how major manufacturers find the right materials data for

www.grantadesign.com

Dr Peter Cherns (Granta Design)

Dr Mark Blagdon (Jaguar Land Rover)

Dr Vesna Savic (General Motors)

How Major Manufacturers Find the Right Materials Data for Simulation

CONFIDENTIAL

Agenda

1. Introduction

2. Guest Speaker– Dr Mark Blagdon, Jaguar Land Rover

3. Guest Speaker– Dr Vesna Savic, General Motors

4. Materials Data Management for CAE– Dr Peter Cherns, Granta Design

5. Q&A

CONFIDENTIAL

The Problem

• Materials data is essential for simulation, but…

• For authors of data:– Generating data is time-

consuming, inefficient and complex

– Data is not always traceable to its source

• For consumers of data:– Often many silos of data to

choose from; or none at all– The best data may not always

be reused– Without context, it’s not always

easy to know which data to use

What’s needed?

…they can be consistently generated and traceable to

their source…

…and consumers are notified if anything is

changed.

Ensure that validated materials models are quickly accessible here…

GRANTA MI for CAE

Material reference data from Granta Design

In-house material, test and CAE data

Regular updates

Capture, link,manage, maintain

PUBLISH AND USECOMPARE AND ANALYSE

IMPORT AND MANAGE

CONFIDENTIAL

GRANTA MI for CAE

Analysis

PAM-CRASH/ PAM-STAMP, LS-DYNA, CFD formats, etc.

Card Exporter

Material Simulations

Pedigree• Composition,• Microstructure,• Processing…

Test data• Tensile• Dynamic• Bulge test• FLD• Cyclic• Fatigue…

• Data reduction

• Curve fitting• Model

generation/ calibration

PLM

CAD

CAEA

cces

s &

Ver

sion

Con

trol

Acc

ess

& V

ersi

on C

ontr

ol

Specs• Name / identity• Standards / specs• Selection rules• Engineering properties

Simulation Data

• Linear-Elastic parameters

• Plastic parameters• Rate-dependent

parameters• Cleaned Stress-

strain curves…

Test labs, suppliers, etc.

Material simulation / ICME

GRANTA MI MI:MaterialsGateways

CONFIDENTIAL

Agenda

1. Introduction




5. Q&A

CONFIDENTIAL

Guest Speaker

• Dr Mark Blagdon

• Materials Characterisation Technical Specialist

• Jaguar Land Rover

Materials Data Management Overview at JLR

Materials Data Management Overview at Jaguar Land Rover

Dr Mark Blagdon – Jaguar Land Rover

Materials Characterisation Technical Specialist

Materials Data Management Overview at JLR

Virtual Design -CAE and CAD

Virtual Physical

Mat

eria

lsC

hara

cter

isat

ion

Phy

sica

lVal

idat

ion

Test

Launch and

Production

Design Freeze

Granta MI being integrated into all aspects of materials data management at JLR• CAD data• CAE data• Validation tests• FMEA Investigations• Lessons Learnt

Virtual Engineering key to fast and robust vehicle design-• 1200+ CAD engineers• 500+ CAE engineers• 24 months in virtual design phase• 1 year from virtual design sign off to start of production!

CAE = Computer Aided Engineering – Software for modelling automotive load cases.

Only as good as inputs and methods!

Three main inputs to CAE• Geometry• Loads and Constraints• Material Model

Materials properties are complex and can vary due to:-• Manufacturing Process• Operating Environment• Loading Method

Materials Data Overview – Supporting Robust Design

Granta MI Overview – Test to Virtual Engineering Database

Test Data

Metal Tensile Metal Fatigue

Polymer Impact

Crush Tube

Composites

Data AnalysisAnd

Reports

Fatigue

Metal Characterisat

ion

JLR Virtual Engineering Materials Data Hub

JLR Virtual EngMaterials Hub Table

CAD CATIA V5

CATIA V5

CAEBIW

Stiffness ‐NASTRAN

PowertrainBy

Component

Chassis Structural

BIW DYNA‐Metals and

Plastics

BIW NVHFEA

BIW NVHSEA

BIW Crash‐ CrachFEM

BIW Fatigue ‐ncode

BIW Strength ‐ABAQUS

Joints Fatigue

ABAQUS DYNA NASTRAN Ncodexml

DYNACrachFEMDYNA QS

Polymer Characterisat

ion

PowertrainStrength

Three Point Bend

Polymer Tensile

External Testing Results

CATIA V6

CADCATIA V6

TASE ‐Thermal

Forming ‐AUTOFORM

Rad‐THERM

AUTOFORM

Granta MI - Virtual Engineering Data Hub – Supports Test to CAE card trace-ability

• Test Data – Tensile, Fatigue, Crush Tube• Data Analysis Methods – Test to design data process• CAE ‘design data’ – Supports all JLRs structural CAE software codes• CAD ‘material assignment’ – Standard naming and approval• CAD to CAE name mapping – Automated CAE model build

Granta MI Overview – Virtual Engineering Database

Data Overview Data Summary

Data Record

CAE Teams

CAE File

Granta Overview Virtual Engineering Database benefits

Benefits of Granta MI use for CAE and CAD

Source data traceability• Test Data to CAE file history• Compare materials at test data stage• Avoid unnecessary CAE analysis

CAE file written from Granta MI record data• Easy to update CAE data decks• Consistency of CAE file formatting• Key data in file header• Data traceability – hyperlink to source record

Granta Overview Virtual Engineering Database benefits

Benefits of Granta MI use for CAE and CAD

CAE data re-use – robustness and time saving• Convert between CAE code formats• Rewrite all CAE files at one time• Enables simulation in CAD using same data as CAE

