CAE System│TOYOBO CAE System│ENPLA Department │TOYOBO

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Engineering Plastics

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TOYOBO MC Engineering Plastics CAE (Computer Aided Engineering) supports the design of injection molding products and molds through simulations of the molding process using software developed over many years.

System Overview

Our CAE team has performed analysis for more than 1,000 project proposals over the past 20 years, and we constantly strive to improve our simulation and analysis for molding processes.

We provide high-quality design support through simulation and analysis suited to the characteristics of the highly-reinforced polymer and elastomer material TOYOBO MC's line-up of high quaility products. We are particularly strong in structural studies that make full use of topology optimization, which can help to reduce the man-hours needed in the design phase.

In recent years, we have been developing simulation technologies that focus on the heat dissipation and shock absorption properties of materials from the perspective of promoting CASE(Connectivity, Autonomous, Shared, and Electric) technologies in the automotive industry, both in injection molding applications and beyond.

Global Support

The TOYOBO MC Cloud System allows us to offer safe, secure, and prompt CAE support.Contact your sales representative at any of our locations for services.

Data Management

CAE results are intended as a guideline and are not guaranteed values.
The application examples listed are not intended to guarantee the safety of similar products.

Types of Analysis and Case Studies

Flow Analysis (Injection Molding)

    • ●Predict flow pattern in the mold
    • ●Propose optimal part thickness
    • ●Propose optimal gate location
    • ●Propose mold designs that reduce molding defects
    • ●Automatic calculation of runner optimization

Case Studies Automotive Headlamp Bezel

Warpage Analysis

  • ●Proposal of gate location and part thickness to reduce warpage
  • ●Optimization of rib structure to reduce warpage
  • ●Analysis incorporating the effects of fiber orientation in anisotropic material
  • ●Prediction of Mold shrinkage
  • ●Proposal of mold design to minimize the need for extensive prototyping
Case Studies on Door Mirror Base Bracket
１.Relationship between gate location and glass fiber orientation

２.Relationship between gate location and warpage

Structural Analysis　Large Deformation Analysis

  • ●Prediction of stress and deformation in molded parts
  • ●Design proposal for optimum strength design in molded parts
  • ●Structural design proposals based on impact analysis
  • ●Structural design proposals based on large deformation analysis
  • ●Structural design proposals incorporating anisotropy due to fiber orientation

Case Studies

・Large Deformation Analysis of a CVJ Boot

・Impact analysis of a honeycomb structure

  • Honeycomb Structure Analysis Model

  • Comparison of Deformation Behavior

  • Comparison of Load-Displacement Curves: FEM vs Physical Testing

Vibration Analysis　Eigenvalue Analysis

  • ●Proposal of optimal rib pattern and wall thickness for part design
  • ●Proposal of ideal material for your project
  • ●Multi-component assembly analysis is available
  • ●Analysis that incorporating anisotropy due to fiber orientation
Case Studies

  • Eigenvalue Analysis

    Analysis Model

    Analysis Model

    Eigenvalue Analysis Result

    Eigenvalue Analysis Result

  • Vibration Damping Analysis

    Vibration Damping Analysis

Topology Optimization

  • 3D printers

    • ●Part Design Proposals
    • ●Part design proposals using 3D printers
    • ●Can speed up the development process
    • ●Proposals for weight reduction based on our injection molding experience
Case Study：Topology Optimization

Software Lineup

CAE for Injection Molding

    • ●Flow Analysis
    • ●Pressure and Cooling Analysis
    • ●Fiber Orientation Analysis
    • ●Warpage Analysis
    • Software Lineup
    • Autodesk Moldflow
    • Software developed in-house

CAE for Product Design

    • ●Linear Stress Analysis
    • ●Nonlinear Stress Analysis
    • Software Lineup
    • MSC Marc
    • Ansys LS-DYNA
    • Simulia Abaqus
    • Altair HyperWorks

CAE for Thermoplastic Elastomers

    • ●Large Deformation Stress Analysis
    • ●Contact and Material Nonlinear Analysis
    • ●Impact and Creep Analysis
    • ●Vibration Damping Analysis
    • Software Lineup
    • MSC Marc
    • Simulia Abaqus

CAE for Fiber Reinforced Thermoplastic Resin

    • ●Anisotropic Mechanical Property Prediction
    • ●Anisotropic Linear Stress Analysis
    • ●Anisotropic Vibration Damping Analysis
    • Software Lineup
    • MSC Marc
    • Ansys LS-DYNA
    • Simulia Abaqus
    • Altair HyperWorks

Extrusion Analysis, Blow Molding Analysis

    • ●3D Flow Analysis through extrusion die
    • ●Parison Formation Flow Analysis
    • Software Lineup
    • TEX-FAN
    • Simulia Abaqus
  • MSC Marc is a registered trademark of MSC Software Corporation.
  • Ansys LS-DYNA is a registered trademark of Livermore Software Corporation.
  • Autodesk Moldflow is a registered trademark of Moldflow Corporation, USA.
  • Simulia Abaqus is a registered trademark of Dassault Systèmes.
  • Altair HyperWorks is a registered trademark of Altair Engineering, Inc.

