Roadmap Composite Simulation - Summary 2015
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The document discusses a survey of experts on composite simulation. It finds that automotive and aerospace are dominant industries for application, with component failure/crash and material description as top areas. Material models are seen as the most significant technology. High R&D demands exist for material models, failure prediction, service life, and manufacturing processes. Researchers see above average needs for research in these areas.
Roadmap Composite Simulation - Summary 2015
- 1. Composite Simulation Industries, Areas of Application, Technologies, R&D Demands © Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC) Dr.-Ing. Dipl.-Kfm. Christoph Runde Virtual Dimension Center (VDC) Fellbach Auberlenstr. 13 70736 Fellbach www.vdc-fellbach.de Ulrike Möller Allianz Faser-basierte Werkstoffe Baden-Württemberg (AFBW) www.afbw.eu
- 2. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Data acquisition for the Composite Simulation Roadmap Conduct of the survey in February 2015 at the congress Composite Simulation 2015 Thus limiting the panel to experts regarding the topic 43 usable answers Not all answers are complete. In the case of percentage evaluations, the Data Acquisition Not all answers are complete. In the case of percentage evaluations, the population selected (= 100%) was always only the set of answers that have explicitly responded to a question Additional information as a result of the industrial work group Composite Simulation, which exists since 2013 2
- 3. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Survey Composite Simulation – Question 1 Question 1: „In which industry do you work?“ 19 users Industries Automotive Aerospace Mechanical Engineering 3 12 provider 12 researcher Mechanical Engineering Electrical and automation technology Engineering and simulation provider Software Universities, research
- 4. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Survey Composite Simulation – Question 2 Question 2: „In which sectors do you see applications for the simulation of composites?“ Industries 4
- 5. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Survey Composite Simulation – Question 2 Conclusion question 2: The Automotive and Aerospace sectors are dominating in their importance for composite simulation (95% high or very high importance) Sport & Leisure, Commercial vehicle construction, Mechanical engineering, Medical technology and Rail vehicle construction follow by a clear margin Industries Medical technology and Rail vehicle construction follow by a clear margin Other industries are Protection device construction, Architecture, Plant construction, Packaging technology Compared to the other panel groups, users see less need in the Architecture sector In comparison with the other panel groups, service providers see less demand in Mechanical engineering 5
- 6. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Survey Composite Simulation – Question 3 Question 3: „In which areas of application do you see the use of composite simulation?“ Areas of Application 6
- 7. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Survey Composite Simulation – Question 3 Conclusion question 3: The most important application fields of composite simulation are component failure/ crash and material description At great distance follow component analyzes (sandwich, vibrations, fatigue), material development and drape simulation Areas of Application material development and drape simulation Basically, the assessments of the panel groups regarding the importance of composite simulation in fields of application are similar Differences can still be identified in component analyzes (especially in the examination of vibration and sandwich structures): users tend to see less importance here than other panel groups; service providers see more importance 7
- 8. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Survey Composite Simulation – Question 4 Question 4: „ What are relevant technologies (technological basics) for the simulation of composites?“ Technological Basics 8
- 9. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Survey Composite Simulation – Question 4 Conclusion question 4: All respondents rate material models as "significant" (19%) or "very significant" (81%) Solver technologies, contact algorithms and parallelization techniques follow at great distance (still at least 2/3 of the respondents consider these as Technological Basics at great distance (still at least 2/3 of the respondents consider these as "significant" or "very significant") AI methods are of low importance or insignificant for the majority of those surveyed The assessments of the panel groups regarding the importance of composite simulation technologies are very similar 9
- 10. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Survey Composite Simulation – Question 5 Question 5: „Where do you see R&D demand for the simulation of composites?“ R&D Demands 10
- 11. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Survey Composite Simulation – Question 5 Conclusion question 5: High R&D requirements in the context of composite simulation are seen in the areas of material models, failure, service life and manufacturing process Fluid/ structure interaction, joining, contact algorithms follow at distance Researchers mostly see an above-average need for research, with the R&D Demands 11 Researchers mostly see an above-average need for research, with the exception of the topics "failure" and "contact algorithms" Nobody rated R&D demands in the field of "failure" as "insignificant"
- 12. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Composite Simulation Roadmap: R&D demands Further findings regarding R&D demands: Results of the industrial work group Composite Simulation ƌďĞŝƚƐŬƌĞŝƐ R&D Demands 12
