A multiscale strategy for the simulation of braided composites with ENVYO
Abstract
Manufacturing processes and parameters have played a crucial role in the design and analysis of composite structures. To exploit potential advantages of composite materials, it is necessary to predict and optimize the manufacturing steps in respect to the optimization of the structure itself. During the past years, the project DigitPro (Digital Prototype) has been developed within the research campus ARENA2036. A multiscale simulation strategy is investigated to cover a full product generation cycle of textile composite components from structure pre-design up to part manufacturing. Start parameters are firstly identified for each step of the cycle. Subsequently, appropriate materials, geometries and manufacturing parameters are found during optimization loops. Finally, the result is sent into real manufacturing process. The mapping tool ENVYO stands as a connector between the various simulations and simulation softwares. Hence, ENVYO allows the transmission of information from one simulation to another. The presentation will focus on two key aspects of the simulation of textile composites. On the mesoscopic scale, detailed finite-element models of the textile laminate are generated, representing closely the complex yarn architecture. The mechanical properties of the laminate are numerically identified by simulating the models under tension, compression and shear loading. The transition to the structure simulation on macroscopic scale is performed via the tool ENVYO following two approaches. The first approach directly uses the material properties generated on the mesoscale for the structure simulation. In the second approach, information from the process simulation is mapped on the structure mesh to take into account the influence of local yarn architecture on the structural behaviour. Both methods will be compared to standard structure simulation and to experimental results. The developed methodology will be illustrated with the example of braided composites and the potential of the process chain will be discussed.
... In the recent past, a lot of effort has been made towards the closing of the simulation process chain for all different kinds of materials. Besides the regular transfer of resulting stress, strain, and history data, main focus from a material's perspective has been on the transfer of fiber orientations from process simulations for continuous fiber reinforced composites [1] together with various homogenization approaches for short fiber reinforced plastic materials [2]. ...
In the recent past, a lot of effort has been made towards the closing of the simulation process chain for all different kinds of materials. Besides the regular transfer of resulting stress, strain, and history data, main focus from a material’s perspective has been on the transfer of fiber orientations from process simulations for continuous fiber reinforced composites [1] together with various homogenization approaches for short fiber reinforced plastic materials [2]. In the following, three new features of the mapping software envyo® [3] will be presented. The first one allows for the mapping of resulting temperature-time curves from a preliminary simulation using the software tool THESEUS-FE OVEN, which is used to simulate paint-drying processes. This process also effects the degree of hardening, e.g. of aluminum structures and therefore leads to locally varying material properties such as the yield stress, strengths etc. It will be explained how these parameter variations can now be considered with the proper mapping and homogenization approach. The second new feature allows for the identification of different parts and therefore material properties based on a portable graymap (*.pgm) format. Therefore, any arbitrary colored image can be translated into a grayscale representation given in the ascii based *.pgm format, using a third-party software such as GIMP. In the mapping input command file, the user can then define ranges between 0 and 255 which will be assigned to the various parts and therefore material properties. The applicability of the method will be investigated on a wood-forming use case [4]. Another new feature is the consideration of simulation results gained with the Finite Pointset Method (FPM) [5]. Based on a resulting HDF5® data container which stores the coordinates of the particles and their pressure results at specific simulation stages, load curves can be generated which will be used to calculate the component’s deformation with LS-DYNA®, making use of the *LOAD_SEGMENT keyword.
... The logical successor to DigitPro is the new Digitaler Fingerabdruck (DFA) research project in which the intelligent data collection, processing and transfer across the entire value creation chain -from the idea, through design, production and in-service to end-of-life -for the intelligent component and the versatile, autonomous factory of tomorrow [2] is to be realized. Whereas in DigitPro the focus was on closing the simulation process chain [3] for various fiber-based manufacturing processes such as braiding [4,5,6], infiltration [7], draping and Open Reed Weaving (ORW) [8] via various scales from the micro to the meso to the macroscopic scale, the focus of the research project DFA is now to collect data from production as well as sensor data from the life cycle of a component. These data can then be fed back into the simulation and thus enable conclusions to be drawn about an in-situ life cycle assessment, adaptation of the production environment and improvement of future components with similar requirements. ...
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