ALTAIR Composites Forming Activities 2014
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Transcript of ALTAIR Composites Forming Activities 2014
Innovation Intelligence®
Thursday, April 3rd
Erwan Beauchesne, Vincent Diviné …
Composite Forming Activities
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Introduction/Context
UD and woven fabric modeling
B-Pillar model example
Hyperform updates
Mapping
Meso to macro multiscale approach
Draping
Conclusion
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Introduction/Context/History
• Simple set up with reduced numbers of input data
• Accurate enough to give main tendencies
• Fast enough to be used in an industrial context
1) To provide a simple solution which gives tendencies
2) Seamless crash model initialization with forming results
Batch mode
Manufacturing
+
Mapping
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2010 First meeting with Solvay which was looking for a stamping simulation
tool able to manage their material laws coming from Digimat
2012 January we got a benchmark from Solvay about composite forming
June 13th and 14th Solvay presented our results at the SFIP conference
April 2013 Solvay presented coupling in composite crash simulation at ATC
in Turino
2012 Cedrem contacted us to exchange with us their experience
with mesoscopic approach using Radioss and to discuss about mapping.
May 25th 2012 presentation with Cedrem at DynaComp conference in France
History
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History
2012 September : thanks to Solvay presentation at SFIP Conference, PO
asked us to present them our works
2012 September : thanks to Solvay presentation at SFIP Conference, PO
asked us to present them our works
2013 January we got a benchmark from PO about dry composite forming
2013 April : first meeting with DUPONT about composite forming with resin …
2014 Paper presentation at Numisheet’14 conference (January 6th-9th
Mebourne Australia)
« Double dom composite forming simulation » V. DIVINE1 and E. BEAUCHESNE2 and al. …
2014 Ongoing benchmarks …
To be continued ….
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Introduction/Context
UD and woven fabric modeling
B-Pillar model example
Hyperform updates
Mapping
Meso to macro multiscale approach
Draping
Conclusion
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Two modeling approaches
Sandwich approach Independant layers approach
One part of shell elements
One material (law 25)
One multi-layers property
(type 10, 11, 17 or 19)
Fast, use to gives tendancies
No possible sliding between layers
No coupling between warp and weft
direction in case of woven fabric
N parts of shell elements
N material laws (law25 or law58)
N properties (type10, 11 or 16)
Contact between layers
Heavier but more accurate
Sliding between layers
Coupling between warp and weft
directions
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Two modeling approaches
s11 s11 ~
s11 >> s11
~
Sandwich approach Independant layers
approach
No sliding between layers Sliding between layers
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• Non-linear stiffsness behavior
• Softening, nominal stretch, bending factor
• Isotropic material
• Associated property (FABRIC) allows to
define the initial angle between warp and
weft.
Two materials
Material COMPSH (law 25) Material law FABRICA (law58)
nPP bWWF 1
PWFFF
FFFFF
2112
2
1244
2
222
2
1112211
2 sss
sssss
• Linear stiffsness behavior
• Plasticity domain available
• Pure orthotropic material
• Compatible properties (COMP,
SANDW, STACK, PLY) allow to define
only one fiber direction per layer
Coupling between fibers
warpweft
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Sandwich approach for a 4 layers composite
UD
• 4 layers defined in the property
• Orientations : 0°, 45°, 90°, -45°
• Same thickness in each layer
• Material reference direction : X
• 2x4 layers defined in the property
• 4 layers for warp direction
• 4 layers for weft direction (coincidents
positions with warp’s layers )
Woven fabric
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Independant layer approach for a 4 layers composite
UD
• Weft direction parameters >> Warp
direction parameters
• 4 independant parts of shell elements
• Contact interface in between
• Orientations : 0°, 45°, 90°, -45°
• Material reference direction : X
• Material FABRIC_A (law 58) :
Woven fabric
warpweft
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Resin modeling for a sandwich approach
• Ogden Material (law 42) with basic shell property
r = 3/7*rresin = 1.09*10-09 Mg/mm³
Go = 0.50 MPa Gs= Go – Gl
Gl = 0.35 MPa β = Gs / η
Β = 5000 s η = 30 Pa*s
=> Soften heated resin parameters
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Resin modeling for a sandwich approach
0°
45° 90°
/VISC/PRONY + CRASURV under validation ( 12.0.210 release )
Two parts with coincident nodes
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Resin modeling for an independant layer approach
• Additional solids elements with coincidents nodes with upper and lower fiber
layers
+ =
