2015 hbm ncode products user group meeting · 2015 hbm ncode products user group meeting • 2...

2015 HBM nCode Products User Group Meeting

March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)

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Fiber Reinforced Plastic Durability

From Material Microstructureto Structural Part Life Predictions


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Intro to Solvay and e-Xstream engineering

• Advanced materials – Engineering Plastics

• TECHNYL – PA66

– Advanced Polymers

• Global company,– TECHNYL center in France

• Software and engineering services– Digimat– Part of MSC Software

• Headquarters in Belgium– Offices in most major global engineering

centers

Off-the-shelf material models that use multi-scale modeling with FEA


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Background: Material Modeling from Metals to Composites

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• Heterogeneous• Mechanical Properties dependent on Matrix & fiber properties +

fiber orientations• Anisotropic• Stiffness, failure, fatigue• Highly dependent on the manufacturing process

Modeling Fiber Reinforced Plastics

Strain

Str

ess

Flow direction

Cross Flow

MetalsComposites


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• 1 Material Model for any Load & Fiber oreintation• Discontinuous (FRP’s) & continuous fiber composites• Stiffness & failure• Temperature dependence (varying CTE)*• Strain-rate dependence• Fatigue

Bringing Manufacturing Results into FEA – Material Model


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fibers

failure

ANISO

Bringing Manufacturing Results into FEA – Part Level

Measurements/ curves

Process SimulationOrientation data on processing mesh

FEAStructural analysis

Structural mesh

Mapping

Anisotropic (non)linear

Material Model

ISO


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Multi-scale modeling


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g to save weight replace aluminium by reinforced polyamide

TrelleborgVibracoustic designed a new engine mounting system


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Failure location

Multi-scale modeling adequately accounts

Validation test:Quasi-static Loading

Response

Experimental

Digimat

Isotropic

• 40% mass reduction• 15% cost reduction• Production started in 2012


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Fatigue material modeling - Composites

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Challenge: adapt fatigue analyses for composites

• Characterize the local mechanical state stress state prediction

• Simplify the 3D historyin an equivalent 1D history stress combination method

• Convert the stress historyinto damage increments rainflow counting

• Accumulate damage increments Miner’s rule

Stress field

Stress history

Numbers of cycles

Stress amplitudes

Local stress & damage must change WRT:

• Local fiber orientations• Loading


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• 2 dedicated composite fatigue models in Digimat• Phenomenological based on macroscopic failure indicator

• Fiber reinforced plastics

• High-cycle fatigue (linear elastic)

• Strength based fatigue life prediction

• Tsai-Hill 3D Transversely Isotropic criterion with FPGF

• Applied locally to each integration point relative to the local fiber orientation

• Micromechanical based on damage accumulation in the matrix• Uni-directional Composites

Composite Damage Models

Tsai-Hill 3D Transversely Isotropic criterion

X, Y & S: Fatigue strengths depending over N (nb cycles to failure)X: Fiber direction ; Y: Transverse direction ; S: Shear in X-Y plane


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Generating the Composite Damage Model

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• Input test data for 1 uniaxial loading & 3 fiber orientations• Predict fatigue life (s-n curve) for multi-axial loadings with any fiber

orientation

Digimat predicts SFRP S-N curves


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for any microstructure

The phenomenological model predicts S-N curves


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into correct local stresses

Multi-scale modeling translates the influence of manufacturing

fibers

failure


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into appropriate S-N curves

Multi-scale modeling translates the influence of manufacturing


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Application

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the fatigue behavior of an injection-molded beammade of TECHNYL A 218 V30 material (PAGF30)

Solvay characterized experimentally

R = 0.1and 4 maximum loads

45 cm


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internally consistent S-N curvesrepresentative for dumbbell testsat varying angles with respect to flow direction

The automated reverse engineering provides

90°


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easily delimited based on the unit load case results

The beam exhibits 2 characteristic regions

Compressive regionLarger compressive strengths No fatigue failure expected thusneglected

Tensile region Fatigue failure expected


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a life prediction within the experimental variability

The Digimat/nCode interface yields

R = 0.1and 4 maximum loads


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Conclusion


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composite performances such as fatigue

• Enriches classical CAE with key microstructural information

• Accounting for variable fiber orientationshaped by SFRP manufacturing process

• Applicable to structural lifetime predictionsthanks to interfaces to fatigue software

Multi-scale modeling accurately predicts


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e.g., cyclic loading with VEVP material model

Beyond usual fatigue analysis simplifications…


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2015 HBM nCode Products User Group Meeting

Thank you!

Kurt DanielsonBusiness Development Manager, e-Xstream [email protected]


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2015 hbm ncode products user group meeting · 2015 hbm ncode products user group meeting • 2...

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