History of TOYOBO MC

Development Progress

  • ●Melt spinning analysis(1960-)
  • ●Melt-blow analysis(1970-)
  • ●Film forming analysis (1975-)
  • ●Injection molding analysis (1980-)
  • ●Elastomer deformation analysis (1985-)

Awards

  • ●Studies on Melt Spinning (1966)
  • Best Paper Award, Society of Textile Machinery Society of Japan
  • Inducted into the University of Akron Hall of Fame (1996)
  • ●Theoretical Analysis of Melt-and Dry-Spinning Processes (1970)
  • Society of Polymer Science Technical Award
  • ●Studies on Melt Spinning
  • Velocity field within the thread (1977)
  • Draw resonance as a limit cycle (1977)
  • Best Paper Award, Society of Textile Machinery Society of Japan
  • ●Elastomer Deformation Analysis (1985-)
  • ●Dynamic Characteristics of New Material Protective Device For Ship Collision (1999)
  • The 15th annual meeting of the Polymer Processing Society POSTER AWARD
  • ●Compressive deformation behavior of polyurethane foam materials (1999)
  • Poster Award, Japan Society of Polymer Processing
  • ●Interfacial Delamination Analysis of Plastic Composites (1999)
  • Poster Award, Japan Society of Polymer Processing
  • ●Deformation Behavior of Thermoplastic Elastomer Molded Products (2000)
  • Dynamic Compression and Deformation Behavior of Honeycomb Shaped Molded Products
  • Poster Award, Japan Society of Polymer Processing
  • ●Deformation Behavior of Thermoplastic Elastomers with Notched Specimens - Observation by Digital Image Correlation Method During Tensile Testing (2014)
  • Poster Award, Japan Society of Polymer Processing
  • ●Deformation Behavior of Molded Thermoplastic Polyester Elastomer ―Compressive Deformation of Molded Honeycomb Structures― (2017)
  • Best Paper Award, Japan Society of Polymer Processing
  • ●Nonlinear Finite Element Analysis for Three-point Bending Behavior of Discontinuous and Randomly-Oriented Chopped Carbon Fiber Tape-Reinforced Thermoplastics (2018)
  • Technology Award, Japan Society of Composite Materials

Total simulation of products from product design through mold design

Contract Analysis Services

TOYOBO MC Corporation also offers contract CAE analysis services (for a fee) for plastic products ranging from flexible elastomers to rigid reinforced thermoplastics.
By applying our proprietary numerical analysis technology for resin flow and deformation behavior of polymer materials such as synthetic fibers and films, we provide highly accurate simulations that are useful in the design of molded products and molds based on our many years of experience. While prediction was difficult in the past, we can now perform CAE analysis on large deformation issues with elastomers and warpage deformation of reinforced resins with a high degree of accuracy.

CAE Features

Our CAE technology consists of a combination of general-market software and customized software.

  1. 1. Stress analysis of elastomers can predict problems such as large deformation and creep deformation by simultaneously considering nonlinear behavior of geometry, materials, and boundary conditions.
  2. 2. Reinforced resin warpage analysis can model the orientation of reinforcing materials in detail and predict molding shrinkage and warpage.
  3. 3. Stress analysis and vibration analysis of reinforced resins can be predicted by considering the anisotropy of the material.
  4. 4. We have our own CAE measuring instruments, evaluation and testing equipment, injection, extrusion, and blow molding machines, and various other testing facilities, allowing us to quickly measure gather material data and conduct verification experiments.

Scope of Services

The following items are available as CAE analysis service items. Prices vary depending on the difficulty of the requested simulation.

  1. 1. CAE Analysis Services for Injection Molding
    • ●Melt flow analysis, pressure-retention cooling analysis, glass fiber orientation analysis, warp deformation analysis
  2. 2. CAE Analysis Services for Product Design
    • ●Linear stress analysis, nonlinear stress analysis
  3. 3. Elastomer Deformation Analysis Services
    • ●Large deformation stress analysis, contact and material nonlinear analysis
    • ●Impact analysis, creep deformation analysis
  4. 4. Analysis Services for Reinforced Resin Molding
    • ●Anisotropic property prediction analysis
    • ●Anisotropic linear stress analysis, anisotropic vibration damping analysis
  5. 5. CAE Analysis Services for Extrusion and Blow Molding
    • ●3D flow analysis through extrusion die
    • ●Parison formation flow analysis

  • Elastomer deformation analysis

  • Injection molding simulation

Contract Analysis Services

This is a contract service that supports the development of resin products from product design through the molding process. We support efficient product development by proposing optimal solutions. We offer solutions with short delivery times by utilizing our global network.

  • Advantages of Incorporating CAE into Product Development

    • ●Proposal of optimal rib pattern and wall thickness for part design
    • ●Proposal of ideal material for your project
    • ●Multi-component assembly analysis is available
    • ●Analysis that incorporating anisotropy due to fiber orientation

    • Example Analysis

    • ●Flow analysis, warpage analysis, deformation stress analysis,Vibration Damping Analysis

Vibration Damping Analysis

Flow Pattern

Flow Pattern

Warpage Analysis Results

Warpage Analysis Results