Projektledare: Ragnar Larsson Projektet: treårsprojekt total budget: 4.95MSEK från FFI-VINNOVA MSEK totalt. Altair Engineering

Transkript

1 Modelling crash behaviour in future lightweight composite vehicles - step 1 Ragnar Larsson, Martin Fagerström, Jim Brousoulis, Johannes Främby, Robin Olsson, Sergio Costa, Thomas Bru, Renaud Gutkin, Mats Landervik, Kaj Fredin, Thomas Andersson, Göran Peterson, Bengt Pipkorn, Fredrik Stig, David Lundgren, 10 parter: Projektledare: Ragnar Larsson Projektet: treårsprojekt total budget: 4.95MSEK från FFI-VINNOVA MSEK totalt Altair Engineering 1

2 Bakgrund Dagens teknologi för fordonsstrukturer! Snabb utveckling map energieffektivitet! På alla nivåer! Nya teknologier, innovationer och forskning behövs! Framtidens fordonsstrukturer!? Framtidens energieffektiva samhälle!? 2

3 EXAMPLES OF AUTOMOTIVE STRUCTURES IN LAMINATED COMPOSITES E s kj/kg Porsche 918 Spyder BMW i Porsche Cars North Steel America 1015 Al 6061 CFRP 2015 FKA (PEEK) Composites historically used in aerospace structures [6] Jacob, G. C., & Fellers, J. F. (2002). Journal of Composite Materials. Specific energy absorption [7] Carruthers, J. J., Kettle, A. P., & Robinson, A. M. (1998. Applied Mechanics Reviews. No assessment of crashworthiness in aerospace structures No suitable CAE tools exist absolute requirement in automotive industry 3

4 Modellering av krockbeteendet i framtida lättviktsfordon Modellering/experimentell validering Utveckling av simuleringsverktyg Stort område omfattas av projektet: Industriellt perspektiv på framtidens CAE-verktyg Mekanisk modellering/validering Materialvetande om kompositer Frågeställningar: Kort om projektet Modellering av skadeprocesser hos polymera kompositer map krock Beräkningseffektiv modellering av tunnväggiga kompositstrukturer map energiupptagning vid krock En viktig möjliggörare till framtidens lätta/säkra/ hållbara fordon i industriperspektivet! Fyra arbetspaket: WPA: Utveckling av modeller för skadeutveckling i kompositer för krockanalys! WPB: Strukturanalys av kompositskal baserat på flerskalig modellering! WPC-D: Experiment/verifiering och spridning/förädling av forskningsresultat 5

5 Version 1 Described in SICOMP CR Software V1.0 delivered April 2015 Software V1.1 delivered June 2016 WPA - Model delivery Version 2 Described in two journal articles Software 2.0 to be delivered imminently Mesh objectivity and stability in uniaxial loading assessed Experimental validation for uniaxial compression in 0 and 90 directions 6

6 WPB Current status ADAPTIVE ENRICHMENT METHODOLOGY FOR SIMULATING PROPAGATING DELAMINATIONS 1. Starts with simple ESL model; Equivalent Single- Layer (ESL) zz Layer Wise (LW) zz xx, y xx, y Few DOFs Efficient but no delaminations Many DOFs Needed for delaminations When necessary: Local refinement 7

7 WPB Current status of the methodology ADAPTIVE ENRICHMENT METHODOLOGY FOR SIMULATING PROPAGATING DELAMINATIONS h xx 3 LL (pp, 0.5pp, 0) xx 1 1. Starts with simple ESL model; 2. Stress recovery used to find critical delamination areas; (0,0, pp) Shell Ref 3D SR Delamination criterion: ff I = σσ 33 + σσ fn 2 + σσ σσ 23 2 σσ fs rr I 8

8 Goals of WPC as formulated in the project plan SOTA assessment of software platforms Done my Master thesis at ÅF. Although only considering LS-DYNA and a small part of RADIOSS Master thesis: Andersson M, Liedberg P (2014). Crash behavior of composite structures - A CAE benchmarking study. Master thesis at Chalmers University of Technology. available on the project server and Chalmers publication library Implementation of constitutive models and the shell element of WPB into commercial software platforms The academic and institute partners deliver basic software routines to be further implemented by the software companies into their specific platforms Results: Constitutive models implemented in Abaqus VUMAT format at SICOMP LS-DYNA wrapper available Soon official VUMAT functionality in LS-DYNA 9

9 Goals of WPC as formulated in the project plan Benchmark test development and model validation development of two main crash events: front crash member and a side crash protection beam Done! Swerea SICOMP, will define the considered composite system and the consequent coupon manufacture. Done! AB Volvo is going to carry out characterization and coupon testing Done! VCC is going to work with component manufacturing and dynamic crash failure testing. Done! 10

10 WPD dissemination Contribute with results in international conferences, journal paper publication and the producing of 2 Lic. Eng. theses. Results in terms of publications: 1 licentiate of engineering thesis (second one to be presented in November 2016) 4 journal papers out of which 2 are still under review (see WPA and WPB) 3 conference publications 7 conference presentations two technical reports (Literature review on crash modelling and material model description) and four master thesis reports (see above) 11

11 New project step 2 => Link to other initiatives Compcrash 1 SICOMP FFI-Crash 1 design methods in automotive Compcrash 2 SICOMP FFI-Crash 2 ICONIC (European ITN on crash modelling) MATISSE (European project on crash modelling of composites) Kompress Chalmers Ductile Composites (STEM) FFI-Crash 2 will be an essential key to continued coordinated national efforts 12

12 Modelling crash behaviour in future lightweight composite vehicles - step 2 Martin Fagerström, 13