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© 2012 Autodesk Bridging the Gap between Autodesk Moldflow and Nonlinear FEA of Reinforced Plastic Parts Dr. Roger A. Assaker CEO, e-Xstream engineering.

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Presentation on theme: "© 2012 Autodesk Bridging the Gap between Autodesk Moldflow and Nonlinear FEA of Reinforced Plastic Parts Dr. Roger A. Assaker CEO, e-Xstream engineering."— Presentation transcript:

1 © 2012 Autodesk Bridging the Gap between Autodesk Moldflow and Nonlinear FEA of Reinforced Plastic Parts Dr. Roger A. Assaker CEO, e-Xstream engineering Chief Material Strategist, MSC Software

2 © 2012 Autodesk Class Objectives  To learn about the latest developments in modeling nonlinear behavior of structures made of fiber reinforced plastics, including:  Long Fibers & MuCell Materials  Injection and Compression Molding Compression  Fatigue and Creep Performance  High Performance Computing

3 © 2012 Autodesk Class Structure  Introduction & Motivation  Compression Molding  Long Fiber Reinforced Plastics  MuCell  Fatigue  Creep  Hybrid Solution Procedure

4 © 2012 Autodesk Introduction & Motivation

5 © 2012 Autodesk Composites in Automotive

6 © 2012 Autodesk Opportunities: Weight Reduction  Average/Indicative Facts:  1995  2005: +17% of mass (1118 kg  1310kg)  +200 kg  +18% of Fuel consumption (4.8 l/100km  5.7 l/100km)  Objective : -200 kg or -15 to 20 g CO 2 /km by 2020  Plastic parts: interior, under the hood, …  Optimize using advanced CAE/Material Modeling  Optimize design: e.g. engine mount: -40% weight & -15% in cost  Reduce thickness  Part consolidation  Metallic parts: Platform, Cabin Frame, Skin,…  Optimal mix of materials : Plastics, Composites, … 6

7 © 2012 Autodesk Mutli (Composite) Materials

8 © 2012 Autodesk Chopped Fibers/Injection Molding Fully aligned flow Flow lines Weld lines

9 © 2012 Autodesk Challenges of Reinforced Plastics  Process-dependent (Local)  Moldflow (Fiber orientation)  Nonlinear  Stain-rate dependent  Anisotropic 9

10 © 2012 Autodesk Process  Material  Structure Material Processing Injection molding Compression modling D-LFT Material Microsturcure Chopped fibers Nano,... Material Chracteristics Mechanical Thermal Electric,... Structural Performance Stiffness Strength Fatigue, … …

11 © 2012 Autodesk Material Behavior: Measured 11 Source: LKT, Prof. Drummer Friedrich-Alexander-Universität Erlangen-Nürnberg Skin-core effect Source: DatapointLabs e-Xstream Users‘ Meeting 2011

12 © 2012 Autodesk  Material properties from ISO 527 specimen  Average orientation  OT {Trace} = [ 0.80 | 0.15 | 0.05 ]  Scaling (factor = 0.6 – 0.8)  Material properties from injection molded plate  0° properties  Scaling (factor = ???)  Material properties from injection molded plate  0° / 30° / 45° / 60° / 90° properties  Reverse engineering  Skin-Core effect  OT = [ multi-layer RVE ] Measured Properties  FEA ? Global isotropic Local anisotropic

13 © 2012 Autodesk Local, Nonlinear, Anisotropic Material ISO % IM 22% 2D 36% Loading

14 © 2012 Autodesk Local Results: Plastic Strain 14 anisotropic isotropic equivalent scaling Without Moldflow & Digimat) With Moldflow & Digimat)

15 © 2012 Autodesk Local Results: Weldline 15 Accumulated plastic strain in material matrix Fiber orientations

16 © 2012 Autodesk Materials: Long Fiber Thermoplastics (LFT)

17 © 2012 Autodesk LFT – Effect of Fiber Waviness Tortuose Straight

18 © 2012 Autodesk LFT – Effect of Fiber Bundling Without bundling With bundling ~ 2300 MPa ~ 2800 MPa + ~ 500 MPa    [MPa]  

19 © 2012 Autodesk LFT - Effect of Bundling in Digimat-MF + 5% fibers 5% bundling a r = 50 a r = 5    [MPa]  

20 © 2012 Autodesk Materials: MuCell

21 © 2012 Autodesk MuCell RVE Generation Source: 15 % fibers 20 % voids

22 © 2012 Autodesk Strain Distribution in the Microstructure Tensile Direction mean local Tensile Direction