Fiber layers Resin layers Fibers + resin composite
Shell element layers ( mat 58 /
prop 16 )
Solid elements layers ( mat
59 / prop 43 )
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Resin modeling for an independant layer approach
• Material law « Connect » definition
• Elastic behavior then yield stress threshold in normal and tangential directions
• Plasticity domain defined from a yield stress and then by user functions,
• Strain rate dependancy available for user defined curves
• Contact interface is still maintain between layers of shell elements
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Resin thinning during forming
Sandwich approach with a
coincident part for resin
Independant layers approach
with connected solid elements
for resin
Initial blank thickness = 1.5mm
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Resin modeling and cooling
Cooling stage modeling
• Forming simulation is done without any thermal parameter
Resin material is set up to match with a cold resin
Stresses are then unbalanced between final stage of the
forming and initial stage of the spring back simulation
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Introduction/Context
UD and woven fabric modeling
B-Pillar model example
Hyperform updates
Mapping
Meso to macro multiscale approach
Draping
Conclusion
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B-Pillar model kinematic
The Die is going down
to the binder
The Die is going down
to the punch
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Glass fibers (70%) Resin (30%)
• UD
E11 = 70%Eglass = 50400 MPa
E22 = 0.3 MPa
E33 = 50 MPa
r = 3/7*rresin = 1.09*10-09 Mg/mm³
Go = 0.50 MPa Gs= Go – Gl
Gl = 0.35 MPa β = Gs / η
Β = 5000 s η = 30 Pa*s
=> Soften heated resin parameters
Material description
• Woven fabric
E22 = E11
E33 = 50 Mpa
Initial shear angle 90°
4 layers : 0°, 45°, 90°, -45°
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Sandwich approach for a 4 layers composite
UD
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Sandwich approach : Blank end shape
High Shear
areas
Wrinkles Compression
UD
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Sandwich approach : Fiber orientations
Fiber orientations are consistent with
blank shape
UD
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Independant layer approach : 4 layers composite
UD
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• Sliding effect between layers
Due to fiber orientations 0°, 45°, 90°, -45° regarding X axis, the behavior
during stamping is different for each layer
Independant layers approach : Blank end shape
UD
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Independant layers approach : Blank end shape
• The same compression, tension and shear zone can be observed
• Wrinkles may also occur
High Shear areas
Wrinkles
Compression
UD
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Independant layers approach : fiber rotations
UD
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Independant layers approach : fiber rotations in layer 1
First direction
angle versus X
axis
Second direction
angle versus first
direction
Woven
Fabric
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Time computation
• Computer configuration
SPMD 12 domains – 1 Thread per domain
Intel(R) Xeon(R) CPU E5649 @ 2.53GHz (x86_64), 2533 MHz, 64449 MB RAM, 62416 MB swap
Sandwich Number of cycles Elasped Time
UD 81986 1h57
Woven fabric 81986 2h35
Independant layers Number of cycles Elasped Time
UD or Woven fabric 81986 3h47
UD or Woven fabric + resin 81986 10h30
• Independant layers • 344423 nodes
• 345060 elements
• Sandwich • 103826 nodes
• 106260 elements
• Independant layers + connect • 344423 nodes
• 583860 elements
AMS x20
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Introduction/Context
UD and woven fabric modeling
B-Pillar model example
Hyperform updates
Mapping
Meso to macro multiscale approach
Draping
Conclusion
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HyperForm Radioss 13.0 updates for composite forming
• A composite option is available in User Process tree browser settings
• Type of modeling is then requested
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Plies definiton
Layers are treated as
independant blanks
HyperForm Radioss 13.0 updates for composite forming
Sandwich approach Independant layers approach
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Composite material
• Possibility to define an user material, and to save it into a database
• For the independant layer approach, new components need to be created
as for multi-layer blank configuration
• Then HF sets up automatically
• Contact interfaces tools and blank(s)
• Contact interface between layers
• Post-treatment cards in engine
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Introduction/Context
UD and woven fabric modeling
B-Pillar model example
Hyperform updates
Mapping
Meso to macro multiscale approach
Draping
Conclusion
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Mapping algorithm
Target integration points
Stamping integration points
Forming side Crash side
Mapping
??
