Accurate Simulation of Short-Fiber-Reinforced Plastic Parts
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For fiber reinforced automotive parts the consideration of anisotropic material behavior is required to receive reliable results. In the scope of this fact a procedure is described how to consider these effects in terms of process-structure interaction and how to achieve possible benefits such as weight reduction and shorter development cycles. The procedure is outlined with practical applications from company Valeo Ligthing Systems and another industrial partner projects that are currently still in progress. Speakers Sascha Pazour, CAE Engineer, PART Engineering GmbH
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Accurate Simulation of Short-Fiber-Reinforced Plastic Parts
- 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 • Over 20 years experience in FEA • Over 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. 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 Material Complexity
- 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. 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 Material Complexity
- 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 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
- 23. Comparison of Real Part and Structural Simulation Result Fig. 22 By courtesy of Huf Hülsbeck & Fürst GmbH & Co. KG ? Problem Process Simulation Weld Line Mapping Solution Structural Simulation !
- 24. Fig. 23 www.part-gmbh.de What´s New? Converse Installation
- 25. Fig. 24 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! Please don´t hesitate to ask a question!