2014 Automotive Simulation World Congress

October 9-10, Tokyo, Japan

Composite Press Forming Simulation

of Dry Textile Fabric Preform.
CYBERNET SYSTEMS CO.,LTD.
Mechanical CAE Division
Koji Yamamoto
 Agenda
Motivation
 Technical issues for composite material analysis
 Resin Transfer Molding(RTM) Process

Analytical Approach for RTM Process

 ANSYS Composite Prepost (Drape Sim.) & Transfer Molding Analysis
 LS-DYNA (Explicit FEM Press Sim.) & Transfer Molding Analysis

Multiscale analysis add on tool for ANSYS Workbench.

 Homogenization and Localization

Press Simulation for Dry Fabric.

 Material Model.
 Identification material constants by Multiscale Analysis.

Transfer Molding Simulation for Dry Fabric

 How to consider fiber orientation and fineness of preform.

Summary

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 2

 Motivation 1 : Technical Issues for Composite
Characteristic of composite materials
Material modeling
 Light and Hard.
・Prepare material constants
 Concurrency production for material and molding. (An-isotropic properties)
 Airplane industry is preceding to apply.
Key point to reduce vehicle weight
Structural modeling
 Apply to primary structure. ・ Fiber orientation
Post process
- Body ・ Damage
・ Laminate
- Panel (Hood, Roof) ・ Destruction
・ Molding process
 Mass production process.
 Simulation technique. Technical issues for simulation
Panel(hood, roof)
Spray Up White body etc..
Manual
Autoclave
Mass
production Front end module
RTM SMC(Press) Small parts etc..
Mechanical Molding Compound
MMD BMC(Press or Injection)
FRP Molding Prepreg(Press)
Pultrusion
Continuous
Continuous lamination
Filament winding
Propeller Shaft
Other Pressure tank etc..
Rotation
© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 3
 Motivation 2 : RTM Process

RTM = Resin Transfer Molding

Forming Impregnation
Preform Resin injection
Press
（Dry Fabric）

Blank（Sheet）

Important factor for product quality.

Forming Mold release Warping
- Fiber coarseness and fineness
- Fiber orientation
- Wrinkle
Thermal（or Curing）
Impregnation shrinkage
- Void
- Warping
- Residual stress CFRP

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 4

 Analytical Approach for RTM Process
Approach 1 Approach 2
Prepare material properties for dry and wet fabric Multiscale.Sim™※

Composite Prepost LS-DYNA

Forming
Drape Analysis Explicit Analysis

Fineness
Orientation Orientation
Design Explorer

Resin Flow Analysis Tool※ Resin Flow Analysis Tool※

Impregnation
Resin Flow Analysis Resin Flow Analysis

Shrinkage Shrinkage

Mechanical Mechanical
Warping
Structural Analysis Structural Analysis

Low Analytical Validity High

Low Calculation Cost High
※ CYBERNET has developed original ANSYS add-on tool for Multiscale analysis and resin flow analysis.
© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 5
 Deformation of Dry Fabric during Forming Process

Top view

Uniaxial Direction = Hard

Bias Direction = Soft Front view
Forming simulation example for weave plain fabrics
Using spherical punch (Tow geometry is modeled).
Fiber orientation

(a) (b) (a) (b)

(fine to corase⇒flow resistance is decrease) (coarse to fine⇒flow resistance is increase)
Fiber fineness (a:Original blank shape, b: Deformed blank shape)
© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 6
 Drape Simulation vs. Explicit Simulation
We have to consider the material properties of dry fabric to perform press forming analysis with
accuracy. Multiscale analysis is very useful to reduce time cost to prepare the an-isotropic material
constants.
Comparison of properties for weave styles※
Property Plain Twill Satin Basket Leno Mock Leno Drape properties are
strongly depended on
Good Stability *** *** ** ** ***** *** weave styles.
Good Drape ** **** ***** *** * **
Drape Properties
Symmetrical **** *** * *** * ****

≒
Low Crimp ** *** **** ** ***** ** Shear modulus

(*****=excellent, ****=good, ***=acceptable, **=poor, *=very poor)

Plain Twill Satin Basket Leno Mock Leno

Typical weave styles
※ Reference “Woven Fabrics in Polymeric Composite Materials” (http://www.azom.com/article.aspx?ArticleID=1091)

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 7

 Multiscale Analysis Overview

Numerical
σ Material tests
ε homogenization
σ
ε

Microscale design Macroscale design

Macroscopic constitutive E
model available in our
analysis software
Macroscale analysis
Microscale analysis
localization

Micro-scale CAE Macro-scale CAE

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 8

 Development organization
Multiscale.Sim™ ※is an ANSYS add-in tool which is based on the homogenization method
and developed by Industry-university cooperation projects of four organizations that have been
established since 2007.

