advanced design against fatigue seminar – china 2014...
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Unrestricted © Siemens AG 2014 All rights reserved. Smarter decisions, better products.
New materials - Composites – Damage and Fatigue
Advanced Design against Fatigue Seminar – China 2014
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Siemens Industry Software Dedication to the “Future of Light Weight Vehicle Engineering”
Continuing to Invest in Leading Technologies Bringing intelligence to the entire lightweight vehicle development & production process
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Huge improvements to fuel economy required by 2025!
Past: ~0.5 mpg per year
Future: ~2.0 mpg per year
4X CURRENT RATE
Time to act is NOW!
Fuel Economy & Emissions Reductions Are Driving Innovation To New Levels
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And the Survey Says… Expect Big Changes For Automotive
TOP PRESSURES DRIVING CHANGE
Automotive companies
report fuel efficiency and emissions regulations are the # 1 pressure
THE SOLUTION: NEW MATERIALS
New material strategies
show results of producing vehicles at least 40% lighter
January, 2014, Aberdeen Group, Inc.
TIME IS RUNNING OUT
Automotive companies
respond by planning lightweighting strategies
now!
Recognize lightweighting as a top strategy to meet impending regulations
Identify reducing vehicle weight as the top challenge for meeting fuel efficiency and emission standards
Have or will develop new material strategies
Plan to use mixed materials, including composites, to produce lightweight vehicles
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Mixed Material Lightweighting Bringing the Biggest Changes in 50+ Years
Vehicle Packaging
Part Manufacturing
Factory Design
Supply Chain
Repair Process Safety (Crash)
Strength & Durability
Noise, Vibration, Harshness (NVH)
Fundamental Changes to How Vehicles are Designed and Built
Joining Methods
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Biggest Change in 50+ Years Fundamental changes to how cars are designed and built
Rethinking the way vehicles are engineered and manufactured
New generation of vehicles cannot be built from past 50+ years of steel-focused experience
Adoption of engineering software will accelerate creation of needed expertise
Fuel Efficiency and Emissions Regulations
Utilization of new materials and joining technologies
New application experience required
RESPONSE IMPACT SOLUTION
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Analysis & Simulation
Accurate data for FEA composites models!
Maximized Strength & Durability performance!
Best-in-class NVH & Acoustics performance!
Integrated simulation & test based engineering!
Balanced multi attribute integration!
Concurrent Engineering
Key Challenges of Innovative Composites Engineering
Design & Manufacturing
Must design producible composite parts!
Need to design the composite material!
Requires a predictive manufacturing simulation!
Close the loop from manufacturing to design!
Enable a seamless link to the manufacturing floor!
Rapid materials & process selection!
A flexible optimization process!
Faster & frequent design & analysis iterations!
Include early cost estimation!
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New mixed material cars must satisfy stringent competitive cost and time to market criteria
The automotive industry must drastically rethink the way vehicles are engineered and manufactured
New lighter cars must meet the consumer demand for differentiated branding and better performance
Environmental challenges and world urbanization are forcing a new level of lighter car innovation
Market Pressures Driving Automotive Lightweighting and Mixed Material Engineering
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Semi-load carrying Components Non-Laminated Composites – Short/Long Fibre
Non-Load Carrying components Wheel rims, bumpers, radiator parts, …
Chopped Fibre - Short Fibre – Long Fibre Glass/metal fibre
In production
Manufacturing method has
implications on material
properties
Production method : Resin Injection Molding
Non-laminated composites
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Structural Load Carrying Components Laminated Composites
Load Carrying components Body, leaf springs,…
In development/production
Continuous fibers Glass-Carbon fibre UD NCF Woven
Multi-axial plies Non Crimp Fabric Woven fabric
Production method : resin infusion molding, prepreg autoclave, …
Uni-Directional plies
Manufacturing method has
implications on material
properties
Laminated or layered composites
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Load-Carrying Axi-symmetric components
Structural Load Carrying Components Filament wound composites
Continuous fibers
Drive shafts, gas tanks,..
