Digimat. The Material Modeling Platform. Tools. Solutions. expertise

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1 Digimat The Material Modeling Platform Tools. Solutions. expertise

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3 Contents I Nonlinear Multi-Scale Modeling with Digimat I.1 Simulation Strategy Material Engineering Structural Engineering Material exchange I.2 Platform Multi-Scale Modeling Industrial Usage Composite Materials I.3 Tools Digimat-FE Digimat-MF Digimat-MX Digimat-CAE Digimat-MAP I.4 Solutions Digimat-RP Digimat-HC I.5 expertise Training Services Certified Consultants

4 Part I Nonlinear Multi-Scale Modeling with Digimat

5 Digimat I.1 Simulation Strategy The core of micro/macro multi-scale modeling is micromechanics using homogenization technology. Homogenization is the combination of per-phase material data with microstructure information to obtain the macroscopic response of a composite. In the approach a representative volume element (RVE) is set up that describes the composite material under investigation. A virtual test is applied and its effect on the composite, as well as on the microscopic (per-phase) level, is observed. Digimat offers two complementary technologies that serve this purpose. Finite Element Analyses gain an in-depth view into composites by the direct investigation of realistic RVEs Mean-Field Homogenization rapidly converts model based RVE definitions into macroscopic and per-phase properties Figure I.1.1: Homogenized properties arise from virtual tests performed on representative volume elements of composite materials.

6 Material engineering Material Engineering is the art of understanding composites in-depth, to innovate materials based on this knowledge and to follow a micromechanical approach to describe their real performance. Material engineering influences composites on the microscopic scale and investigates effects on the microscopic and macroscopic scales. In general a direct engineering approach is used, meaning that per-phase properties of composite constituents are given directly in combination with microstructure information and composite properties are computed on that base. In research the approach allows to gain deep insight into materials and to systematically under- stand mechanisms that dominate the macroscopic material properties arising from the microscopic composition. Based on this understanding the purpose of material engineering is to further identify promising candidates for new composite materials thereby reducing the amount of experimental effort needed. This helps to save money and to reduce the time required to develop new materials. In industrial application the approach supports the design of composite structures by providing high quality micromechanical material models that can be used in integrative simulations to describe the performance of the part in the best way possible. The set-up of quantitative micromechanical models typically follows a reverse engineering strategy. The constituents parameters are varied in a characteristic physical range to match the global performance of the material as observed in anisotropic measurements. Material experts know the characteristics of their materials best. This knowledge arises from activities that cover the Measurement of anisotropic data Set-up & parameterization of micromechanical material models Figure I.1.2: Material experts deal with an in-depth view into materials, the screening of material candidates for innovation and the setup of micromechanical models that describe the

7 Structural Engineering Structural Engineering is the art of designing producable composite parts with low weight and best possible performances. The design of composite parts is a challenge due to the many influencing factors that impact the targeted performance. Composite material properties are highly sensitive to changes in their microstructure. Those changes can arise from the manufacturing of the part. Integrative simulations take into account local effects arising from the manufacturing process. Mi- crostructure information is fed into a micromechanical material model to describe realistically the distribution of material properties over the part. Results from coupled analyses can give quantitative correlation with the performance of the part as observed in measurements. In the simulation strategy the micromechanical model is used as a tool to map the influence of manufacturing onto the material properties as found in the part. Structural designers know the performance of their composite parts best. Modeling of composite parts is often performed in collaborative efforts that cover Design of composite structures Investigations on the manufacturing to assess the feasibility to produce the part Integrative strategies to understand the performance of the part in its application environment under the influence of the manufacturing process Figure I.1.3: Structural designers use integrative strategies to understand the performance of the part in its application environment under the influence of the manufacturing process.

