samo gazvoda technical director , tecos slovenia togliatti, russia , 16 th october 2013

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Samo Gazvoda Technical Director, TECOS SloveniaTogliatti, Russia, 16th October 2013

YOUR RELIABLE PARTNER IN DEVELOPMENT OF NEW PRODUCTS, TOOLS AND TECHNOLOGIES

SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Who we are?

Technology center for applied research and development in the fields of toolmaking and production technologies

Established in 1994

17 employees, 1,2 MIO income (2012)

CELJE

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Who we are?

OUR VISION

To become the long-term strategic development partner of production companies in Slovenia and the wider region. Furthermore, to become a renowned European technological centre in the areas of the development of new products, moulds and technologies.

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

What we do?turnkey projects in product development (from concept to real prototype)

design optimisation & reducing of material costs

eliminating trial by error costs

reducing time to market and production start up costs

troubleshooting and problem solving in production

shortening of production cycles

dimensional inspection

3D-scanning and reverse engineering

Slika 13: Meritve vzorca – barvna skala in GD&T (ETI GUM).

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Case Study 1: Engineering SimulationsBearing bush made of fiber reinforced thermoset material

Coupled Moldflow and Abaqus analyses

Filling analysis

Velocity analysis

Fiber orientation

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Case Study 1: Engineering SimulationsResults confirmed by practical experiment

stresses in perpen-dicular direction to fiber orientation

experimental data

stresses in direction of fiber orientation

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Case Study 2: Engineering SimulationsAnalysis and optimisation of warpage of a plastic oil filter housingseveral parameter setups analysed

Material: PA66 Durethan AKV 35 H2.0 Lanxess

Melt temperature: 280 °CMold surface temperature: 80 °CVelocity/pressure switch-over 98 % Injection time: automaticPacking settings: 20 s, 80 % filling pressure (61,23 MPa)

20 s, 60 % filling pressure (45,92 MPa)

10 s, 40 % filling pressure (30,61 MPa)

Cooling time: 60 sMold open time: 5 s

Two cavities have been considered

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Case Study 2: Engineering SimulationsAnalysis and optimisation of warpage of a plastic oil filter housing

Filling analysis

The maximum pressure at the polymer injection locations (at 98 % filled the mold) is 76,53 MPa (765,3 bar). Pressure drop in runner system is 64,1 MPa (641 bar) and in cavity is 13,43 MPa (134,3 bar).

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Case Study 2: Engineering SimulationsAnalysis and optimisation of warpage of a plastic oil filter housing

Roundness analysis

Deviation of selected points

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Case Study 3: Reverse engineering3D scanning and reverse engineering for duplicate stamping dies

3D scanning at customer’s location

Final result – CAD model of top surface

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Case Study 4: 3D scanningDeviation analysis of a stamping die after manual rework

Roundness analysis

Colour deviation plot

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

Case Study 5: Digital mock-upScanning of existing components for virtual assembly of newly designed parts

Camper industry

:: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16th Oct 2013

:: www.tecos.si :: info@tecos.si:: cae@tecos.si

QUESTIONS?samo.gazvoda@tecos.si

+386 31 800 306

Thank you for your attention!