Title:SimulationoffatigueincompositecomponentsusingANSYSnCode

DesignLife

Abstract: Rapiddevelopmentofeffectiveandrobustcomponentsrequires
CAEsimulationtechniquescapableofmodellingperformanceandpossible
failuremodes,includingfatigue. Compositematerialshavemanyadvantages
fordifferentclassesofautomotivecomponents,butpresentadditional
challengestotheanalystduetothefactthatpartsmanufacturedfrom
compositematerialsareingeneralinhomogeneousandanisotropic. This
presentationdescribeshowANSYSnCode DesignLife maybeusedtomodel
thedurabilityofsuchcompositecomponents,particularlythosemadefrom
shortfibrereinforcedinjectionmouldedthermoplastics.
 SimulationofFatigueinComposite
ComponentsusingANSYSnCode DesignLife

PeterHeyes,HBMnCode
Summary

Introduction fatigue,DesignLife,composites
Fatigueanalysisofcomposites:thechallenges
Modelling process
ImplementationinDesignLife
Furtherwork

2012AutomotiveSimulationWorldCongress 3
Fatiguelife acriticalconsiderationinmany
industrial(andother!)sectors

4
Historicalperspective

Test

Build

Fix

5
CAEcentredprocessforfatiguedurability
Material Customer
Test usage

CAD Manufacturing

Geometry Materials Loads

Analysis Test

Life Life

6
HBM:Fromphysicalmeasurementtovirtual
testing
Projects Services Calibration

DAQ DAQ Analysis & Data

Sensors
Hardware Software Processing

Simulation and Prediction

 nCodeproductrange
DataProcessingSystemforDurability StreamliningtheCAEDurability MaximizingROIonTestand
Process Durability

Complex analysis to report, simply done
Graphical, interactive & powerful analysis
World leading fatigue analysis capabilities
Fatigue analysis technology for FEA
Process encapsulation
Fast, configurable, and scalable
Enables collaboration, manages data,
and automates standardized analysis
Search, query and reporting through
secure web access.
Data to information to decisions

nCode DesignLife integratedwithANSYS14.0Workbench

DurabilitybyAnalysis
FE Fatigue
LOADS modelling STRESS modelling LIFE

SN(StressLife)
Localstrainapproach
Welds
Spotjoints
Multiaxial fatigue
Hightemperatures
etc
Staticsuperposition
SN Plot of : Z-Specimen

800
-0.5

0.1

0.5

Modalsuperposition
0.9 Database :
nmats

600 Mean Type :

R-ratio

Stress type:

Transient
RANGE

Stress Units:

S tr e s s
MPa

400 UTS:
1030.00000

E value:

Nonlineartimestep
1.17000e+005

200

Randomvibration 1000 1E4 1E5

Cycles
1E6 1E7

Thermaletc
9
MetalFatiguecrackinitiationandgrowth

Fatiguecrackinitiationandgrowthisdrivenbylocalstress/strainvariations
10
Metalfatiguelife often
dominatedbyinitiationandgrowthofshortcracks

100m
Cracksize

11
Numberofcycles
Diversityofcomposites

12
Challengesforfatiguelifepredictionofcomposites
LOADS STRESS LIFE

Processwellestablishedformetallicstructures
Materialsnormallyhomogeneousandisotropic
Failureoftenduetoasingledominantcrack
Lifetimeoftendominatedbycrackinitiation

13
Challengesforfatiguelifepredictionofcomposites
LOADS STRESS

Materialisinhomogeneousandanisotropic
Localpropertiesstronglydependonfibreorientations
whichareafunctionofthemanufacturingprocess
ElasticFE:eachintegrationpointneedsaunique
anisotropicstiffnessmatrix!
Nonlinearbehaviouriscomplex(e.g.elastoviscoplastic
matrix+elasticfibres)
Whichstressdoyouwant(whatscale)?
Composite?Perlayer?
Microscopic?Averagedbymatrix/fibres?

14
Challengesforfatiguelifepredictionofcomposites
STRESS LIFE

Anisotropicfatigueproperties
Forlaminatesinparticular
Whatisthefailurecriterion lossofstiffness,strength,etc?
Multipledamagemechanismsmayoperate
Localapproachmaynotbeenough(progressivedamage)
Growthofdamagefromedges,plydropoffsetc
Interactionwithotherformsofdamage
Rainflow?Damagesummation?
Sensitivitytoenvironment,temperature,strainrate, etc
MORESOPHISTICATEDMATERIALMODELLINGREQUIRED!

