1. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th Oct 2013 :: www.tecos.si :: info@tecos.si :: cae@tecos.si Samo Gazvoda Technical Director, TECOS Slovenia Togliatti, Russia, 16 th October 2013 YOUR RELIABLE PARTNER IN DEVELOPMENT OF NEW PRODUCTS, TOOLS AND TECHNOLOGIES SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING

2. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th 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

3. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th 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.

4. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th 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

5. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th Oct 2013 :: www.tecos.si :: info@tecos.si :: cae@tecos.si Case Study 1: Engineering Simulations  Bearing bush made of fiber reinforced thermoset material  Coupled Moldflow and Abaqus analyses Filling analysis Velocity analysis Fiber orientation

6. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th Oct 2013 :: www.tecos.si :: info@tecos.si :: cae@tecos.si Case Study 1: Engineering Simulations  Results confirmed by practical experiment stresses in perpen- dicular direction to fiber orientation experimental data stresses in direction of fiber orientation

7. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th Oct 2013 :: www.tecos.si :: info@tecos.si :: cae@tecos.si Case Study 2: Engineering Simulations  Analysis and optimisation of warpage of a plastic oil filter housing  several parameter setups analysed Material:PA66 Durethan AKV 35 H2.0 Lanxess Melt temperature: 280 °C Mold surface temperature:80 °C Velocity/pressure switch-over98 % Injection time:automatic Packing 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 s Mold open time:5 s Two cavities have been considered

8. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th Oct 2013 :: www.tecos.si :: info@tecos.si :: cae@tecos.si Case Study 2: Engineering Simulations  Analysis 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).

9. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th Oct 2013 :: www.tecos.si :: info@tecos.si :: cae@tecos.si Case Study 2: Engineering Simulations  Analysis and optimisation of warpage of a plastic oil filter housing Roundness analysis Deviation of selected points

10. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th Oct 2013 :: www.tecos.si :: info@tecos.si :: cae@tecos.si Case Study 3: Reverse engineering  3D scanning and reverse engineering for duplicate stamping dies 3D scanning at customer’s location Final result – CAD model of top surface

11. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th Oct 2013 :: www.tecos.si :: info@tecos.si :: cae@tecos.si Case Study 4: 3D scanning  Deviation analysis of a stamping die after manual rework Roundness analysis Colour deviation plot

12. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th Oct 2013 :: www.tecos.si :: info@tecos.si :: cae@tecos.si Case Study 5: Digital mock-up  Scanning of existing components for virtual assembly of newly designed parts Camper industry

13. :: SOME CASE STUDIES FROM AUTOMOTIVE ENGINEERING :: Samo Gazvoda, TECOS, Togliatti, 16 th 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!