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Dr Gasser Abdelal

VEC Workshop 201125/26 October 2011

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PRODUCTION PROCES

SIMULATION

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COMPOSITES

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Virtual Manufacturing - Composites

Objectives of Composite Manufacturing Simulation

Early estimation of Mechanical and Thermal propert

Optimize the manufacturing process and/or (fibre

weave layout) to improve strength, fatigue, weight.

Theoretical and Numerical Tools:

Micromechanics theory [homogenization Finite ele

TEXGEN [2D & 3D Weave CAD].

ABAQUS [FE tool] + Material Subroutines.

Multi-Scale Finite Element [Macro Micro (RVE)].

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Virtual Manufacturing - Composites

Building Experience Through Case Studies

Case 1

Autoclave cure simulation (unidirectional composites).

ABAQUS (FE) [Thermal/Chemical module + Sequential Stress Analysis]applying Micromechanics.

Case 2

Estimation of Mechanical and Thermal properties 2D & 3D weavecomposites laminatesusing RVE (Representative Volume Element).

TEXGEN + ABAQUS (using Python to apply Periodic boundary conditions).

Case 3

Applying Multi-Scale (Macro-Micro) Finite Element method to estimateproperties of 3D complex composite structure (landing gear).

Autoclave cure of 2D woven composites applying Multi-Scale FE.

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VEC Workshop 2011

We need Real Test Cases to

verify our numerical

approach

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METALLIC - PLASTICS

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Virtual Manufacturing

Metallic

Objectives of Metallic-Plastics Manufacturing Simulatio

Choose between different design variants to fit both

criteria and your cost.

Optimize the manufacturing process to improve strefatigue, weight, and reduce cost.

Theoretical and Numerical Tools:

ABAQUS [FE tool] + Material Subroutines.

Isight v5 for Surrogate, Sensitivity analysis, and Opt Multi-Scale Finite Element [Macro Micro (RVE)].

HPC for high speed computing.

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Virtual Manufacturing - Metallic

Case 1

AIRBUS

Riveting Simulation of Large Aircraft Panels.

ABAQUS (FE) [Coupled Thermal/Stress analysis nonlinear material models].

Developed 2 Surrogates that can be used in Optimization [either Manufacturing process orDesign Parameters].

Case 2MAST

Studying different design variants of medical products using Injection molding.

Objective is to achieve better performance with minimum cost.ABAQUS (FE) explicit solver with contact analysis.

Case 3CGYNET

Verify mechanical design strength of an offshore structure products using ABAQUS (FE).

Case 4VEC

Shot Peen Simulation of metallic panels.

ABAQUS (FE) explicit solver nonlinear material models Isight.

Objective: effect of shot peen process on residual stress caused by other manufacturing processdevelop a Surrogate.

VEC W k h 2011

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WHY COME TO VEC ?