m3 program accelerating the engineering process: from ......06 june 2017 23/# dept. of materials ,...
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Prof. Wim VAN
PAEPEGEM06 June 2017 1/#
Dept. of Materials , Textiles
and Chemical Engineering
Partners:
M3 program – accelerating the
engineering process: from materials to
applications
Twin M3Strength projects
Prof. Wim VAN
PAEPEGEM06 June 2017 2/#
Dept. of Materials , Textiles
and Chemical Engineering
• M3 Program and addressed domains in the twin M3Strength
projects
• Key R&D details of the twin M3Strength projects and related
industrialization1. Composites fatigue modelling
2. Quasi-static and dynamic multi-scale modelling
3. Effect of defects by multi-scale modelling
4. Composites dynamic modelling for crash and crush
• Summary
Outline
Prof. Wim VAN
PAEPEGEM06 June 2017 3/#
Dept. of Materials , Textiles
and Chemical Engineering
Knowledge centers
Industry
Solving lightweight
challenges
by
advanced testing
& simulation
M3 MacroModelMat program
Prof. Wim VAN
PAEPEGEM06 June 2017 4/#
Dept. of Materials , Textiles
and Chemical Engineering
Twin projects “M3Strength”
Multi-attribute strength of composites
Application-driven, multi-
attribute (static-, fatigue-,
impact-strength) efficient
simulation methods
Efficient
predictive
modeling
…
Virtual Material
Characterization
…
As-manufactured properties…
Composite simulation Composite testing
Fatigue of inter- and intra-
ply
Strain-rate dependent
behavior of composites
Micro- and meso-scale unit
cell modeling
Homogenization techniques
Effect of defects in
composites
Modeling and testing of 3D
woven
Behavior of foams an link to
helmet CAE challenge
… by multi-scale modeling
Prof. Wim VAN
PAEPEGEM06 June 2017 5/#
Dept. of Materials , Textiles
and Chemical Engineering
Understanding behaviour of materials by
Experimental characterization
Foams
Static + fatigue Effect of defects
(static)
Impact and
crushing
Intralaminar
properties
(inside the
plies)
Interlaminar
properties
(between
the plies)
UD and Woven fabric +
0//0 and off-axis
interfaces
➢ Mode I
➢ Mode II
➢ Mixed I-II
UD and Woven fabric
Static : T & C
Fatigue: TT, CT and CC
3 lay-up sequences
Voids
Delamination
(defect)
Challenges
Key points
• Full mechanical material
characterization in static, fatigue
and dynamic (Multi-attribute)
• Robust testing method
development
• Link between material
characterization and parameter
identification for simulation
• Large amount of samples (~3000)
and data processing
• Non-standard testing to be
developed
• Cover several material factors
(e.g. strain-rate, temperature)
Foams
Delamination
3D woven
fabrics
Prof. Wim VAN
PAEPEGEM06 June 2017 6/#
Dept. of Materials , Textiles
and Chemical Engineering
• M3 Program and addressed domains in the twin M3Strength projects
• Key R&D details of the twin M3Strength projects and related
industrialization1. Composites fatigue modelling
2. Quasi-static and dynamic multi-scale modelling
3. Effect of defects by multi-scale modelling
4. Composites dynamic modelling for crash and crush
• Summary
Outline
Prof. Wim VAN
PAEPEGEM06 June 2017 7/#
Dept. of Materials , Textiles
and Chemical Engineering
Composites fatigue modelling
Intra- and inter-laminar behaviour
Challenges
Efficient and reliable
simulation of fatigue damage
phenomena
Key points
• Intraply damage – Continuum
Damage Modelling (CDM)
•Micro-cracking
•Meta-delamination
• Interply damage – Cohesive
zone model (CZM)
•Delamination onset and
propagation
Based on failure type, amplitude & max.
stress Accurate
Micro-crack initiation prediction
Stress transfer matrix Efficient mapping
of global stress to local stresses
Brittle failure Shear failure
COUPON
FEM
with
CZM
G-N curve
(DIC)FEM
(CZM)
1
Prof. Wim VAN
PAEPEGEM06 June 2017 8/#
Dept. of Materials , Textiles
and Chemical Engineering
Continuous fiber composites
Intra/Interlaminar fatigue prediction
Added values
• Prediction of continuous fiber
composite behavior for high cycle
fatigue
• Intra/inter-laminar coupling fatigue
• Multiaxial and variable amplitude
loadings.
