ATOAST multiphysics multimaterial and or composite CAE design

ATOA Scientific Technologies
Multiphysics CAE for Innovation TM
Multiphysics and Multimaterial
Design with COMSOL
Dr Raj C Thiagarajan, PhD
ATOA Scientific Technologies Pvt Ltd
05 APR 2013
Visit
http://www.comsol.co.in/events/953/multiph
ysics-and-multimaterial-design-with-comsol/

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar
Raj@atoastech.com
2
• Raj C Thiagarajan, MD of ATOAST,
Currently providing Multiphysics
CAE Design Services for Industrial
Innovation.
• Computational mechanics and
composite product development
since 1988
• ATOA Scientific Technologies is a
leading Multiphysics CAE Solution
provider
• First COMSOL certified Consultant
from India.
www.atoa.com
http://in.linkedin.com/in/ctraj

INTRODUCTION
3
Engineering
Design
Multimaterial Multiphysics
Innovative
Product
Engineering is Conversion of Material into Useful Product
Industrial Drivers: Cost, Weight and Performance
CAE product development for first time right
Multimaterial and Multiphysics for Optimal Design

Overview
4
 Multiphysics Product Design
 Materials
• Engineering Materials
• Materials in product design
 Multiphysics design of Material
• Composite mechanics
• Examples: CFRP
 Focus: Product and Material
Design Link
Material Design/
Mechanics
Multiphysics
Product Engineering
Composites Multimaterials

Nature & Multifunctional Composites
5
• Nature uses simplest material in optimal
form for efficient function.
• Composites are used for single
functionality ~ 80% structural
• The future growth is expected from
multifunctional composites.
• The availability of Multiphysics modeling
capability will accelerate adaptation of
Multifunctional composites.

Engineering Materials
6
• Conventional Engineering Materials
– Metals
– Ceramics
– Polymer
– Cellular and
– Natural Materials
• Composite Designer Materials
• Emerging Materials
– Smart
– Nano
– Meta

Composites
Multi
Material
Advanced
Materials
Noble Aluminum Steel
Multimaterial Product Design
7
• From “ All steel” ,
“All Aluminum ” All
Composites” To
Multimaterial
• Leverage the best of
material for product
performance.
• Challenges
• Fabrication
• Multiphysics
• Multifunctional
High COST Low
HighWEIGHTLow
Performance: High

Composites
8
• Combination of any two are
more materials to perform better
than individual constituents.
• Macroscopically (n scale)
homogeneous and
microscopically (n-1 scale)
heterogeneous.
• Composite principle can be
applied to multimaterial at
macro scale.

Constituents
Fibers: Glass, Carbon,
Kevlar, HDPE, SiC, Boron,
Matrix: Polymer, Metal,
Ceramic
Polymer matrix:
Thermoset, Thermoplastics
Thermoset: Epoxy, Vinyl
Ester, Polyester, Polyimides
Thermoplastics: PP, PMI,
PEI, PEEK, PES, PC,ULTEM
Intermediates
Semi Finish:
Prepregs
Comingled/ Cowoven
Sheet/bulk molding
compounds
Reinforced pellets
Intermediates:
Pultruded rods
Laminates
Sandwich panels
Composite films/fabrics
DesignandProcessing
Design: Constituents, Ply,
laminate, product ,
process and life
Polymer: PMC:
Hand layup, Spray up,
Resin Transfer Molding,
Autoclave Molding,
Filament, Tape Winding,
Pultrusion,
Compression Molding,
Injection Molding,
Thermoforming.
CompositeApplications
Aerospace
Automobile
Transportation
Consumer
Industrial
Medical
Packaging
Oil and Gas
Energy
Electronics
Infrastructure
Mining
AfterService
Smart Structural
health
monitoring,
Condition
monitoring
maintenance,
Repair,
Retrofitting of
composite
products
Composite Industry Value Chain
• Simulation tools are use at every stage of value chain
• We shall focus on the Material Design of composite products
Reinforcement
Matrix
Semi-Finish Intermediate
Design
Processing
Composite
Products
After
Service
9

Type of Composites
• Particulate
Composites
• Short Fiber
Reinforced
composites
• Long Fiber
Reinforced
composites
• Continuous
Fiber reinforced
composites
• Multimaterial
PerformanceParameter(Strength,Stiffness..)
TypicalProcessingcost
Macro Composites
Metal polymer hybrids
Sandwich structuresMetal hybrid picture from Injection molding,
www.plastictechnology.com, pp11.
Constituents
Form
Physics
Load:
Static
Dynamic
Time
Results:
Singlepoint
Multipoint
10

Material Design/Property Prediction
11
• Additive
• Product
• Super
– Stiff and tough
– Ultra low weight
• Meta
– Beyond Nature
Nano
Micro
Macro
After US 7838108
Vf
NormalizedProperty
Material 1 Material 2
Metamaterials

COMPOSITE Material Modeling
12
• Analytical
– Rule of Mixtures
• Micromechanics
– 2D/3D
• Lamination Theory
– Ply, Laminates
• Product performance
– Multiphysics
• Failure mechanics
– Damage, progressive
failure
• Analytical
tools
• Micromechanics
codes
• Classical
Lamination Theory
• General
purpose FEA
software
• COMSOL for
composite
modeling

