Flying Off The Line: How Aerospace Knowledge Can Accelerate the Use of Composites in Mass Produced Autos

Transcription

1 Flying Off The Line: How Aerospace Knowledge Can Accelerate the Use of Composites in Mass Produced Autos Rani Richardson Composites Product Specialist Etienne Ardouin Composites Consultant

2 Body in White Challenges Body have to be more & more lighter. New Material introduction Composite material introduction for Body panel mass market. Steel BiW Plastic BIW + Steel BiW Aluminium BiW Composite BiW + Steel / Alu BiW Now! 2030+

3 Why composites in automotive? To reduce weight To decrease number of parts For structural robustness For styling innovations For NVH improvements (reducing noise) For fatigue resistance, no corrosion -> Lower fuel consumption, lower emissions -> Design flexibility -> Safety improvement -> New aesthetics -> Better comfort -> Improved life cycle compared to steel

4 Composites as a core business Many Industrial Choices Transformation of core / non core business In-house or externally subcontracted activity Earlier Supply Chain involvement Synergies development Traditional Sequential Process No efficient collaboration capability No ability to get feedback Limited ability to anticipate Best-in-class Composites Products Required to Design and manufacture every part in an optimum way Harmonize processes, methods and tools Support a single harmonized end-to-end process with a single toolset at OEM and for its Supply Chain

5 Composites on the rise Evolution in types of composite parts over the past 30 years Today s premium and luxury cars are beginning to slowly break through in mass markets New vehicle: BMW s Mega-city vehicle due 2013

6 Compelling benefits of composites Automotive Composites Alliance Prototype benchmark Metals vs. Composites Trunk: 50% mass reduction Composites hood: 30 to 40% weight savings Deck lid: 25 to 35% mass reduction Tooling is less costly Vehicle more resistant to damage dents, corrosion Composite assemblies have fewer parts

7 From metal to composites: facing new challenges Current status Tools for design, analysis and manufacturing are in different formats Lack of collaboration, automation and communication CAD/CAE tools intended to work with metals Trial and error on the Shop Floor Future New tools for end-to end process Product design ->virtual testing->ensure manufacturability Unified platform to accelerate collaboration Concurrent engineering reduces cycle time Validate manufacturing by simulating what will happen on the Shop Floor

8 Mastering a complex design process Factors to take into account: Material properties Software tool must be able to handle frequent design changes Balance between weight and design optimization Design software must be able to automatically communicate with and receive feedback from analysis and manufacturing Manufacturing constraints must be integrated into the design model Simulate manufacturing during the design phase to ensure designed intent and as-built model match

9 From Manual to Automated Manufacturing Processes Challenges Time consuming trial and error Cutting plies, placing them on the mold using manual measurement If they don t fit, start the process over Complex shapes make it hard to predict how material will drape on the mold Not repeatable or optimized Improvements on PLM platform Output for various shop floor systems for automated fiber placement and tape laying systems. Simulation capabilities ensure that the detailed design is manufacturable Generation of flat patterns to be exported to a ply cutting machine or laser projection systems Generate output for RTM machines directly from CAD design software Shop floor documentation can be printed, created as a PDF file or an electronic ply book

10 Composites challenges require an PLM integrated solution Mostly all composites structures are designed in CAD solutions not intended for Composites, where Design, Analysis and Manufacturing are not integrated. A sequential process where the different components interface with no efficient collaboration capability, no ability to get feedbacks, and limited ability to anticipate doesn t meet anymore the increasingly demanding requirements for Composites development. Only a PLM Integrated Solution allows to fully optimize the complete process. Hand Lay-Up Physical world RTM, VARTM, VARI Automated Tape Laying IP Capitalization Automated Fiber Placement Unique ability or the Designer to work in functional context, get accurate feedbacks from Simulation and Manufacturing and even better, anticipate and avoid problems early in the process.

