Nonlinear Multi-Scale Modeling

A Paradigm Shift in the Accurate & Efficient

Modeling of Composite Materials & Structures

e-Xstream engineering
Roger A. Assaker, CEO
Roger.Assaker@e-Xstream.com
+352 661 52 56 53

www.e-Xstream.com

Outline
Motivation
Introduction
e-Xstream
DIGIMAT Products & Solution Workflow

DIGIMATs Major Capabilities

Applications
1- Material Engineering:
2- Advanced Composite Modeling
Failure of an Injection Molded Beam subject to a 3- Point Bending
Impact
Barely Visible Impact Damage in a 24-layer CFRP Plate

Conclusions

Tuesday, May 11, 2010

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Motivation
The use of composites continues to increase in the Automotive,
Aerospace, ... Industries
One of the drivers for using composites is:
High stiffness/weight ratio Lighter Greener

The two main barriers to using composites are:

1. Technical: Relative low familiarity with the material and
suboptimal design & simulation tools
2. Economical: Is the composite part cheaper that its metallic
equivalent ?

Predictive Simulation Tools can make the difference

e-Xstream engineering
e-Xstream:
Simulation Software & Services
100% focused on material modeling

Value Proposition
For material suppliers & transformers who
suffer from long and costly development
cycles of sub-optimal products, e-Xstream
offers the material modeling software and the
expertise needed to use in the development
of optimal materials and products faster &
cheaper.

DIGIMAT,

The nonlinear multi-scale

material & structure modeling platform.

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Bus & Fin

14%

MS Eng
29%

PhD
57%

Target Materials & Industries

Target (Mutli-Phase) Materials :

Reinforced Plastics
Rubber: Carbon or Silica Filled
Woven & Non-Woven Composites (CFRP,)
Nano-Composites: Nano Clays, Carbon Nano Tubes,
Hard Metals: CoWC
Carbon

Target Industries
Material Suppliers: Plastics, Rubber, Carbon,
Automotive: OEMs & Suppliers, Tires,
Aerospace: Airplanes composite structures, Satelites, Launchers,
Electronic & Electric Products: Mobile phones, Electric connectors,
Industrial Goods: Cutting tools, furnaces, Generators, Transformes,
Sports & Leisure,

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DIGIMAT 4.0.2

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DIGIMAT: Workflow
Promising Material Candidates

Improved MF Modeling
Composite behavior

Constituents Behavior

Constituents Behavior

Strong,
2-Way Coupling

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Digimat-MF & Digimat-FE: MicroMechanics

Global behavior

c (cr ) :

r ( x) r H r : E
Localization

a)

b)

Averaging

Local phase behavior

r

Pros

r cr : r

Pros

Fast model preparation/solution

Accurate predictions at the micro scale

Accurate predictions

Complex inclusion shapes (non ellipsoidal)

Enables fully coupled nonlinear multiscale Analyses

Explicit modeling of clustering & percolation

Cons

Relatively Complex RVE generation

Ellipsoidal inclusions

Large RVE models (CPU intensive FEA)

Uniformly distributed inclusions

Average per phase (micro) results
26-Nov-08

Cons

Uncoupled multi-scale analyses

Requires mesh optimization

Copyright e-Xstream engineering, 2009

Digimat-MF: Major Capabilities

Material Models (for each Phase of a Composite)
Mechanical (For each phase of a multi-phase material)
Linear, Nonlinear, strain-rate dependent
Small/Large Deformation

Thermo-Mechanical
Thermal
Electric
Failure Models

Max Stress, Max Strain, Tsai-Hill,

Failure Scale: Micro (Fiber/Matrix), Pseudo-Grain, Macro (Composite)
Microstructures
Multi-Phase (1, 2 or more)
Reinforcement type: Fillers/Platelets/Fibers/voids
Fiber length: Short/Long/Continuous
Orientaiton: Constant/Random/Distribution
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Digimat-FE: Materials & Microstructure

Materials
Linear & Nonlinear
Strain-Rate Dependent
Mutli-Physics: Mechanical, Thermal, Electric

Microstructure

Ellipsoids of Revolution
Pre-defined shapes
Custom (from CAD)
Inter-face/phase Debonding
Clustering
Percolation
Imbedded Curved fibers

2D/3D

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DigimatMX: Material eXpert

Database Input/Output

Import/Store/Export DIGIMAT models

Import/Store/Export exp/ data
Query xDB from MX, MF or FEA
Exchange (encrypted) mat. models

Reverse Engineering
E, EP and EVP models based on:
One curve,
A set of curves
(strain rates, orientation, mass or volume fraction)
Several sets of strain rate curves
(orientation, mass or volume fraction) MX+

Identification of material models

E, EP and EVP models

Data Supplier
MXDB IDB
EDB
WDB

Report generation
Identification report,
Reverse Engineering report.

