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Thermostamping simulation for woven thermoplastic composites (PA) with HyperForm
The document discusses advancements in thermostamping technology, focusing on the calculation, characterization, and simulation of composite materials in automotive applications. It highlights the importance of accurate modeling for performance simulation and outlines ongoing research efforts to enhance simulation tools and processes. Key topics include the development of constitutive laws, validation methods, and the future direction of composite product design and manufacturing.
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Thermostamping simulation for woven thermoplastic composites (PA) with HyperForm
- 1. EATC 2015: CompositeThermoforming Calculation G. CHAMBON, R. TIE BI October 1rst, 2015
- 2. Company presentation What is thermostamping ? State of the Art Thermostamping constitutive laws Characterization / identification Validation Mapping Transfer from process results to performance meshing Structural law creation Performance simulation : Results & correlation Synthesis - Next steps Agenda 2
- 3. Company presentation What is thermostamping ? State of the Art Thermostamping constitutive laws Characterization / identification Validation Mapping Transfer from process results to performance meshing Structural law creation Performance simulation : Results & correlation Synthesis - Next steps Agenda 3
- 4. 4 Leader in automotiveequipment * of which €14.1 billion of product sales 34 countries 99,500 employees 330 sites €18.8 billion of total sales* 6,000 engineers and technicians 30 R&D centers 515 programs in development 505 patents filed in 2014
- 5. 5 Faurecia Automotive Exteriors Plasticbody parts Modules Composite Bumpers Trims & Rocker Panels Outside Body Panels A-class Semi-Structural Structural €1.7 billion product sales 2014 8,100 employees employees 32 production sites 4 R&D centers 9 countries #1 in Europe for plastic body parts Front End Modules Front End Carriers Engine Cooling Systems
- 6. Company presentation What is thermostamping ? State of the Art Thermostamping constitutive laws Characterization / identification Validation Mapping Transfer from process results to performance meshing Structural law creation Performance simulation : Results & correlation Synthesis - Next steps Agenda 6
- 7. 7 Continuous Fiber ReinforcedThermoplastic Thermostamping Composite What is it ? CAD of part Sheet of CFRT Heating of CFRT (hoven) Manufactured part Transfer and Stamping 170 mm
- 8. Company presentation What is thermostamping ? State of the Art Thermostamping constitutive laws Characterization / identification Validation Mapping Transfer from process results to performance meshing Structural law creation Performance simulation : Results & correlation Synthesis - Next steps Agenda 8
- 9. State of theart: Based on commercial codes Codes HyperForm one step PamForm Catia Mainproperties Reverse engineering (grid projection) (grid projection) Basic strain calculation (only shear) (only shear) Locking angle - Initial assessment of formability of a component - Preform and fiber architecture predictions (reduction of raw material waste) - Highligthing possible forming problems (locking and wrinkage, aspect…) 9 2 families of codes 1/ Non incremental Codes
- 10. State of theart: Based on commercial codes Codes Ls-Dyna incremental Radioss incremental Mainproperties suitable and complete GUI suitable post-analyse and mapping GUI suitable multi layers approach thermomechanical coupling suitable constitituve laws (less than LS-Dyna) Die outer element Die Punch Blank Binder 2 families of codes identified according to incremental calculation or not 2/ Incremental Codes - realistic forming approach with dynamic non-linear explicit codes - forming pressure modelized w/ contact properties for die & punch - if necessary, boundary or/and initial conditions modelized - suitable approach for material laws 10
- 11. Company presentation What is thermostamping ? State of the Art Thermostamping constitutive laws Characterization / identification Validation Mapping Transfer from process results to performance meshing Structural law creation Performance simulation : Results & correlation Synthesis - Next steps Agenda 11
- 12. Thermostamping constitutive laws Radioss:Mat 58 with Prop 16. Fiber behavior Ls-DYNA Mat 34 (bending effect compared to Mat 234) 12 BIAS Test Mat 58 (Radioss) and Mat 34 (LS-DYNA) are quit equivalent and realistics (without thermomechnical effect) Radioss / LS-Dyna comparison
