Post on 13-Apr-2018
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Dr Gasser Abdelal
VEC Workshop 201125/26 October 2011
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VEC Workshop 2011
PRODUCTION PROCES
SIMULATION
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VEC Workshop 2011
COMPOSITES
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VEC Workshop 2011
Virtual Manufacturing - Composites
Objectives of Composite Manufacturing Simulation
Early estimation of Mechanical and Thermal propert
Optimize the manufacturing process and/or (fibre
weave layout) to improve strength, fatigue, weight.
Theoretical and Numerical Tools:
Micromechanics theory [homogenization Finite ele
TEXGEN [2D & 3D Weave CAD].
ABAQUS [FE tool] + Material Subroutines.
Multi-Scale Finite Element [Macro Micro (RVE)].
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VEC Workshop 2011
Virtual Manufacturing - Composites
Building Experience Through Case Studies
Case 1
Autoclave cure simulation (unidirectional composites).
ABAQUS (FE) [Thermal/Chemical module + Sequential Stress Analysis]applying Micromechanics.
Case 2
Estimation of Mechanical and Thermal properties 2D & 3D weavecomposites laminatesusing RVE (Representative Volume Element).
TEXGEN + ABAQUS (using Python to apply Periodic boundary conditions).
Case 3
Applying Multi-Scale (Macro-Micro) Finite Element method to estimateproperties of 3D complex composite structure (landing gear).
Autoclave cure of 2D woven composites applying Multi-Scale FE.
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VEC Workshop 2011
We need Real Test Cases to
verify our numerical
approach
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VEC Workshop 2011
METALLIC - PLASTICS
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VEC Workshop 2011
Virtual Manufacturing
Metallic
Objectives of Metallic-Plastics Manufacturing Simulatio
Choose between different design variants to fit both
criteria and your cost.
Optimize the manufacturing process to improve strefatigue, weight, and reduce cost.
Theoretical and Numerical Tools:
ABAQUS [FE tool] + Material Subroutines.
Isight v5 for Surrogate, Sensitivity analysis, and Opt Multi-Scale Finite Element [Macro Micro (RVE)].
HPC for high speed computing.
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VEC Workshop 2011
Virtual Manufacturing - Metallic
Case 1
AIRBUS
Riveting Simulation of Large Aircraft Panels.
ABAQUS (FE) [Coupled Thermal/Stress analysis nonlinear material models].
Developed 2 Surrogates that can be used in Optimization [either Manufacturing process orDesign Parameters].
Case 2MAST
Studying different design variants of medical products using Injection molding.
Objective is to achieve better performance with minimum cost.ABAQUS (FE) explicit solver with contact analysis.
Case 3CGYNET
Verify mechanical design strength of an offshore structure products using ABAQUS (FE).
Case 4VEC
Shot Peen Simulation of metallic panels.
ABAQUS (FE) explicit solver nonlinear material models Isight.
Objective: effect of shot peen process on residual stress caused by other manufacturing processdevelop a Surrogate.
VEC W k h 2011
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