Hyperform & Mfs

8/17/2019 Hyperform & Mfs

1/22

Innovation Intelligence®

Forming Simulation of Woven Composite

Fibers and its Influence on Crash

Performance

Dr Subir Roy

Senior Director, Industry Solutions

Altair


2/22

Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Outline

• Product Overview

• Study Objective

• Manufacturing processes

• Process simulation

• Mapping fiber orientation to crash model

• Crash simulation results

• Additional options


3/22


Altair Manufacturing Solutions

Stamping Extrusion CastingInjection

MoldingMapping

HyperForm

(HW)

HyperXtrude

(HW/Inspire)

Click2Cast

NovaCast

(APA)

Moldex

(APA)

HCRM (HW)

Converse (APA)

OptiStruct / HyperStudy


4/22


HyperForm: Advanced Solution for Sheet Metal Forming

• Early feasibility analysis

• Material cost analysis

• Die face design

• Virtual try-out and process optimization

• Press hardening

• Die stress analysis and topology optimization

Composite forming

Initialization of structural CAE models


5/22


Objective

1. Double Dome simulation of a composite weave [Ref. NUMISHEET’05]

2. Map fiber orientations from forming to crash model

3. Crash simulation to check influence of fiber orientations


6/22


Composite Forming Process: RTM

Ref. CAMX 2014


7/22


Composite Forming Process: Thermoforming

Ref. CAMX 2014


8/22


Forming Simulation Model

• Blankholder force : 350N• Initial blank size : 290mm * 190mm

• Tool speed : 170mm/sec

Blankholder

Punch

Die

Blank


9/22


Weave Material Properties

• 1 layer of a Balanced Twill weave

• Stiffness behavior is non-linear in both warp and weft directions

• Shear stress is a function of shear angle


10/22


Forming Simulation Results

• Shear angles at 13 points

Consistent with shear stress distribution

Maximum shear angle = 36,9°


11/22


Forming Simulation Results

• Stress and strain in warp direction

• Stress and strain in weft direction


12/22


Crash Simulation Model

• Final fiber orientations are mapped on a coarser crash mesh using

HyperCrash Results Mapper (HCRM)

• Rupture criteria : Hashin failure

Maximum stress value in direction 1 and 2, tension and compression

800mm/sec

Rigid wall


13/22


Crash Simulation Results

• Normal resultant force against rigid wall shows a significant difference


14/22


Summary

• Fabric material law in RADIOSS is able to model composite weave forming

Physical behavior such as non-linearity of stiffness for warp and weft direction,

shear stress as a function of shear angle are modeled

• Final fiber orientations can be mapped to crash simulation model

Fiber orientations resulting from stamping simulation influence rupture mode and

stiffness response for crash simulation


15/22


Rapid Drape Estimator for Composite Fibers (13.0)

• Calculate

• Fiber orientation (draping) angles

• Thickness variation

• Interfaces

• OptiStruct

• Nastran

HM Drape Estimator (white) versus competition (red)

http://localhost/var/www/apps/conversion/tmp/scratch_5/HM_OS_Draping_demo_12_9_2013.wrfhttp://localhost/var/www/apps/conversion/tmp/scratch_5/HM_OS_Draping_demo_12_9_2013.wrfhttp://localhost/var/www/apps/conversion/tmp/scratch_5/HM_OS_Draping_demo_12_9_2013.wrfhttp://localhost/var/www/apps/conversion/tmp/scratch_5/HM_OS_Draping_demo_12_9_2013.wrfhttp://localhost/var/www/apps/conversion/tmp/scratch_5/HM_OS_Draping_demo_12_9_2013.wrf


16/22


Rapid Drape Estimator for LSDyna (14.0)


17/22


• Model bands of woven fibers using shell elements

• Model individual woven fiber using solid elements

Advanced Meso-scale Modeling of Draping

http://localhost/var/www/apps/conversion/tmp/scratch_5/video_tissu_coin3bis.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/video_tissu_coin3bis.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Process_half2.avihttp://localhost/var/www/apps/conversion/tmp/scratch_5/Process_half2.avi


18/22


SPH to model resin flow

Advanced Meso-scale Modeling with Resin

390 000 nodes

320 000 SPH cells

6 h on 24 CPUs

CPUs (Troy Cluster)


19/22


• Macro-scale model

• Meso-scale patch at critical area

Coupling Macro and Meso-scale Modeling

Maximum shear angle region


20/22


1. Forming simulation at macro-scale

2. Map the meso patch boundaries on the flat mesh

3. Extract the displacement history at boundaries

4. Simulate meso-scale model with displacement history

Indirect Coupling of Macro and Meso-scale Modeling


21/22


Design Optimization Cycle

Forming:

(HyperForm)

Mapping

(HWRM )Performance

(OS/RADIOSS)

Design changes :

HyperMorph,

HyperStudy

Weave layup:

(CEDREM/HyperMesh)

OK?

C i ht © 2013 Alt i E i i I P i t d C fid ti l All i ht d


22/22


Thank you

Documents

Hyperform & Mfs