Survey regarding relevant industries, areas of application, technological basics and R&D demand

1. 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 Runde
Virtual Dimension Center (VDC) Fellbach
Auberlenstr. 13
70736 Fellbach
www.vdc-fellbach.de
Ulrike Möller
Allianz Faser-basierte
Werkstoffe Baden-Württemberg
(AFBW)
www.afbw.eu

2. Industries R&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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3. Industries R&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 and
automation technology
Engineering and
simulation provider
Software
Universities, research

4. Industries R&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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5. Industries R&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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6. Industries R&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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7. Industries R&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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8. Industries R&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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9. Industries R&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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10. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics
Survey Composite Simulation – Question 5
Question 5:
„Where do you see R&D demand for the
simulation of composites?“
R&D Demands
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11. Industries R&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"

12. Industries R&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
ƌďĞŝƚƐŬƌĞŝƐ
R&D Demands
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13. Industries R&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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14. Industries R&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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15. Industries R&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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16. Industries R&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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17. Industries R&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 mesostructural
characterization methods necessary
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18. Industries R&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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19. Industries R&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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20. Thank you very much for your interest!
You are interested in this topic and you are looking for contact persons/ implementation
partners? Please contact us.
© Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC)
Virtual Dimension Center (VDC) Fellbach
Auberlenstraße 13
70736 Fellbach
www.vdc-fellbach.de
Ulrike Möller
Allianz Faser-basierte Werkstoffe Baden-
Württemberg (AFBW)
www.afbw.eu