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2015 HBM nCode Products User Group Meeting
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com
Fiber Reinforced Plastic Durability
From Material Microstructureto Structural Part Life Predictions
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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Intro to Solvay and e-Xstream engineering
• Advanced materials – Engineering Plastics
• TECHNYL – PA66
– Advanced Polymers
• Global company,– TECHNYL center in France
• Software and engineering services– Digimat– Part of MSC Software
• Headquarters in Belgium– Offices in most major global engineering
centers
Off-the-shelf material models that use multi-scale modeling with FEA
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com
Background: Material Modeling from Metals to Composites
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March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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• Heterogeneous• Mechanical Properties dependent on Matrix & fiber properties +
fiber orientations• Anisotropic• Stiffness, failure, fatigue• Highly dependent on the manufacturing process
Modeling Fiber Reinforced Plastics
Strain
Str
ess
Flow direction
Cross Flow
MetalsComposites
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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• 1 Material Model for any Load & Fiber oreintation• Discontinuous (FRP’s) & continuous fiber composites• Stiffness & failure• Temperature dependence (varying CTE)*• Strain-rate dependence• Fatigue
Bringing Manufacturing Results into FEA – Material Model
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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fibers
failure
ANISO
Bringing Manufacturing Results into FEA – Part Level
Measurements/ curves
Process SimulationOrientation data on processing mesh
FEAStructural analysis
Structural mesh
Mapping
Anisotropic (non)linear
Material Model
ISO
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com
Multi-scale modeling
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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g to save weight replace aluminium by reinforced polyamide
TrelleborgVibracoustic designed a new engine mounting system
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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Failure location
Multi-scale modeling adequately accounts
Validation test:Quasi-static Loading
Response
Experimental
Digimat
Isotropic
• 40% mass reduction• 15% cost reduction• Production started in 2012
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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Fatigue material modeling - Composites
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March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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Challenge: adapt fatigue analyses for composites
• Characterize the local mechanical state stress state prediction
• Simplify the 3D historyin an equivalent 1D history stress combination method
• Convert the stress historyinto damage increments rainflow counting
• Accumulate damage increments Miner’s rule
Stress field
Stress history
Numbers of cycles
Stress amplitudes
Local stress & damage must change WRT:
• Local fiber orientations• Loading
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com
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• 2 dedicated composite fatigue models in Digimat• Phenomenological based on macroscopic failure indicator
• Fiber reinforced plastics
• High-cycle fatigue (linear elastic)
• Strength based fatigue life prediction
• Tsai-Hill 3D Transversely Isotropic criterion with FPGF
• Applied locally to each integration point relative to the local fiber orientation
• Micromechanical based on damage accumulation in the matrix• Uni-directional Composites
Composite Damage Models
Tsai-Hill 3D Transversely Isotropic criterion
X, Y & S: Fatigue strengths depending over N (nb cycles to failure)X: Fiber direction ; Y: Transverse direction ; S: Shear in X-Y plane
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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Generating the Composite Damage Model
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March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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• Input test data for 1 uniaxial loading & 3 fiber orientations• Predict fatigue life (s-n curve) for multi-axial loadings with any fiber
orientation
Digimat predicts SFRP S-N curves
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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for any microstructure
The phenomenological model predicts S-N curves
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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into correct local stresses
Multi-scale modeling translates the influence of manufacturing
fibers
failure
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com
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into appropriate S-N curves
Multi-scale modeling translates the influence of manufacturing
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com
Application
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March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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the fatigue behavior of an injection-molded beammade of TECHNYL A 218 V30 material (PAGF30)
Solvay characterized experimentally
R = 0.1and 4 maximum loads
45 cm
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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internally consistent S-N curvesrepresentative for dumbbell testsat varying angles with respect to flow direction
The automated reverse engineering provides
90°
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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easily delimited based on the unit load case results
The beam exhibits 2 characteristic regions
Compressive regionLarger compressive strengths No fatigue failure expected thusneglected
Tensile region Fatigue failure expected
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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a life prediction within the experimental variability
The Digimat/nCode interface yields
R = 0.1and 4 maximum loads
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com
Conclusion
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
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composite performances such as fatigue
• Enriches classical CAE with key microstructural information
• Accounting for variable fiber orientationshaped by SFRP manufacturing process
• Applicable to structural lifetime predictionsthanks to interfaces to fatigue software
Multi-scale modeling accurately predicts
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com
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e.g., cyclic loading with VEVP material model
Beyond usual fatigue analysis simplifications…
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com
2015 HBM nCode Products User Group Meeting
Thank you!
Kurt DanielsonBusiness Development Manager, e-Xstream [email protected]
March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)
www.ncode.com