Tuesday, May 11, 2010

Encrypted & Licensed Data

MX
Data Request

Suppliers Data

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Material DB

Data Recipient
MXDB IDB
EDB
WDB

MXDB

Digimat to CAE: Digimat interfaces to Injection

Molding & Structural FEA
Process

Material

Structure

Phase Material &

Composite Microstructure
-Fiber Shape
-Fiber Weight Fraction
-Fiber Length Distribution

Fiber Orientations

Fiber Length Distribution

Structural FEA

100
90
80

Number

70
60
50
40
30
20
10
975

925

1125

875

1075

825

1025

775

725

675

625

575

525

475

425

375

325

275

225

175

125

75

25

Length [m]

Courtesy
Trelleborg
& Rhodia
Tuesday, of
May
11, 2010

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Interaction between DIGIMAT and FEA

Classical FE process

Coupled FE/DIGIMAT process

FE model level

Internal forces and

element stiffness

Nodal coordinates,

Element level

FE model level

Nodal coordinates,

Internal forces and

element stiffness

Element level

Strain increments,
material state,

Stresses and
material stiffness

Strain increments,
material state,

Stresses and
material stiffness

Material level

In code model

Material level

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13

Map: 2D & 3D Mapping

Mesh Types
Mid-plane (Tri.) Shell (Tri. or Quad)
3D (Tet) 3D (Tet or Hex)

Mesh Formats
Abaqus, Ansys, Ls-Dyna, Radioss,

Moldflow, Moldex3D, 3D Timon,

Data type
fiber Orientation
Initial Stresses
Initial Temperature
Weldline Nodes

Geometric Transformation
Error Indicators
Global & Local

Visualization

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Applications
1 Material Engineering
2 Advanced Composite Modeling
- Failure of an Injection Molded Beam subject to a 3Point Bending Impact
- Barely Visible Impact Damage in a 24-layer CFRP Plate

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Material Engineering: Nonlinear Mechanical

Response
360
gate

50
50

Tensile specimen

100

200
180

True stress (MPa)

160

0_exp
15_exp
30_exp
45_exp
60_exp
90_exp
0 Digi
15_Digi
30_Digi
45_Digi
60_Digi
90_Digi

140
120
100
80
60
40
20
0
0

Tuesday, May 11, 2010

0,02

0,04

True
strain 2010
Copyright e-Xstream
engineering,

0,06

0,08

Material Engineering: Thermal Conductivity

Materials : thermal conductivity (isotropic)
Kerimid 601:
0.23
W/mK
Al2O3 :
30.7
W/mK
2-phase Microstructure : Kerimid matrix with Al2O3 fibers
matrix : Kerimid
inclusions : Al2O3 fibers
volume fraction : from 0.0 to 0.4
AR = 6
orientation : random in xy-plane (Random2D)

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17

Material Engineering: Percolation and Electric

Conductivity
Percolation threshold in polymer/carbon composite (AR=1)
1.00E+03
1.00E+02

Composite electrical conductivity [S/m]

1.00E+01
1.00E+00
1.00E-01

Conduct. X

1.00E-02
1.00E-03

Conduct. Y

1.00E-04
1.00E-05

Conduct. Z

1.00E-06
1.00E-07

Digimat-MF (t=2.6,
phi_c=0.28)

1.00E-08
1.00E-09

Experiment [Agari 1991]

1.00E-10
1.00E-11

1.00E-12
1.00E-13

0%
18

10%

20%
30%
Filler Volume Fraction

40%

50%

Advanced Composite Modeling: Failure of an

Injection Molded Beam subject to a 3-Point Bending Impact

Objective: To predict the local & global behavior of a
reinforced plastic part subject to a 3-Point Bending Impact
Material: PAGF30
PA6
30% short glass fibers

Vz= 5m/s

Courtesy of Rhodia
5/11/2010

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19

Nonlinear Anisotropic Heterogeneous

Material Behavior

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20

Predictive FEA of the Reinforced Plastic Parts

CAE Software Choice: Structural FEA & Injection Molding
Geometric nonlinearities (Large Deformations)
Contact
Implicit/Explicit integration
Optimal mesh refinement
Optimal element choice

AMODEL AS-4133 - stress-strain curves at 23C

dumbell specimen and test samples from mold II

240
220

dumbell

200
180

stress (MPa)

160

Tuesday, May 11, 2010

100

Mold II - across the flow

60
40
20
0

Material Reinforced Plastic

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2.2

2.4

2.6

2.8

3.0

strain (%)
320

Damage, 0, Static
Damage, 0, 1 s-1
Damage, 0, 100 s-1
Damage, 45, Static
Damage, 45, 1 s-1
Damage, 45, 100 s-1

300
280
260
240
220

Stress (N/mm)

Anisotropic
Heterogeneous
Nonlinear
Rate-dependent
Damage
Fatigue
Failure
Etc.

