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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

Unrestricted © Siemens AG 2014 All rights reserved.

Page 2 Siemens PLM Software

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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Page 3 Siemens PLM Software

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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Page 4 Siemens PLM Software

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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Page 5 Siemens PLM Software

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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Page 6 Siemens PLM Software

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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Page 7 Siemens PLM Software

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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Page 8 Siemens PLM Software

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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Page 9 Siemens PLM Software

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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Page 10 Siemens PLM Software

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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Page 11 Siemens PLM Software

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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Page 12 Siemens PLM Software

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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Page 13 Siemens PLM Software

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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Page 14 Siemens PLM Software

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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Page 15 Siemens PLM Software

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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Page 16 Siemens PLM Software

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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Page 17 Siemens PLM Software

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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Page 18 Siemens PLM Software

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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Page 19 Siemens PLM Software

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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Page 20 Siemens PLM Software

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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Page 21 Siemens PLM Software

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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Page 23 Siemens PLM Software

Fiber Orientations in Injection Molded Short-Fiber-Reinforced Components

[BASF] [DKI]

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Page 24 Siemens PLM Software

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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Page 25 Siemens PLM Software

Fibre Orientation

Fig. 25

Solution Orientation mapping (Converse, DIGIMAT)

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Page 26 Siemens PLM Software

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

Unrestricted © Siemens AG 2014 All rights reserved.

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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Page 28 Siemens PLM Software

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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Page 29 Siemens PLM Software

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

Unrestricted © Siemens AG 2014 All rights reserved.

Page 30 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

Unrestricted © Siemens AG 2014 All rights reserved.

Page 31 Siemens PLM Software

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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Page 32 Siemens PLM Software

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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Page 33 Siemens PLM Software

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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Page 34 Siemens PLM Software

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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Page 35 Siemens PLM Software

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

Unrestricted © Siemens AG 2014 All rights reserved.

Page 36 Siemens PLM Software

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

Unrestricted © Siemens AG 2014 All rights reserved.

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

Unrestricted © Siemens AG 2014 All rights reserved.

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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Page 39 Siemens PLM Software

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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Page 45 Siemens PLM Software

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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Page 46 Siemens PLM Software

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

Unrestricted © Siemens AG 2014 All rights reserved.

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

Unrestricted © Siemens AG 2014 All rights reserved.

Page 49 Siemens PLM Software

Thank You

© Siemens AG 2014 All rights reserved.

Page 49 Siemens PLM Software