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NEW in HC 12.113
Second fiber direction mapping
Angle regarding the first
direction as iso-value
Fiber directions mapping
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NEW in HC 12.113
4 layers of shell elements (MID 58, PID 16) on 1 layer of
shell elements (MAT25) associated with a 4 layer
sandwitch property (PROP11)
Target part
Composite
layers
Mapping for independant layers approach
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Full stress tensor and 2 fiber directions mapping from 4x44826 shell elements (MID 58,
PID 16) on 6758 shell elements (4 layers sandwitch property)
Time : 6s (Intel Core 2.8 GHz / 16Go)
Layer 1
Layer 2
Mapping for a independant layers approach
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Mapping of from a woven fabric modeling
• For a UD, the fiber direction is mapped on a target part associated with a
pure orthotropic material (law 25) => no issue
• For woven fabric, two fiber directions have to be on a target part
associated with a pure orthotropic material (law 25) => issue
The layers and the material associated to the target part will be duplicate.
The material parameters will be spread thru these new layers so that
NEW in HC 12.116
Reference
model Splitted layers
1 layer = 1 layer
1 layer
+
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Mapping of from a woven fabric modeling
• Split method validation
Reference model Splitted layers
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Introduction/Context
UD and woven fabric modeling
B-Pillar model example
Hyperform updates
Mapping
Meso to macro multiscale approach
Draping
Conclusion
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Two modeling scales
No resin, only bi-directional composite fabric
Meso-scopic scale : modeling fibers with strip of shell elements
Macro-scopic : classical FE mesh and fabric Radioss material law
To provide customers with different levels of accuracy
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4343
Meso-scopic scale approach
nPP bWWF 1
PWFFF
FFFFF
2112
2
1244
2
222
2
1112211
2 sss
sssss
Material : /MAT/LAW25 (COMPSH)
With E11 >> E22, E33
Property : /PROP/TYPE11 (SH_SANDW)
Angle < 50°
Angle ~90°
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Dry composite with mesoscopic approach
• « Classical » crash model
• Imposed velocity : 0.1 m/s
• Impact on a rigid wall
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Mapping from meso-scopic model to crash
Angle < 55°
Model to map and target mesh
Second direction after mapping : angle with the first direction
Target part after mapping and Re-zoning according to an angle of 55° criteria
E = 70%E, G = 70%G etc … ~ ~
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Crash results comparison
Two models : free from forming results on the left side and with forming results and
rezoning on the right side
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Comparison ref-global
=> Failure mode is not the same for the model with forming results
=> The model with forming results is stiffer than the one without.
Vertical failure mode
Horizontal failure mode
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Comparison reference-meso-global
Models with forming results are stiffer than the one free from initial results.
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Comparison reference-meso-global
=>Internal energy is higher when forming results are taken into account
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Introduction/Context
UD and woven fabric modeling
B-Pillar model example
Hyperform updates
Mapping
Meso to macro multiscale approach
Draping
Conclusion
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Drape Estimator for Composite Fibers
• Calculate
• Draping angles
• Thickness variation
• Interfaces
• OptiStruct
• Nastran
HM Drape Estimator (white) versus competition (red)
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Drape Estimator for Composite Fibers
Material/Fiber direction defined on
the flat reference shape
Finale part geometry OneStep result : flat shape
Finale part initialised with
Material/fiber directions
OneStep
Fiber direction
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Introduction/Context
UD and woven fabric modeling
B-Pillar model example
Hyperform updates
Mapping
Meso to macro multiscale approach
Draping
Conclusion
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Several works and studies around composite forming with Radioss
Reduced input data, simple set up, reasonably fast and accurate
Different scales modeling approaches depending on the expected results
Influence of forming results on crash simulation results has been shown
Mapping with re-zoning allows to take into account material degradation
Mapping compatible with sandwitch (HC11.430) and multi-layers modeling (HC 12.113)
Validation is in progress …
Conclusion
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THANK YOU !