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1M3 public summary – Feb 2017

Partners:

“MacroModelMat” (M3)

Macro-level predictive modeling, design &

optimization of advanced lightweight material

systems


M3 MacroModelMat programInternational network of academia and industry

Knowledge centers

Industry

Solving lightweight

challenges

by

advanced testing

& simulation


M3 MacroModelMat programOverview of research projects and topics

Many synergies

between scientific &

technology areas• Multi-scale modeling

• Virtual Material

Characterization (VMC)

• Effect of defects

• Advanced testing

• 3D-printed materials

• Fatigue simulation

• Impact (test & simulation)

• Vibration modeling

• …

IBO2 M3StrengthFatigue & multi-scale

industrial CAE solutions for composites

Modeling effect of defects

Foams & 3D woven simulation

SBO1 M3StrengthEfficient predictive modeling for

composite strength

[static, dynamic (fatigue) &

high speed (crash-crush) strength]

IBO3 M3NVHDesign and analysis of

NVH behavior of

lightweight panel and

material systems

using advanced CAE

tools

IBO1

M3AMCAEPredictive CAE

work flow and

engineering

refinement loop for

lightweight Additive

Manufacturing (AM)

IBO4 M3FATAMFatigue life

assessment

(by test

and simulation)

of AM parts:

effect of process

conditions

SBO2 M3DETECT-IV

Model-supported NDT for defects

in composite parts with industrial complexity


Composites &

Metal Lightweight Materials – CAESBO M3Strength

IBO M3Strength

IBO M3NVH


M3Strength – twin projects

Multi-attribute strength of composites

Application-driven, multi-

attribute (static-, fatigue-,

impact-strength ) efficient

simulation methods

Efficient

predictive

modeling

Virtual Material

Characterization

As-manufactured properties

Composite simulation Composite

testing

Fatigue of inter- and intra-

ply

Strain-rate dependent

behavior of composites

Micro- and meso-scale unit

cell modeling

Homogenization techniques

Effect of defects in

composites

Modeling and testing of 3D

woven

Behavior of foams an link to

helmet CAE challenge


SBO1 M3Strength

Developing the fundamental knowledge

Quasi-static & fatigue modeling Impact (crash/crush) modeling

Advanced testing and material characterization

Dynamic tension

pure epoxy

Dynamic delamination C/E

weave in drop tower

Dynamic micro-modeling

Crushing Strain-rate effect

Crushing of C/E tubes

(drop tower)Fatigue and quasi-static testing

Static and fatigue modeling at meso-scale and homogenization

Inter-ply fatigue modeling by cohesive zones


IBO2 M3Strength

Leveraging and industrializing knowledge

loads,

materials load scenarios

damage

behavior

Fatigue simulation

models/methods

validations

validated

methodology

porosity inclusion

Tests vs.

simulations

µCT

3D Woven

Effect of defects

Virtual Material

Characterization

Foam for helmets


M3NVH: Design and analysis of the NVH behavior of

lightweight panel and material systems using advanced CAE tools

The Main Goal: Designing Light Weight systems with better NVH properties

‘Simple’ treatments:

Insight and modelling of

NVH behavior for

‘Complex’ treatments

Analysis and modelling of

NVH behavior for

Industrial standardization

Application of accumulated

insight from WP1 and WP2

Flat metallic plates with

homogenous viscoelastic

add-on treatment

FRP panel

Curved metallic plates with

viscoelastic add-on treatment

FRP panel + viscoelastic

treatment

Robustifying of inverse material

characterization techniques for

industrial problems

+


M3NVH

Highlights

• An inverse material characterization technique

using high fidelity 3D numerical models has

been applied on viscoelastic damping

treatments

• Two methods for damping homogenization of

composites have been developed (multi-scale

modelling); one based on time domain and one

based on frequency domain techniques.

• Two new fast frequency sweep algorithms

have been developed that can be applied as

black box solutions. Speed-ups up to 45 for

constraint layer and 20 for unconstraint layer

cases have been achieved.


