Modeling of reinforced plastic structural parts: concrete solutions for win!

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1 Modeling of reinforced plastic structural parts: concrete solutions for win! Innov Days ICP 29 septembre 2016, Bellignat Alexandre Roussel Business Development Manager Tel: +33 (0) Mob: +33 (0)

2 Outline Industry challenges Challenges in modeling composites Introduction to Digimat technology and value proposition Typical industrial applications Digimat RP Users community Conclusion 9/29/2016 Copyright e-xstream engineering,

3 CHALLENGES IN THE INDUSTRY High-Performing Products Eco-Friendly MSC Software Confidential 3 Cost-Effective

COMPOSITES IS THE ANSWER BUT WHICH MATERIAL TO

5 What are the Challenges in Modeling Composites? Nonlinear Anisotropic Strain Rate Dependent Process Dependent MSC Software Confidential 5

6 Let s take a simple example MSC Software Confidential 6

7 With Classical FE Modeling tools MSC Software Confidential 7

8 Front-end Injection Process Skin Core MSC Software Confidential 8

9 Digimat Nonlinear Material Model Replace the usual basic material models by Digimat material models! Accounting for Local microstructure (AR,, w.f.) Nonlinearity Strain-rate dependency Thermo-dependency MSC Software Confidential 9

10 Digimat: From Process to Performance Material Processing Molding: Injection, Compression,... Drapage, AFP,... Material Microstructure Chopped fibers Continuous fibers: UD/Woven Nano,... Material Characteristics Mechanical Thermal Electric,... Part/Vehicle Performance Process DIGIMAT Performance MSC Software Confidential 10

11 Digimat Your Solution for Composites Modelling and Design Optimization

12 Digimat: the material modeling platform MSC Software Confidential 12

13 Team 100% Dedicated to (Composite) Materials Founded in 2003, 3 main offices in Europe Team of 50 (++TBH), 100% focused on (composite) materials MSC Company since September 12 MSC Software Confidential 13

15 Compression process Injection process Drapping process DIGIMAT COVERS MULTIPLE PROCESSES IN AUTOMOTIVE 9/29/2016 Copyright e-xstream engineering,

16 DIGIMAT COVERS MULTIPLE MATERIALS MSC Software Confidential 16

17 DIGIMAT COVERS MULTIPLE PERFORMANCES IN AUTOMOTIVE Oil filter MSC Software Confidential 17

18 DIGIMAT COVERS MULTIPLE SCALES MSC Software Confidential 18

19 DIGIMAT COVERS MULTIPLE CAE SOLUTIONS MSC Software Confidential 19

20 Digimat THE Standard Solution today for Composites AUTOMOTIVE exemples

21 DIGIMAT COVERS MULTIPLE APPLICATIONS IN AUTOMOTIVE Viscous Fans Engine Mount Airbag Housings Air Duct Seat Bearing System Car Roof Oil Pan Pillar Side Impact Pads Oil Filter Engine Cover Car Body Engine Cooling Radiator Lower-Pillar Air Intake Electronic Connectors Aircooler Brackets FAN System Pedestrian Protection Front-end MSC Software Confidential 21 Pedal Overmolded

22 What difference between isotropic and anisotropic approach?

23 Thrust Pedal: Injection Molding Simulation MSC Software Confidential 23

24 Thrust Pedal Fiber Orientation MSC Software Confidential 24

25 Thrust Pedal Displacement & Stress Displacement 900 N Force Applied Stress isotropic anisotropic 0-50 mm range MPa range MSC Software Confidential 25

26 Fiber Orientation Engine Cover: Injection Molding Simulation MSC Software Confidential 26

27 Engine Cover Modal Analysis Natural Frequency Max. Displacement Mode Isotropic Anisotropic Isotropic Anisotropic MSC Software Confidential 27

28 What about reality and simulation?

29 ENGINE COOLING VIBRATION Courtesy of Fan System Copyright e-xstream engineering, 2014

orientation (From Moldflow) Fiber Length Fiber Content

30 DIGIMAT MATERIAL MODEL Courtesy of Fiber Reinforced Plastic Matrix Polymer Fiber Glass Microstructure Fiber orientation (From Moldflow) Fiber Length Fiber Content Fiber Orientation Tensor Copyright e-xstream engineering, 2014

31 FLAP MODAL ANALYSIS Courtesy of Copyright e-xstream engineering, 2014

32 Could simulation help to optimize design of SFRP parts?

ENGINE BACKFIRE IN AN AIR INTAKE MANIFOLD Calibration of an EP DIGIMAT material Simulation of the load case with Digimat-CAE/LS-DYNA based on fiber orientations