11 Applying Lessons Learned in the Aerospace Industry 3 main objectives : Development lead time reduction Go to Market with full maturity Increase ramp-up capacity With the expertise acquired in the Aerospace field, CAD designers can propose not only technological solutions but also to help customers accelerate the learning curve by leveraging scalable practices. Best in Class on the market Best Practices - Secure Deployment Best solution on existing platform Enhancement to reach baseline Competitiveness Competitive solution development improving baseline Identify & develop market Best In Class end to end solutions

12 V6 Composites in action B-Pillar Example

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14 3D Simulation for Composites Bring FEA for Designer with easy to use integrated tools dedicated to preliminary analysis during design stage. Enhance productivity for Analyst Expert: tighter integrated to Design to allow to build complex simulation model quicker. Perform accurate advanced virtual testing: Non linear Structural and Thermal analysis Fracture and Debonding analysis Crush and Impact simulation

15 3D Simulation for Composites Designer Meshing associative to CAD Laminate import associative to the Composites Design model Plies and Core, Zones Transfer producibility results into simulation model Structural Simulation with fiber direction As Manufactured CAD integrated solver able to simulate laminated structures Assemble plies orthotropic properties Classical Shell Model Laminate theory Plies material properties as defined in the material card Linear static analysis, Frequency, Buckling analysis Post processing dedicated to composites materials Ply per ply visualization, enveloppe Failure criteria for othotropic plies

16 3D Simulation for Analyst Expert- Overview Modeling Approaches Simulation model Classical shell model Continuum shell model Stacked model Stacked elements: Continuum shells/solids Delamination modeling Cohesive elements/ cohesive contact VCCT Microscopic modeling Trend More virtual tests Increased model complexity/nonlinearity TREND Accuracy Complexity Nonlinearity Simplification Analysis speed Global stress analysis Preliminary component design Analysis of critical regions Local failure analysis Simulation of Composites with Abaqus Unified FEA 17

17 3D Simulation for Analyst- Link to Design & Manuf Composites Modeler for ABAQUS CAE Simulation Geometry Zone Model Ply Model Manufacture Composites Link for CATIA Composites Design

18 3D Simulation for Analyst Expert- Overview Depending on the purpose of the analysis, different modeling techniques for composites can be used (e.g., microscopic, layered, smeared, rebar, and submodeling). 19 smeared Composite layered Ply-1 microscopic Matrix-1 Fiber-1 Ply-1 (a) Microscopic modeling Ply-1 Ply-2 (b) Layered modeling Matrix-2 Fiber-2 Ply-1 is the equivalent homogeneous material model for the Matrix-1 and Fiber-1 combine (similar definition for Ply-2) Composite is the equivalent homogeneous material model for the Ply-1 and Ply-2 combine (c) Smeared modeling

19 3D Simulation for Analyst Expert- Overview Comprehensive Composites Capabilities with SIMULIA Partnership with Firehole Technologies (Helius:MCT) Partnership with Engenuity (CZone for Abaqus) Composites Crush Delamination (cohesive elements) Composites Fracture / Failure (VCCT) Partnership with Boeing (VCCT) Isight Optimization Partnership with Simulayt (CMA) Manufacturability and draping (Composites Modeler for Abaqus/CAE) Easy to use Pre/Post (Abaqus/CAE) 20

20 Barely Visible Impact Damage (BVID) 21 Abaqus allows the import of the damage model for fiber-reinforced composites from Abaqus/Explicit to Abaqus/Standard to model the analysis of Barely Visible Impact Damage (BVID) in composite structures. 1 ABAQUS/Explicit is used to model low speed impact which results in damage. Impact Analysis Abaqus/Explicit 2 Further analysis of the damaged plate is conducted in Abaqus/Standard. Tensile Analysis Abaqus/Standard In-plane tension 36-ply composite face sheet modeled with continuum shells and damage definitions Honeycomb core

21 XFEM: extended Finite Element Method Mesh independent crack modeling Key features Allows moving and stationary cracks First-order continuum elements Static procedure Comprehensive modeling and visualization Application to Composites Structures Can be used with VCCT or cohesive surfaces to model delamination New fracture initiation criteria in Abaqus 6.10 (request from the composite industry) XFEM and cohesive elements 22

22 Simulation of Crushing Processes CZone for Abaqus (CZA) Required material data Composite stiffness/strength, parameters for damage law Determined from regular material tests (tension, compression, shear) Govern composite behavior outside crushing zone Composite crushing stress Including angle and velocity dependency Determined from crash tests (coupons or simple structures) Governs energy absorption in crushing zone Benefits More realistic prediction of crushing process/transition to global cracking Without well-known force oscillations due to shell element deletion Cone crushing in test and CZA simulation 23

23 CZone for Abaqus : Virtual vs. Real Testing

24 Thank you!