In development / production
Production method : Filament winding – resin injection
Manufacturing method has
implications on material
properties
Filament wound composites
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Optimized Lightweight Car
Light-weighting Triggers Most Fundamental Change in Vehicle Engineering in 50+ Years
Performance Validation
Production CAD
Laminate definition
Composite Models
Structural Design Analysis
Composite Design Analysis
New Materials
Going Mainstream
Damage Durability NVH
Manufacturing Dataset
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Composites Part Design Innovation
Challenge Designing composites with short time to market and design cycle that emphasizes weight and cost reduction Solution CAD integrated laminate model definition Benefits • Automate design definition and change by
efficiently and accurately capturing the laminate definition “the way designers think”
• Make design changes transparent, increase change cycle speed
• Facilitate rapid communication of detailed design data to suppliers
• Support open, multi platform hybrid IT environment: NX, CATIA, Creo
Multi-ply laminate definition
Car body in carbon fiber composites
Laminate A Laminate A+B Laminate A+B+C
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Upfront Manufacturing Producibility Assessment
Challenge Reducing production cost and reliance on prototypes Solution Accurate simulation of part producibility for high volume automotive processes such as forming Benefits • Identify issues related to manufacturing
process and material to speed transfer of designs to manufacturing
• Eliminate need for prototypes with accurate process simulation and design tools
Accurate producibility assessment for high volume automotive processes such as forming
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Developing thermo-mechanical insight for curing and crystallization processes
Challenge • Residual stresses and shape distortion are
induced by the manufacturing process • Design first-time-right tooling and
determine correct process parameters for manufacturing of composites
Solution Simulation and design technologies supporting higher insight of crystallization and curing processes Benefits • Time and cost saving for the tooling
definition by using simulation • Tune the curing process parameters and
the mold shape on a real part • Accurate analysis of the influence of these
effects on the mechanical behavior of the composite part and the tolerance for assembly
Technology transfer from aviation to automobile industry
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Concurrent Design and CAE
Challenge Reducing design and analysis cycle time to enable faster optimization and increased part performance Solution Bi-directional interface between design and analysis Benefits • Speed analysis-to-analysis optimization
loop and shortens design cycle time by over 50%
• Improve quality and accuracy of analysis models
• Support open bi-directional data exchange with major pre/post processors used in automotive industry
As-manufactured fabric properties
Validated ply layup
Complete laminate
definition with as-built fiber orientations
Strength, NVH, Acoustics,
Durability, thermal analysis
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Complete CAE Modeling and Performance Analysis for Composites
Ply and Zone Meshing Assembly Modeling & Meshing
Composites Design Optimization Access to Internal & External FE Solvers
Static Dynamic Thermal
NVH Acoustic Durability
Crash
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Multi-attribute Structural Performance Validation and Optimization
Strength
Stiffness Degradation under cyclic loading
Durability
Progressive damage for intra-laminar & inter-laminar and coupling
Classic Failure Analysis
Vibro-acoustics
Lightweight composite affects NVH
Core Composite Modeling Manufacturing
Process Technology
Partners
Long and short fiber
manufacturing
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NX Laminates: laminate modeler, draping (UD) , link to Fibersim
Composite volumes, solid shells, Mindlin and heterosis shells and membranes multilayer elements
Introduction of cohesive elements through the Layup Modeler for delamination
Ply damage and delamination damage material models & non-local behaviour (coupling of inter- & intra-laminate damage)
Various constraints, loads, contacts available
Post-processing: ply-level stress/strains, failure criteria, damage propagation
Advanced Pre- & Post-processing capabilities for composite analysis
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Using Damage Tolerant Design for Maximized Weight Reduction