8 Material exchange exchange is the idea to provide close communication between experts in material modeling and their counterparts in the design of composite structures. State-of-the-art micromechanical material modeling is a necessity for the realistic prediction of the performance of composite parts. But not all structural engineers are experts in material modeling. To set-up an integrative simulation on a high level of quality both parties must be involved and focus on their specific area of expertise. Material and structural experts are often distributed between different departments and companies. People who know their materials best are typically located directly at the material suppliers research centers. Key to success for the application of integrated composite modeling is a lively exchange of micromechanical material models between the experts groups. Digimat exchange offers access to different anisotropic measurements and quantitative microme- chanical models as provided by material suppliers. Current contributors to the public database are Solvay Engineering Plastics Solvay Speciality Polymers Sabic Ticona EMS Grivory LyonDellBasell Evonik Industries AG In addition, e-xstream engineering offers a broad range of generic models describing the performance of a family of composite materials in a global fashion. Figure I.1.4: exchange is the idea to provide close communication between material experts and structural designers.

9 Digimat I.2 Platform e-xstream engineering develops and commercializes the Digimat suite of software, a state-ofthe-art multi-scale material modeling technology that speeds up the development process for composite materials and structures. Figure I.2.1: The Digimat nonlinear multi-scale modeling platform Multi-scale modeling Digimat offers 3 different categories of products to its users: Tools A complete set of complementary interoperable software products focusing on expert usage for the purpose of material and/or structural engineering. Solutions Non-expert usage of Digimat technology from fully integrated GUI guided environments for specific tasks (e.g. running coupled analyses for short fiber reinforced plastic parts with Digimat-RP). expertise Knowledge transfer from 10+ years of experience in micromechanical modeling. Includes the Digimat documentation, a rich examples manual as well as access to e-xstream offers for support and training. Digimat related web forums can directly be accessed.

10 Industrial Usage Digimat is a predictive software that helps its users to design and manufacture innovative materials and parts with great efficiency in time and costs. Digimat users are found amongst CAE engineers, materials scientists and specialists in manufacturing processes of composite materials. Digimat is spread widely amongst material suppliers and end users in versatile industries: Automotive Aerospace Consumer Electrics and Electronics Industrial goods Defense Medical device etc. Today, the Digimat community covers the entire globe with major customers in Europe, America and Asia. Composite Materials Digimat is used to accurately predict the nonlinear micromechanical behavior of complex multi-phase composite materials and structures. A broad range of materials can be addressed: Short Fiber Reinforced Plastics UD Composites Woven Composites Nano Composites Hard Metals Ceramics Rubber

11 Digimat I.3 Tools Digimat tools can be combined in any fashion to result in an expert solution tailor made for the individual composite challenge. Figure I.3.1: Digimat expert tools for material microscopic and macroscopic scales. and structural engineering on the

12 Digimat-FE Digimat-FE is the tool used on the microscopic level to obtain an in-depth view into the composite material by the direct investigation of Representative Volume Elements (RVEs). Digimat-FE acts as a stochastic generator of highly realistic RVEs covering a large variety of materials: Plastics Rubbers Metals Ceramics Nano-filled materials Based on material input and the microstructure definition, a finite element model is built and run. The results of the FE analysis is post-processed in the sense of probabilistic distribution functions that give detailed insight into the RVE. Mean homogenized values are computed and can be used in subsequent FE analysis on the structural part level. Figure I.3.2: Digimat-FE analyses the distribution of properties in RVEs and derives homogenized mean values for subsequent computations.

13 Digimat-MF Digimat-MF is the mean field homogenization tool to rapidly compute the macroscopic performance of composite materials from their per-phase properties and microstructure definition. Digimat-MF is accurate, efficient and very easy to learn and use. Digimat-MF aims at the realistic prediction of the nonlinear constitutive behavior of multi-phase materials taking into account temperature and strain rate dependencies. The composite morphology such as filler content, length, aspect ratio and orientation take full impact on the resulting composite behavior. The technology is especially well suited to describe fiber reinforced composites: Short fiber reinforced plastics Long fiber thermoplastics Unidirectional composites Woven composites A broad range of performances can realistically be predicted: Stiffness Failure Creep Fatigue Conductivity (thermal & electrical) Figure I.3.3: Digimat-MF realistically predicts the stiffness & failure of fiber reinforced composite materials.

