atoast multiphysics multimaterial and or composite cae design
DESCRIPTION
Engineering structures and products are inherently multimaterial and multiphysics in nature. However, they are usually designed for dominant physics and single monolithic material. Recent development at PDE level model and software allows us to design for Multiphysics and Multimaterial. This webinar will give an overview of multiphysics modeling and multimaterial mechanics. Multimaterial design can be considered as composite product design at macro scale. Multiphysics design of products for macro performance (nth level) and the linkage to material design at ((n-1)th level) will be demonstrated with industrial examples for weight and cost reduction. The computational design of material and prediction of structural, thermal, acoustics, and electromagnetic properties using a single model will be detailed. The macro, micro, and nano scale effects of composites will also be highlighted. The link between multiphysics engineering application and the design of material will be detailed.TRANSCRIPT
ATOA Scientific Technologies Multiphysics CAE for Innovation TM
Multiphysics and Multimaterial Design with COMSOL Dr Raj C Thiagarajan, PhD
ATOA Scientific Technologies Pvt Ltd
05 APR 2013
Visit
http://www.comsol.co.in/events/953/multiphysics-and-multimaterial-design-with-comsol/
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
2
• Raj C Thiagarajan, MD of ATOAST, Currently providing Multiphysics CAE Design Services for Industrial Innovation.
• Computational mechanics and composite product development since 1988
• ATOA Scientific Technologies is a leading Multiphysics CAE Solution provider
• First COMSOL certified Consultant from India.
www.atoa.com
http://in.linkedin.com/in/ctraj
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
INTRODUCTION
3
Engineering Design
Multimaterial Multiphysics
Innovative Product
Engineering is Conversion of Material into Useful Product
Industrial Drivers: Cost, Weight and Performance
CAE product development for first time right
Multimaterial and Multiphysics for Optimal Design
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Overview
4
Multiphysics Product Design
Materials
• Engineering Materials
• Materials in product design
Multiphysics design of Material
• Composite mechanics
• Examples: CFRP
Focus: Product and Material Design Link
Material Design/ Mechanics
Multiphysics Product Engineering
Composites Multimaterials
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Nature & Multifunctional Composites
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• Nature uses simplest material in optimal form for efficient function.
• Composites are used for single functionality ~ 80% structural
• The future growth is expected from multifunctional composites.
• The availability of Multiphysics modeling capability will accelerate adaptation of Multifunctional composites.
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Engineering Materials
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• Conventional Engineering Materials
– Metals
– Ceramics
– Polymer
– Cellular and
– Natural Materials
• Composite Designer Materials
• Emerging Materials
– Smart
– Nano
– Meta
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Composites Multi
Material
Advanced Materials
Noble Aluminum Steel
Multimaterial Product Design
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• From “ All steel” , “All Aluminum ” All Composites” To Multimaterial
• Leverage the best of material for product performance.
• Challenges
• Fabrication
• Multiphysics
• Multifunctional
High COST Low
Hig
h
W
EIG
HT
Lo
w
Performance: High
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Composites
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• Combination of any two are more materials to perform better than individual constituents.
• Macroscopically (n scale) homogeneous and microscopically (n-1 scale) heterogeneous.
• Composite principle can be applied to multimaterial at macro scale.
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Co
nsti
tue
nts
Fibers: Glass, Carbon, Kevlar, HDPE, SiC, Boron,
Matrix: Polymer, Metal, Ceramic
Polymer matrix: Thermoset, Thermoplastics
Thermoset: Epoxy, Vinyl Ester, Polyester, Polyimides
Thermoplastics: PP, PMI, PEI, PEEK, PES, PC,ULTEM
Inte
rme
dia
tes
Semi Finish:
Prepregs
Comingled/ Cowoven
Sheet/bulk molding compounds
Reinforced pellets
Intermediates:
Pultruded rods
Laminates
Sandwich panels
Composite films/fabrics
De
sig
n a
nd
Pro
ce
ssin
g
Design: Constituents, Ply, laminate, product , process and life
Polymer: PMC:
Hand layup, Spray up, Resin Transfer Molding, Autoclave Molding, Filament, Tape Winding, Pultrusion, Compression Molding, Injection Molding, Thermoforming.
Co
mp
osit
e A
pp
lica
tio
ns
Aerospace
Automobile
Transportation
Consumer
Industrial
Medical
Packaging
Oil and Gas
Energy
Electronics
Infrastructure
Mining
Aft
er
Se
rvic
e
Smart Structural health monitoring,
Condition monitoring
maintenance,
Repair,
Retrofitting of composite products
Composite Industry Value Chain
• Simulation tools are use at every stage of value chain
• We shall focus on the Material Design of composite products
Reinforcement
Matrix
Semi-Finish Intermediate
Design
Processing
Composite
Products
After
Service
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ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Type of Composites
• Particulate Composites
• Short Fiber Reinforced
composites
• Long Fiber Reinforced
composites
• Continuous Fiber reinforced
composites
• Multimaterial
Pe
rform
ance
Param
eter (Stre
ngth
, Stiffne
ss..)
Typical P
roce
ssing co
st
Macro Composites Metal polymer hybrids Sandwich structures Metal hybrid picture from Injection molding,
www.plastictechnology.com, pp11.
