WS 2013 04 Advanced Materials Aerospace PDF

Aerospace Industry
Multi-Scale Modeling of Composite Materials & Structures

Dr. Jan Seyfarth
Product Manager Digimat April 2013
Copyright e-Xstream engineering, 2013
2

Aerospace Industry
A Very Short Introduction...

Digimat
e-Xstream & Simulation Strategy
Software

Materials
Technology & Applications

From Materials to Structure
Current Status and Ongoing Developments

Structures
Technology & Applications

Summary

Aerospace Industry

Digimat

e-Xstream engineering
Simulation Strategy
Nonlinear Multi-Scale Simulation Platform

3
Aerospace Industry
4

Who are we...? A MSC Software Company!

Team of ~30 persons
- PhDs (~65%)
- MS & BS Engineering (~ 25%)
- Marketing, Finance & Admin (~10%)

+ TBH in 2013

Material experts
- Micromechanics

It`s all about...

COMPOSITES
A
m
s
t
e
r
d
a
m
,

O
c
t
o
b
e
r

2
0
1
2

Digimat
5

What are we concerned about?

Inter-dependencies in the Design of a Composite Part

Digimat
Structural design
influences processing
Manufacturing sets
local microstructure
Local microstructure
sets material
properties

What do we do...? Multi-Scale!

MICRO

- Material

MACRO

- Dumbbell

- Part

- System
6
Micro-
structure Material model
Part
performance
Characterization
Process
System level
Simulation Strategy
Digimat
7

Material Related Design Challenges

Manage Material Data
- Generate Data (Cost & Time of Test)
- Manage, Trace, Protect (IP)
- Comply (Regulation)

Model (composite) Materials, Part & Systems
- Nonlinearity: Progressive damage & failure
- Anisotropy
- Heterogeneity
- Process dependency

Use
- The optimal mix of material
- The Material(s) as a design parameter to innovate
- The optimal manufacturing process

Simulation Strategy
Digimat

Nonlinear Multiscale Modeling Platform
8
Digimat
- Performance
- Stiffness
- Failure
- Fatigue

- Technology
- Linear/Nonlinear
- Mean Field/FEA
- Micro/Hybrid

9


Holistic modeling

- Materials
- Chopped Fibers: Short/Long
- Continuous Fibers
- Fillers

- Physics
- (Thermo-) Mechanical
- Thermal Conductivity
- Electric Conductivity

- Manufacturing
- Injection
- Compression
- Draping
- Fiber placement
- MuCell

Digimat


MICRO

- Virtual Material

MACRO

- Data management
- Reverse Engineering

- FEA Interfaces
- Mapping

10
Material Engineering
Structural Engineering
Digimat

Interfaces to MSC Nastran

SOL 101 - linear
- Weak coupling [Nastran material card used]
- Including SOL 103 for vibration
- Including SOL 105 for buckling

SOL 400 - nonlinear
- Implicit
- Strong coupling [Digimat user subroutine]

SOL 700 - nonlinear
- Explicit
- Strong coupling [Digimat user subroutine]

11
Available in 4.4.1
Specification phase
Under development
Digimat

Materials

Composites
Materials Engineering
Applications

12
Aerospace Industry
13

A Vast Mix of Different Materials

Metal (Alloys)
- Aluminium / Magnesium
- Molybdenum / Titanium / Tungsten

Reinforced Plastics
- Thermoplastics + Carbon fibers
- Epoxy + Glass / Carbon / Aramid fibers

Ceramics
- Titanium + SiC fibers

Composites
Materials
Complex structures Pores
Stacking Weaving
Structure / Orientation
Random
Material's
Performance (Stiffness, failure, fatigue, ...)
Anisotropy

Digimat-FE

Fast & Efficient Prediction of Composite Material Properties

14
Materials

UD Composites

Defects & influence of processing

- ISEMP
- Integrative Simulation and Engineering of Materials and Processes
Aims at the simulation of material details and not only the
macroscopic overall properties
Aims at considering manufacturing process by the simulation
Uses commercially available software tools

CHALLENGE
- Processing of CFRP results in residual stresses in the material
- Residual stresses lead to micro-damage & failure of CFRP
- Goal is to simulate residual stresses of a carbon fiber composite
material at the micro scale with realistic topology

15
Applications
Materials

UD Composites

Defects & influence of processing

- E.g. already generated in the material during processing
- Source for the failure of the composite.

16
Segmentation
Matrix enrichment
Pores
Delamination
Applications
Materials

UD Composites

RVE Generation
- Periodic boundary conditions
- Enhanced flexibility
- 45 orientation
And other...

