Efficient air technology is indispensable for applications such as data centers, heat pumps, industrial plants and wind turbines. ZIEHL-ABEGG, based in Künzelsau, Germany, develops axial and radial fans in numerous sizes that must operate quietly, energy-efficiently and with a long service life. To reliably meet these high requirements, the company has for several years been consistently relying on simulation-based component development using modern software solutions.
Simulation as an integral part of product development
Many of ZIEHL-ABEGG’s fans are made predominantly of glass fiber–reinforced plastics. Especially for large injection-molded parts with shot weights of up to 20 kilograms, material behavior, fiber orientation, weld lines and warpage play a decisive role. Simulation makes it possible to take these factors into account in a realistic way even before the first mold is built. Flow and structural analyses are directly coupled with results from the injection molding simulation, so that the mechanical properties and dimensional accuracy can be predicted reliably.
Particularly important is the precise representation of the glass fiber orientation, because it has a strong influence on a component’s stiffness and strength. When these orientations are transferred into the structural analysis, anisotropies can be evaluated correctly and critical areas identified. Equally crucial is the location of the weld lines, which becomes visible through simulation and can be specifically controlled so that they are relocated to less highly loaded zones.
Software creates an end-to-end process chain
To implement this approach, ZIEHL-ABEGG uses an integrated system of injection molding and structural simulation. In addition to established injection molding software Cadmould, solutions from PART Engineering are also used, enabling a seamless process chain from the material data set all the way to service life prediction. Material information is captured and prepared with MatScape, then transferred into structural mechanics with Converse, and finally evaluated with respect to load limits using S-Life Plastics.
Faster route to a robust component
By closely interlinking simulation and design, ZIEHL-ABEGG significantly reduces the number of iteration loops. Tool modifications can be carried out in a much more targeted manner because the critical areas are already known in advance. The benefits also become apparent in reverse engineering: injection-molded components from the initial sampling are scanned and compared with the simulation results, allowing the material parameters to be continuously optimized. This steadily improves the prediction quality from project to project, shortens development times and increases the robustness of the components.
Efficiency, sustainability and safety
The use of simulation-supported development offers several advantages for ZIEHL-ABEGG. Fans become lighter because material can be saved in a targeted way; they operate more efficiently because flow geometries are precisely matched to one another and they are safe because critical weak points are identified and eliminated at an early stage. At the same time, energy consumption in manufacturing is reduced because fewer prototypes and less rework are required.
The combination of in-house expertise, modern injection molding simulations and the supplementary software from PART Engineering shows that simulation is far more than just an auxiliary tool. It has become an indispensable part of product development, enabling the high demands placed on modern air technology to be met while saving material, time and energy.
Authors:
Lothar Ernemann, Product Development, ZIEHL-ABEGG SE, Künzelsau, Germany
Sascha Pazour, Sales & CAE Engineer, PART Engineering GmbH, Bergisch Gladbach, Germany
