Accurate Simulation of Short-Fiber-Reinforced Automotive Parts

Sascha Pazour
PART Engineering GmbH
pazour@part-gmbh.de
0049 2204 30677 26

PART

Engineering GmbH, www.part-gmbh.de

PART Engineering Key Facts

Hamburg

Berlin

Founded in 1999 as FEM services supplier

Focus on structural mechanics

Mission is to provide CAE services and software in

order to add value to our customers CAE chain

20 years experience in FEA

10 years experience in CAE software development

Two software products by our own:

Wolfsburg

Cologne

Bergisch
Gladbach
Frankfurt
Rsselsheim

Stuttgart

Life

Ingolstadt
Munich

Development partner of major CAE software vendors

material: PA6+GF30

in flow

120

100

100

cross flow

400
350

350

100

300
80

250
65

60

58

200
150

40

100

100
20

50
0

0
Stiffness

Strength

therm. Expansion

Influence of Fiber Orientation onto Material Properties

Fig. 2

S1 Shear layer: Fibers oriented parallel to flow direction

S2 Mid layer: Fibers oriented perpendicular to flow direction

Flow Direction

Cut View X
Flow Direction
S1
S2

S1
Example Micrograph Pictures:

Thick
Mid Layer

Thin
Mid Layer

Fiber Orientations in Short-Fiber-Reinforced Plastics

Fig. 3

1
2

unidirectional

general case

a11 a12

. a22
.
.

-90 -45

1 0 0

0 0 0
0 0 0

a13

a23
a33

0 +45 +90

-90 -45 0 +45 +90

quasi-isotropic

0
0.33 0

0.33 0
0
0

0
0
.
33

-90 -45 0 +45 +90

Degree of Orientation
Fig. 4

Youngs Modulus

Poissons Ratio

Coeff. of Lin. Therm. Exp.

Isotropic

Temperature Dependant

Anisotropic

x
Thermo-Mechanical
Simulation

Fiber Orientation
(Local System)
z

Material Complexity
Fig. 5

xy

yz
zx

Local Directions

-40C

23C

80C

Temperature

120C

Degree of Orientation
(Fiber Distribution)

(0,5/0,5/0)

(0,7/0,2/0,1)

(0,33/0,33/0,33)

(1/0/0)
y

Fiber Orientation
(Local System)
z

Material Complexity
Fig. 6

Orthotropic Material Model

G12

Needs 15 lin.-elastic temp.

dependant material properties:

12

12

E3

G23
23

23

E2

xy

yz

G31

31

x
E1

Coeff. of lin. Therm. Expan.:

1, 1, 1, 12, 23, 13,
Tensile moduli: E1, E2, E3
Shear moduli: G12, G13, G23
Poisson ratios: 12, 13, 23

zx
23C

31

Material Complexity
Fig. 7

Common Approach:
Isotropic

Example: Weld Lines

Isotropic Approach
Fig. 8

CONVERSE Approach:
Anisotropic

Example: Weld Lines

Anisotropic Approach
Fig. 9

Fiber Orientation and Anisotropic Material

[Part: Mann & Hummel]

Converse Graphical User Interface

Fig. 10

IM solver

Converse

mechanical solver

unequal meshes
possible

shell (mid-plane/surface) => shell (tria, quad)

shell (mid-plane/surface) => solid (tet, hex)
solid => solid (tet, hex)

Mesh Topology
Fig. 11

Injection Moulding
Solver

Mechanical Solver

Orientations
Pressures
Temperatures
Wall Thicknesses
- Moldex 3D
- Moldflow
- Cadmould
- Sigma
- Fluent
- Simpoe
- 3D Timon

Residual Stresses
Shrinkage & Warpage
Weldlines

- Optistruct
- femfat
- nCode
- Abaqus
- Ansys
- Marc
- Nastran
- LS-Dyna

Converse Features and Interfaces

Fig. 12

1400

1200

1000

[N]
force[N]
Kraft

800

600

400
Messung
1
test 1
test 2
Messung
2
FEA
isotropic
isotrop
FEA anisotropic
orthotrop

200

0
0

[Part: Mann & Hummel]

2
3
Verschiebung
displacement[mm]
[mm]

Material: Grivory HTV 3H1

Example: Rotary Valve

Fig. 13

Material: Ultramid A3WG6

[Part: Mann & Hummel]

Example: Air Intake Manifold

Fig. 14

1000

x-Richtung
- isotrop
x-direction-isotropic

y-Richtung
- isotrop
y-direction-isotropic

z-Richtung
- isotrop
z-direction-isotropic

x-direction-anisotropic
x-Richtung
- orthotrop

y-direction-anisotropic
y-Richtung
- orthotrop

z-direction-anisotropic
z-Richtung
- orthotrop

900

mass [kg]
effectiveMasse
[g]
effektive

800
700
600
500
400
300
200
100
0
250,00

270,00

[Part: Mann & Hummel]

290,00

310,00

330,00

350,00

370,00

390,00

Frequenz [Hz]
frequency
[Hz]

Eigenfrequencies and Eigenmodes

Fig. 15

Part Geometry

Fiber Orientation in Converse

[Valeo Lighting Systems]

Lens Bracket Example

Fig. 16

Frequency correlation simulation to Xp. modal analysis

+30Hz

Isotropic

+5Hz

Converse

Average error 4 Modes

Mode

Experimental (Hz)

Isotropic (Hz)

Converse (Hz)

44

76

60

56

77

62

91

114

94

224

270

218

[Valeo Lighting Systems]

Lens Bracket Example

Fig. 17

Material: PP + GF20

Example: Burst Pressure

Fig. 18

Gate location

Gate location
Water pump housing

Supplier 1

Supplier 2

Two suppliers but parts are geometrically up to 95% equal.

Same material supplier, same mashine settings, etc.
Different gating location means two completly different engine components!

Moldflow results show different orientation

Influence Of Production on Fiber Orientation

Fig. 19

1. distributed pressure on sealing contact surface

Untolerable error if homogeneous

isotropic material is used!

4. isotropic vs. anisotropic results

2. results evaluated on a path

fiber orientation and material model by

Blue Supplier 1
Red Supplier 2

3. displacements

Displacement

Dotted Isotropic material

- 62%

True distance along path

Influence Of Production on Anisotropic Part Stiffness

Fig. 20

www.part-gmbh.de

Whats New?

Converse Installation
Fig. 21

consider
the real part
properties

get better
predictions of
strength &
deformation

by using data
already
available

Thank you for your attention!

Please dont hesitate to ask a question!

Add Value to Your Mechanical Simulation

Fig. 22