3. Collaboration
*MAT_ADHESIVE_CURING_VISCOELASTIC (277)
• DOW chemical
• FORD
*MAT_COMPRF (293)
• FORD
• Northwestern university
*MAT_REINFORCED_THERMOPLASTIC (249)
• BMW
*MAT_LAMINATED_FRACRURE_DAIMER_PINHO (261)
*MAT_LAMINATED_FRACTURE_DAIMER_CAMANHO (262)
• Mercedes
*MAT_ANISOTROPIC_ELASTIC_PLASTIC with IHIS for short fiber
• OPEL
4. Manufacturing of Carbon Fiber
Compression molding of thermoplastic pre-preg
Epoxy resin curing is modeled by *MAT_277 (Dow chemical)
Woven fabric part can be modeled by *MAT_234 & 235
heating positioning forming cooling final part
6. Manufacturing of Carbon Fiber
*MAT_ADHESIVE_CURING_VISCOELASTIC
• Single element test case
• Initial curing degree set to be 0
• Applied temperature boundary condition
• Applied displacement boundary condition
• Simulate complete compression molding process
10. Manufacturing of Carbon Fiber
*MAT_MICROMECHANICS for continuous woven pre-preg
• Consists both loose fabric and epoxy resin
• Models fiber reorientation due to mechanical deformation and resin curing
• Viscoelastic properties of epoxy resin are functions of curing degree
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11. Manufacturing of Carbon Fiber
*MAT_278 single dome preforming simulation
Fiber original orientation 0°/90° vs 45°/-45°
Testing Fiber
Orientation
12. Manufacturing of Carbon Fiber
*MAT_278 single dome preforming simulation
Fiber original orientation 0°/90°
13. Manufacturing of Carbon Fiber
*MAT_278 single dome preforming simulation
Fiber original orientation 45°/-45°
14. Manufacturing of Carbon Fiber
*MAT_293 (Northwestern University, Ford)
Stress caused by stretch in
fiber directions:
Experiment: uniaxial tension
Or
RVE: tension stiffness data
Stress caused by fiber-fiber
angle change:
Experiment: bias-extension
Or
RVE: shear stiffness data
Combine the two stress:
Implement the stresses as
functions of fiber stretch
and rotation into the user
defined material.
15. Manufacturing of Carbon Fiber
*MAT_293
Non-orthogonal stress calculation is included in the flowchart.
After shear locking, the stress calculation algorithm is converted.
Deformation
gradient
tensor F
Fiber directions
and angle
Fiber angle <
Shear locking angle
βlock
Before
locking
Stress caused by
fiber rotation
Stress caused by
fiber stretch
After
locking
Stiffened shear
stress caused by
fiber contact
Total stress before
locking
Total stress after
locking
Yes
No
βlock
Bias-extension test specimen.
Shear stress evaluation:
𝑑𝜎𝑋𝑌
𝑚
= 𝑑𝜎𝑌𝑋
𝑚
= 𝐸 ∙ 𝑑𝜀𝑋𝑌
𝐸: transversecompressionmodulus.
16. Manufacturing of Carbon Fiber
*MAT_293
Strain (fiber stretch)-stress curve from
uniaxial tension tests.
Uniaxial tension tests demonstration1.
17. Manufacturing of Carbon Fiber
*MAT_293
Shear angle-stress curve from
bias-extension tests.
Bias-extension tests demonstration1.
18. Manufacturing of Carbon Fiber
*MAT_293
Bending shape comparison at 70 ºC for bending
stiffness reverse calculation.
Bending tests demonstration.
MAT_COMPRF (MAT_293) input deck.
19. Manufacturing of Carbon Fiber
*MAT_293
• Simulation was performed on LS-DYNA with corresponding fiber orientations and boundary
conditions.
• Prepreg-prepreg interaction: static/dynamic friction factor=1.9.
• Prepreg-tool interaction: static/dynamic friction factor=0.2.
Double-dome simulation setup.
Punch, rigid, Belytschko-Tsay
shell, disp=89 mm
Binder, rigid, Belytschko-Tsay
shell, disp=0.06 mm
Composite, MAT_293, 3.8mm
X 3.8mm fully integrated shell
elements (Material unitcell
side length is 9.2 mm)
Die, rigid, Belytschko-Tsay shell
20. Manufacturing of Carbon Fiber
*MAT_293
• The prediction capability of the material model is validated on the basis of one-
direction draw-in distance and fiber angle distribution.