• DYNA to ABAQUS• ncode to Optistruct• ABAQUS to CATIA V6

Granta CAE record stored in common format• Materials Engineers can understand CAE data• Easy to compare material properties• Search for materials based on properties

Example CAE Format

Typical Granta Format

Materials Data Management Overview – Benefits

Benefits• Robustness of CAE material data input

• Creating “One Source of the Truth” – where validated materials data is stored

• Data visibility and understanding:• Show the company what data is available – no data = non-robust design• Materials Engineers: understanding what CAE need and use• CAE users: understanding how their data was generated• CAE users: compare data sets

• Materials knowledge –• “Attribute Notes” explain attributes via linked webpage• Store CAE material modelling reports alongside materials data

• Data re-use –• Converted ncode to Optistruct format in 2 hours• Use same properties in CATIA V6 and CAE structural analysis

• Process Automation -• CAD to CAE name mapping – Automated CAE model build scripts

CONFIDENTIAL

Agenda

1. Introduction




5. Q&A

CONFIDENTIAL

Guest Speaker

• Dr Vesna Savic

• Sr. Project Engineer – CAE Material Property Characterization and Database Lead

• General Motors

V. Savic12/7/2016

SUPPORTING CAE WITH MATERIALS INFORMATIONVesna SavicGeneral MotorsGlobal CAE Strategy

December 7, 2016

V. Savic12/7/2016

OUTLINE

Introduction GM Material Properties Database Materials Focus Group Challenges and Opportunities

2 1

V. Savic12/7/2016

GM MATERIAL PROPERTIES DATABASE

Global single source of material properties for CAE analysis Link to Material Approvals Database Link to test data Knowledge depository

2 2

V. Savic12/7/2016

MATERIALS FOCUS GROUP

Global team Provides material information for CAE analysis Material characterization and test data processing Material cards development and validation Material modeling methodology development

Divided in smaller teams based on material type Metals Joining Plastics and Composites Foams/Elastomers/Textiles

Closely engaged with CAE analysis teams Material modeling based on application Material characterization road map and prioritization

2 3

V. Savic12/7/2016

CHALLENGES AND OPPORTUNITIES

Diverse material landscape Focused teams leveraging global expertise for specific material types

Widening role of CAE in design and performance prediction Increasing material model fidelity by comprehending fracture, anisotropy, etc.

Large amount of material data needed Balancing internal and external resources for material characterization Leveraging consortia driven material development Leveraging material suppliers in material characterization Advanced planning, prioritization and development road map

Consistent material usage for CAE analysis Deliver material information globally through solver specific master material files Address material usage in analysis guidelines

Knowledge capture Material traceability through links to approval, test records Material modeling guidelines Lessons learned shared with the global CAE community

2 4

CONFIDENTIAL

Agenda

1. Introduction




5. Q&A

GRANTA MI for CAE

Material reference data from Granta Design

In-house material, test and CAE data

Regular updates

Capture, link,manage, maintain

PUBLISH AND USECOMPARE AND ANALYSE

IMPORT AND MANAGE

CONFIDENTIAL

GRANTA MI for CAE

CONFIDENTIAL

Materials Data Management for CAE

Analysis


Card Exporter




• Data reduction



PLM

CAD

CAEA

cces

s &

Ver

sion

Con

trol

Acc

ess

& V

ersi

on C

ontr

ol


Simulation Data




strain curves…




CONFIDENTIAL

Test Data Capture

Analysis


Card Exporter




• Data reduction



PLM

CAD

CAEA

cces

s &

Ver

sion

Con

trol

Acc

ess

& V

ersi

on C

ontr

ol


Simulation Data




strain curves…




CONFIDENTIAL

• Capture test data from a variety of test machines and test partners

• Capture pedigree, e.g. microstructure, composition, etc.

• Manage with complete traceability

ZWICK

INSTRON

Test Data Capture

CONFIDENTIAL

Data Analysis

Analysis


Card Exporter




• Data reduction



PLM

CAD

CAEA

cces

s &

Ver

sion

Con

trol

Acc

ess

& V

ersi

on C

ontr

ol


Simulation Data




strain curves…




CONFIDENTIAL

• Support standard workflows for curve smoothing, averaging, model fitting, etc.

• Integrate with Excel, MATLAB, Python, in-house tools

• Store analysis in system with full traceability

• Store model parameters and visualize stress-strain curves on the fly

Data Analysis

CONFIDENTIAL

CAE material model access

Analysis


Card Exporter




• Data reduction



PLM

CAD

CAEA

cces

s &

Ver

sion

Con

trol

Acc

ess

& V

ersi

on C

ontr

ol


Simulation Data




strain curves…




CONFIDENTIAL

CAE material model access options

Cardexport to solver

Measured data,Imported data

Design curves,Material models

Interactiveaccess from

pre-processor

API

CONFIDENTIAL

Gateways for material import to CAE

Abaqus/CAE from Dassault Systèmes / SIMULIA

ANSYS Workbench

HyperMesh

CONFIDENTIAL

MI:Materials Gateway for Abaqus/CAE

CONFIDENTIAL

Browse for materials data

CONFIDENTIAL

Preview and import CAE Material Models

CONFIDENTIAL

Data transfer with full traceability

CONFIDENTIAL

Summary

• Common material definition across CAD, PLM and CAE

• Save time & cost through fast, easy access to vital input data within CAE

• Quick, controlled, error-free analysisto generate materials data for simulation

• Ensure traceability for simulation data & repeatability for simulations

CONFIDENTIAL

Agenda

1. Introduction




5. Q&A

how major manufacturers find the right materials data for

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