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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
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
IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
Survey Composite Simulation – Question 2
Question 2:
„In which sectors do you see applications for the simulation of composites?“
Industries
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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
Survey Composite Simulation – Question 2
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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
Survey Composite Simulation – Question 3
Question 3:
„In which areas of application do you see the use of composite simulation?“
Areas of Application
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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
Survey Composite Simulation – Question 3
Conclusion question 3:
� 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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
Survey Composite Simulation – Question 4
Question 4:
„ What are relevant technologies (technological basics) for the simulation of composites?“
Technological Basics
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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
Survey Composite Simulation – Question 4
Conclusion question 4:
� 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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
Survey Composite Simulation – Question 5
Question 5:
„Where do you see R&D demand for thesimulation of composites?“
R&D Demands
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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
Survey Composite Simulation – Question 5
Conclusion question 5:
� 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"
IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
Composite Simulation Roadmap: R&D demands
Further findings regarding R&D demands:
Results of the industrial work group Composite Simulation
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R&D Demands
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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
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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IndustriesR&D Demand
OutlookData Acquisition Areas of Application Technological Basics
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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© 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
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