Forming Simulation of Woven Composite Fibers and Its Influence on Crash Performance

Forming Simulation of Woven Composite Fibers and Its Influence on Crash Performance

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  Innovation Intelligence® Forming Simulationof Woven Composite Fibers and its Influence on Crash Performance Dr Subir Roy Senior Director, Industry Solutions Altair
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Altair Manufacturing Solutions Stamping Extrusion Casting Injection Molding Mapping HyperForm (HW) HyperXtrude (HW/Inspire) Click2Cast NovaCast (APA) Moldex (APA) HCRM (HW) Converse (APA) OptiStruct / HyperStudy
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Composite Forming Process: RTM Ref. CAMX 2014
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  Copyright © 2013Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Composite Forming Process: Thermoforming Ref. CAMX 2014
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair 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°
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  Copyright © 2013Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Forming Simulation Results • Stress and strain in warp direction • Stress and strain in weft direction
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Crash Simulation Results • Normal resultant force against rigid wall shows a significant difference
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair 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)
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  Copyright © 2013Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Rapid Drape Estimator for LSDyna (14.0)
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair 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)
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair 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
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  Copyright © 2013Altair 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?
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  Copyright © 2013Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Thank you