Challenge Enable maximum weight reduction using a damage tolerant composite design approach Solution Simulation and design guidelines developed through in-depth understanding of composite failure modes Benefits • Reliable parameter identification of
damage material models enabled by coupon testing protocols
• Accurate damage modeling including delamination
• Accurate progressive damage prediction including intra-laminar & inter-laminar behavior
Fiber breaking Matrix cracking
Delamination
Decohesion fibre/matrix
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Accurate structural optimization
Challenge • Avoid overdesign and propose solutions of
minimum weight • Determine the best location of the plies in
the structure • Propose solutions satisfying the classical
design rules and the manufacturing constraints
Solution Best-in-class structural optimization solution of composite structures Benefits • Determine the optimal stacking sequence
in each region • Control the buckling load and the post-
buckling behavior with optimization • Detect automatically the zones that require
a reinforcement thanks to topology optimization
Optimal stacking sequence table
Optimal fiber orientation in composite plies
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Page 22 Siemens PLM Software
Fatigue of Short Fibre Composites Ensure reliable connections
Background: Composites replace aluminium for load-carrying parts Production process (e.g. injection molding) leads
to locally statistically distributed fibers
Customer challenge Today: lot of extra testing
LMS Solution: Accurate fatigue analysis using local material behavior Interface to manufacturing simulation
Customer benefit:
Less testing Fully exploit weight reduction potential,
through more accurate simulation
S
N
( )S N
Fiber orientations
Fatigue results
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Fiber Orientations in Injection Molded Short-Fiber-Reinforced Components
[BASF] [DKI]
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Problem - Mesh Topology
Fig. 24
Converse IM solver mechanical solver
shell (mid-plane/surface) => shell (tria, quad)
shell (mid-plane/surface) => solid (tet, hex)
solid => solid (tet, hex)
unequal meshes
possible
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Fibre Orientation
Fig. 25
Solution Orientation mapping (Converse, DIGIMAT)
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Optimizing Durability Performance Short Fibre Composite Structures
Manufacturing Simulation
Injection Mold Modeling
Material Behavior
S
N
( )S N
Local Anisotropic effects
- Fiber Orientation Tensors
Enabling an efficient SN-based durability assessment based on minimal set of coupon testing
Efficient Durability Prediction
Durability
Stress Analysis
Structural performance behaviour determined by
local short fiber orientation and material behaviour
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Page 27 Siemens PLM Software Fig. 27
Step by step
Simulate manufacturing
process
Results (on very fine mesh):
• Orientation • Length • Residual
stresses
Mapping of FE mesh
Results
• Local stiffness
• Local fatigue behavior
FE Analysis
Virtual.Lab Fatigue analysis
3rd party tools
3rd party tool
Open to any solver
Moldflow Cadmould Sigma Moldex
Converse DIGIMAT
LMS Virtual .Lab
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Fatigue of Short Fibre Composites New developments – Master SN curve approach
• Problem: How to achieve the progressive damage • Solution: Main damaging effect – Fiber – matrix
debonding • Observation: Part of inclusion affected by debonding
carries reduced load • Hypothesis: Elastic modulus of inclusion is reduced
as a function of projected length of debonded surface.
• Validation: Debonded inclusion is modeled in FE and equivalent inclusion is modeled by Mori-Tanaka formulation- Good match was observed
Increasing zone of debonding Propagating from
tip to center
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Fatigue of Short Fibre Composites Step forward to interface to manufacturing simulation
Only 1 measured SN-curve needed. Extrapolation for different fiber orientations
done in LMS Virtual.Lab Durability Key benefit: fewer, cheaper tests
Rev12: Test based interpolation Interpolation approach by open interface and 3rd party solution (MSC.DIGIMAT)
Durability SN-curves for 2, 3 or even more fiber orientations needed
Coupons need to be orientated in specific directions expensive testing!!
Rev13: Master SN-curve Approach implemented by LMS with interfacing with technology partner
SN Curves Easier to characterize
material
More accurate results
