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)4 28 27 10 63 Mob: +33 (0)7 86 98 93 06 E-mail: alexandre.roussel@e-xstream.com
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, 2014 2
CHALLENGES IN THE INDUSTRY High-Performing Products Eco-Friendly MSC Software Confidential 3 Cost-Effective
COMPOSITES IS THE ANSWER BUT WHICH MATERIAL TO SELECT? Copyright 2014 e-xstream engineering 4
What are the Challenges in Modeling Composites? Nonlinear Anisotropic Strain Rate Dependent Process Dependent MSC Software Confidential 5
Let s take a simple example MSC Software Confidential 6
With Classical FE Modeling tools MSC Software Confidential 7
Front-end Injection Process Skin Core MSC Software Confidential 8
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
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
Digimat Your Solution for Composites Modelling and Design Optimization
Digimat: the material modeling platform MSC Software Confidential 12
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
Market Segments Multi-Phase Materials Plastics Composites Other Material Suppliers Auto Aero E&E Aero Auto Material Suppliers All Industries Copyright 2014 e-xstream engineering 14
Compression process Injection process Drapping process DIGIMAT COVERS MULTIPLE PROCESSES IN AUTOMOTIVE 9/29/2016 Copyright e-xstream engineering, 2014 15
DIGIMAT COVERS MULTIPLE MATERIALS MSC Software Confidential 16
DIGIMAT COVERS MULTIPLE PERFORMANCES IN AUTOMOTIVE Oil filter MSC Software Confidential 17
DIGIMAT COVERS MULTIPLE SCALES MSC Software Confidential 18
DIGIMAT COVERS MULTIPLE CAE SOLUTIONS MSC Software Confidential 19
Digimat THE Standard Solution today for Composites AUTOMOTIVE exemples
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
What difference between isotropic and anisotropic approach?
Thrust Pedal: Injection Molding Simulation MSC Software Confidential 23
Thrust Pedal Fiber Orientation MSC Software Confidential 24
Thrust Pedal Displacement & Stress Displacement 900 N Force Applied Stress isotropic anisotropic 0-50 mm range 0-100 MPa range MSC Software Confidential 25
Fiber Orientation Engine Cover: Injection Molding Simulation MSC Software Confidential 26
Engine Cover Modal Analysis Natural Frequency Max. Displacement Mode Isotropic Anisotropic Isotropic Anisotropic 1 96.0 101.4 214.9 205.1 2 322.2 329.8 245.4 220.7 3 345.0 357.3 235.4 227.4 4 410.5 423.2 311.2 288.7 5 464.9 485.8 374.5 355.3 6 616.5 641.9 320.6 310.6 MSC Software Confidential 27
What about reality and simulation?
ENGINE COOLING VIBRATION Courtesy of Fan System Copyright e-xstream engineering, 2014
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
FLAP MODAL ANALYSIS Courtesy of Copyright e-xstream engineering, 2014
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 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 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
What about metal replacement and functionalization by SFRP parts?
Simulation driven product development 9/29/2016 Copyright e-xstream engineering, 2014 36
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, 2014 37
What about return on investment for early design modeling of SFRP parts?
AIR DUCT: STIFFNESS Copyright 2014 e-xstream engineering 39
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! $500 000 saved in testing costs per program MSC Software Confidential 40
How to use Digimat tools for your applications? Example of Digimat RP
3 key steps in plastic part design with Digimat RP? 9/29/2016 Import FEA model Select Digimat model Copyright e-xstream engineering, 2014 42 Provide Estimatelocal fiber microstructure orientation inside Digimat-RP
Digimat-RP/ Fiber orientation estimator 9/29/2016 Copyright e-xstream engineering, 2014 43
Optimazing gating system 9/29/2016 Copyright e-xstream engineering, 2014 44
More than a modeling platform an users community
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
Customer Testimonials MSC Software Confidential 47
DIGIMAT, fully adopted by the Automotive supply chain Efficient Materials & Components Integration User-Friendly Data Exchange MSC Software Confidential 48
Copyright 2014 e-xstream engineering 49
Conclusions
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 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
More demonstrations on the e-xstream booth! MSC Software Confidential 53
Thank you! Alexandre Roussel Business Development Manager alexandre.roussel@e-xstream.com Tel: +33 (0)4 28 27 10 63 Mob: +33 (0)7 86 98 93 06