- 13. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Further problems from an expert´s point of view: 1. Modeling Objectives Reduction of experiments, better simulation Reduce conservative assumptions, no inadequate oversizing, load-adapted components Faster qualification Optimal sandwich or lightweight solution for the respective component Simulation capability of sandwich structures; influence of production parameters, R&D Demands Simulation capability of sandwich structures; influence of production parameters, structure and material Virtual design of sandwich structures Deepening material knowledge of sandwich structures Crash boxes/ elements for series vehicles, production/ crash models Simplification of the simulation process (automatic calibration), free programming of an individual material model Cost-effective core materials and processes for the car application Description of total stress in sandwich structure with reinforced foam core 13
- 14. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Further problems from an expert´s point of view: 1. Modeling Problems Elaborate modeling, no modeling type generally validated Company-oriented modeling (no academic approaches/ models) Efficient modeling - consistency of the process chain/ design/ production structure - programmable models Lifecycle and fatigue simulation, simulation of vibrations Illustration of failure mechanisms and validation of complex manufacturing processes R&D Demands Illustration of failure mechanisms and validation of complex manufacturing processes Tasks Calibration between real components and simulation Characteristic value determination - linking failure models with experiments Characteristic values from process simulation Cost-optimized simulation of fiber composite structures – closed process simulation (VAP / RTM) Understanding of failure mechanisms Material models, material separation: crack Dynamic behavior: stiffness, damping/ fatigue strength Manufacturing simulation 14
- 15. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Further problems from an expert´s point of view: 2. Material parameters Objectives Creation of a material model database (time saving) Macroscopic material modeling Illustration: chemistry/ material properties "RTM" Problems Many possible material combinations, therefore, several material models are R&D Demands Many possible material combinations, therefore, several material models are necessary Reliable material parameters, models for damage formation and propagation Tasks Better simulation of material properties through better understanding of the material Calculation methodology: calculation tools to develop material models, including failure 15
- 16. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Further problems from an expert´s point of view: 3. Sandwich structures Problems Illustration of adhesion of core surface layer, to which thickness shell formulation is usable for sandwich structure Illustration of inhomogeneous foams, simulation of operational stability (especially of the joining technique) Forecasting quality for CFRP and sandwich structures Modeling cover layer connection (gluing) R&D Demands Modeling cover layer connection (gluing) Adaptive load-dependent linkage switching Large edge length does not allow representation of sandwich honeycomb structures Sandwich modeling: calculation times are too long Residual stress in the sandwich, characteristic values for reinforced foam cores Assignment sandwich construction to requirement/ structure Tasks Fast FE model derivation of sandwich structures using (adapted) CT software Establishment of systematic selection procedures and validated material characteristics for sandwich components 16
- 17. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Further problems from an expert´s point of view Open interface definition between measurement technology and FE modeling: Need for coordination between measurement technology and software providers and users Ambiguities in determining optimal material parameters due to the model properties: Mathematical investigation of material models necessary, mechanism-based R&D Demands Mathematical investigation of material models necessary, mechanism-based material modeling better than a phenomenological Ambiguities in determining optimal material parameters due to material inhomogeneities: Combination of full field measurement techniques with mesostructural characterization methods necessary 17
- 18. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Outlook: Starting points collaborative research Guiding theme "Predictability of textile-based sandwich structures with consideration of process technology" Subtopics "Experimental and numerical investigation of the influence of textile construction and core properties on the bonding in sandwich structures." Outlook construction and core properties on the bonding in sandwich structures." "Simulation capability of failure behavior of sandwich structures in crash applications." "Application-oriented modeling and identification of sandwich structures with honeycomb core." 18
- 19. Industries R&D Demand OutlookData Acquisition Areas of Application Technological Basics Outlook Composite simulation is currently a fast-moving area with well identifiable fields of application Like many other technologies, it migrates from heavily oligopoly-characterized industries (aerospace, automotive) to polypol industries (such as engineering) with smaller structures There are many good approaches, but there is still a great need for research in Outlook There are many good approaches, but there is still a great need for research in these fields for the foreseeable future Further evaluations and analyzes of secondary literature on the Composite Simulation Roadmap will follow this year Topics are continuously processed in the industrial work group “Composite Simulation" of the VDC and the AFBW Publications are made on the websites of the VDC and the AFWB 19
- 20. Thank you very much for your interest! You are interested in this topic and you are looking for contact persons/ implementation partners? Please contact us. © Competence Centre for Virtual Reality and Cooperative Engineering w. V. – Virtual Dimension Center (VDC) Virtual Dimension Center (VDC) Fellbach Auberlenstraße 13 70736 Fellbach www.vdc-fellbach.de Ulrike Möller Allianz Faser-basierte Werkstoffe Baden- Württemberg (AFBW) www.afbw.eu