17
Applications
Materials

UD Composites

RVE Generation

- Fibers
- Stochastic
- Intersection with
Matrix
Voids

- Voids
- Stochastic
- Complex shapes
- Clustering, control over
Position
Shape
Orientation

18
[ 0 / 90 ]
fibers intersecting voids
complex
shapes
Applications
Materials

UD Composites

Curing effects

- Replacement experiment:
- Shrinkage due to temperature decrease
19
Applications
Materials

UD Composites

Curing effects

- Delamination due to change in orientation
20
Applications
Materials

UD Composites

Curing effects

- Crack propagation due to stochastic distribution of fibers

21
Applications
Materials

Strategic Simulation Tool

Digimat

- Recommended tool for investigations
22
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Applications
Materials

Sandwich Panels

Micross - Stand-Alone Digimat Module
- Input Data @ micro and/or macro scale
- Fast Solution in less than 10 minutes
- Loading
- 3-Point & 4-Point Bending
- In-Plane Shear

Tuesday, 23 April 2013
23
Applications
Materials

Micross

Stand-alone module
- Definition of honeycomb core
- Definition of skin plies

24
Applications
Materials

Micross

Stand-alone module
- Visualization of results
- Failure indicators
- Skins: max. stress, Tsai-Wu, Tsai-Hill, Azzi-Tsai-Hill
- Core: shear, compression

25
Applications
Materials


Critical Development Phase
Current Status
Ongoing Developments

26
Aerospace Industry

Digimat-MF

Fast & Efficient Prediction of Composite Material Properties

27
Output

Homogenization

DIGIMAT material model
sensitive to composite
microstructure
State-of-the-art
homogenization
methods
Per-phase material
properties +
microstructure
information
Input

a
r

w [%]
matrix
filler


Digimat-MX

Material eXchange & Reverse Engineering
28
Reverse
Engineering

Input

Output

Calibrated DIGIMAT
Material Model, stored in
database and ready to be
shared and used
Calibration of
DIGIMAT models
based on
experimental data
Experimental data,
DIGIMAT material
models stored in
database

Multi-Scale Approach

Top Down |
Reverse Engineering
29

Multi-Scale Approach

Bottom Up |
Prediction of performance
30

Material Models - Standart

(Thermo-) Elastic
(Thermo-) Elastoplastic
(Thermo-) Viscoelastic
(Thermo-) Elasto-Viscoplastic
31
f(T)
TEMPERATURE
f( )
STRAIN RATES
High strain rates
Creep
f(OT)
ANISOTROPY
Current Status

Material Models - Advanced

(Thermal) Creep

- Viscoelasticity
- Elasto-Viscoplasticity
32
time

aligned
VE Matrix Composite
TVE Matrix Composite
G
0
, K
0
and CTE Constant
TVE Matrix Composite
G
0
=G
0
(0), K
0
= K
0
(0) and CTE Constant
Current Status

Stiffness

Eshelby approach for UD & woven composites

- Mean field homogenization
- Glass fibers isotropic
- Carbon fibers transversely isotropic
33
Current Status

Stiffness

UD Composites - RVE definition

- Layered microstructure

34
Current Status
Stiffness
Failure

Stiffness

Woven Composites - Basic model

- Superposition of fibers

35
Current Status

Stiffness

Woven Composites - Advanced model

- Realistic woven structure

36
yarn definition
woven modeler
Current Status

Stiffness

Woven Composites - Advanced model

- Realistic woven structure

37
visualization &
property
computation
Current Status

Stiffness

Virtual testing

- Stress & strain
- Tension & compression
- Creep & relaxation

38
uniaxial
shear
biaxial
Current Status

Stiffness

Input / Definition

- Epoxy matrix
- Density
- Isotropic elastic
Youngs modulus
Poisson ratio

- Carbon fibers
- Density
- Transversely isotropic elastic
In-plane Youngs modulus
Axial Youngs modulus
In-plane Poisson ratio
Transverse Poisson ratio
Transverse shear modulus
39
Current Status
ksi
t/mm
3
ksi
t/mm
3

Stiffness

Input / Definition

- Ply
- Microstructure
Continuous fiber
Volume fraction of fibers: 61%

- Laminate
- Stacking sequence
3 different laminates
- Computation of
Laminate
Stress response
Engineering properties
Ply
Engineering properties
Per-phase
Stress response

40
Current Status
10/30/60
Laminate 1
60/30/10
Laminate 2
10/40/50
Laminate 3

Stiffness

Output

- Laminate
- Stress response

41
Current Status
11

Stiffness

Output

- Laminate
- Stiffness matrix
In coordinate system of the RVE
Tensile direction: 11
Orthotropic

