Short glass fiber reinforced plastics (SFRP) are increasingly employed in load-bearing structural parts. Especially, for automotive applications it now becomes essential to be able to predict their long-term performance.
On the one hand, SFRP lifetime prediction is very challenging as it is affected by many factors typical for this class of materials, like: anisotropy (micro-structure), load amplitude, load ratio, load frequency, and temperature. On the other hand, in the FEA simulation, mesh density needs to be considered carefully. This requires to account for the effect of stress concentrations on the lifetime prediction. This can only be achieved by developing advanced post-processing tools.
This webinar presents how DSM and e-Xstream partner to equip Digimat with the tools needed to face those challenges : in Digimat-MX, a dedicated environment for SFRP high cycle fatigue calibration, and in Digimat-RP, a fatigue simulation result post-processing environment.
5. Confidential5
Rely on accurate fatigue failure indicator
and easily interpret FEA simulation results
to compute part lifetime
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Use Digimat to reach
accurate SFRP fatigue
lifetime predictions
Dedicated environment for
fatigue failure indicator calibration
Dedicated environment for
fatigue lifetime computation
Partner to push limits
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Goal : Implement DSM framework in e-Xstream’s Digimat tools
• Enable more accurate part fatigue lifetime predictions
• Improve efficiency and accuracy to calibrate
and validate material cards for high cycle fatigue
(Digimat-MF, Digimat-MX)
• Enable DSM customers by providing an efficient workflow
for part fatigue lifetime evaluation
(Digimat-RP)
So how about the prediction results ?
DSM / e-Xstream collaboration
Improving SFRP fatigue lifetime prediction
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Framework CAE fatigue prediction
Flow simulation
Fatigue data Digimat material model Part prediction
Stress concentration
correction
R-value dependence
Anisotropy
Microstructure
Glass fiber orientation
Notch sensitivity
A full overview will be presented at the Digimat User’s Meeting, October 2019
This webinar
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Microstructure comparison
Over the path at this location (near failure location), the measured fibre
orientation and predicted orientation (Moldflow V2019) correspond well.
Milled and CT-
scanned domain
Failure
location
Fiber orientation at failure location is predicted well
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Part level – Experimental data
0.5
0.1
-0.5
-1
-2𝑅 𝐹 =
𝐹 𝑚𝑖𝑛
𝐹𝑚𝑎𝑥
PA66 GF50, DAM, 23°C
Load bracket test data
Nf,
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Part level – Local stress ratio
PA66 GF50, DAM, 23°C
F = -1500 N
F = 1500 N
𝜎 𝑚𝑖𝑛 = −34.3 𝑀𝑃𝑎
𝑅 =
𝐹 𝑚𝑖𝑛
𝐹𝑚𝑎𝑥
𝑡
𝐹 < 0
𝐹 > 0
𝐹
𝜎 𝑚𝑎𝑥 = 94.3 𝑀𝑃𝑎
𝑅 𝜎 ≠ −1
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Part level – Local stress ratio
PA66 GF50, DAM, 23°C
𝑅 =
𝐹 𝑚𝑖𝑛
𝐹𝑚𝑎𝑥
𝑡
𝐹 < 0
𝐹 > 0
𝐹
Local stress ratio
The local stress ratio is not equal to the applied load ratio.
The local stress ratio also depends on the magnitude of the load
One needs to correct for the local stress ratio to enable accurate liefetime predictions!
𝑅 = −1
𝑅 = −2
𝑅 = −0.5
𝑅 = 0.1
𝑅 = 0.5
failure location 1
𝑅 ≥ −1
failure location 2
𝑅 < −1
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Part level – Local stress ratio
PA66 GF50, DAM, 23°C
anisotropy x R-value x stress concentration x GF prediction
(ans o3ro x -va3 e x stre ss co5centrtion x G?ic =45 x ?)
x10
overestimation
x3
/3 /10
• Failure location captured
• Predictions of complex parts
with accuracy of factor 5-30x
for most R-values.
• R-value dependence
accurately captured
safe
Load bracket
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We keep pushing now accounting for local plasticity
Stress
Strain
න 𝜀𝑖𝑗
𝑒
𝑑𝜎𝑖𝑗
𝑒
= න 𝜀𝑖𝑗
𝑒𝑝
𝑑𝜎𝑖𝑗
𝑒𝑝
3D extension of ESED rule
Glinka correction
Elastic
Elastoplastic
• Maintained CPU time
Perform the same elastic simulation
• Enriched inputs for lifetime computation
Estimate plastic stress field
Compute new local R
× 𝐾𝑓
Fatigue data notched specimensFEA results
0°, 0.25mm, R=-1
DSM communication at SPE ACCE 2019
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overestimation
Load bracket
safe
x10
x3
/3
/10
Plasticity and stress gradient correction allow
to reach targeted results at part level.
