KnowledgeUK-DATACOMP

Dr. Donna DykemanSenior Project ManagerCollaborative R&DGranta Design Ltd.

Understanding the behaviour of composite structures for crash is vital to improve confidence and encourage more widespread use.

Automotive products sold in Europe are homologated against stringent crash legislation. A qualification audit trail is needed.

Automotive sector is increasingly reliant on simulation tools to drive design.

Reliable material data represents the greatest challenge to accurate predictive simulation for high energy impacts.

High volume manufacture will drive down cost e.g. BMW i3.

UK-DATACOMPMotivation

To generate a material database to facilitate the use of established virtual prototyping methodologies for composite product development.

The database will also facilitate validation & quality assurance of composite materials used within the UK supply chain.

Standardize and harmonize quality, reliability and accessibility of material data provided by the composite supply chain.

Facilitate material selection to product developers and reduce time-to-market for end users.

To create a material Library of correlated composite material FE data for automotive crash analysis.

UK-DATACOMPObjectives

UK-DATACOMPPartner Overview

Project Lead

Simulation Lead

Methods Development

Material processing

Subsystem supply

FE simulation

Resin supply

Material Technology

Materials Information Management

DataComp Test/Design/ Simulation Database

Test Pyramid

Material Testing

Test Methods

Panel Manufacture

Material Testing

Certification

Panel Manufacture

Fabric Supply

Material Technology

Work Packages

WP1: Material Technology

Phase 1: Carbon

Phase 2: Hybrids

WP2: Test Pyramid

Level 0 Standard

Level 1 Non-Standard

Level 2 Component

WP3: Simulation

Material Model

Characterisation

WP4: Database

Test Programme Progress

Data Processing

Material Card Generation

Material Card Library

Materials

Test Data

Processed

Data

Correlated

Material Models

UK-DATACOMPComposites Qualification for Design & Simulation

Investment

COUPON

969

24

718 Materials

1000 Tests

UK-DATACOMPCoupon Level – material property and failure behaviour

Coupon

Non-standard

(IMPERIAL COLLEGE)

• Dynamic tension, shear

• Dynamic comp, impact

• Double edge notch

• Compact tension, crush

• Open hole tension, comp

• Fibre tension, pull-out

• Resin tension, compression

• Tension

• Compression

• In-plane shear

• Interlaminar shear

• Fracture toughness

• Fibre volume fraction

• Extent of cure

Coupon

ISO standard

(NCCEF)

UK-DATACOMPModel Validation – Based on coupon test results and behaviour observation

CorrelationTest tolerances

Model sensitivityTuning/optimisation

Pre-simulationMaterial card inputsInstrumentationMesh sensitivityElement formulation

Test SupportSetupChannel dataFilteringTest variation/deviation

Data collectionCoupon geometryComposite layupBoundary conditionsLoadcases

Baseline SimulationTest parametersRevised geometryMean input variablesInstrumentation

Correlated CardIterative ProcessFinal card to solver

UK-DATACOMPMaterial Card Library – Four primary solvers

Radioss

LS-Dyna

PamCrash

Abaqus

UK-DATACOMPSub-System & System – analysis verification

• Crush – Axon braided tubes

• 3-point bend – Axon braided tubes

• Crush – Sigmatex NCF tubes

• 3-point bend – Sigmatex NCF tubes

• Crush – NCF, ST bonnet

• Impact – NCF, ST bonnet

• Fibre volume fraction

• Extent of cure

Sub-System & System

UK-DATACOMPComposite Qualification for Design & Simulation

The Data Challenge

• Composites data is complex

• Anisotropy

• Process history-dependence

• Statistical variability

• Database models for steel won’t work

The Workflow Challenge

• Blurred boundaries between material characterization and product design

• Complex test plans

• Material, batch and test identification

• Full traceability required

UK-DATACOMPSome Key Infrastructural Elements

Integration with downstream designExport of data and embedded MI:Materials

Gateway technology

Intuitive tools & reportsUp-to-the-minute reporting on every step in the qualification process

Flexible importer technologyGet data in, e.g., from specific test machines. Easy, remote upload.

SchemaConfigurable, industry standard data structures to capture specific data types and their inter-relationships

SUPPORT CAD, CAE, PLM

~Material Card Generation,

Solver & Units Conversion~

MAKE DECISIONS

~Material & Process

Selection~

BROWSE, SEARCH & REPORT

~Fully Traceable Pedigree~

VISUALIZE & ANALYZE

~Test Support, Data Analysis~

EXTERNAL

REFERENCE DATA

~DataComp Crash DB~

RAW TEST DATA DIRECT

FROM EQUIPMENT

~Remote Import~

CORPORATE

DATABASE

CONSOLIDATE

& MANAGE

DATA

MI

UK-DATACOMPMaterial Technology – Phase 1 materials

Textile Areal weight Reinforcement fibres Received Material Code

NCF +/-45° 246gsm Toray T700 12K 50C AXON MCX2181350

NCF +/-45° 300gsm Toray T700 12K 60E IC/NCCEF DMC2831041

NCF +/-45° 300gsm Toray T700 12K 60E IC/NCCEF DMC2711041

NCF-UD 90° 150gsm Toray T700 12K 60E IC/NCCEF DMC4481270

ST woven 88gsm Toray T700 12K 50C IC/NCCEF ST0081270

3D weave LL 3260gsm IM7 12K NCCEF JQ3240400

3D weave AI 3044gsm IM7 12K NCCEF JQ3250400

WNC UD 270gsm IM7 12K NCCEF DV8561000

Plain weave 225gsm Aksa A38 3K IC/NCCEF PC6791087

Plain weave 230gsm Toray T700 12K 50C IC/NCCEF DV5081050

DATACOMP Materials – Phase 2

Textile Areal weight Reinforcement fibres Received Material Code

Woven ST/S2 glass 400gsm T700SC 12K 50C/406 tex S2 IC ST008/DV845

Thermoplastic NCF 376gsm T700GC 12K 31E AGC DMC4721270

Thermoplastic NCF 410gsm T700GC 12K 31E WMG DMC4711270

Hybrid 2D woven 1 520gsm Vectran1670dtex/T700SC 12K 50C IC DV9081000

Hybrid 2D woven 2 510gsm Innegra2800 denier/T700SC 12K

50C

IC DV9101000

Hybrid 2D woven 3 540gsm E glass 408tex/T700SC 12K 50C IC DV9091000

NCF +/-45 stitch study

x3

343gsm Zoltek Panex 35, 50K AXON DMC4851270_DMC

4861270_DMC4871

270

SigmaRF 360gsm RF:PP

DATACOMP Outcomes

A stronger UK supply chain for composites materials

• New material systems

• Equipped testing capabilities

• Simulation expertise for crash modelling

• Materials data management for qualification

Materials Database for composites crash information

• Fully traceable material and process pedigree

• Importers

• Gateways to CAD, CAE, FE (e.g. Hypermesh)

• Qualification implementation package

• Raw and analysed test data

• Analysis tool for material property and behaviour evaluation

• Design allowables

• Material cards for simulation

DATACOMP

Thank you!

Dr. Donna Dykeman

Granta Design Ltd.

Donna.Dykeman@grantadesign.com