approach achieves the necessary precision for warpage prediction while dramatically reducing the total number of elements and calculation time required.
3Manufacturing precision
If region division and parameter optimization are performed for warpage analysis, then warpage prediction capability is improved, but designing period is extended
Solution Approach 1:
The patent performs preliminary action by conducting a coarse-mesh warpage analysis early in the design process to identify critical regions and general warpage trends before detailed design optimization begins. This preliminary identification of problem areas allows subsequent detailed analysis to be focused only where necessary, significantly reducing the overall design period while maintaining accurate warpage prediction capability.
4Measurement precision
If more detailed set regions are used for optimization calculation, then warpage analysis precision is improved, but labor and time required for division are greatly increased
Solution Approach 1:
The patent applies self-service by implementing an automated workflow where the preliminary coarse-mesh analysis automatically identifies critical regions and generates the basis for subsequent detailed mesh generation in those specific areas. This automation eliminates the need for manual region division and reduces the complexity of mesh generation, allowing detailed precision analysis to be achieved with minimal human intervention and effort.
Data Source
AI summary
There is provided an analysis method whereby, when a proposed plan for deforming a resin molded article is created, it is possible to create a more effective proposed plan in a short time. In an deformation state analysis method of analyzing, for a resin molded article to be deformed, a deformation state of the resin molded article by optimizing an objective function under a prescribed restraint condition and a prescribed limiting condition, using a topology optimization method dividing the resin molded article into micro regions, the restraint condition is a trend of the amount of deformation of the resin molded article, the prescribed limiting condition is a contribution rate expressing an extent to which deformation of each micro region contributes to deformation of the resin molded article, and in the optimization of the objective function optimization is performed so as to minimize rigidity of the resin molded article.