Additive Manufacturing (AM)

– design and simulationIBO M3AMCAE

IBO M3FATAM


M3AMCAE: Basic mechanical properties simulation of

Additive Manufactured lightweight materials through CAE

Additive

manufacturing

AMCAE challenge

Conventional

manufacturing

Exploiting the strengths of AM:

e.g. organic shapes, lightweight structures…

CAEDESIGN

Focus on design of 3D printed lightweight structures:1. Where to put lightweight structures?

2. How to create lightweight structures?

3. How to size lightweight structures for best mechanical performance?

4. How to accurately model lightweight structures with FEM?

Predictive CAE work flow and engineering refinement loop for

lightweight AM

Backed up by experimental material characterization


M3AMCAE: Basic mechanical properties simulation of

Additive Manufactured lightweight materials through CAE

Design space & FE Model preparation for Topology Optimization (TO)

1

(*)

Print final lightweight design

5

Towards an optimal design of 3D printed lightweight structures

TO drives solution to find zones for

Lightweight (Lattice) and Bulk considering

true lattice material properties and

manufacturability

Red = Bulk

Blue = Lattice

2

Octet

Lightweight structure creationVariable local truss diameter based on TO results

Post TO treatment3

FE verification of design for any load case

4

(*) Model based on the Alcoa AFSR Airplane Bearing Bracket: https://grabcad.com/challenges/airplane-bearing-bracket-challenge


• ICON Project title: Fatigue of Additive Manufactured components Relating AM process conditions to long-term dynamic performance of metallic AM parts

• ICON Project Acronym: FATAM

• SIM Program title: Macro-level predictive modeling, design & optimization of

advanced lightweight material systems

• SIM program Acronym: MacroModelMat (M3)

• Project coordinator: Siemens Industry Software

• Partners:

M3FATAMFatigue of Additive Manufactured components


• Build up an evolving and online database containing AM material fatigue

properties for Ti6Al4V and 316L samples produced by Selective Laser Melting

(SLM), Electron Beam Melting (EBM) and Direct Energy Deposition (DED) with

fixed optimal scanning parameters.

• Establish numerical methods and tools to design and improve the design

of AM structural components for safe fatigue life:

‣ by accurate prediction of the effect of fatigue-critical factors

(e.g. build orientation, surface roughness, staircase effect, porosity…)

‣ using validated S-N curve based methods: Multi-Attribute Interpolation of SN-Curves

‣ supported by multi-scale modeling: “Smart” extrapolation SN-Curves

This project should result in a unique material database combined with novel

simulation tools that enable AM service providers and/or end-users to design,

build and use reliable structural AM components with predictable fatigue properties.

M3FATAMObjectives


Composites – NDTSBO M3DETECT-IV


SIM SBO-project M3DETECT-IV

• Model-supported development of

nondestructive testing (NDT) methods for

defect DETECTion in composite parts with

Industrial complexity and Volume production

• Coordinator: UGent-MMS

• Partners: KU Leuven-PMA and VUB-AVRG

• Focus on development of novel NDT methods

for composite components

• Industrial partners:

Siemens, OptoMET, Honda R&D, Eddy Merckx, SABCA, Engie Lab


SIM SBO-project M3DETECT-IV

KULeuven-PMA VUB-AVRG

UGent-MMS

Local defect resonance

Novel cooled InfraRed camera

Seeing stress by temperature

Advanced excitation and data processing for

scanning vibrometry and IR thermographyVibro-Acoustics

Figure adapted from A. WONG, keynote lecture ICEM16

Scanning vibrometry

Measure vibrational response

Thermography


Acknowledgements

The MacroModelMat (M3) research program

coordinated by Siemens (Siemens PLM Software, Belgium),

funded by

SIM

(Strategic Initiative Materials in Flanders) and

VLAIO(Flemish government agency Flanders Innovation & Entrepreneurship)

is gratefully acknowledged.

Thanks to:

Documents

MacroModelMat” (M3) - Home | SIM-Flanders · Towards an optimal design of 3D printed lightweight structures ... MacroModelMat (M3) ... defect DETECTion in composite parts with