Key points
• Intralaminar fatigue prediction via
stiffness degradation
• Combined with interlaminar
fatigue onset/ re-onset prediction
via energy release rate
degradation
• Non-Linear calculation to predict
accurate stress and strain fields
Road condition =
Variable Amplitude loading
Multi-axial loading
Intralaminar
Interlaminar
Energy release rate degradation
Linear damage accumulation
Intralaminar
Stiffness degradation
Permanent strain
Mean stress effects
Initial damage due to first loading
cycle➢ Considering stress/strain redistribution after damage accumulation for
both intralaminar and interlaminar elements
➢ Non-Linear FE calculation for delamination onset/re-onset prediction
Interlaminar
Free edge
Buckling
Radius , Ply drop-off…
1
Prof. Wim VAN
PAEPEGEM06 June 2017 9/#
Dept. of Materials , Textiles
and Chemical Engineering
• M3 Program and addressed domains in the twin M3Strength projects
• Key R&D details of the twin M3Strength projects and related
industrialization1. Composites fatigue modelling
2. Quasi-static and dynamic multi-scale modelling
3. Effect of defects by multi-scale modelling
4. Composites dynamic modelling for crash and crush
• Summary
Outline
Prof. Wim VAN
PAEPEGEM06 June 2017 10/#
Dept. of Materials , Textiles
and Chemical Engineering
Composites quasi-static and dynamic
Multi-scale modelling
Challenges
•Sequential multiscale:
micro meso macro
•Virtual tests reduce
experimental ones
Key points
• Dedicated models for each scale.
• Non-linear and damage response.
• Static, fatigue or impact loads.
• Simulation tools for:
• composite design
• mechanical improvement
• cost reduction.
Microscale Mesoscale Macroscale
[0/90]4
2
Prof. Wim VAN
PAEPEGEM06 June 2017 11/#
Dept. of Materials , Textiles
and Chemical Engineering
Virtual Material Characterization (VMC)
by multi-scale modelling
Added values•Multi-scale simulation replacing
experimental testing
•Support of different composites and
different scales
•Efficient generation of mechanical
material data
Key points•CAD interface to geometry modeler
WiseTex (KULeuven MTM)
• Fast homogenization method by
TexComp (KULeuven MTM) for
stiffness predictions
•Advanced FE-based homogenization
by ORAS (UGent MMS)
Models Material data
Homogenization
Micro scale (yarn level)
Meso scale (textile/ UD level)
VMC ToolKit
2
Prof. Wim VAN
PAEPEGEM06 June 2017 12/#
Dept. of Materials , Textiles
and Chemical Engineering
3D Woven performance
by multi-scale modeling
Added values
•Simulation-based
optimization of 3D-woven
structures
Key points
Virtual testing
Woven fabrics
Resin selection
• Viscosity, rheology
• Wettability, permeability
• Mechanical properties
→Synolite 8388-P-1
Flatwise and edgewise
compression (square)
Material selection
New set up to open up the
fabric during impregnation
• Innovative weaving
capabilities to meet multi-
attribute requirements at
minimal weight
•Extensive experimental
program on coupons and
for optimal resin selection
•Feasibility check of multi-
scale simulation
Composite production Mechanical testing
• Honeycomb structures
• Square structures
2
Prof. Wim VAN
PAEPEGEM06 June 2017 13/#
Dept. of Materials , Textiles
and Chemical Engineering
• M3 Program and addressed domains in the twin M3Strength projects
• Key R&D details of the twin M3Strength projects and related
industrialization1. Composites fatigue modelling
2. Quasi-static and dynamic multi-scale modelling
3. Effect of defects by multi-scale modelling
4. Composites dynamic modelling for crash and crush
• Summary
Outline
Prof. Wim VAN
PAEPEGEM06 June 2017 14/#
Dept. of Materials , Textiles
and Chemical Engineering
Effect of defects by multi-scale modelling
Challenges
Predicting the effect of voids
on statistically-controlled
damage in fiber-reinforced
composites confronts the scale
issue
Key points
• Developing a combined micro-
meso approach for simulation of
transverse cracking in the
presence of voids
• In-situ monitoring of mechanical
tests at the meso- and micro-scale
to obtain crack density evolution 0
16
32
48
64
0 0.003 0.006 0.009
σxx
(M
Pa)
εxx
reference model
model with void
Transverse cracks detected by digital image
correlation in loading micrographs
Micro-scale finite element modeling of
transverse damage
3
Prof. Wim VAN
PAEPEGEM06 June 2017 15/#
Dept. of Materials , Textiles
and Chemical Engineering
Modeling evolution
of transverse
cracking linked to
CDM models in
Siemens software
Composites as-manufactured properties
Effect of intra- and inter-laminar defects
Added values
Simulation-based assessment
of effect of defects allowing
analysis of properties
degradation
Key pointsIntra-laminar defects:
• Developing a combined micro-
meso approach for simulation of
transverse cracking in the
presence of voids
Inter-laminar defects:
• 4P bending on omega-stiffener
sections with initial delam.
