Crashworthiness Improvement Through Injection Molding Techniques

This white paper discusses the influence of the injection molding process on the mechanical performance of components, particularly in the context of crashworthiness for lightweight and autonomous vehicles. It outlines an integrated process chain that utilizes ANSA pre-processor, CrachFEM for advanced material modeling, and META post-processor to enhance the crashworthiness of injection-molded products. The paper details the importance of micromechanical results from engineering simulations and the challenges of connecting injection molding with structural analysis. Key aspects such as fiber orientation, weld lines, and their impact on material properties are examined. The document also describes the use of a specialized tool for transferring and mapping weld line locations and the CrachFEM material model for short fiber-reinforced thermoplastics. The paper emphasizes the need for accurate simulation results and the role of various software tools in achieving effective optimization during product development.