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

Transcription

1 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

2 Amsterdam, October 2012 e-xstream engineering, an MSC Software company Who are we...? Software & Engineering company 100% focused on advanced material modeling. Founded in 2003 Acquired by MSC Software in Sept 2012 Team of ~35 persons Material experts Micromechanics It s all about... COMPOSITES DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

3 Multi-Scale Modeling of Composites Challenges Inter-dependencies in the Design of a Composite Part Manufacturing sets local microstructure Structural design influences processing Local microstructure sets material properties DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

4 Digimat, from manufacturing to performance Material Processing Material Microstructure Material Characteristics Component/System Performance Injection, Compression,... Drapage, AFP,... Chopped fibers Continuous fibers: UD/Woven Nano,... Mechanical Thermal Electric,... Stiffness Strength Fatigue Creep, Process FEA Material Testing & Modeling Structural FEA Molding Draping DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

5 Digimat users community today Material Suppliers Plastics Composites Other: Rubber, Metals, Ceramics, Automotive OEMs Tier 1 Aerospace Aero Structures (OEMs) Aero Engines Electric & Electronic Electronic Appliances: Mobile Phones, Cameras, Electric : Connectors, transformers, Defense DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

6 DIGIMAT DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

7 Digimat, The nonlinear multi-scale modeling platform Digimat-MF to predict the nonlinear constitutive behavior of multi-phase material. Digimat-FE to perform Finite Element modeling of realistic Representative Volume Elements (RVE). Digimat-MX platform to reverse engineer, store, retrieve and securely exchange DIGIMAT material models. Digimat-CAE Interfaces to all major injection molding and structural FEA software codes. Digimat-MAP Shell and 3D mapping software. Micross to design honeycomb or foam core composite sandwich panels based on FE analyses. DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

8 Digimat Material Engineering Digimat to model the behavior of material Virtual lab Material database to store & exchange data Reverse engineering tool to characterize the Digimat material model DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

9 Digimat: Prediction of material behavior Fast & efficient prediction of composite material properties (Thermo-)Mechanical Electric Thermal DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

10 Digimat Structural Engineering Digimat to predict the behavior of component Mapping technology Interface to FE, Manufacturing & Fatigue software Bending and in plane shear tests of sandwich panels DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

11 Digimat, to bridge the gap between process and FEA Strain Stress & Stiffness Matrix DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

12 MATERIAL ENGINEERING DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

13 Digimat to predict the material properties DIGIMAT Models Dependent on the microstructure Mori-Tanaka homogenization Influence of fillers: amount, shape, orientation,... DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

14 Digimat to predict the material properties DIGIMAT Models Standard behaviour (Thermo-) Elastic (Thermo-) Elastoplastic (Thermo-) Viscoelastic (Thermo-) Elasto-Viscoplastic f(ot) ANISOTROPY f(t) TEMPERATURE f(t ) STRAIN RATES High strain rates Creep DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

15 Digimat to predict the material properties DIGIMAT Models More complex behaviour Creep (Thermo-) Viscoelastic (Thermo-) Elasto-viscoplastic Viscoelasto-Viscoplasticity Fatigue (Thermo-) Hyperelasticity Leonov Large strain polymer model Viscoelastic-viscoplastic Fatigue VE Matrix Composite TVE Matrix Composite G 0, K 0 and CTE Constant TVE Matrix Composite G 0 =G 0 (θ), K 0 = K 0 (θ) and CTE Constant TVE Matrix G 0 =G 0 (θ), K 0 = K 0 (θ) and CTE=CTE(T) Creep Relaxation (TVE) DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

16 Digimat to predict the material properties Stiffness Use Digimat-MF to get material properties Chopped fiber with skin/core effect Courtesy of: Modulus (MPa) Digimat Experience True stress (MPa) _exp 15 _exp 30 _exp 45 _exp 60 _exp 90 _exp 0 Digi 15 _Digi 30 _Digi 45 _Digi 60 _Digi 90 _Digi Angle ( ) 0 0 0,02 0,04 0,06 0,08 True strain gate α Tensile specimen DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

17 Digimat to predict the material properties Stiffness Use Digimat-MF to get material properties Continuous fiber Woven microstructure DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

18 Digimat to predict the material properties Failure Wide range of failure criteria (2D & 3D) Can be assigned at various level (macro, micro & pseudo-grain) Can be assigned in various axis systems Can be Strain-rate dependent Example on SFRTP Tsai-Hill-3D transversely isotropic Stress or strain based full 3D failure! DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