15
Usecase:injectionmoulded
shortfibre composites
Manyautomotiveapplications
Moreamenabletolocalapproachthanlaminates

16 Courtesy of
Flowduringmanufacturedetermineslocal
materialproperties

17
Microstructurevariations

y
x

Localmaterialpropertiesare
afunctionoffibre
orientations 2-D random
Continuousvariationoffibre
z
orientationdistribution
throughoutthecomponent y Aligned with flow
Evenasimpleflatplatehas
considerablevariation Transverse to
flow
throughthickness
18
Simulationsummary

Manufacturing
simulation

Microstructure Basicmaterial
orientation,aij informationand
physicaltest
data
Basicmaterial StructuralFE Structural
informationand calculation materialmodel
fatiguetest Homogenisation:
data MoriTanaka
Fatiguematerial Fatigue Mission HalpinTsai
model simulation profile etc

Damage,
19 LIFE
Simplefatiguesolver

Fibre share l .a.l T

l

Abs Max Principal or Critical Plane stress calculated

l is critical plane or dominant stress direction
SN curve determined by interpolation based on
Damage calculated by rainflow counting and linear damage summation
Process is repeated at each element, layer/section point, and direction

20
Workflow
Material
parameters
Material data
Moldflow (SN curves)
e.g.

CAD Geometry Manufacturing

simulation
Service loads
elastic orientation
properties tensors

Structural FE

Manufacturing simulation software predicts Fatigue

material stiffness matrix (orthotropic) durability
Properties mapped to structural mesh (FE input
deck) per integration point
Composite level stresses
Orientation tensors transferred to fatigue
analysis
21
Alsopossible
Moldflow
e.g.
Manufacturing Material
simulation parameters
Material data
(SN curves)

CAD Geometry User material model

e.g.
Service loads

Structural FE
e.g.

Fatigue
User material definition plugged into solver durability
Stresses (composite, matrix or fibre) written as
state variables
Orientation tensors from RST (state variables)
22
ImplementationinDesignLife

23
Alternativefatiguemodel
integration

Manufacturing
simulation

Microstructure Basicmaterial
orientation,aij informationand
physicaltest
data
Basicmaterial StructuralFE Structural
informationand calculation materialmodel
fatiguetest
data
Fatiguematerial Fatigue Mission
model simulation profile

Damage,
24 LIFE
 E.g.fatigue
RVE Definition :
Three S-N curves from
specimens cut at different Material properties
angles to fibre orientation/flow Microstructure info: VF, AR, OT
direction
SL

Longitudinal
N Macroscopic
S-N curve
S S-N curve

DIGIMAT
ST Input Output

N
Transversal
N
S-N curve
S

Loading Definition :
Oriented Stress direction
N
S-N curve Stress state

Thursday,25October2012
25
Calculationprocess
Multiaxial assessmentuses3Dregression
algorithmtoassessthestressstateateachpoint xy
inthemodelduringloadingtimehistory
Loadinginmostcasesisproportionalornear
proportional
Inthiscasethestressstatemaybecharacterised
byanaveragednormalisedtensor
Materialmodel(e.g.DIGIMAT)returnsaunique
SNcurveforthatstressstateandmicrostructure

ij t
yy

xx

Fatiguemodel

26
Calculationprocessfornear
proportionalloading otherwiseusecriticalplane
Largestprincipal Normalised
Stresstensor
stress averagedstress
history
tensor

Fatiguemodel
Rainflow

Damage
Life

27
 Implementation:DesignLife 8
Supportforcompositeshellelements
Normalcompositestressesorfromstatevariables
AbsMaxPrincipalorCriticalPlaneStress
Simplefatiguemodel
Interfacetoexternalfatiguemodel(DIGIMAT beta)

Version9:
Solidelements
3Dstressstates
3Dmultiaxial
assessment
3Dcriticalplane

28
Furtherwork

Validationcases
Alternativedamagemodels
Refinematerialcharacterisationmethods
Stressgradients(notcheffect)
Temperature,moisturecontent,meanstresseffects
Laminates

Thursday,October25,2012 2012AutomotiveSimulationWorldCongress 29
Fatigueoflaminates
Firstplyfailurevs
progressivedamage
Multipledamage
mechanisms
Delamination
Plydropoffs
Edgeeffects
Manufacturing
defects
Impactdamage

30
 Thanksforlisteningquestions?

Presentedby:
DrPeterHeyes
HBMUKLtd
peter.heyes@hbmncode.com

Thursday,October25,2012 2012AutomotiveSimulationWorldCongress 31