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Accurate Simulation of Short-Fiber-Reinforced Automotive Parts
Sascha Pazour
PART Engineering [email protected] 2204 30677 26
© PART Engineering GmbH, www.part-gmbh.de
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Cologne
Berlin
Frankfurt
Hamburg
Stuttgart
Munich
Wolfsburg
Ingolstadt
Rüsselsheim
• Founded in 1999 as FEM services supplier
• Focus on structural mechanics
• Mission is to provide CAE services and software in
order to add value to our customers‘ CAE chain
• 20 years experience in FEA
• 10 years experience in CAE software development
• Two software products by our own:
• Development partner of major CAE software vendors
Life
Bergisch
Gladbach
PART Engineering – Key Facts
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Influence of Fiber Orientation onto Material Properties
Fig. 2
100 100
58
65
0
20
40
60
80
100
120
Stiffness Strength
in flow cross flow
100
350
0
50
100
150
200
250
300
350
400
therm. Expansion
material: PA6+GF30
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Fiber Orientations in Short-Fiber-Reinforced Plastics
S1 Shear layer: Fibers oriented parallel to flow direction
S2 Mid layer: Fibers oriented perpendicular to flow direction
Fig. 3
Flow Direction X
X
Cut View XFlow Direction
S1
S2
S1
Example Micrograph Pictures:
Thick
Mid LayerThin
Mid Layer
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Degree of Orientation
Fig. 4
33
2322
131211
..
.
a
aa
aaa
000
000
001
33.000
033.00
0033.0
2
31
general case unidirectional quasi-isotropic
-90° +90°-45° +45°0° -90° +90°-45° +45°0°-90° +90°-45° +45°0°
Schmelzeflussrichtung
Schmelzeflussrichtung
2
1
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Material Complexity
Fig. 5
Thermo-Mechanical
Simulation
E
α
Young´s Modulus
Poisson´s Ratio
Coeff. of Lin. Therm. Exp.
z
yx
Fiber Orientation
(Local System)
Isotropic
Anisotropic
Temperature Dependant
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Material Complexity
Fig. 6
z
yx
Fiber Orientation
(Local System)
(1/0/0)
(0,7/0,2/0,1) (0,5/0,5/0)
(0,33/0,33/0,33)
Degree of Orientation
(Fiber Distribution)
80°C23°C120°C-40°C
Temperature
x
y
z xy yzzx
Local Directions
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Material Complexity
Fig. 7
xy
zx
y
E2
α2
x
E1
α1
z
E3
α3
G12 α1212
23°C
yz
G23
α23
23
G31
α31
31
Orthotropic Material ModelNeeds 15 lin.-elastic temp.
dependant material properties:
Coeff. of lin. Therm. Expan.:
α1, α1, α1, α12, α23, α13,
Tensile moduli: E1, E2, E3
Shear moduli: G12, G13, G23
Poisson ratios: 12, 13, 23
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Example: Weld Lines
Isotropic ApproachFig. 8
Common Approach:
Isotropic
Schmelzeflussrichtung
Schmelzeflussrichtung
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Example: Weld Lines
Anisotropic ApproachFig. 9
CONVERSE Approach:
Anisotropic
Schmelzeflussrichtung
Schmelzeflussrichtung
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Fiber Orientation and Anisotropic Material
Fig. 10
Converse Graphical User Interface
[Part: Mann & Hummel]
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Mesh Topology
Fig. 11
ConverseIM solver mechanical solver
shell (mid-plane/surface) => shell (tria, quad)
shell (mid-plane/surface) => solid (tet, hex)
solid => solid (tet, hex)
unequal meshes
possible
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Fig. 12
Converse Features and Interfaces
Mechanical SolverInjection Moulding
Solver
- Moldex 3D
- Moldflow
- Cadmould
- Sigma
- Fluent
- Simpoe
- 3D Timon
- Optistruct
- femfat
- nCode
- Abaqus
- Ansys
- Marc
- Nastran
- LS-Dyna
Orientations
Pressures
Temperatures
Wall Thicknesses
Residual Stresses
Shrinkage & Warpage
Weldlines
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0
200
400
600
800
1000
1200
1400
0 1 2 3 4 5 6
Kra
ft [N
]
Verschiebung [mm]
Messung 1
Messung 2
isotrop
orthotrop
Example: Rotary Valve
Material: Grivory HTV 3H1
forc
e [N
]
displacement [mm]
test 1
test 2
FEA isotropic
FEA anisotropic
Fig. 13
[Part: Mann & Hummel]
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Example: Air Intake Manifold
Material: Ultramid A3WG6
Fig. 14
[Part: Mann & Hummel]
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Eigenfrequencies and Eigenmodes
0
100
200
300
400
500
600
700
800
900
1000
250,00 270,00 290,00 310,00 330,00 350,00 370,00 390,00
eff
ektive M
asse
[g]
Frequenz [Hz]
x-Richtung - isotrop y-Richtung - isotrop z-Richtung - isotrop
x-Richtung - orthotrop y-Richtung - orthotrop z-Richtung - orthotrop
x-direction-isotropic
x-direction-anisotropic
y-direction-isotropic
y-direction-anisotropic
z-direction-isotropic
z-direction-anisotropic
frequency [Hz]
effe
ctive
ma
ss [kg
]
Fig. 15
[Part: Mann & Hummel]
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Lens Bracket Example
Fig. 16
Part Geometry Fiber Orientation in Converse
[Valeo Lighting Systems]
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Lens Bracket Example
Fig. 17
Frequency correlation – simulation to Xp. modal analysis
+5Hz
+30Hz
Converse
Isotropic
Average error – 4 Modes
Mode Experimental (Hz) Isotropic (Hz) Converse (Hz)
1 44 76 60
2 56 77 62
3 91 114 94
4 224 270 218[Valeo Lighting Systems]
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Example: Burst Pressure
Material: PP + GF20
Fig. 18
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Influence Of Production on Fiber Orientation
Fig. 19
Supplier 2Supplier 1
• Two suppliers but parts are geometrically up to 95% equal.
• Same material supplier, same mashine settings, etc.
• Different gating location means two completly different engine components!
Water pump housing
Gate location
Gate location
Moldflow results show different orientation
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Influence Of Production on Anisotropic Part Stiffness
Fig. 20
Blue – Supplier 1
Red – Supplier 2
Dotted – Isotropic material
fiber orientation and material model by
4. isotropic vs. anisotropic results
∆ - 62%
Untolerable error if homogeneous
isotropic material is used!
3. displacements
1. distributed pressure on sealing contact surface
2. results evaluated on a path
Dis
pla
ce
me
nt
True distance along path
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Fig. 21
www.part-gmbh.de What´s New?
Converse Installation
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Fig. 22
Add Value to Your Mechanical Simulation
consider the real part properties
get better predictions of
strength & deformation
by using data already
available
Thank you for your attention!
Please don´t hesitate to ask a question!