120
80

1st/2nd order
Tet or Hex, Triangle or Quad

Mold II - along the flow

140

200
180
160
140
120
100
80
60
40

TECHNYL C218 V35 Black, 23C, Eh0

20
0
0,0% 0,5% 1,0% 1,5% 2,0% 2,5% 3,0% 3,5% 4,0% 4,5% 5,0% 5,5% 6,0% 6,5% 7,0% 7,5% 8,0%

Which Material Model ?

Strain

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21

DEMO: Multi-scale modeling process

Injection
mat. prop.

Injection
process
param.

Injection
mesh

Structural
mesh

Matrix properties
Reinforcement properties
Composite morphology:
Fiber length/diameter
Fiber weight/volume fraction
Failure indicators

Fiber
orientations

Moldflow

RADIOSS

Residual
stresses

May-10

Residual
temp.

Fiber
orientations

Composite
properties

Copyright e-Xstream engineering SA 2003-2010

Micro/macro
FEA results

22

Digimat-MF Model of PAGF30

Inclusion phase: Glass Fibers

Matrix phase: PA
Behavior: Elastic
Behavior: J2-plasticity
Density = 2.54 E-06 kg/mm3
exponential + linear hardening
Poisson coefficient = 0.22
Density = 1.14 E-06 kg/mm3
Young modulus = 72000 MPa
Young modulus = 3400 Mpa
AR = 23.5
Poisson coefficient = 0.4
Yield stress = 35 MPa
Hardening modulus= 21 MPa
Hardening exponent= 140
Hardening modulus2= 50 MPa
Isotropic method = Spectral
Creep model = Prandtl
Creep coefficient = 30 MPa
Hardening exponent= 3
Creep
coefficient2= 15 MPaCopyright e-Xstream engineering, 2009
Tuesday, May
11, 2010

23

Failure Model
Failure model applied at 3 scales
Micro (or Phase) Scale PA matrix and/or Fiber Reinforcement
Pseudo-Grain Scale UD PAGF
Macro (or Composite) Scale PAGF

Failure Models
Max stress
Max strain
Tsai-Hill

Failure Model
FPGF
E11 max = 0.028
E22 max = 0.052

200
180

Exp Angle 0 QS

160

Exp Angle 90
SR QS

140

Stress MPa

Exp Data on TECHNYL A218 V30

@ T=23C & RH0 - Quasi static tests

120
100
80
60
40
20
0
0

0.01

0.02

0.03

0.04

0.05

0.06

Strain
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24

Digimat to Radioss:

Local/ Anisotropic/Strain-Rate/Pseudo Grain Failure

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25

Advanced Composite Modeling: Barely Visible

Impact Damage (BVID)
Objectives:
To predict the damage caused by low energy impacts on
Carbon/Epoxy UD laminate structures, which is difficult to visually
identify.

Test case:
Clamped Carbon/Epoxy laminate plate [45/90/-45/0]3s subject to
4.81J shock with rigid impactor, equivalent to the drop of a kg
mass from 1 meter height.
4.43
m/s

5/11/2010

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26

3-Barely Visible Damage in a 24 Layer CFRP

Stress (%)

4-side clamped plate:

Width : 4 in. (100 mm)
Length : 6 in. (150 mm)
Lay-up sequence :
[45/90/-45/0]3s
24 layers of UD
Total thickness : 4.8 mm
Materials :
Carbon AS4 (source: Hexcel composites, www.hexcel.com)
Longitudinal Youngs modulus : 228 000 MPa
Transverse Youngs modulus : 6220 MPa
Transverse shear modulus : 7600 MPa
Tensile strength : 4278 MPa
Epoxy 15 parts Bisphenol A-epichlorhydrine, 2 parts tri-ethylenetetramine
Stress-Strain curve for Epoxy
(source: Rensselaer Polytechnic Institute, Troy, New York)
35
ElastoPlastic behavior :
30
Youngs modulus : 1300 MPa
25
Yield stress : 22.5 MPa
20
Isotropic exponential hardening
15
Microstructure :
10
Unidirectionnal fibers
5
Volume fraction of fibers = 57 %

Experiment
Exponential hardening model

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4
Strain (%)

27

Macro/Micro Plastic Strain

The residual macroscopic
deformation after impact
is of the order of
magnitude of 0.1%.

The accumulated plastic

strain in the matrix phase
(micro) is of the order of
magnitude of 10%.

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28

Conclusions
DIGIMAT is a unique software platform for the nonlinear multiScale modeling of a large variety of materials
DIGIMAT is used across the industries to
Model the behavior of composites as the function of their
underlying microstructures Material Engineering
To bridge the gap between the composite microstructure, as

induced by the manufacturing process, and the end-performance

of the composite structure Predictive, Nonlinear Modeling of
Composite Structures

DIGIMAT is Readily Available

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