33 ENGINE BACKFIRE IN AN AIR INTAKE MANIFOLD Calibration of an EP DIGIMAT material Simulation of the load case with Digimat-CAE/LS-DYNA based on fiber orientations coming from injection molding Comparison of maximum principle stresses of the composite material with an isotropic calculation at T1 and T2 MSC Software Confidential 33

ENGINE BACKFIRE IN AN AIR INTAKE MANIFOLD For the high pressure peak T1 and the low pressure region T2 significant differences in the stress distribution are observed compared to the simulation using

34 ENGINE BACKFIRE IN AN AIR INTAKE MANIFOLD For the high pressure peak T1 and the low pressure region T2 significant differences in the stress distribution are observed compared to the simulation using isotropic material The fiber reinforced part shows lower stresses than the isotropic case pointing out an over-designed part Potentially further weight can be saved on the part by introducing DIGIMAT in the design cycle MSC Software Confidential 34

35 What about metal replacement and functionalization by SFRP parts?

36 Simulation driven product development 9/29/2016 Copyright e-xstream engineering,

37 Simulation driven product development Failure Correlation After 10 ms: rib buckling After 28 ms: rib failure After 54 ms: first failure evolution 9/29/2016 Copyright e-xstream engineering,

38 What about return on investment for early design modeling of SFRP parts?

DIGIMAT enabling to save money at OEM Decrease material costs of

study from an OEM based on interior products 10 to 20% mass reduction

material cost reduction Equivalent to $10 per vehicle 2012, 1M Ford

40 DIGIMAT enabling to save money at OEM Decrease material costs of plastic components up to 15% by taking the right design decision : Case study from an OEM based on interior products 10 to 20% mass reduction on plastic component by reducing useless safety factor 5 to 15% material cost reduction Equivalent to $10 per vehicle 2012, 1M Ford Fiesta 10M$ savings! $ saved in testing costs per program MSC Software Confidential 40

41 How to use Digimat tools for your applications? Example of Digimat RP

42 3 key steps in plastic part design with Digimat RP? 9/29/2016 Import FEA model Select Digimat model Copyright e-xstream engineering, Provide Estimatelocal fiber microstructure orientation inside Digimat-RP

43 Digimat-RP/ Fiber orientation estimator 9/29/2016 Copyright e-xstream engineering,

44 Optimazing gating system 9/29/2016 Copyright e-xstream engineering,

45 More than a modeling platform an users community

46 Digimat-MX, Material Exchange plateform Source of Digimat material model Public database directly filled by the most material suppliers! Public Database content in Digimat -MX: Test data 187 grades More than 19,000 Digimat Material Models Elastic Elasto-Plastic Thermo-Elasto-Plastic Visco-Elastic Visco-Plastic ViscoElastic-ViscoPlastic Reinforced Nylon grades from Solvay, Dupont, Radici and E/S Grivory Reinforced PBT grades from Dupont, Sabic and Ticona Reinforced PP grades from LyonDellBasell, Sabic, Trinseo Reinforced PPA, PARA, PEEK, PAEK, PESU from Solvay, Victrex Different type of fillers : CF & GF Generic material model from e-xstream MSC Software Confidential 46

47 Customer Testimonials MSC Software Confidential 47

48 DIGIMAT, fully adopted by the Automotive supply chain Efficient Materials & Components Integration User-Friendly Data Exchange MSC Software Confidential 48

50 Conclusions

51 Conclusions Digimat can help engineering better, lighter & cheaper plastics & composites systems thanks to : Virtual material characterizing The ability to model the large variety of composite from SFRP to CFRP Bridge the gap between manufacturing & part performance Digimat can model plastics & composites for : Stiffness Impact & failure Creep Durability NVH The tools are made Robust/Fast/Easy and can be used from early design iteration until design freeze. MSC Software Confidential 51

Additive Layer Manufacturing Innovation DIGIMAT

Material Engineering Mechanical Thermal Electric

Stress Porosity Part Performance Stiffness

52 Additive Layer Manufacturing Innovation DIGIMAT solution for Additive Layer Manufacturing Material Engineering Mechanical Thermal Electric Warpage FDM/SLS Process Simulation Residual Stress Porosity Part Performance Stiffness Failure Print Direction Reinforcement MSC Software Confidential 52

53 More demonstrations on the e-xstream booth! MSC Software Confidential 53

54 Thank you! Alexandre Roussel Business Development Manager Tel: +33 (0) Mob: +33 (0)

Efficient composite component & System modeling in LS-DYNA using Digimat. Dr. Ir. Guillaume Boisot NE Business development engineer

Efficient composite component & System modeling in LS-DYNA using Digimat Dr. Ir. Guillaume Boisot NE Business development engineer DYNAmore Nordic Conference Gothenburg, SE September 26 th 2013 Amsterdam,