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Best steps to better composite design
Siemens PLM Software combines the knowledge from more than 30 years of composite design with automotive applications and fatigue analysis. Engagement model:
Test set up
Material Characterization
FE Composite Modelling
Assistance for best test design and set-
up
• Workshops • Cookbooks
• Characterize Material • Workshops • Tools based on standard software
• Lead through process • User defined damage models
Lead through material
characterization
Enable fatigue calculation
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Fatigue of continuous fiber composites Advantage and challenge
Composites typically show good fatigue behavior (meaning components withstand many load cycles) But: Fatigue onset is very early in the load cycle and may be leading to macroscopic stiffness changes Therefore: Designing for fatigue vs. no damage at all means: • Benefit from good fatigue behavior • Extra weight reduction
Light weight advantage Unidirection
al ply Multi-axial plies NCF
Woven fabric
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Need to model local stiffness changes
Explore Light weight advantage
Typical stiffness degradation curve – Long stable fatigue life in stage 2
Continuum Damage Mechanics framework with damage growth rate equation dD/dN
Process can use any energy based or micro-structural based curves
𝜕𝜕𝑑𝑑𝐼𝐼𝜕𝜕𝜕𝜕 = 𝑐𝑐1 ∙ Σ𝐼𝐼 ∙ 𝑒𝑒
−𝑐𝑐2𝑑𝑑𝐼𝐼Σ𝐼𝐼 + 𝑐𝑐3 ∙ 𝑑𝑑𝐼𝐼 ∙ Σ𝐼𝐼2 1 + 𝑒𝑒 𝑐𝑐5 Σ𝐼𝐼−𝑐𝑐4
(W.V.Paepegem, 2001)
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trade of
Progressive damage approach as state of the art + Correct global behavior
+ Stiffness degradation
+ Stress redistribution
+ Cross influence of damages / Multi – axiality
+ Material data gives insight in damage stages and is less scattering
− Slow
− Efficient implementation for simple block loads only
SN-Curve approach
+ efficient
+ complex load scenarios
+ leverage knowledge for metals
− No stiffness degradation
− No stress redistribution
− No cross influence of damages / multiaxiality
− Measured data (SN-curves) depend on lay-up
Comparison of state-of-the-art SN-curve & Progressive Damage Approaches
Efficiency Accuracy
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Accurate AND
efficient
LMS unique solution – based on approved methods
Proven cycle jump algorithm • Tests and calculation on ply level • Allows lay-up optimization • No new tests for variable amplitude • Stiffness degradation and stress
redistribution Proven hysteresis operator approach • Only approach to cover continuous loss in
stiffness and fatigue resistance in an efficient way (efficiency comparable to SN-curve approach)
Allows simulation of full structures – avoids the need of testing each variant
Brokate, M; Dressler, K; Krejci, P: Rainflow counting and energy dissipation in elastoplasticity, Eur. J. Mech. A/Solids 15, . 705-737, 1996
Nagode, M., Hack, M. & Fajida, M. “High cycle thermo-mechanical fatigue: Damage operator approach”, Fatigue Fract Engng Mater Struct 32(6), 505-514, Wiley & Son, 2009
Nagode, M., Hack, M. & Fajida, M., “Low cycle thermo-mechanical fatigue: Damage operator approach”, Fatigue Fract Engng Mater Struct 33(3), 149-160, Wiley & Son, 2010
Nagode, M. & Hack, M.: “The damage operator approach, creep fatigue and visco-plastic modeling in thermo-mechanical fatigue”, SAE International Journal of Materials & Manufacturing, 4(1), 632-637. doi:10.4271/2011-01-0485, 2011.
Van Paepegem, W ; Degrieck, J; “Fatigue Degradation modelling of plain woven glass/epoxy composites”, Composites: Part A 32:1433-1441, 2001
Van Paepegem, W.; “Development and finite element implementation of a damage model for fatigue of fiber reinforced polymers” Ph. D. thesis, Department of Material Science and Engineering, Ghent university, 2002.
Xu, J., Lomov, S.V., Verpoest, I. Daggumati, I., Paepegem, W. Van and Degrieck. J., “Meso-scale modeling of static and fatigue damage in woven composite materials with finite element method.” presented in 17th International Conference on Composite Materials (ICCM-17). 2009. Edinburgh: IOM Communications Ltd.
Xu, J; “Meso Finite Element Fatigue Modelling of Textile Composites” Ph. D. thesis, Dept MTM, Katholieke Universiteit Leuven, Belgium, 2011
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Simulate the fatigue damage due to variable amplitude loading whereby progressive stiffness degradation is considered - Solution
Improve the cycle jump with variable amplitude analysis: Problem: Changing fatigue stiffness and fatigue resistance during analysis • Solution: Fatigue damage accumulation
based on the hysteresis damage operator approach.