19 stress Digimat to predict the material properties UD Composites Failure Fiber failure Failure on a test specimen Defined on microscopic level Unique for each ply Reacts differently depending on fiber orientation Application on a test specimen DIGIMAT Experiment Plain compression Open hole compression strain DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

20 COMPONENT / SYSTEM STRATEGY DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

21 Coupled Analyses From Processing to FEA Short Fiber Reinforced Plastics ANISO Measurements FEA Structural analysis s/e curves failure ISO Material Model Anisotropic (non)linear fibers Mapping Structural mesh Process Simulation Injection Molding Copyright e-xstream engineering,

22 Coupled Analyses From Processing to FEA Short Fiber Reinforced Plastics Weldlines / flow lines Automatically included via microstructure Fiber orientations Accumulated plastic strain in material matrix Copyright e-xstream engineering,

23 Coupled Analyses From Processing to FEA UD & Woven Measurements FEA Structural analysis s/e curves Material Model Anisotropic (non)linear UD warp Woven warp & weft Process Simulation Draping Copyright e-xstream engineering,

24 COMPONENT / SYSTEM APPLICATIONS DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

25 Some applications in the automotive industry DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

26 Engine mount Lightweight reduction Coupling to injection molding DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

27 Multi-Scale Modeling of an Over-Molded Beam Overmolded Beam Short fiber reinforced plastics Injection molding HYBRID solution Woven composite Draping MICRO solution DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

28 Multi-Scale Modeling of an Over-Molded Beam Overmolded Beam Coupled analysis Force response Global Injection molded vs. Over molded beam Injection molded SFRP Over molded Woven + SFRP DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

29 DIGIMAT-CAE/LS-DYNA FOR FULL CAR CRUSH DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

30 Full car crush with Digimat-CAE/LS-Dyna Full Vehicle Pedestrian safety Bumper beam Elements Ave. elem size Min. time step 3.1 Mio 5.0 [mm] 0.25 [msec] DIGIMAT 0.84% (26.000) 10 domains have no DIGIMAT elements DIGIMAT elements in 22 domains TME Meeting, July 2013 Copyright e-xstream engineering,

31 Full car crush with Digimat-CAE/LS-Dyna Full Vehicle Acceptable increase of calculation time 9 14 hours on 32 cores Only 8 hours on 64 cores YES WE CAN!!!!! Loss in efficiency for ISOTROPIC On 64 cores Overhead of communication ISOTROPIC improved 16 cores 32 cores 64 cores 17 h 59 m 9 h 17 m 10 h 0 m HYBRID default HYBRID improved HYBRID optimized - 42 h 31 m - 26 h 37 m 14 h 16 m 8 h 15 m - 12 h 5m - MICRO improved h 51 m (6.4 days) - TME Meeting, July 2013 Copyright e-xstream engineering,

32 Full car crush with Digimat-CAE/LS-Dyna Full Vehicle Pedestrian Protection test Max Princ stress Failure point Iso Hybrid 5.0[ms] 10.0[ms] DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

33 Full car crush with Digimat-CAE/LS-Dyna Full Vehicle Front crash Comparison to isotropic Stress distribution different Failure area different ISO 10.0[ms] ANISO 15.0[ms] TME Meeting, July 2013 Copyright e-xstream engineering,

34 CONCLUSION Copyright e-xstream engineering, 2013

35 SUMMARY: DIGIMAT EMPOWERS TO MODEL: Material Plastics Composites Rubber Other (multi-phase)? Industry Chemical (Material Suppliers) Automotive (OEM & Suppliers) Aerospace (OEM & Suppliers) E&E (OEM & Suppliers) Application Compound: Plastics, rubber, Auto Interior: IP, Airbag Auto Powertrain: Oil pan, Engine Cover, Aero: Engine, Body, Performance Stiffness, Vibration Crash/Failure Creep Fatigue Technology Nastran, Marc Abaqus, Ansys, Ls-Dyna, Radioss, Moldflow, Moldex, DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,

36 Thank You!! Dr. Guillaume Boisot Business Development Engineer W: M: +33 (0) E: guillaume.boisot@e-xstream.com IM: ex_gbt (Skype) e-xstream engineering Z.A.E. Robert Steichen 5, Rue Bommel Hautcharage L-4940 LUXEMBOURG DYNAmore Nordic Conference, Sept 2013 Copyright e-xstream engineering,