Digitization

Simulation

Computer-aided simulation offers the potential to optimize the entire development process of plastic products. This means that technical risks relating to process and product can also be identified at a very early stage and subsequent corrections and the necessary number of prototypes can be minimized. In this way, valuable time and costs can be saved with the help of simulations. Our state-of-the-art laboratories also have numerous options for determining material parameters specifically for your simulation.

Whether process or structural simulations, SKZ is happy to support you as a reliable partner in:

  • Filling, shrinkage and warpage analysis
  • Optimization of your component geometry, the gating system and mold temperature control
  • Plastic-compatible component design
  • Strength verification
  • Material data determination for process and structure simulation

We are looking forward to your requirements.

Dipl.-Ing. Thomas Zentgraf
Injection Moulding and Additive Manufacturing
+49 931 4104-232
t.zentgraf@skz.de

Services

Design of injection molds

Rheological design

  • Investigation of fillability
  • Determination of weld lines and air inclusions
  • Optimization of the gate position and the gating system
  • Calculation of fiber orientation
  • Prediction of shrinkage and warpage 
  • Determination of the main causes of calculated warpage

Thermal design

  • Optimization of the tempering system
  • Simulation of the influence of different mold materials

Contact:
Thomas Zentgraf | +49 931 4104-232 | t.zentgraf@skz.de

Simulation of special processes
  • Calculation of 2K components
  • Overmolding of inserts
  • Cascade injection molding

Contact:
Thomas Zentgraf | +49 931 4104-232 | t.zentgraf@skz.de

Structure simulation
  • Deformation and strength analyses
  • Calculation of long-term behavior and fatigue strength verification
  • Calculation of mechanical and material connections
  • Notch stress analyses
  • Thermal analyses
  • Determination of material properties
  • Calibration and validation of material models

Contact:
Malte Nebel | +49 931 4104-133 | m.nebel@skz.de

Integrative simulation
  • Consideration of local process-related influences
  • Calculation of fiber reinforced plastics

Contact:
Malte Nebel | +49 931 4104-133 | m.nebel@skz.de

Simulation-based design of compounding and extrusion processes
  • Calculation of planetary roller extruders and co-kneaders
  • Optimization of process parameters and plant setup
  • Possibility of experimental validation on SKZ equipment

Contact:
Johannes Rudloff | +49 931 4104-528 | j.rudloff@skz.de

Simulation of welding processes
  • Modeling and simulation of joining processes for the targeted development
    of material and process parameters to achieve specific joining seam properties.
  • Associated correlation of parameters, processing conditions and the resulting product properties 

Contact:
Dr. Eduard Kraus | +49 931 4104-480 | e.kraus@skz.de

Material data determination for the simulation
  • Temperature and shear rate dependent viscosity
  • Thermal characteristics (e.g. thermal conductivity, specific heat capacity, coefficient of linear thermal expansion)
  • PVT data
  • Mechanical properties (e.g. modulus of elasticity, creep modulus, Poisson's ratio, stress and strain at break)

Technical equipment

Software solutions

Injection molding simulation

Autodesk Moldflow Insight is available to us for injection molding simulation for the calculation of complex components and tools. The material database includes more than 10,000 materials (thermoplastics, thermosets, elastomers).

With Moldex3D Professional we also have a powerful solution for the design and optimization of your injection molding process. With one of the leading 3D CAE software solutions, we offer a deep analytical view into the interior of the component and mold.

1D simulation of special extruders

1D simulation of special extruders with software solutions specially developed by SKZ. Depending on material data and process parameters, important process variables such as pressure, filling level, residence time or degree of melting can be determined via a parameterized description of the extruder geometry.

Structure simulation

Ansys Mechanical offers numerous possibilities at the component level. Among other things, we perform deformation and strength analyses, evaluate fatigue and long-term behavior, and calculate mechanical and material connections.

Contact:
Kurt Engelsing | +49 931 4104-147 | k.engelsing@skz.de

To the area component properties

Integrative simulation

Converse builds a bridge between process and structural simulation. This means that a tool for integrative simulation is also available at SKZ. In this way, local influences (e.g. weld lines) or anisotropic material behavior in short-fiber-reinforced plastics can also be taken into account in the structure simulation.

Testing equipment

PVT-Data

For the characterization of the specific volume as a function of pressure and temperature, the following device is available in the laboratory at SKZ:

  • Rheograph 20 (Fa. GÖTTFERT Werkstoff-Prüfmaschinen GmbH; high-pressure capillary rheometer).
     
Specific heat capacity

The determination of the specific heat capacity for different temperatures is carried out at SKZ with the differential thermal analysis DSC:

  • DSC 204 F1 Phoenix (Netzsch Gerätebau GmbH)
     
Mechanical parameters

At SKZ, we have extensive testing facilities for determining mechanical parameters. These cover short-term and long-term loads under static or dynamic stress - and all this over a wide temperature and force range. Excerpt from our testing capabilities:

  • Numerous universal testing machines for the determination of stress-strain curves incl. transverse contraction / Poisson's ratio
  • Creep apparatus for the determination of creep deformations and creep rupture strengths
  • Fatigue testing machines for the determination of fatigue behavior 
  • Locally resolved 3D deformation measurement on mechanically loaded components (gray value correlation, Aramis)
     
Temperature and thermal conductivity

For the determination of the temperature-dependent thermal conductivity, the SKZ is equipped as follows:

  • Light flash apparatus LFA447 NanoFlash (Netzsch Gerätebau GmbH)
     
Viscosity

For the determination of the temperature and shear rate dependent viscosity the following devices are available at the SKZ:

  • Rheograph 6000 (GÖTTFERT Werkstoff-Prüfmaschinen GmbH; high-pressure capillary rheometer)
  • Rheograph 20 (GÖTTFERT Werkstoff-Prüfmaschinen GmbH; high pressure capillary rheometer)
  • Haake Mars (Thermo FisherScientific Inc.; rotational rheometer)
  • Kinexus (Malvern, rotational rheometer)
     

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