• Only approach to cover continuous loss in stiffness and fatigue resistance in an efficient way (efficiency comparable to SN-curve approach)
Proven approach for non-linear damage accumulation in thermal fatigue applications
New approach + Correct global behavior
+ Stiffness degradation
+ Stress redistribution
+ Cross influence of damages / Multi - axiality
+ No re-testing for new lay-ups
+ Material data gives insight in damage stages and has less scattering
+ Sufficiently efficient
+ Complex load scenarios
+ Leverage knowledge for metals
Efficiency Accuracy Com-bine
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Increased Durability Based on Progressive Stiffness Degradation Modeling
Fatigue behaviour of Metals & Composites
Exploit full advantage of the gradual stiffness
degradation characteristics of composite in design
Include dynamic loading in the design process
Complex cyclic loading scenarios
FE Composite Modelling
Technology for composite durability evaluation based on progressive stiffness degradation model
Fiber orientation & Ply stacking
Efficiency Accuracy
Fatigue material properties at ply level
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Page 37 Siemens PLM Software
Best steps to better composite design
Siemens PLM Software combines the knowledge from more than 30 years of composite design with automotive applications and fatigue analysis. Engagement model:
Test set up
Material Characterization
FE Composite Modelling
Assistance for best test design and set-
up
• Workshops • Cookbooks
• Characterize Material • Workshops • Tools based on standard software
• Lead through process • User defined damage models
Lead through material
characterization
Enable fatigue calculation
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Page 38 Siemens PLM Software
Challenge Reducing production costs and increasing automation
Solution Automated transfer of detailed design data to the manufacturing floor
Benefits • Fast and accurate generation of digital manufacturing data • Reduce time to create manufacturing technical documentation • Eliminate composite material scrap by up to 90%
Seamless Link from Design Model to Manufacturing
Composite Part Model
Pick/Place Cutting Forming Injection Fiber placement Offset surface (tooling)
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Delivering Unique Value across the Mixed Material Product Development Process
Materials Geometry Manufacturing Process Testing
Coupon
Component
Subsystem
Vehicle
Validation of material models
Model validation on components and joint technology
Validation of complex subsystem modeling
Expertise build-up full vehicle simulation/sign-off
“MacroModelMat” (M3) - Macro-level predictive modeling, design & optimization of advanced lightweight material systems
http://www.sim-flanders.be/
Targeted breakthroughs and progress beyond the state of the art: Develop efficient predictive modeling for macro-level quasi-static, fatigue, crush, crashworthiness. Linking meso-level damage analysis to macro-level damage analysis Macro-scale composites modeling for UD, NCF & textile composites Modeling effect of imperfections (from manufacturing or pre-damage) in textile & NCF composites Development of suitable CAE models for joining technologies for novel and advanced materials
Basic mechanical properties simulation of AM components with CAE (stiffness, strength & NVH). Develop fast simulation strategies for vibro-acoustic analysis of lightweight material systems Virtual material characterization for multi-attribute model parameters of composites & LW materials. Develop a new hybrid joining. Assess feasibility of ‘bonding/debonding on demand’.
IBO2 M3Strength
SIM-Flanders M3 Research Program Overview of all Research Projects
SBO1 M3Strength Efficient predictive modeling for
composites strength [static, dynamic (fatigue) &
high speed (crash-crush) strength]
IBO3 M3NVH Design and analysis of the
NVH behavior of
lightweight panel and material systems
using advanced CAE tools Multi-scale / multi-level modeling:
linking meso-level to macro-level analysis
IBO6 M3AdvStrength&Crash Advanced Strength & Crash modeling
Incl. Modeling imperfections (initial from production, after pre-damage event, or by design)
SBO2 M3VirtTesting Virtual Multi-attribute Material characterization / Testing
IBO1 M3AMCAE
Basic mechanical properties
simulation of AM LW materials
through CAE
IBO4 M3HyBond Development of suitable CAE models for joining technologies for novel
and advanced materials + Innovative hybrid bonding technologies
IBO5 M3META-MAT&NVH Development of resonant META materials
produced with AM + Advanced NVH modeling
SBO: Basic Research Projects IBO or ICON: Industrial Research Projects
A strong M3 consortium has been assembled
Consortium: multiple teams from 3 academic research institutions partners (KULeuven, UGent and VUB), 1 automotive knowledge research center (Flanders’Drive), and 10 industrial partners of which 4 SMEs. KU Leuven:
Department of Metallurgy and Materials Engineering (MTM) Department of Mechanical Engineering, Division Production Engineering, Machine Design and Automation (PMA)
University of Ghent (UGent): Department of Materials Science and Engineering, Mechanics of Materials and Structures (MMS) Research Group Department of Information Technology (INTEC)
Vrije Universiteit Brussel (VUB): Department of Mechanics of Materials and Constructions (MeMC) Department of Mechanical Engineering (MECH) Department of Materials and Chemistry (MACH)
Flanders’ Drive and other companies included via Flanders’ Drive: Alfatex (Joining) – SME DEJOND (Joining) – SME
Siemens Industry Software NV (LMS) – Coordinator for M3 Program. Materialise Automotive sector: • HONDA
Nitto Toyota Europe - TME
Aero sector: SABCA Limburg
Other sectors: recreation Lazer Sports – SME
SME: 3D Weaving
43
A roadmap for Addressing the Automotive attribute challenges in composite development
Together with University Technology Partners
Virtual material Characterization via advanced meso-level micromechanics modeling
Multi-attribute characterization and performance predictions
Outlook: Multi-scale modeling for “as manufactured” properties Pre-forming simulations:
draping, fiber placement,…
kinematic (e.g.
