Hyperform & Mfs
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Description
Forming Simulation of Woven Composite Fibers and its Influence on Crash Performance Dr Subir Roy Senior Director, Industry Solutions Innovation Intelligence®
Altair
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Outline
• Product Overview • Study Objective • Manufacturing processes • Process simulation • Mapping fiber orientation to crash model • Crash simulation results • Additional options
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair Manufacturing Solutions
Stamping
HyperForm (HW)
Extrusion
HyperXtrude (HW/Inspire)
OptiStruct / HyperStudy
Casting
Click2Cast NovaCast (APA)
Injection Molding
Moldex (APA)
Mapping
HCRM (HW) Converse (APA)
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperForm: Advanced Solution for Sheet Metal Forming • Early feasibility analysis • Material cost analysis • Die face design
• Virtual try-out and process optimization • Press hardening • Die stress analysis and topology optimization Composite forming Initialization of structural CAE models
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Objective
1. Double Dome simulation of a composite weave [Ref. NUMISHEET’05] 2. Map fiber orientations from forming to crash model 3. Crash simulation to check influence of fiber orientations
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Composite Forming Process: RTM
Ref. CAMX 2014
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Composite Forming Process: Thermoforming
Ref. CAMX 2014
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Forming Simulation Model • Blankholder force : 350N • Initial blank size : 290mm * 190mm • Tool speed : 170mm/sec Blank
Punch
Die Blankholder
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Weave Material Properties • 1 layer of a Balanced Twill weave • Stiffness behavior is non-linear in both warp and weft directions
• Shear stress is a function of shear angle
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Forming Simulation Results • Shear angles at 13 points
Maximum shear angle = 36,9°
Consistent with shear stress distribution
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Forming Simulation Results • Stress and strain in warp direction
• Stress and strain in weft direction
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Crash Simulation Model • Final fiber orientations are mapped on a coarser crash mesh using HyperCrash Results Mapper (HCRM) 800mm/sec
Rigid wall • Rupture criteria : Hashin failure Maximum stress value in direction 1 and 2, tension and compression
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Crash Simulation Results
• Normal resultant force against rigid wall shows a significant difference
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Summary • Fabric material law in RADIOSS is able to model composite weave forming Physical behavior such as non-linearity of stiffness for warp and weft direction, shear stress as a function of shear angle are modeled
• Final fiber orientations can be mapped to crash simulation model Fiber orientations resulting from stamping simulation influence rupture mode and
stiffness response for crash simulation
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Rapid Drape Estimator for Composite Fibers (13.0) • Calculate •
Fiber orientation (draping) angles
•
Thickness variation
• Interfaces •
OptiStruct
•
Nastran
HM Drape Estimator (white) versus competition (red)
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Rapid Drape Estimator for LSDyna (14.0)
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Advanced Meso-scale Modeling of Draping • Model bands of woven fibers using shell elements
• Model individual woven fiber using solid elements
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Advanced Meso-scale Modeling with Resin SPH to model resin flow
390 000 nodes 320 000 SPH cells
6 h on 24 CPUs CPUs (Troy Cluster)
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Coupling Macro and Meso-scale Modeling • Macro-scale model
• Meso-scale patch at critical area
Maximum shear angle region
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Indirect Coupling of Macro and Meso-scale Modeling 1.
Forming simulation at macro-scale
2.
Map the meso patch boundaries on the flat mesh
3.
Extract the displacement history at boundaries
4.
Simulate meso-scale model with displacement history
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Design Optimization Cycle Forming: (HyperForm)
Weave layup: (CEDREM/HyperMesh)
Design changes : HyperMorph, HyperStudy
Mapping (HWRM )
Performance (OS/RADIOSS)
OK?
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
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