forming simulation of woven composite fibers and its influence on crash performance
TRANSCRIPT
Innovation Intelligence®
Forming Simulation of Woven Composite
Fibers and its Influence on Crash
Performance
Dr Subir Roy
Senior Director, Industry Solutions
Altair
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Outline
• Product Overview
• Study Objective
• Manufacturing processes
• Process simulation
• Mapping fiber orientation to crash model
• Crash simulation results
• Additional options
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair Manufacturing Solutions
Stamping Extrusion CastingInjection
MoldingMapping
HyperForm
(HW)
HyperXtrude
(HW/Inspire)
Click2Cast
NovaCast
(APA)
Moldex
(APA)
HCRM (HW)
Converse (APA)
OptiStruct / HyperStudy
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperForm: Advanced Solution for Sheet Metal Forming
• Early feasibility analysis
• Material cost analysis
• Die face design
• Virtual try-out and process optimization
• Press hardening
• Die stress analysis and topology optimization
Composite forming
Initialization of structural CAE models
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Objective
1. Double Dome simulation of a composite weave [Ref. NUMISHEET’05]
2. Map fiber orientations from forming to crash model
3. Crash simulation to check influence of fiber orientations
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Composite Forming Process: RTM
Ref. CAMX 2014
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Composite Forming Process: Thermoforming
Ref. CAMX 2014
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Forming Simulation Model
• Blankholder force : 350N
• Initial blank size : 290mm * 190mm
• Tool speed : 170mm/sec
Blankholder
Punch
Die
Blank
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Weave Material Properties
• 1 layer of a Balanced Twill weave
• Stiffness behavior is non-linear in both warp and weft directions
• Shear stress is a function of shear angle
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Forming Simulation Results
• Shear angles at 13 points
Consistent with shear stress distribution
Maximum shear angle = 36,9°
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Forming Simulation Results
• Stress and strain in warp direction
• Stress and strain in weft direction
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Crash Simulation Model
• Final fiber orientations are mapped on a coarser crash mesh using
HyperCrash Results Mapper (HCRM)
• Rupture criteria : Hashin failure
Maximum stress value in direction 1 and 2, tension and compression
800mm/sec
Rigid wall
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Crash Simulation Results
• Normal resultant force against rigid wall shows a significant difference
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Summary
• Fabric material law in RADIOSS is able to model composite weave forming
Physical behavior such as non-linearity of stiffness for warp and weft direction,
shear stress as a function of shear angle are modeled
• Final fiber orientations can be mapped to crash simulation model
Fiber orientations resulting from stamping simulation influence rupture mode and
stiffness response for crash simulation
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Rapid Drape Estimator for Composite Fibers (13.0)
• Calculate
• Fiber orientation (draping) angles
• Thickness variation
• Interfaces
• OptiStruct
• Nastran
HM Drape Estimator (white) versus competition (red)
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Rapid Drape Estimator for LSDyna (14.0)
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Model bands of woven fibers using shell elements
• Model individual woven fiber using solid elements
Advanced Meso-scale Modeling of Draping
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
SPH to model resin flow
Advanced Meso-scale Modeling with Resin
390 000 nodes
320 000 SPH cells
6 h on 24 CPUs
CPUs (Troy Cluster)
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Macro-scale model
• Meso-scale patch at critical area
Coupling Macro and Meso-scale Modeling
Maximum shear angle region
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
1. Forming simulation at macro-scale
2. Map the meso patch boundaries on the flat mesh
3. Extract the displacement history at boundaries
4. Simulate meso-scale model with displacement history
Indirect Coupling of Macro and Meso-scale Modeling
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Design Optimization Cycle
Forming:
(HyperForm)
Mapping
(HWRM )Performance
(OS/RADIOSS)
Design changes :
HyperMorph,
HyperStudy
Weave layup:
(CEDREM/HyperMesh)
OK?
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Thank you