Material theory and experiment

Multi-scale Theory Program Development

Prof Terada (TOHOKU UNIV.) NITTO BOSEKI CO.,LTD.

Quint Corporation CYBERNET SYSTEMS CO.,LTD.

Sales and Product Support

※ Multiscale.Sim is trademark in Japan and applying in Global at now.
© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 9
 Homogenization:
Micro-/macro-scopic boundary value problems
x3
x2 y3

x1 y2

y1
Macro-scale governing equation
• Equilibrium eqn. Micro-scale
• Displ.-stain relation governing equation
• Constitutive eqn.（Anisotropic elasticity）

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 10

 Homogenization:
Numerical material testing (NMT)

Calculation of macroscopic elastic constants by NMT

Volume average of
Micro-scale FE analysis Volume average of
microscopic straina microscopic stress

Input: macroscopic strain Output: macroscopic stress

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 11

11
 Homogenization:
Numerical material testing (NMT)

Unknown parameters

Homogenization
(Volume averaging)
© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 12
 Multiscale.Sim™ GUI for Workbench
Multiscale.Sim™ GUI menu for Workbench 14.5 and 15.0 has been developed by using
ANSYS Customization Toolkit. Mechanical APDL GUI is also implemented by UIDL.
Main function
① Model creation templates (DM)
② Store the homogenization results to engineering
database.
③ Contour and vector plot for numerical material
testing.
③
②

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 13

 Supported Material Models on Multiscale.Sim™
Useful function for RTM simulation.
 Non-Linear numerical material testing. (However, dry fabric model is not supported.)
 Homogenization function to identify seepage coefficient using “darcy’s law”.
Analysis Field Analysis Type Material Models Material anisotropy
Elastic Coefficient Anisotropic & Orthotropic
Linear Density -
Thermal Expansion Orthotropic
Structural Elasto-Plastic Orthotropic (Hill)※2
Visco-Elastic Anisotropic(Anisotropic maxwell)※1,2
Non-Linear
Hyper-Elastic Orthotropic (Kariske)※2
Creep Orthotropic (Hill)※2
Thermal Conduction Anisotropic & Orthotropic
Thermal Linear
Specific Heat -

Fluid Linear Seepage coefficient Anisotropic & Orthotropic

Permittivity Anisotropic & Orthotropic

Electromagnetic Linear Permeability Anisotropic & Orthotropic
Electrical Resistivity Anisotropic & Orthotropic
※1 Orthotropic visco-elastic model is implemented by “usermat” subroutine.
※2 Curve fitting function is implemented by “userop” subroutine
© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 14
 How about the Material Property of Dry Fabric?
Dry fabric material property for pure shearing mode is evaluated by numerical material testing.
Analysis Conditions
Condition Detail

Shear stress [MPa]

Fiber Carbon
Weave style Plane
Volume Fraction 35.0 [Vol.%]
Pure Shearing
Testing
(in plane)

Material properties for carbon tow Shear strain [-]

Deformation shape during pure shearing
Condition Detail Macroscopic material response
numerical material testing
r 1.44 [g/cm3] Good correlation
E1 99.1 [GPa]
E2 7.4 [GPa]
G12 2.5 [GPa]
G23 5.0 [GPa]
n12 0.2 [-]
n23 0.2 [-]
m 0.0 [-]
Results of reference paper※
※Reference : Journal of the Society of Materials Science, Japan, Vol.63, No.5, pp.380-385, May.2014
© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 15
 Material Model for Dry Fabric of LS-DYNA
Characteristic of dry fabric material property
 Shear modulus is increased drastically by shear locking.
 Other deformation mode show linear behavior.
*MAT_MACROMECHANICS_DRY_FABRIC
 1 
n 12 
n 12 0 0 0 
 E1 E1 E1 
 n 12 n  Free state
 E  23
1 0 0 0 
E2 E2
 n 1 n 23 
 12 1 0 Discount
0 
0factor
C 1   E1 E2 E2 
 0 0 0 1 0 0 
 mG12 
 0 0 0 0 1 0 
 mG23  Locking state by shearing
 0 0 0 0 0 1 
 mG12 
Shear stress

qlock
Dq

Shear strain
Rough estimating procedure Discount factor as a function of braid angle. Locking angle

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 16

 Curve Fitting to Identify Material Constants
Material constants are identified by fitting the numerical material testing results using GA
optimization algorism. Initial value of optimization is estimated from stress-strain curve of
shear testing as mentioned previous slide.

