Deformation of the AL insert

[sklar]

Hello everyone
I have a question for you to think about please. Will Moldflow help us find out if the aluminum insert (thickness 0.5mm) will be deformed by sink marks on the part? The aluminum insert is overmolded on its entire underside.
I plan to calculate the simulation with the insert and check the deformations, but I don't know if it will be sufficient to answer the question.

Thank you

[bernor_mf]

@sklar 

Hi,
first, I have not conducted such an investigation of thin foil as part insert and sink deformation.

I believe it could be possible though, as you describe in your workflow.

You really need fine 3D tetra mesh in the rib region to capture the effect volumetric shrinkage has in the region for the warp solver to capture deflection.
(Sink mark plot only a reference, the deflection plot to be used.)
The mesh needs to be able to deform as sink mark.
As foil and plastic sticks in simulation, the deflection result could be exaggerated to see if the foil bends with volumetric shrinkage or is stiff enough to withstand the shrinkage.

So I think the approach you suggest could work.

A first step is to look for worst case region, and refine mesh in that region, for faster solution turn around.

Hope this helps somewhat.

Regards,
Berndt