Structural composites in industrial applications: future solutions for today's engineering challenges in design and simulation

Transcription

1 Structural composites in industrial applications: future solutions for today's engineering challenges in design and simulation Prof. dr. ir. Wim VAN PAEPEGEM Mechanics of Materials and Structures (MMS) research group Department of Materials Science and Engineering Ghent University (UGent) - Faculty of Engineering Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 1

2 Outline What are composites? Design and simulation Composites are not isotropic! Homogenization of elastic properties From single ply to structural analysis Predicting damage/nonlinearity Virtual testing for manufacturing simulations Conclusions Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 2

3 What are composite materials? Composites = a combination of two or more chemically different phases with a distinct interface between them. (< Latin: componere = combine) Focus in this presentation on fibre-reinforced plastics (FRP) for structural applications Reinforcing fibres (typical size of 10 m) > glass fibre > carbon fibre > aramid fibre Polymer matrix > thermoset (epoxy, polyester, vinylester) > thermoplast (polypropylene, polyether-ether-keton/ PEEK, thermoplastic polyester/ PET ) Slide 3

4 Different reinforcement architectures Random mat of chopped fibres unidirectional (UD) alignment of reinforcing fibres Textile architectures (weaving, knitting, braiding, etc.) Mat with chopped glass fibres Unidirectional alignment of carbon fibres Layers of plain weave glass fabric (with warp and weft directions) Slide 4

5 Individual ply (= lamina) Stacking of multiple plies (=laminate) z x y [0 /+15 /-15 /90 /90 /-15 /+15 /0 ] = [0 /+15 /-15 /90] s Slide 5

6 Materials of the future Today s engineering challenges Nanocomposites Graphene composites Ultralight and ultrastrong carbon fibres Ductile reinforcement fibres Bio-composites Self-healing composites Source: Mercedes, BMW, Airbus, LM Glasfiber Slide 6

7 Outline What are composites? Design and simulation Composites are not isotropic! Homogenization of elastic properties From single ply to structural analysis Predicting damage/nonlinearity Virtual testing for manufacturing simulations Conclusions Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 7

8 C C C C C C C C C C C C e 1 e 2 Local material axes, and e 3 9 independent elastic constants: - 6 stiffnesses E 11, E 22, E 33, G 12, G 13 and G 23, - 3 Poisson s ratios 12, 13 and 23 Slide 8

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10 Shear deformation of pultruded beam elements 63% bending deformation 37% shear deformation W. De Corte (2013). Structural application of composites in civil engineering : case study based opportunities and challenges. SAMPE Benelux meeting, VUB, Belgium Slide 10

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12 Outline What are composites? Design and simulation Composites are not isotropic! Homogenization of elastic properties From single ply to structural analysis Predicting damage/nonlinearity Virtual testing for manufacturing simulations Conclusions Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 12

13 Micro-meso-macro homogenization methods Experimental Numerical Wednesday, 23 March 2016 Slide 13

14 DONE Finite element micro-mechanical homogenization Homogenisation principle FIBRE (carbon) [Mpa] 36,320 elements MATRIX (epoxy) [Mpa] Slide 14 [Mpa]

15 Micro-scale modelling F.E. mesh of SERVE containing CPE4R and 9014 CPE3 elements Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 15

16 Meso-scale modelling X-ray micro-ct scan Abaqus FE model 16 Slide 16

17 Meso-scale modelling 3D periodic boundaries infinite stack of plies 2D periodic boundaries one ply 17 Slide 17

18 Outline What are composites? Design and simulation Composites are not isotropic! Homogenization of elastic properties From single ply to structural analysis Predicting damage/nonlinearity Virtual testing for manufacturing simulations Conclusions Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 18

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20 For closed rib deck : shear failure not expected W. De Corte (2013). Structural application of composites in civil engineering : case study based opportunities and challenges. SAMPE Benelux meeting, VUB, Belgium Slide 20

21 20MW turbine Rotor diameter: ~250m Tower: ~150m Source: UpWind Top: 279m Hub: 153m Atomium: 102m A380: 80m span Slide 21

22 1.9. Uitbreiding van de wet van Hooke voor anisotrope materialen Slide 22

23 Structural analysis Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 23

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25 Eigenmodes and eigenfrequencies Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 25

26 Source: Fraunhofer IWES, Saddles on blade surface via distributing couplings Department of Materials Science and Engineering Ghent University Faculty of Engineering Loads -> cables: force orientation changes as the blade deflects Slide 26 Pulleys (attached to the floor)

27 Outline What are composites? Design and simulation Composites are not isotropic! Homogenization of elastic properties From single ply to structural analysis Predicting damage/nonlinearity Virtual testing for manufacturing simulations Conclusions Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 27

28 Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 28

29 Slide 29

30 Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 30

31 14680 hours = 1835 working days of 8 hours 60 months 5 years Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 31

32 TOP-VIEW BOTTOM-VIEW yy [-] x y Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 32

33 Impact of composite bumper beam Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 33

34 18 fibers Vol fraction = 60.3 % Slide 34

35 Coated fabrics for tent structures Structural level Macro-scale level Meso-scale level Slide 35

36 Coated fabrics for tent structures Slide 36

37 Coated fabrics for tent structures Experimental data Simulation data Slide 37

38 Outline What are composites? Design and simulation Composites are not isotropic! Homogenization of elastic properties From single ply to structural analysis Predicting damage/nonlinearity Virtual testing for manufacturing simulations Conclusions Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 38

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40 Draping simulation of dry fabric on mould tool Spare wheel well (outer part) draping simulation with glass/pet fabric problems expected for draping cuts are necessary Source: M. Huebner, TUDresden Slide 40 40

41 Draping simulations need a lot of experimental input Source: J.-E. Rocher, G. Hives, S. Allaoui (Universite d Orleans) Slide 41 41

42 Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 42

43 Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 43

44 Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 44

45 Virtual draping of the dry fabric Overall view Top view Slide 45

46 Virtual draping of the dry fabric Excessive opening of fabric Shearing and compaction Slide 46

47 Slide 47

48 Outline What are composites? Design and simulation Composites are not isotropic! Homogenization of elastic properties From single ply to structural analysis Predicting damage/nonlinearity Virtual testing for manufacturing simulations Conclusions Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 48

49 Slide 49

50 Comparison of static deflection analysis with geometric nonlinearity Y Z X Slide 50

51 Composites UGent MMS Additional information? Contact: Wim Van Paepegem (Wim.VanPaepegem@UGent.be) Ghent University Faculty of Engineering Department of Materials Science and Engineering Technologiepark - Zwijnaarde 903 B-9052 Gent Belgium Slide 51