1. Accurate Simulation of Short-Fiber-Reinforced Automotive Parts
Sascha Pazour
PART Engineering GmbH
pazour@part-gmbh.de
0049 2204 30677 26
© PART Engineering GmbH, www.part-gmbh.de

2. Cologne
Berlin
Frankfurt
Hamburg
Stuttgart
Munich
Wolfsburg
Ingolstadt
Rüsselsheim
• Founded in 1999 as FEM services supplier
• Focus on structural mechanics
• Mission is to provide CAE services and software in
order to add value to our customers‘ CAE chain
• 20 years experience in FEA
• 10 years experience in CAE software development
• Two software products by our own:
• Development partner of major CAE software vendors
Life
Bergisch
Gladbach
PART Engineering – Key Facts

3. Influence of Fiber Orientation onto Material Properties
Fig. 2
100 100
58
65
0
20
40
60
80
100
120
Stiffness Strength
in flow cross flow
100
350
0
50
100
150
200
250
300
350
400
therm. Expansion
material: PA6+GF30

4. Fiber Orientations in Short-Fiber-Reinforced Plastics
S1 Shear layer: Fibers oriented parallel to flow direction
S2 Mid layer: Fibers oriented perpendicular to flow direction
Fig. 3
Flow Direction X
X
Cut View X
Flow Direction
S1
S2
S1
Example Micrograph Pictures:
Thick
Mid Layer
Thin
Mid Layer

5. Degree of Orientation
Fig. 4










33
2322
131211
..
.
a
aa
aaa










000
000
001










33.000
033.00
0033.0
2
31
general case unidirectional quasi-isotropic
-90° +90°-45° +45°0° -90° +90°-45° +45°0°-90° +90°-45° +45°0°
2
1

6. Material Complexity
Fig. 5
Thermo-Mechanical
Simulation
E
α

Young´s Modulus
Poisson´s Ratio
Coeff. of Lin. Therm. Exp.
z
y
x
Fiber Orientation
(Local System)
Isotropic
Anisotropic
Temperature Dependant

7. Material Complexity
Fig. 6
z
y
x
Fiber Orientation
(Local System)
(1/0/0)
(0,7/0,2/0,1) (0,5/0,5/0)
(0,33/0,33/0,33)
Degree of Orientation
(Fiber Distribution)
80°C23°C
120°C-40°C
Temperature
x
y
z xy yz
zx
Local Directions

8. Material Complexity
Fig. 7
xy
zx
y
E2
α2
x
E1
α1
z
E3
α3
G12 α12
12
23°C
yz
G23
α23
23
G31
α31
31
Orthotropic Material Model
Needs 15 lin.-elastic temp.
dependant material properties:
Coeff. of lin. Therm. Expan.:
α1, α1, α1, α12, α23, α13,
Tensile moduli: E1, E2, E3
Shear moduli: G12, G13, G23
Poisson ratios: 12, 13, 23

9. Example: Weld Lines
Isotropic Approach
Fig. 8
Common Approach:
Isotropic

10. Example: Weld Lines
Anisotropic Approach
Fig. 9
CONVERSE Approach:
Anisotropic

11. Fiber Orientation and Anisotropic Material
Fig. 10
Converse Graphical User Interface
[Part: Mann & Hummel]

12. Mesh Topology
Fig. 11
ConverseIM solver mechanical solver
shell (mid-plane/surface) => shell (tria, quad)
shell (mid-plane/surface) => solid (tet, hex)
solid => solid (tet, hex)
unequal meshes
possible

13. Fig. 12
Converse Features and Interfaces
Mechanical SolverInjection Moulding
Solver
- Moldex 3D
- Moldflow
- Cadmould
- Sigma
- Fluent
- Simpoe
- 3D Timon
- Optistruct
- femfat
- nCode
- Abaqus
- Ansys
- Marc
- Nastran
- LS-Dyna
Orientations
Pressures
Temperatures
Wall Thicknesses
Residual Stresses
Shrinkage & Warpage
Weldlines

14. 0
200
400
600
800
1000
1200
1400
0 1 2 3 4 5 6
Kraft[N]
Verschiebung [mm]
Messung 1
Messung 2
isotrop
orthotrop
Example: Rotary Valve
Material: Grivory HTV 3H1
force[N]
displacement [mm]
test 1
test 2
FEA isotropic
FEA anisotropic
Fig. 13
[Part: Mann & Hummel]

15. Example: Air Intake Manifold
Material: Ultramid A3WG6
Fig. 14
[Part: Mann & Hummel]

16. Eigenfrequencies and Eigenmodes
0
100
200
300
400
500
600
700
800
900
1000
250,00 270,00 290,00 310,00 330,00 350,00 370,00 390,00
effektiveMasse[g]
Frequenz [Hz]
x-Richtung - isotrop y-Richtung - isotrop z-Richtung - isotrop
x-Richtung - orthotrop y-Richtung - orthotrop z-Richtung - orthotrop
x-direction-isotropic
x-direction-anisotropic
y-direction-isotropic
y-direction-anisotropic
z-direction-isotropic
z-direction-anisotropic
frequency [Hz]
effectivemass[kg]
Fig. 15
[Part: Mann & Hummel]

17. Lens Bracket Example
Fig. 16
Part Geometry Fiber Orientation in Converse
[Valeo Lighting Systems]

18. Lens Bracket Example
Fig. 17
Frequency correlation – simulation to Xp. modal analysis
+5Hz
+30Hz
Converse
Isotropic
Average error – 4 Modes
Mode Experimental (Hz) Isotropic (Hz) Converse (Hz)
1 44 76 60
2 56 77 62
3 91 114 94
4 224 270 218
[Valeo Lighting Systems]

19. Example: Burst Pressure
Material: PP + GF20
Fig. 18

20. Influence Of Production on Fiber Orientation
Fig. 19
Supplier 2Supplier 1
• Two suppliers but parts are geometrically up to 95% equal.
• Same material supplier, same mashine settings, etc.
• Different gating location means two completly different engine components!
Water pump housing
Gate location
Gate location
Moldflow results show different orientation

21. Influence Of Production on Anisotropic Part Stiffness
Fig. 20
Blue – Supplier 1
Red – Supplier 2
Dotted – Isotropic material
fiber orientation and material model by
4. isotropic vs. anisotropic results
∆ - 62%
Untolerable error if homogeneous
isotropic material is used!
3. displacements
1. distributed pressure on sealing contact surface
2. results evaluated on a path
Displacement
True distance along path

22. Fig. 21
www.part-gmbh.de What´s New?
Converse Installation

23. Fig. 22
Add Value to Your Mechanical Simulation
consider
the real part
properties
get better
predictions of
strength &
deformation
by using data
already
available
Thank you for your attention!
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