fishnet)
FE (more physics)
Flow, curing & distortion
RTM, Injection molding, spring-
back,…
Experimental/numerical identification
Manufacturing imperfections/defects: fiber waviness, buckling/wrinkling/kinking, misalignments, gaps/voids, porosity
Predicted fiber waviness
Voids
Meso-scale modeling Macro-level performance predictions
Stiffness strength damage
Mapping
Shear angles,…
Dry fabric mechanics
sensitivities Research umbrella:
M3 > 20 PhD
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Example: Magna Exteriors & Interiors Structural Applications
Tubs
Load Floors
Plastic-Metal Hybrids & RIW Carriers
Thermoplastic Liftgates
Business challenge • Light weight parts to reduce overall vehicle energy use • Deliver same attribute and function at lower mass • Commercialize high volume composite parts and structures
Keys to success • Integrated Fibersim design and analysis environment • Excellent results with static linear predictions • Rapid initial baseline model facilitating ease of adjustment
between CAE model and design files • Development of complex geometry parts and models
Results • Accurate representation and analysis of laminate formability
and drapability • Accelerate exchange of fiber laminate data with CAE tools • Moving forward with first ply failure prediction and efforts to
model the non-linear behavior and relation to the FPF • Achieved flat plate plaque correlation, and 3d geometry studies • Yields a refined laminate model for structural evaluations
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Business Challenges • Weight saving requirements instigate adoption of lightweight laminated
composite materials in body design • Use of new materials necessitates the development of new design
performance evaluation methodology • The damage & strength behaviour of composites under complex loading is
non-linear • Need for development of predictive models and related material
characterization procedures for progressive damage analysis and body performance evaluation
Key to Success • LMS Samcef Mecano non-linear finite element solver • LMS Engineering Services for composite damage model identification Results • Sophisticated material models comprehensively implemented for:
• Progressive ply damage (strength, non-linearities, plasticity, coupling effects in the matrix)
• Delamination (possibly coupled to damage in the plies) • Development of the parameter identification procedure, based on a limited
amount of physical tests on coupons • Predictive damage models at the coupon level and at composite subsystem
design concept level
Example: Honda R&D Co., Ltd. Innovative Methodology for Progressive Damage Analysis of Composites
Composite Delamination Progressive Ply Damage
Coupon
Subsystem Design Damage Prediction
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Page 47 Siemens PLM Software
Your development partner for innovation in automotive composite development processes
Engineering Expertise • Methodology & Development support Project Management References
Highly skilled engineers • Leveraging manufacturing
simulation & performance simulation & testing knowledge
Strong global teaming Flexibility
Software tools and technology Manufacturing Simulation Composite modeling Strength and Damage Durability NVH & Acoustics
Frontloading Development Multi-attribute Engineering Technology Transfer
coupon
component
subsystem
vehicle
validation material models
model validation on components/ joint technology
validation of complex subsystem modeling
expertise build-up full vehicle simulation/ sign-off
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Page 48 Siemens PLM Software
Summary
Challenges and Solutions for the Automotive Mixed Material Lightweighting Process • Enable a consistent, model based engineering process • Support accurate simulation based on as-manufactured material
properties • Provide access to a complete range of product performance
solutions • Enable faster and more frequent design/analysis optimization
iterations • Make design changes transparent and reduce change cycle times • Reduce time to create product documentation and digital
manufacturing data • Support customer with best-in-class multidisciplinary team of
experts • Facilitate rapid communication of detailed design, analysis and
manufacturing data across the supply chain
• Benefit from expertise