Roadmap Composite Simulation v01 · Survey Composite Simulation – Question 5 Conclusionquestion5:...

Composite Simulation Industries, Areas of Application, Technologies, R&D Demands

© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)

Dr.-Ing. Dipl.-Kfm. Christoph RundeVirtual Dimension Center (VDC) FellbachAuberlenstr. 1370736 Fellbachwww.vdc-fellbach.de

Ulrike MöllerAllianz Faser-basierte Werkstoffe Baden-Württemberg (AFBW)www.afbw.eu

IndustriesR&D Demand

OutlookData Acquisition Areas of Application Technological Basics

Data acquisition for the Composite Simulation Roadmap

� Conduct of the survey in February 2015 at the congress Composite Simulation 2015

� Thus limiting the panel to experts regarding the topic

� 43 usable answers

� Not all answers are complete. In the case of percentage evaluations, the

Data Acquisition

� Not all answers are complete. In the case of percentage evaluations, the population selected (= 100%) was always only the set of answers that have explicitly responded to a question

� Additional information as a result of the industrial work group Composite Simulation, which exists since 2013

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Survey Composite Simulation – Question 1

Question 1: „In which industry do you work?“

19 users

Industries

Automotive

Aerospace

Mechanical Engineering

3

12 provider

12 researcher

Mechanical Engineering

Electrical andautomation technology

Engineering andsimulation provider

Software

Universities, research




Question 2:

„In which sectors do you see applications for the simulation of composites?“

Industries

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Conclusion question 2:

� The Automotive and Aerospace sectors are dominating in their importance for composite simulation (95% high or very high importance)

� Sport & Leisure, Commercial vehicle construction, Mechanical engineering, Medical technology and Rail vehicle construction follow by a clear margin

Industries

Medical technology and Rail vehicle construction follow by a clear margin

� Other industries are Protection device construction, Architecture, Plant construction, Packaging technology

� Compared to the other panel groups, users see less need in the Architecture sector

� In comparison with the other panel groups, service providers see less demand in Mechanical engineering

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Question 3:

„In which areas of application do you see the use of composite simulation?“

Areas of Application

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� The most important application fields of composite simulation are component failure/ crash and material description

� At great distance follow component analyzes (sandwich, vibrations, fatigue), material development and drape simulation

Areas of Application

material development and drape simulation

� Basically, the assessments of the panel groups regarding the importance of composite simulation in fields of application are similar

� Differences can still be identified in component analyzes (especially in the examination of vibration and sandwich structures): users tend to see less importance here than other panel groups; service providers see more importance

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Question 4:

„ What are relevant technologies (technological basics) for the simulation of composites?“

Technological Basics

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� All respondents rate material models as "significant" (19%) or "very significant" (81%)

� Solver technologies, contact algorithms and parallelization techniques follow at great distance (still at least 2/3 of the respondents consider these as

Technological Basics

at great distance (still at least 2/3 of the respondents consider these as "significant" or "very significant")

� AI methods are of low importance or insignificant for the majority of those surveyed

� The assessments of the panel groups regarding the importance of composite simulation technologies are very similar

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Question 5:

„Where do you see R&D demand for thesimulation of composites?“

R&D Demands

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� High R&D requirements in the context of composite simulation are seen in the areas of material models, failure, service life and manufacturing process

� Fluid/ structure interaction, joining, contact algorithms follow at distance

� Researchers mostly see an above-average need for research, with the

R&D Demands

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� Researchers mostly see an above-average need for research, with the exception of the topics "failure" and "contact algorithms"

� Nobody rated R&D demands in the field of "failure" as "insignificant"



Composite Simulation Roadmap: R&D demands

Further findings regarding R&D demands:

Results of the industrial work group Composite Simulation

��

R&D Demands

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Further problems from an expert´s point of view: 1. Modeling

Objectives

� Reduction of experiments, better simulation

� Reduce conservative assumptions, no inadequate oversizing, load-adapted components

� Faster qualification

� Optimal sandwich or lightweight solution for the respective component

� Simulation capability of sandwich structures; influence of production parameters,

R&D Demands

� Simulation capability of sandwich structures; influence of production parameters, structure and material

� Virtual design of sandwich structures

� Deepening material knowledge of sandwich structures

� Crash boxes/ elements for series vehicles, production/ crash models

� Simplification of the simulation process (automatic calibration), free programming of an individual material model