Normal stress [MPa]

Shear stress [MPa]

Shear strain [-] Normal strain [-]

Shear in plane direction Axial direction
Curve fitting results for each testing mode.
Identified parameter for MICROMECHANICAL_DRY_FABRIC.
mid ro e1 e2 g12 g23 v12 v23
1 1440 99.1e9 1.0e9 2.5e9 5e9 0.2 0.2
xt thi thl(qlock) bfi bwi dscf cnst altr(Dq)
1.0 45.0 30.0 3.65 3.65 1000.0 0.02 5.0

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 17

 Validation for Homogenized Model

Analysis result for homogenized model is validated by comparing direct model.

Blank sheet is modeled as
shell163 element. k file is R50.0[mm]
created by “LS-DYNA Export”
component systems in
workbench environment and
modified the fabric material
properties using text editor.

 Analysis conditions
・Press Velocity
5000.0[mm/sec]
・Material Model
Punch : *MAT_RIGID
Die : *MAT_RIGID
Tow : *MAT2※1
Weave : *MAT235※2

 Model Statistics
Direct Homogenized
Direct Model Homogenized Model
Nodes 117595 16314
※1 : ORTHOTROPIC_ELASTIC (for Direct Model)
Elements 129857 42501 ※2 : MICROMECHANICS_DRY_FABRIC (for Homogenized Model)
© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 18
 Validation for Homogenized Model

Direct Model Homogenized Model

X-displacement

umax=1.262[mm] umax=1.129[mm]
xy-strain

Direct model : 5h31min

Calculation cost
Homogenized model : 0h22min
© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 19
 Drape Simulation vs. Explicit FEM Simulation
There are two modeling approach for press forming simulation.
1. Drape sim. of ANSYS Composite Prepost 2. Explicit FEM Simulation LS-DYNA and so on.
 Shear angle is estimated using energy algorithm  Deformation properties are estimated using FEM taking
assuming shear modulus distributed uniformly. into account nonlinear properties of shear modulus.

M un  C un  K un   Fn 

4
1
min E  G   cos 2  i
2

2 i 1

Drape direction

Drape origin

ANSYS Composite Prepost result LS-DYNA result (Homogenized model)

Shear angle distribution for press forming by spherical punch

(Dot line means outline of punch : Pushing depth = 15.0[mm])

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 20

 Fiber Reorientation by shear deformation

F   x  RU   V R
Element motion is composed
of stretch and rigidly moving
X
component. q`
q` Stretch Rigidly
Moving
In plane
shear U R
Stretch dx
dX
Push forward op.
2 q 1
q Uniaxial

R V
Rigidly Stretch
Moving
Rigidly
: Fiber orientation Moving Deformation gradient tensor [F]
: Material axes.

1` F q f 
Influential factor for reorientation
In-plane
Uniaxial
Rigidly 2`
q 
'

q 
Shear Moving f

Fiber f
Ori. ○ × × Reference Current
configuration configuration
Material
Axes × × ○ Push forward operation

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 21

 Coupled analysis : Structural to Resin Flow

Multiscale.Sim™ Design Explorer

Fitting

[K] at q’=** [K] at q’=** [K] at q’=**

Darcy`s law
Homogenization analysis for each K ij
qi   p j
Response surface
microstructure model.
m [Seepage coefficient vs. (1,2,12)strain ]

y LS-DYNA Resin Flow Analysis Tool

z x

Mapping
Fiber orientation
(xy comp.) (xx comp.) (zz comp.) &
[K]
Shear component Nominal component
(xy) (xx, yy, zz)
Distribution for each strain component Seepage Coefficient [K]

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 22

 Summary

Purpose : Development explicit press simulation system for RTM process.

Forming process
 Macro Analysis
・ Explicit press simulation by LS-DYNA.
・ Dry fabric microstructure is homogenized

 Micro Analysis (=Predict material properties)

・ Predict material properties for dry fabric using homogenization method of Multiscale.Sim™.
・ Material constants for dry fabric constitutive law is identified by GA algorithm.
 Post process
・ Fiber Reorientation
- Extraction from deformation gradient tensor.
・ Fiber fineness
- Response surface of seepage coefficient vs. strain component

- Future plan -
Impregnation process
 Resin transfer simulation taking into account seepage coefficient distribution.
Mold release process
Verification & Validation

© 2014 CYBERNET SYSTEMS CO.,LTD. All Rights Reserved. 23

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