Constituents Form Physics Load: Static Dynamic Time Results: Singlepoint Multipoint
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Material Design/Property Prediction
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• Additive
• Product
• Super
– Stiff and tough
– Ultra low weight
• Meta
– Beyond Nature
Nano
Micro
Macro
After US 7838108
Vf
No
rmal
ized
Pro
per
ty
Material 1 Material 2
Metamaterials
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
COMPOSITE Material Modeling
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• Analytical
– Rule of Mixtures
• Micromechanics
– 2D/3D
• Lamination Theory
– Ply, Laminates
• Product performance
– Multiphysics
• Failure mechanics
– Damage, progressive failure
• Analytical tools
• Micromechanics codes
• Classical Lamination Theory
• General purpose FEA
software
• COMSOL for composite modeling
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COMSOL Example CFRP Composites
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• Structure
• Part
• Laminate
• Fiber
• Matrix
• Molecular
• ATOMIC
0.3345 nm
0.142 nm
0.669 nm
c
ba
• Carbon T300 / Epoxy 914
• Multiphysics – Structural+ Electrical
– Structural + Thermal
– Damage Mechanics
– Structural Health Monitoring
• Micromechanics – UD composites
– Particulates
– Laminates
• Constituent – Graphene Sheet
– Carbon fiber
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Structural
Thermal
Electromagnetic
Acoustic
COMSOL Modeling Steps
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• Select a suitable physics (Governing, Constitutive equation)
• Model a representative volume with periodic boundary condition
• Develop Global/macro and Local/ micro relationship (Virtual Testing)
• Solve and post process for Material property prediction.
Eε ε jEω) ε ε (σJ '
r0
"
r0 t
H
t
EE
Ex Hx
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Micromechanics
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• Continuum Micromechanics based on homogenization theory
• Aims at finding a volume elements (Representative Volume Element – RVE, periodic Micro field- PMA response to prescribed macro response)
• Prediction of macro properties from micro structure and constituents.
Localization relationship
Micro fields
Macro fields
Homogenization relationship Where,
W volume, G-surface,
u(x)– deformation vector t(x)– surface traction vector nG – surface normal vector
Homogenization Theory/ Methods
• Mean Field Theory
• Variational Bounding methods
• RVE (Representative Volume Element) or PMA ( periodic Micro field)
• Generalized Method of Cells
• Embedded Cell
• Windowing Approach
• Variational Asymptotic Method
• Multiscale Models
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Representative Volume
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• Square Array
• Hexagonal Array
• Random
Micrograph -> Image map -> Material properties
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Numerical Implementation 2D
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• Periodic boundary condition
• u xl= u x0 + ex
• v yl= u y0 + ey
• Load
• Body force
• Global (macro) vs local (micro) stress and strain
• Integration of variables
• Parametric model to predict the stress strain behavior
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
2D Results
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• Isotropic property prediction
• Polymer composite anisotropic property prediction
• Macro performance
• Micro mechanical exploration for novel materials
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
2D Results CFRP
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• T300, Epoxy914, Vf 60%
• Quarter segment
• Periodic BC
• Global vs Local
• Transverse Modulus
• Experiments :
8.96+0.06 GPa
• COMSOL:
9.127 GPa
T300 Carbon Fiber
Matrix Epoxy
914
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
2D Random Results
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2D: Thermo Elastic Performance
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• Design of a Dynamic Thermal conductivity Material
• Thermal Insulator to conductor
• Coupled Thermo elastic Analysis + DoE: Commercial Materials, Vf, packaging
• Virtual Design of novel Thermal material
0 80
100
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
3D RVE
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• Reinforcement shapes
– Fiber
– Whiskers
– Flakes
– Platelets
– Spherical Particles
• Regular or Random
• Create your own 3D RVE using geometrical modeling tools
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
3D Results
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• CFRP UD: 60% Vf
• T300 /Epoxy 914
• Longitudinal Modulus
• Experiments :
140+1.2 GPa
• COMSOL:
139.04 GPa
• Transverse Modulus
• Experiments :
8.96+0.06 GPa
• COMSOL:
9.095 GPa
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Nonlinear Performance
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• Elasto Plastic Performance polymer matric composites
• Polycarbonate + Glass
Strain
Stre
ss
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
COMPOSITE Damage Mechanisms
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• Self sensing of Carbon fiber composites
• Good Thermal and Electrical Conductor
• Fiber
• Fiber breaks
• Matrix
• Matrix crack
• Interface
• Delamination
• cracks
(d)
(a)
(b)
(c)
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Numerical investigation
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• The electrical conduction mechanism and the effect of damage in CFRP composites were simulated in COMSOL using AC/DC Electric Currents Interface.
• Homogeneous composite model with effective properties
• Micromechanical model with constituent properties
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Results : Fiber breaks
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• UD composites
• Electrode on edge
• Resistance change vs fiber breaks
• Parallel resistance model behavior
• Very sensitive to fiber breaks.
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Results: Matrix Cracks
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• Matrix crack density vs change in resistance
• Can detect matrix cracks also
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Results : Delamination
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• Delamination length vs resistance change.
• Delamination growth between fibers
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Negative refraction
Electrostatic resonance
Composite cloaks
Acoustic super lens
Summary
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• Materials, Multiphysics product design
• Micromechanical modeling with COMSOL
• 2D and 3D modeling method and results
• CFRP Simulation vs Experiments -> good
• Design for Multiphysics and Multimaterial is the way forward for First time Right Product Design
• Refer COMSOL CONFERENCE PAPERS for more
• Visit for the Presentation @
• http://www.comsol.co.in/events/953/multiphysics-and-multimaterial-design-with-comsol/
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Abstract
31
• Engineering structures are inherently multimaterial and multiphysics in nature. However, they are usually designed for dominant physics. Recent development at PDE level model and software allows us to design for Multiphysics and Multimaterial. This webinar will give an overview of multiphysics and multimaterial mechanics. The computational design of material and prediction of structural, thermal, acoustics, and electromagnetic properties will be detailed. The macro, micro, and nano scale effects of composites will also be highlighted. The link between multiphysics engineering application and the design of material will be detailed.