42
Current Status
Laminate 1
10/30/60
Laminate 2
60/30/10
Laminate 3
10/40/50
11

Stiffness

Output

- Ply level
- Engineering constants
In coordinate system of the ply
Tensile direction: x
Unique for all three laminates

43
Current Status
Lamlna Angle 0 43 90
?oung
Modulus (ksl)
Axlal (along x-axls) 23.044 2.139 1.318
1ransverse (along y-axls) 1.318 2.139 23.044

Stiffness

Output

- Matrix level
- Microscopic properties
Stress 11 vs. Strain 11 [ksi]
- Per ply information
Different stresses ( ) & strains are reached
Dependent on the ply and sensitive to changes in the laminate design
44
Current Status
imposed strain imposed strain imposed strain
0 45 90
matrix strain matrix strain matrix strain
11

Stiffness

Output

- Fiber level
- Microscopic properties
Stress 11 vs. Strain 11 [ksi]
- Per ply information
Dependent on the ply and sensitive to changes in the laminate design
45
Current Status
imposed strain imposed strain imposed strain
fiber strain fiber strain fiber strain
11
0 45 90

Stiffness

Coupled Analysis
46
Current Status

Stiffness

Coupled Analysis - Global Response

- Laminate level
- Force / displacement curve
Digimat-MF Fraction of a second to solve micromechanics
Nastran Minutes for FEA analysis

47
Current Status

Stiffness

Coupled Analysis - Local Response

- Ply level
- Macroscopic properties in each ply
Max. Princ. Stress [ksi]
Influence of the hole on local behavior

48
Current Status
Laminate 1
10/30/60
Laminate 2
60/30/10
Laminate 3
10/40/50

Failure

Matrix strain per ply
- Differs from macroscopic strain
- Input for unique strain based failure criteria

49
Current Status
0
45
90
-45
O
r
i
e
n
t
a
t
i
o
n

i
n

p
l
y

No matrix failure in 0 ply
Average matrix strain in other plies
for failure of the composite
Matrix
Macroscopic

Failure

Per ply definition

- Derived from microstructure
- Stress in fibers / strain in matrix

50
Current Status

Progressive Failure Analysis

Explicit solver

- Element deletion triggered by
- Stress in fibers / strain in matrix

51
Fiber failure
Current Status


Validation of stiffness & failure

- Predictive modeling
52
RE on ply level of plain
specimen
Prediction of performance
of open whole specimen
Current Status


The idea

- Feed the indicator, control stiffness & failure...
53
Indicator

Matrix
Strain
Transverse tensile

Fibers
Stress
Tension
Compression
Matrix
stresses & strains
Fibers
stresses & strains
Composite
stresses & strains
Pre-Failure

Stiffness Reduction
Damage controled by
failure indicator

Failure

Element Deletion
Final composite
failure controled by
critical damage


Preliminary results 2013/02 release
54
Partial
failure
No
failure
Complete
failure


Preliminary results 2013/02 release

- Stiffness degradation
- Failure
55
Deformation: d11 & d22 Element deletion: progressive & classical

Structures

Applications

56
Aerospace Industry

Short Fiber Reinforcement
57
Structures
fibers
failure
ANISO
Measurements
/ curves
Process Simulation
Orientation data on processing mesh
FEA
Structural analysis
Structural mesh
Mapping
Anisotropic (non)linear
Material Model
ISO

Short Fiber Reinforcement

Fittings

Turbine parts

58
Structures

UD & Woven

59
Measurements
/ curves
FEA
Structural analysis
Anisotropic (non)linear
Material Model
UD
Woven
Draping
Warp/weft angles
Structures

Summary

60
Aerospace Industry
61

Summary

Materials

- In-depth study of a broad range of materials & performances
- SFRP, UD & woven composites, hard metals, ceramics, nano composites
- Complex RVEs - micro stresses & strains
- (Thermo-)Mechanical, thermal & electrical conductivity


- Material property evaluation
- Screening / Selection / Specification / Allowables

Structures
- Influence of processing on final performance
- Injection molding
- Draping
- Fiber placement
- ...

Aerospace Industry

Digimat 4.4.1 -New Release

Soon available on e-Xstream
FTP!

(see separate email announcement)

62
Licensing
sales.admin@e-Xstream.com

Support
support@e-Xstream.com
Training
bernard.alsteens@e-Xstream.com

Software
jan.seyfarth@e-Xstream.com
Aerospace Industry

Thanks a lot for your attention!

63
Aerospace Industry

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Aerospace Industry

Multi-Scale Modeling of Composite Materials & Structures

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