SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Summary Barcelona – results & setting the scene: Materials Characterisation Trevor Dutton, NAFEMS/Dutton Simulation Summary of topics presented and discussion from 1 st AUTOSIM workshop, Barcelona, January 2006
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SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES.
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SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Summary
Barcelona – results & setting the scene:Materials Characterisation
Trevor Dutton, NAFEMS/Dutton Simulation
Summary of topics presented and discussion from 1st AUTOSIM workshop, Barcelona, January 2006
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Initial topics - Materials Characterisation
Initial topics from Munich:
– Composites, foams, new materials
– Fracture mechanics & durability
– Manufacturing simulation
– Constitutive models and material data
– Modelling connections
Not yet fixed – initial suggestions for discussion
Objective: To refine the list of topics to be addressed during the course of the AUTOSIM project
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Composites, Foams, New Materials
Crashworthiness of composites
– energy absorbed in delamination
Structural foams for stiffness
Polymers (inc. fibre reinforced)
Crushable foams for occupant protection
Specialist materials for occupant models
New metals e.g., magnesium, HSS
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Fracture Mechanics & Durability
Fatigue Life Prediction
Creep & time-related phenomena
Probabilistic methods
Modelling Crack Growth
– Automatic re-meshing
– Damage models
– Element-free methods
Links to:
– Manufacturing simulation
• effects of forming & assembly (esp. residual stress)
– Weld / Bond Modelling
– Material properties / material models
• S-N data etc. (new materials)
• Crack initiation (initial defects?)
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Manufacturing Simulation
New Processes = new analysis & data needs– confirm feasible e.g., hot forming of Boron steel
Cost analysis & optimisation?Effects of forming (sheet metal)
Effects of forming (forging)– Residual stress – Shape distortion on cooling– Effect on residual ductility (material failure)– Phase change
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Manufacturing Simulation (cont.)
Effects of forming (casting)
– Defects (porosity, inclusions)
– Shape distortion on cooling
Effects of forming (moulding)
– Directional properties
– Weld line
Assembly and Paint Process (& Heat Treatment)
Process flow, handling, logistics
NB Links to Integration Theme
Eagerness for using new materials but
manufacturing issues not appreciated
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Cowper Symonds Strain Rate Enhancement
0
100
200
300
400
500
600
700
800
900
0.00 0.10 0.20 0.30 0.40 0.50 0.60True Strain
Tru
e S
tre
ss (
Mp
a)
Strain rate 0.1/s
Strain rate 10/s
Strain rate 100/s
Constitutive Models / Material DataDo we have the models needed to represent the effects believed to be
important?– Effects of forming– Multi Physics (one model for all applications?)– Model complexity vs. Ease of Use– Analysis efficiency
What data do we need and how is it to be managed?– Full range of parameters
• Strain rate, Failure, etc– Micro-characterisation– Use of optimisation– Material Suppliers?
Links to Confidence Theme5M element models but wrong input data!
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Modelling Connections
Different types:
– Welds; Spotwelds, MIG, laser, …
– Joining; SPR, clinching
– Bonding
Stiffness
Failure, including ductility
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Presentations • FENET
– Topics for consideration• Smart use of materials• Innovations based on new materials
– Method of classification (TRL, SoP, PLI)• Modelling elastomerics x2
– Variety of Models– Differing Degrees of Data Required– Complexity vs. acceptability of results
• Simulation of new metal forming processes– New materials need new processes– Need to be able to simulate with confidence (e.g., TRIP steel)– Balance complexity / accuracy / computation cost
• Materials Issues / Effects of forming– Importance of manufacturing simulation in predicting product performance– Software Usability vs. User Skill
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Requirement Indices - FENET
Technological Maturity
– Material related issues all at 5 bar one (at 6) i.e., method (no better than) validated on test cases
– Hence, these issues are far from “ready for use” in the opinion of FENET members
State of Practice
– Contrastingly, most issues are 6 or above and many are deemed necessary for sign off (9)
Priority Level
– Reflecting this, most issues are seen as high priority
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Discussion Points• Place of Materials in the project
– Links to both Integration & Confidence themes, e.g.;• Effects of forming in Integration• Confidence depends on data and models
• Number & complexity of material models– Help with selection – recommended values?– Availability of relevant data– Use of optimisation for data fitting– Micro-characterisation – may eventually eliminate test dependency
• Desire to utilise new materials demands forming simulation plus consideration of effects of forming
– Best Practice?– Other new materials / new processes that should be considered?
• Usability– Relates to Front Loading– Training / Benchmarking– Software design implications
Integration Issue?
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Way forward
• Use Materials theme to explore “gaps” determined from Confidence and Integration theme?
• How to determine topics for further review / detailed presentations?
– Questionnaire
• Based on FENET topics – expanded following discussion
• Based on FENET classification
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM
Topics for Questionnaire
New MaterialsMetals (including High Strength & Ultra High Strength Steels, Aluminium, Magnesium, Stainless Steel) as well as Polymers, Composites, Foams, Elastomerics
Manufacturing SimulationForming simulation, Effects of Forming, Assembly simulation, Paint simulation, Process Flow, Handling, Logistics, Cost analysis
SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT]012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM