Virtual Process Design

BASF

BASF Polyurethanes GmbH in Lemförde, Germany, have enhanced their Ultrasim simulation tool considerably. According to company information, it can now provide reliable prediction on the behavior of PU systems during foaming in a closed as well as open mold. The simulation system includes the process of component production into the calculation of component behavior. In order to predict injection, foaming and hardening of the polyurethane, specially tailored material models are available for the PU systems. Their analyses are based on the properties that are typical of these materials: temperature-related course of reaction, in addition to foam structure including the resulting density profile and flow behavior during foaming. This allows for spatially resolved calculation of the foaming process: starting from foam injection to mold filling, up until the final component thickness is achieved. What is more, the filling simulation enables the user to analyze gating position, path of the mixing head and mold alignment, in addition to flow promoters, venting concepts and mold closing times.

If using closed molds, the simulation results can serve to evaluate different gating concepts, so as to prevent, e.g. air entrapments or weld lines. With open molds, the system can optimize the PU system’s injection lines by conducting several virtual runs. The simulation includes added value, in particular, if applied at the early stage of a project, because it reduces the time required for development. In this way, large moldings for car interiors can be produced today from Elastoflex E, a semi-hard PU system. The parts are tailored to the respective requirements.

Hall 5, booth C21 and D21

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