COMSOL Example
CFRP Composites
13
• Structure
• Part
• Laminate
• Fiber
• Matrix
• Molecular
• ATOMIC
0.3345 nm
0.142 nm
0.669 nm
c
ba
• Carbon T300 / Epoxy 914
• Multiphysics
– Structural+ Electrical
– Structural + Thermal
– Damage Mechanics
– Structural Health Monitoring
• Micromechanics
– UD composites
– Particulates
– Laminates
• Constituent
– Graphene Sheet
– Carbon fiber

Structural
Thermal
Electromagnetic
Acoustic
COMSOL Modeling Steps
14
• Select a suitable physics
(Governing, Constitutive
equation)
• Model a representative volume
with periodic boundary condition
• Develop Global/macro and Local/
micro relationship (Virtual Testing)
• Solve and post process for Material
property prediction.
EεεjEω)εε(σJ '
r0
"
r0 
t
H
t
E
E





  ExHx

Micromechanics
15
• Continuum Micromechanics based on
homogenization theory
• Aims at finding a volume elements
(Representative Volume Element – RVE, periodic
Micro field- PMA response to prescribed macro
response)
• Prediction of macro properties from micro
structure and constituents.
Localization relationship
Micro
fields
Macro
fields
Homogenization relationship
Where,
W volume, G-surface,
u(x)– deformation vector
t(x)– surface traction vector
nG – surface normal vector
Homogenization Theory/
Methods
• Mean Field Theory
• Variational Bounding
methods
• RVE (Representative
Volume Element) or
PMA ( periodic Micro
field)
• Generalized Method of
Cells
• Embedded Cell
• Windowing Approach
• Variational Asymptotic
Method
• Multiscale Models

Representative Volume
16
• Square
Array
• Hexagonal
Array
• Random
Micrograph -> Image map -> Material properties

Numerical Implementation 2D
17
• Periodic boundary condition
• u xl= u x0 + ex
• v yl= u y0 + ey
• Load
• Body force
• Global (macro) vs local (micro)
stress and strain
• Integration of variables
• Parametric model to predict the
stress strain behavior

2D Results
18
• Isotropic property
prediction
• Polymer composite
anisotropic property
prediction
• Macro performance
• Micro mechanical
exploration for novel
materials

2D Results CFRP
19
• T300, Epoxy914, Vf 60%
• Quarter segment
• Periodic BC
• Global vs Local
• Transverse
Modulus
• Experiments :
8.96+0.06 GPa
• COMSOL:
9.127 GPa
T300
Carbon Fiber
Matrix
Epoxy
914

2D Random Results
20

2D: Thermo Elastic Performance
21
• Design of a Dynamic
Thermal conductivity
Material
• Thermal Insulator to
conductor
• Coupled Thermo
elastic Analysis + DoE:
Commercial Materials,
Vf, packaging
• Virtual Design of novel
Thermal material
0 80
100

3D RVE
22
• Reinforcement shapes
– Fiber
– Whiskers
– Flakes
– Platelets
– Spherical Particles
• Regular or Random
• Create your own 3D RVE using
geometrical modeling tools

3D Results
23
• CFRP UD: 60% Vf
• T300 /Epoxy 914
• Longitudinal
Modulus
• Experiments :
140+1.2 GPa
• COMSOL:
139.04 GPa
• Transverse
Modulus
• Experiments :
8.96+0.06 GPa
• COMSOL:
9.095 GPa

Nonlinear Performance
24
• Elasto Plastic
Performance polymer
matric composites
• Polycarbonate + Glass
Strain
Stress

COMPOSITE Damage Mechanisms
25
• Self sensing of Carbon fiber composites
• Good Thermal and Electrical Conductor
• Fiber
• Fiber breaks
• Matrix
• Matrix crack
• Interface
• Delamination
• cracks
(d)
(a)
(b)
(c)

Numerical investigation
26
• The electrical conduction
mechanism and the
effect of damage in CFRP
composites were
simulated in COMSOL
using AC/DC Electric
Currents Interface.
• Homogeneous composite
model with effective
properties
• Micromechanical model
with constituent
properties

Results : Fiber breaks
27
• UD composites
• Electrode on edge
• Resistance change vs
fiber breaks
• Parallel resistance
model behavior
• Very sensitive to fiber
breaks.

Results: Matrix Cracks
28
• Matrix crack
density vs
change in
resistance
• Can detect
matrix cracks
also

Results : Delamination
29
• Delamination
length vs
resistance
change.
• Delamination
growth
between
fibers

Negative refraction
Electrostatic resonance
Composite cloaks
Acoustic super lens
Summary
30
• Materials, Multiphysics product design
• Micromechanical modeling with COMSOL
• 2D and 3D modeling method and results
• CFRP Simulation vs Experiments -> good
• Design for Multiphysics and Multimaterial is the
way forward for First time Right Product Design
• Refer COMSOL CONFERENCE PAPERS for more
• Visit for the Presentation @
• http://www.comsol.co.in/events/953/multiphysics
-and-multimaterial-design-with-comsol/

Abstract
31
• Engineering structures are inherently multimaterial and
multiphysics in nature. However, they are usually
designed for dominant physics. Recent development at
PDE level model and software allows us to design for
Multiphysics and Multimaterial. This webinar will give an
overview of multiphysics and multimaterial mechanics.
The computational design of material and prediction of
structural, thermal, acoustics, and electromagnetic
properties will be detailed. The macro, micro, and nano
scale effects of composites will also be highlighted. The
link between multiphysics engineering application and
the design of material will be detailed.

ATOAST multiphysics multimaterial and or composite CAE design

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