14 Digimat-MX Digimat-MX is the exchange platform that allows to reverse engineer, store, retrieve and securely share micromechanical models between material experts and designers of composite parts. The Digimat-MX platform stores anisotropic measurements and related micromechanical models. Embedded parameterization tools allow to adapt the material performance according to the experiments. Resulting Digimat models can be shared within large communities of different users. Intellectual property is assured by built-in encryption technology. Digimat-MX comes along with Public Data Ready-to-run Digimat material models Experimental data as a base for building Digimat material models Database setup & tools Flexible user/group scenarios Data import & reverse engineering of Digimat material models Encryption technology for secured sharing Figure I.3.4: The concept of exchange operates fully interactive with related Digimat tools and solutions.

15 Digimat-CAE Digimat-CAE centralizes the upstream and downstream interfaces for Digimat material models and bridges the gap between processing and the final performance of composite parts. It is the central tool for building coupled multi-scale analyses based on the manufacturing process. Local microstructure is taken into account and translated into a macroscopic material response. This results in a highly accurate prediction of the final performance of the composite part. Digimat-CAE offers GUI guidance for the set-up of integrative simulations and supports this approach via embedded Plug-Ins for GUI guidance in native FEA environments. Choices of Digimat multi-scale solution methods (MACRO/MICRO/HYBRID) allow to balance individually the need for accuracy and fast computa- tional time. Digimat-CAE supports interfaces to the following FEA solvers: Finite Element Analyses Marc MSC Nastran SOL400 & SOL700 Abaqus STD & explicit Ansys Samcef LS-Dyna implicit & explicit Figure I.3.5: Digimat-CAE bridges the gap between processing and the final performance of composite parts.

16 Plug-Ins to FEA Marc Mentat Abaqus CAE Ansys Workbench Hypermesh Lifetime Prediction (HCF) HBM ncode LMS Virtual.Lab Durability Microstructure input can be read from various sources. Typically an integrative approach is based on results from manufacturing simulations, but also coupling to experimentally obtained microstructure is possible: Molding Simulation Different processes can result in microstructure information: Injection molding MuCell Injection-compression molding Compression molding The following software formats are supported: Moldflow Midplane & 3D Moldex3D Midplane & 3D Sigmasoft Timon3D REM3D Simpoe Digimat (open format) Draping Simulation The following software formats are supported: Simulayt PAM-Form Digimat (open format) Computer Tomography The following software format is supported: Volume Graphics

17 Digimat-MAP Digimat-MAP is the mapping software used to transfer data between dissimilar meshes. A rich set of embedded tools allows full control over the required workflows: Manipulation of meshes Measurement of positions, distances and angles Manual superposition Automated superposition Transfer of data Fiber orientation, volume fraction & aspect ratio Temperature Residual stresses Location of weldlines Quality Assessment Global & local error analysis Visualization & Post-Processing Display of mapped microstructure (scalar, tensor vector & ellipsoidal plot) Investigation of local stiffness Figure I.3.6: Digimat-MAP comes with a rich set of tools to allow full control over all required steps in the mapping workflow.

18 Digimat I.4 Solutions Digimat solutions offer GUI guided workflow environments to aid the user in specific and well defined tasks of the virtual design of composite materials & structures. Figure I.4.1: Digimat solutions convert complex multi-scale modeling workflows into easy-to-use GUI environments. State-of-the-art in the design of composite parts is bringing together material experts, composite part designers and the analysts of the part manufacturing. Multi-scale simulations and in-depth knowledge in micromechanical material modeling is needed to realistically compute the performance of a composite part. Digimat solutions Transfer high-end micromechanical modeling to the composite communities Offer GUI oriented platforms for the virtual design of composite materials & parts Can easily be used by the non-experts Enable all involved parties in the composite design to collaborate in a synergetic fashion Digimat solutions are based on expert workflows that have been tested for robustness and efficiency. Each environment is dedicated to a specific composite design task only. Micromechanical modeling is embedded as the central link between the composite s complex microstructure and the impact on the final performance. Material models are either part of Digimat solutions or can easily be accessed via Digimat exchange. Templates allow to manage different simulation scenarios without in-depth knowledge of the underlying pa- rameters of the multi-scale engine.