experiments vs. simulations
•Modeling the same
geometry and lay-up as
in the real specimen in
Siemens software
•Cohesive zone between
flange and skin
homogenized
Micro-level modeling of effect of
voids on transverse failure
3
Prof. Wim VAN
PAEPEGEM06 June 2017 16/#
Dept. of Materials , Textiles
and Chemical Engineering
• M3 Program and addressed domains in the twin M3Strength projects
• Key R&D details of the twin M3Strength projects and related
industrialization1. Composites fatigue modelling
2. Quasi-static and dynamic multi-scale modelling
3. Effect of defects by multi-scale modelling
4. Composites dynamic modelling for crash and crush
• Summary
Outline
Prof. Wim VAN
PAEPEGEM06 June 2017 17/#
Dept. of Materials , Textiles
and Chemical Engineering
Composites dynamic modelling for
Impact and crushing
Challenges
1: Interpretation of dynamic test
results
2: Capturing all relevant
aspects in computationally
feasible numerical models
Key points
•Strain-rate dependency of
mechanical properties
•Many different damage types:
→ Fibre- and matrix cracking
→ Delamination of the plies
→ µ-scale debonding & yielding
→ Failure patterns in crushingFor delamination
For intra-
laminar fracture
Various failure patterns in different specimens under crush loading
Impact
Crushing
Modelling side-impact on 24-ply quasi-isotropic carbon/epoxy Dynamic tension results of
woven ±45 glass/polyamide-6
Load cell ringing at high speed.
How to interpret?
4
Prof. Wim VAN
PAEPEGEM06 June 2017 18/#
Dept. of Materials , Textiles
and Chemical Engineering
Validated EPS foam model for impact
Challenges
Accurate model dynamic
model of EPS foam
Key points
•Cover strain-rate (loading
speed) dependence
•Cover temperature
dependence
•Cover various densities
76.7 J
115.1 J
143.9 JFoam density = 80 g/l,
room temperature (≈
18°C)
4
Prof. Wim VAN
PAEPEGEM06 June 2017 19/#
Dept. of Materials , Textiles
and Chemical Engineering
Impact simulation of helmets
Added values
Using simulation model with
advanced foam model to
decrease helmet
development time
Key points
•Cover standard EN1078
•Cover new standard NTA 8776
(for electric bikes)
-10000
-8000
-6000
-4000
-2000
0
2000
4000
-0.01 0.01 0.03 0.05
Ro
t A
ccel
erat
ion
( r/
s2)
Time (sec)
Rot Acceleration
Rot Acc - Xaxis
Simulationwithoutcrack
4
Prof. Wim VAN
PAEPEGEM06 June 2017 20/#
Dept. of Materials , Textiles
and Chemical Engineering
• M3 Program and addressed domains in the twin M3Strength projects
• Key R&D details of the twin M3Strength projects and related
industrialization1. Composites fatigue modelling
2. Quasi-static and dynamic multi-scale modelling
3. Effect of defects by multi-scale modelling
4. Composites dynamic modelling for crash and crush
• Summary
Outline
Prof. Wim VAN
PAEPEGEM06 June 2017 21/#
Dept. of Materials , Textiles
and Chemical Engineering
Fatigue simulation of composites
Virtual Material Characterization (VMC)
…of 3D Woven structures
Effect of defects
Impact simulation (helmets)
Key industrial outcome of the joint R&D
Beneficiaries
1
2
Technology
3
4
by multi-scale modelling
Prof. Wim VAN
PAEPEGEM06 June 2017 22/#
Dept. of Materials , Textiles
and Chemical Engineering
• SIM and VLAIO offers an effective collaboration setup to address real industrial
challenges
• In todays product engineering, many aspects (e.g. defects) are still accounted for
by extensive testing and safety factors
• The lightweight advantage of complex materials can be better exploited with the
predictive & validated simulation tools developed in M3
• Help industry to shift away from the test-intensive lightweight engineering
Summary
Prof. Wim VAN
PAEPEGEM06 June 2017 23/#
Dept. of Materials , Textiles
and Chemical Engineering
Acknowledgements
This work has been funded by the SBO/IBO project
“M3Strength”, which fits in the MacroModelMat (M3)
research program, coordinated by Siemens (Siemens
PLM Software, Belgium),
funded by
SIM (Strategic Initiative Materials in Flanders) and
VLAIO (Flemish government agency Flanders Innovation
& Entrepreneurship).
Thanks to:
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