23 © 2012 Autodesk MuCell: Effect of Void on the Material Stiffness aligned

24 © 2012 Autodesk MF vs FE modeling of MuCell 7.8% voids15% voids

25 © 2012 Autodesk MuCell: Distribution of the VF of Air Inclusions

26 © 2012 Autodesk MuCell: 3-Point Bending Beam

27 © 2012 Autodesk MuCell: Armrest Vertical Load

28 © 2012 Autodesk MuCell: Horizontal Side Impact

29 © 2012 Autodesk MuCell: Horizontal Impact CAE Performance Curves

30 © 2012 Autodesk Performance: Fatigue

31 © 2012 Autodesk Chopped Fiber Reinforced Plastics: Fatigue Analysis Workflow  DIGIMAT reinforces the fatigue life computation at two levels:  Computation of the unit load case (Digimat-CAE/Structural)  Computation of the fatigue life prediction (Digimat-CAE/Fatigue)

32 © 2012 Autodesk Fatigue: Chopped Fiber Reinforced Plastics

33 © 2012 Autodesk First Pseudo Grain Fatigue (FPGF) Model  Ply composite Using fatigue failure criteria (i.e. Tsai-Hill)  Pros : Different « strengths » per direction, multi-axial  Cons : Purely meso/macro if not coupled with multi-scale methodology  Tsai-Hill  S: Fatigue strengths depending over N (nb cycles to failure)  1/L: Fiber direction 2/T: Transverse direction  Users workflow  Exp measurement: S-N curves measured for 0°, 45° 90° UD specimens  Material modeling: Define the measured S-N curves and corresponding microstructure (0° vs 90°)  Fatigue solution: Prediction of local S-N curves in each integration point (ply in each element) of the FE model, accounting for any Stress amplitude Mean stress Loading direction / Fiber alignment Damage accumulation:  Miner’s rule Tensile 0° Tensile 90°

34 © 2012 Autodesk Fatigue of Chopped Fiber Reinforced Plastics Unit Load: Stress S11 Fatigue life

35 © 2012 Autodesk Creep & Relaxation

36 © 2012 Autodesk Creep & Relaxation

37 © 2012 Autodesk Creep: Affine vs General vs Spectral vs FE

38 © 2012 Autodesk Thermo-ViscoElasticity

39 © 2012 Autodesk Thermo-ViscoElastic Relaxation

40 © 2012 Autodesk CPU Optimization: Digimat Hybrid

41 © 2012 Autodesk Hybrid Solution Procedure

42 © 2012 Autodesk Crush Simulation: Digimat-CAE/LS-Dyna

43 © 2012 Autodesk 2012 DIGIMAT Users’ Meeting 43  Bumper Beam impact  Material definition  Digimat v4.3.1  Viso-plastic propety  FPGF failure  Tsai-Hill-2D strains § Micro: strain base § Hybrid: stress base  Mircostructure Morphology  Orientation  Length: Short Fibers (AR=20)  Weight Fraction of Fibers  Isotropic  Use MD property from Digimat-MF result  Viso-plastic property  Failure : end point of MF curve MD TD FPGF failure defined at this strain-rate Digimat Nonlinear Micro Material Model

44 © 2012 Autodesk üOptimization Decomposition Default decomposition Digimat elements in 3 domains 29 domains have no Digimat elements Improved decomposition Digimat elements in 22 domains 10 domains have no Digimat elements Optimized decomposition –Almost same as improved but all domain has Digimat elements. Optimal Domain Decomposition

45 © 2012 Autodesk 16 cores32 cores64 cores Iso (improved) 17 h 59 m9h 17m10h 0m Hybrid (default) -42h 31m- Hybrid (improved) 26 h 37 m14h 16m8 h 15 m Hybrid (optimized) - 12h 5m - Micro (improved) h 51 m (6.4 days) - Iso Hybrid Iso Hybrid CPU Performance: Digimat vs Isotropic

46 © 2012 Autodesk Conclusions  Reinforced Plastics is a light weight alternative to metals  Advanced CAE, including nonlinear multi-scale material modeling, enables effective & efficient design of reinforced plastic parts by  Taking advantage the process simulation done with Moldflow  The latest developments in Multi-Scale Material & Structural Modeling support:  Long Fiber and MuCell  Fatigue and Creep Performance  Hybrid Solution Procedure and HPC make Nonlinear Multi-Scale a efficient solution procedure for accurate part and system simultion

47 © 2012 Autodesk Autodesk, AutoCAD* [*if/when mentioned in the pertinent material, followed by an alphabetical list of all other trademarks mentioned in the material] are registered trademarks or trademarks of Autodesk, Inc., and/or its subsidiaries and/or affiliates in the USA and/or other countries. All other brand names, product names, or trademarks belong to their respective holders. Autodesk reserves the right to alter product and services offerings, and specifications and pricing at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document. © 2012 Autodesk, Inc. All rights reserved.


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