19 Digimat-RP Digimat-RP is the solution for the virtual design of injection molded fiber reinforced plastic parts. Lightweight engineering re-designs metal parts into fiber reinforced plastics produced by injection molding. For reinforced plastics manufacturing procedures influence the material microstructure. The effect of local fiber orientation leads to a distribution of material properties over the part. This can drastically influence its final performance and must be taken into account in the design procedures. Multi-scale simulations read local fiber orientations from injection molding simulations and feed them into a micromechanical material model. The distribution of local properties is taken into account in the computation of the final performance of the part. Digimat-RP allows to Load finite element analyses of a broad range of different solvers Assign a micromechanical material model to a specific part Choose a robust & fast multi-scale simulation method for a coupled analysis Map local microstructure information onto the part Launch & monitor the coupled analysis Access the results of the multi-scale simulation Figure I.4.2: Digimat-RP is dedicated to the setup of integrative simulations for fiber reinforced plastics and leads through the full workflow based on injection molding simulations.

20 Digimat-HC Digimat-HC is the solution for the virtual design of honeycomb composite sandwich panels. The performance of composite sandwich panels depends on the properties of the skin and the core. These are determined by the choice of the underlying microstructure. The core is sensitive to the structure of the constituting honeycomb. The composite skins feel the selected type of fibers and stacking of layers with different orientations. Design choices are typically investigated in bending and shear tests. The virtual design of a composite sandwich panel requires a multi-scale modeling strategy to be able to map the effect of the microstructure onto the macroscopic performance of the panel. In a coupled analysis the full setup of the panel can be varied and the impact on the final performance under bending and shear investigated in an easy & efficient way. Digimat-HC allows to Set up the structure of a composite sandwich panel Define the properties of the core (honeycomb & foam) Define the properties of the skins (UD, woven & chopped fibers) Investigate the panel design under different scenarios (3-/4-point-bending & shear) Flexibly access the results of the analysis (field plot & through-thickness path analysis) Figure I.4.3: Digimat-HC enables to investigate the performance of honeycomb composite sandwich panels under bending or shear.

21 Digimat I.5 expertise e-xstream engineering accumulates over 10 years of experience in innovation and knowledge transfer for material scientists in all industries of Europe, America and Asia. e-xstream engineering develops and commercializes Digimat, the state of the art multi-scale material modeling technology that speeds-up the development of composite materials and parts. Missions are to Investigate and predict the behavior of a large mix of composite materials Reduce material testing and prototyping Improve prediction of structural FEA by accounting for manufacturing process Guide the design & manufacturing of innovative high-performance composite parts Minimize weight, cost and time-to-market for industrial composite parts e-xpertise is structured in separate categories: Training Services Partnership Certification

22 Training e-xstream engineering provides a complete training service with the Digimat software package. The aim is to transfer knowledge about the best practice of Digimat usage. Digimat trainings are organized regularly in Europe, USA and Asia. Basic and Advanced Levels target the topics of Material Engineering (focus on Digimat-MF, Digimat-FE and Digimat-MX) and Structural Engineering (focus on Digimat-CAE and Digimat-MX). e-xstream engineering also offers customized training, 100% tailored to the customers specific needs and organized at the customer site. Besides general training and technology transfer the aim is to directly set up customer specific models. More information on training services are available at support@e-xstream.com Services The Engineering Services team works closely with customers to support their specific needs in getting more accurate predictions of the micro-mechanical behavior of composite materials and parts. Typical engineering projects involve: The use of Digimat to solve advanced material and structural modeling problems The development and collaborative validation of new Digimat capabilities of interest for the customer The Engineering Services team can be contacted at engineering.services@e-xstream.com Certified Consultants Digimat Certified Consulting Partners are independent engineering companies combining a high level of technical and industry expertise with hands-on skills to deliver best in class engineering services to their customers. Collaborative projects with a Digimat Certified Consulting Partner offer: Expertise in Digimat along with direct support Experience in multi-industry engineering projects Local services, flexible team and customizable projects Enrolling in the Digimat Certified Consulting Partner network empowers to: OFFER Comprehensive and Fully-Integrated Composite Simulation Analyses MASTER State-of-the-art Material and Structural Modeling Technologies OPTIMIZE Simulation Workflow from Process to Structure INNOVATE By bringing Composites Insight in your Engineering Projects GROW Your Market Share and Business Profitability Join the Digimat Certified Consulting Partners network! Contact: zoubida.elhachemi@e-xstream.com

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