� Cost-effective core materials and processes for the car application

� Description of total stress in sandwich structure with reinforced foam core

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Further problems from an expert´s point of view: 1. Modeling

Problems

� Elaborate modeling, no modeling type generally validated

� Company-oriented modeling (no academic approaches/ models)

� Efficient modeling - consistency of the process chain/ design/ production structure -programmable models

� Lifecycle and fatigue simulation, simulation of vibrations

� Illustration of failure mechanisms and validation of complex manufacturing processes

R&D Demands

� Illustration of failure mechanisms and validation of complex manufacturing processes

Tasks

� Calibration between real components and simulation

� Characteristic value determination - linking failure models with experiments

� Characteristic values from process simulation

� Cost-optimized simulation of fiber composite structures – closed process simulation (VAP / RTM)

� Understanding of failure mechanisms

� Material models, material separation: crack

� Dynamic behavior: stiffness, damping/ fatigue strength

� Manufacturing simulation

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Further problems from an expert´s point of view: 2. Material parameters

Objectives� Creation of a material model database (time saving)

� Macroscopic material modeling

� Illustration: chemistry/ material properties "RTM"

Problems

� Many possible material combinations, therefore, several material models are

R&D Demands

� Many possible material combinations, therefore, several material models are necessary

� Reliable material parameters, models for damage formation and propagation

Tasks

� Better simulation of material properties through better understanding of the material

� Calculation methodology: calculation tools to develop material models, including failure

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Further problems from an expert´s point of view: 3. Sandwich structures

Problems

� Illustration of adhesion of core surface layer, to which thickness shell formulation is usable for sandwich structure

� Illustration of inhomogeneous foams, simulation of operational stability (especially of the joining technique)

� Forecasting quality for CFRP and sandwich structures

� Modeling cover layer connection (gluing)

R&D Demands

� Modeling cover layer connection (gluing)

� Adaptive load-dependent linkage switching

� Large edge length does not allow representation of sandwich honeycomb structures

� Sandwich modeling: calculation times are too long

� Residual stress in the sandwich, characteristic values for reinforced foam cores

� Assignment sandwich construction to requirement/ structure

Tasks

� Fast FE model derivation of sandwich structures using (adapted) CT software

� Establishment of systematic selection procedures and validated material characteristics for sandwich components

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Further problems from an expert´s point of view

Open interface definition between measurement technology and FE modeling:� Need for coordination between measurement technology and software providers and users

Ambiguities in determining optimal material parameters due to the model properties:� Mathematical investigation of material models necessary, mechanism-based

R&D Demands

� Mathematical investigation of material models necessary, mechanism-based material modeling better than a phenomenological

Ambiguities in determining optimal material parameters due to material inhomogeneities:� Combination of full field measurement techniques with mesostructuralcharacterization methods necessary

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Outlook: Starting points collaborative research

� Guiding theme "Predictability of textile-based sandwich structures with consideration of process technology"

Subtopics

� "Experimental and numerical investigation of the influence of textile construction and core properties on the bonding in sandwich structures."

Outlook

construction and core properties on the bonding in sandwich structures."

� "Simulation capability of failure behavior of sandwich structures in crash applications."

� "Application-oriented modeling and identification of sandwich structures with honeycomb core."

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Outlook

� Composite simulation is currently a fast-moving area with well identifiable fields of application

� Like many other technologies, it migrates from heavily oligopoly-characterized industries (aerospace, automotive) to polypol industries (such as engineering) with smaller structures

� There are many good approaches, but there is still a great need for research in

Outlook

� There are many good approaches, but there is still a great need for research in these fields for the foreseeable future

� Further evaluations and analyzes of secondary literature on the Composite Simulation Roadmap will follow this year

� Topics are continuously processed in the industrial work group “Composite Simulation" of the VDC and the AFBW

� Publications are made on the websites of the VDC and the AFWB

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Thank you very much for your interest! You are interested in this topic and you are looking for contact persons/ implementationpartners? Please contact us.

© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)

Virtual Dimension Center (VDC) FellbachAuberlenstraße 1370736 Fellbachwww.vdc-fellbach.de

Ulrike MöllerAllianz Faser-basierte Werkstoffe Baden-Württemberg (AFBW)www.afbw.eu

Roadmap Composite Simulation v01 · Survey Composite Simulation – Question 5 Conclusionquestion5:...

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