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ATOAST multiphysics multimaterial  and or composite CAE design
 

ATOAST multiphysics multimaterial and or composite CAE design

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Engineering structures and products are inherently multimaterial and multiphysics in nature. However, they are usually designed for dominant physics and single monolithic material. Recent development ...

Engineering structures and products are inherently multimaterial and multiphysics in nature. However, they are usually designed for dominant physics and single monolithic material. Recent development at PDE level model and software allows us to design for Multiphysics and Multimaterial. This webinar will give an overview of multiphysics modeling and multimaterial mechanics. Multimaterial design can be considered as composite product design at macro scale. Multiphysics design of products for macro performance (nth level) and the linkage to material design at ((n-1)th level) will be demonstrated with industrial examples for weight and cost reduction. The computational design of material and prediction of structural, thermal, acoustics, and electromagnetic properties using a single model 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.

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    ATOAST multiphysics multimaterial  and or composite CAE design ATOAST multiphysics multimaterial and or composite CAE design Presentation Transcript

    • 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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.
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar Engineering Materials 6 • Conventional Engineering Materials – Metals – Ceramics – Polymer – Cellular and – Natural Materials • Composite Designer Materials • Emerging Materials – Smart – Nano – Meta
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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.
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar Representative Volume 16 • Square Array • Hexagonal Array • Random Micrograph -> Image map -> Material properties
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 2D Results 18 • Isotropic property prediction • Polymer composite anisotropic property prediction • Macro performance • Micro mechanical exploration for novel materials
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 2D Random Results 20
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 3D RVE 22 • Reinforcement shapes – Fiber – Whiskers – Flakes – Platelets – Spherical Particles • Regular or Random • Create your own 3D RVE using geometrical modeling tools
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar Nonlinear Performance 24 • Elasto Plastic Performance polymer matric composites • Polycarbonate + Glass Strain Stress
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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)
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar Results : Fiber breaks 27 • UD composites • Electrode on edge • Resistance change vs fiber breaks • Parallel resistance model behavior • Very sensitive to fiber breaks.
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar Results: Matrix Cracks 28 • Matrix crack density vs change in resistance • Can detect matrix cracks also
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar Results : Delamination 29 • Delamination length vs resistance change. • Delamination growth between fibers
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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/
    • ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 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.