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