• Failure location captured
• Predictions of complex parts
within 1 decade.
• R-value dependence
accurately captured
Part level – Plasticity correction results
PA66 GF50, DAM, 23°C
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overestimation
fine mesh (0.1mm)
coarse (0.75mm)
intermediate (0.5mm)
Load bracket
safe
x10
x3
/3
/10
Plasticity and stress gradient correction allow
to reach targeted results at part level.
• Failure location captured
• Predictions of complex parts
within 1 decade.
• R-value dependence
accurately captured
• Robust to mesh size
Part level – Mesh size robustness
PA66 GF50, DAM, 23°C
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Digimat-MX: DSM cards for high cycle fatigue prediction
PA66 GF50
PPA GF50
Two material cards available on request to perform structural analyses
Next: Confirm good results on more applications, are you interested?
DSM / e-Xstream collaboration
Improving SFRP fatigue lifetime prediction
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Numerical simulations require extreme care to predict part fatigue lifetime
Elastic
Stress saturation
Stress relaxation
• Elastic material model
• No stress saturation (plasticity)
• No stress relaxation (viscous effects)
Stress
Strain
• Geometric simplification drawbacks
• Faceting
• Non convergence of local extrema
Notched coupon
stress field under
tensile load
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Force
Time
𝑰𝒏𝒄.
Constant R
for all elements
Force
Time
𝑰𝒏𝒄. 𝒎𝒊𝒏 and 𝑰𝒏𝒄. 𝒎𝒂𝒙
Spatially varying R
with result assembly
Several workflows allowing a time-accuracy trade off
𝜎 𝑎 and 𝑹 𝝈
𝜎 𝑚𝑖𝑛
𝜎 𝑚𝑎𝑥
𝜎 𝑎 and 𝑹 𝝈
𝜎 𝑚𝑖𝑛
𝜎 𝑚𝑎𝑥
𝜎 𝑎 and 𝑹 𝝈
Force
Time
𝑰𝒏𝒄. 𝒊𝒏𝒊𝒕. and 𝑰𝒏𝒄. 𝒆𝒏𝒅
Spatially varying R
with full cycle
Early design Loading screening Design validation
MarcAvailable for :
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Numerous lifetime corrections to account for stress concentration are available
Stress gradient
Interpolation
Correct stress field and
re-compute lifetime
II
I
L
𝝈 𝒆𝒇𝒇. = 𝝈 𝒂𝒕 𝑳
No correction
Same results as FEA
simulation based on
stress field
Lifetime averaging
Average lifetime
predictions in log domain
over a given volume
Stress averaging
Average stress over a
given volume and
re-compute lifetime
Stress gradient
Linear averaging
I
II2L
𝝈 𝒆𝒇𝒇. =
𝟏
𝟐𝑳
න
𝟐𝑳
𝝈𝒅𝒙
Correct stress field and
re-compute lifetime
Stress gradient
Tangent
I
II
𝝈 𝒆𝒇𝒇. =
𝝈 𝒎𝒂𝒙
𝟏 +
𝑳
𝝈 𝒎𝒂𝒙
𝒅𝝈
𝒅𝒙
Correct stress field and
re-compute lifetime
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Use Digimat to reach
accurate SFRP fatigue
lifetime predictions
Dedicated environment for
fatigue failure indicator calibration
Dedicated environment for
fatigue lifetime computation
Partner to push limits
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Benefit from material supplier calibrations
• They already feed Digimat-MX database heavily : +27 fatigue material cards in Digimat 2019.1
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Next steps
• What’s new ? → Look at Digimat 2019.1 release webinar
• Interested ? → Look at our case study and come to us to learn more
• Yet customer ? → Benefit from our capabilities and from material cards present in Digimat-MX
• Looking for guidance ? → Benefit from our expertise in testing, calibration and simulation
33. Leverage reinforced plastics
durability prediction, from
calibration to post-processing
Webinar, 18th September 2019
DSM load bracket fatigue
demonstrator
Thank you!
Q&A
Pierre Savoyat
Digimat Product Manager
pierre.savoyat@e-xstream.com
Lucien Douven
Research Scientist / Design Engineer
lucien.douven@dsm.com