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
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
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
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
Individual ply (= lamina) Stacking of multiple plies (=laminate) z x 0 15-15 90 90-15 15 0 y [0 /+15 /-15 /90 /90 /-15 /+15 /0 ] = [0 /+15 /-15 /90] s Slide 5
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
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
11 22 33 23 13 12 C C C 0 0 0 11 12 13 C C C 12 22 23 0 0 0 C C C 13 23 33 0 0 0 C 0 0 0 44 0 0 0 0 0 0 C 0 55 0 0 0 0 0 C66 11 22 33 23 13 12 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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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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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
Micro-meso-macro homogenization methods Experimental Numerical Wednesday, 23 March 2016 Slide 13
DONE Finite element micro-mechanical homogenization Homogenisation principle FIBRE (carbon) [Mpa] 36,320 elements MATRIX (epoxy) [Mpa] Slide 14 [Mpa]
Micro-scale modelling F.E. mesh of SERVE containing 308821 CPE4R and 9014 CPE3 elements Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 15
Meso-scale modelling X-ray micro-ct scan Abaqus FE model 16 Slide 16
Meso-scale modelling 3D periodic boundaries infinite stack of plies 2D periodic boundaries one ply 17 Slide 17
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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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
20MW turbine Rotor diameter: ~250m Tower: ~150m Source: UpWind Top: 279m Hub: 153m Atomium: 102m A380: 80m span Slide 21
1.9. Uitbreiding van de wet van Hooke voor anisotrope materialen Slide 22
Structural analysis Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 23
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Eigenmodes and eigenfrequencies Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 25
Source: Fraunhofer IWES, www.compositesworld.com 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)
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
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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
TOP-VIEW BOTTOM-VIEW yy [-] x y Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 32
Impact of composite bumper beam Department of Materials Science and Engineering Ghent University Faculty of Engineering Slide 33
18 fibers Vol fraction = 60.3 % Slide 34
Coated fabrics for tent structures Structural level Macro-scale level Meso-scale level Slide 35
Coated fabrics for tent structures Slide 36
Coated fabrics for tent structures Experimental data Simulation data Slide 37
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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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
Draping simulations need a lot of experimental input Source: J.-E. Rocher, G. Hives, S. Allaoui (Universite d Orleans) Slide 41 41
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Virtual draping of the dry fabric Overall view Top view Slide 45
Virtual draping of the dry fabric Excessive opening of fabric Shearing and compaction Slide 46
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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
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Comparison of static deflection analysis with geometric nonlinearity Y Z X Slide 50
Composites Research @ 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