- 13. X-ray Calcination Samples level :Tests performed to identify Behavior of woven Process simulation at sub-system level Simple part level : Tests performed to establish simulation procedure Sub-system level on FAE representative mold Microscope FromsamplestoSub-System Correlation of fiber orientation to improve representativeness of mechanical simulation Thermostamping constitutive laws Building processus
- 14. Multi-layers approachto represent discriminating defects Left 100 mm Right 25 mm Right 0 mm Right 100 mm Thermostamping constitutive laws Results & Correlation 14
- 15. Thermostamping constitutive laws Results& Correlation : Step by step Production of uncompleted parts for step by step correlation with simulation Shapes and fiber’s orientation comparison 15
- 16. Company presentation What is thermostamping ? State of the Art Thermostamping constitutive laws Characterization / identification Validation Mapping Transfer from process results to performance meshing Structural law creation Performance simulation : Results & correlation Synthesis - Next steps Agenda 16
- 17. Fiber’s orientations post-analyzedand mapped by Hypercrash Test component Mapped results 17
- 18. Structural law consideringnon-orthogonal angles + UD2 Fabric material decomposition in 2 UDs Qij = f(Eij, ij, (k=1,2)) identified by reverse Engineering ≠90° 18 Reverse Engineering initialization Axial modulus: Qij (UD) = Qij (Fabric) Transverse modulus : Qij (UD) = Qij (Matrix) Shearing: Qij (UD) = Qij(Fabric)/2 UD1 1 2 FAE approach
- 19. Structural law consideringnon-orthogonal angles - Linear elasticity - Non-linear damage - Failure Elasticity, damage and failure properties of the 2 UDs are re-identified by reverse Engineering method from specimen and sub-system tests specimen tests (dynamic tensile, compression and shear) sub-system test (dynamic bending) LS-DYNA material law 58 19
- 20. Company presentation What is thermostamping ? State of the Art Thermostamping constitutive laws Characterization / identification Validation Mapping Transfer from process results to performance meshing Structural law creation Performance simulation : Results & correlation Synthesis - Next steps Agenda 20
- 21. Part Effort Failure High stamping spare wheelbox Structural law Results & Correlation : Static tests Good accuracy, including failure representation
- 22. Config. FLAT Config.Spare Wheel Box Structural law Results & Correlation : Dynamic tests Trial Trial Simulation w/o process consideration Simulation w process simulation Important improvement regarding flat conf. confirming process influence Need to enhance SWB conf. models
- 23. Company presentation What is thermostamping ? State of the Art Thermostamping constitutive laws Characterization / identification Validation Mapping Transfer from process results to performance meshing Structural law creation Performance simulation : Results & correlation Synthesis - Next steps Agenda 23
- 24. Synthesis Mandatory toconsider thermostamping process for performance simulation of complex parts Necessity to use incremental calculation (i-o geometrical) for good accuracy on singularities (sliding, locking angle, wrinkles …) Need to have a good characterization of material (Product & Process) Need to simulate individual behavior of each ply stacked (multi-layer or other approach) Simulation tool compatible with daily engineering
- 25. Next steps : Modelizationof thermal effect Coolingvelocity(°C/s) From 0 to 30 seconds Air Contact plate/mold From 30 to 60 seconds 25 Cooling down velocities depending on time and contact nature Quick T° drop, with influence on material behavior, especially in mold
- 26. Die Part of binder Punch BlankCFRT Binder 26 Next steps : Boundary and initial conditions effect Considering frame or any means used for processing material (frame, blank holders…)
- 27. Next steps : software Enhanced thickness variation Thermomechanical effect (Radioss incremental) Fiber density computation (Hyperform) Non-orthogonal angles elements for performance simulation
- 28. NEXT STEP FAE InnovativeApplication : One-Shot Process for composite Liftgate : 28 State of the art: Structural parts (non visible) Innovation: Structural and aspect parts Overmolded composite inserts CFRT positionning in mold Infra Red heatingCFRT blanks Robot handling from hooven to mold, Draping + injection Injection over-molding Gripper: pre-forming Aspect surface Challenges: Complete overmolding of three composite inserts Delivery of a high-quality surface with graining Visible side Back side
- 29. 29 NEXT STEP FAE InnovativeApplication : One-Shot Process for composite