Single layer double dome simulation and experiment
results comparison for draw-in distance and yarn angle
validation.
experiment Non-ortho Ortho
Draw-in /
mm
49 42 (85.7%) 73 (149.0%)
Draw-in validation and comparison
Angle validation and comparison
Location experiment Non-ortho Ortho
A 80º 81º (101.3%) 70º (87.5%)
B 88º 88º (100.0%) 85º (96.6%)
C 71º 73º (102.8%) 86º (121.1%)
D 49º 46º (93.9%) 47º (95.9%)
E 56º 60º (107.1%) 59º (105.4%)
F 66º 70º (106.1%) 77º (116.7%)
21. Manufacturing of Carbon Fiber
*MAT_293
±45o
0/90o
• Inter-layer sliding and wrinkling pattern are compared qualitatively for the double layers
double dome preforming case.
• Overall geometry and inter-layer sliding are well captured.
• The discrepancy in the geometry, sliding, and wrinkle location might be caused by the
inaccurate temperature and interaction factor.
Double layers double dome experiment results. Double layers double dome simulation results.
23. Manufacturing of Carbon Fiber
*MAT_249_UDFIBER
• Option for dry continuous non crimped fabric
• User material developed by BMW
*MAT_249_CRASH
• Failure/damage of thermoplastics reinforced with WOVEN fabric
• Based on simplified *MAT_249
• A phenomenological model implemented
• Damage defined by load curves
• Experiments done by A German university and Brose
• Material calibration with LS-OPT
24. Crash Application of Carbon Fiber
*MAT_LAMINTATED_COMPOSITE_FABRIC (*MAT_058)
– EA, EB, PRBA, PRCA, PRCB, GAB
– XC, XT, YC, YT, SC
– SLIMT1, SLIMC1, SLIMT2, SLIMC2 are stress limits in softening part.
SLIMTx starts with 0.3, and SLIMCx starts with 1.0
– AOPT is used, if coordinate system is defined for material direction
25. Crash Application of Carbon Fiber
*MAT_LAMINTATED_COMPOSITE_FABRIC (*MAT_058)
– Load vs displacement: UD
26. Crash Application of Carbon Fiber
*MAT_LAMINTATED_COMPOSITE_FABRIC (*MAT_058)
– Load vs displacement: woven 0-90
27. Crash Application of Carbon Fiber
*MAT_LAMINTATED_COMPOSITE_FABRIC (*MAT_058)
– Load vs displacement: Quasi Isotropic
30. Crash Application of Carbon Fiber
*MAT_LAMINTATED_COMPOSITE_FABRIC (*MAT_058)
– Load vs displacement: NCAP
31. Crash Application of Carbon Fiber
*MAT_LAMINTATED_COMPOSITE_FABRIC (*MAT_058)
– Load vs displacement: offset
32. Crash Application of Carbon Fiber
*MAT_LAMINTATED_COMPOSITE_FABRIC (*MAT_058)
– Load vs displacement: rigid center pole
33. Crash Application of Carbon Fiber
*MAT_LAMINTATED_COMPOSITE_FABRIC (*MAT_058)
– Load vs displacement: low speed quarter
34. Crash Application of Carbon Fiber
*MAT_LAMINATED_FRACTURE_DAIMER_PINHO (*MAT_261)
• Coupled failure criterion based on 3d stress state
• Complex 3d fiber kinking model
• Matrix failure invokes search for controlling facture plane
• Linear softening law based on facture toughness
• 1d plasticity model for in plane shear behavior defined by load curve
* MAT_LAMINATED_FRACTURE_DAIMER_CAMANHO (*MAT_262)
• Coupled failure criterion based on 2d stress state
• Constant fiber misalignment angle based on shear and
longitudinal compressive strength
• Matrix failure fixed planes
• Bi-Linear softening law based on facture toughness
• 1d plasticity model for in plane shear behavior defined by load curve
35. Crash Application of Carbon Fiber
*MAT_LAMINATED_FRACTURE_DAIMER_PINHO (*MAT_261)
36. Crash Application of Carbon Fiber
*MAT_LAMINATED_FRACTURE_DAIMER_CAMANHO (*MAT_262)
37. Short fiber
*MAT_157 with *INITIAL_STRESS
• *MAT_147 is anisotropic elastic platic material with C 6x6 matrix input
• With AOPT=0, initialize orientation and stiffness matrix with *INITIAL_
STRESS_SHELL card
Data mapping between Moldflow/Moldex3d to
*INITIAL_STRESS card
• Fiber orientation and probability information, q1 q2
• Fiber and matrix elastic properties
