atoast multiphysics multimaterial and or composite cae design

ATOA Scientific Technologies Multiphysics CAE for Innovation TM

Multiphysics and Multimaterial Design with COMSOL Dr Raj C Thiagarajan, PhD

ATOA Scientific Technologies Pvt Ltd

05 APR 2013

Visit

http://www.comsol.co.in/events/953/multiphysics-and-multimaterial-design-with-comsol/
















ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar

[email protected]

2

• Raj C Thiagarajan, MD of ATOAST, Currently providing Multiphysics CAE Design Services for Industrial Innovation.

• Computational mechanics and composite product development since 1988

• ATOA Scientific Technologies is a leading Multiphysics CAE Solution provider

• First COMSOL certified Consultant from India.

www.atoa.com

http://in.linkedin.com/in/ctraj

http://in.linkedin.com/in/ctraj


INTRODUCTION

3

Engineering Design

Multimaterial Multiphysics

Innovative Product

Engineering is Conversion of Material into Useful Product

Industrial Drivers: Cost, Weight and Performance

CAE product development for first time right

Multimaterial and Multiphysics for Optimal Design


Overview

4

Multiphysics Product Design

Materials

• Engineering Materials

• Materials in product design

Multiphysics design of Material

• Composite mechanics

• Examples: CFRP

Focus: Product and Material Design Link

Material Design/ Mechanics

Multiphysics Product Engineering

Composites Multimaterials


Nature & Multifunctional Composites

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• Nature uses simplest material in optimal form for efficient function.

• Composites are used for single functionality ~ 80% structural

• The future growth is expected from multifunctional composites.

• The availability of Multiphysics modeling capability will accelerate adaptation of Multifunctional composites.


Engineering Materials

6

• Conventional Engineering Materials

– Metals

– Ceramics

– Polymer

– Cellular and

– Natural Materials

• Composite Designer Materials

• Emerging Materials

– Smart

– Nano

– Meta


Composites Multi

Material

Advanced Materials

Noble Aluminum Steel

Multimaterial Product Design

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• From “ All steel” , “All Aluminum ” All Composites” To Multimaterial

• Leverage the best of material for product performance.

• Challenges

• Fabrication

• Multiphysics

• Multifunctional

High COST Low

Hig

h

W

EIG

HT

Lo

w

Performance: High


Composites

8

• Combination of any two are more materials to perform better than individual constituents.

• Macroscopically (n scale) homogeneous and microscopically (n-1 scale) heterogeneous.

• Composite principle can be applied to multimaterial at macro scale.


Co

nsti

tue

nts

Fibers: Glass, Carbon, Kevlar, HDPE, SiC, Boron,

Matrix: Polymer, Metal, Ceramic

Polymer matrix: Thermoset, Thermoplastics

Thermoset: Epoxy, Vinyl Ester, Polyester, Polyimides

Thermoplastics: PP, PMI, PEI, PEEK, PES, PC,ULTEM

Inte

rme

dia

tes

Semi Finish:

Prepregs

Comingled/ Cowoven

Sheet/bulk molding compounds

Reinforced pellets

Intermediates:

Pultruded rods

Laminates

Sandwich panels

Composite films/fabrics

De

sig

n a

nd

Pro

ce

ssin

g

Design: Constituents, Ply, laminate, product , process and life

Polymer: PMC:

Hand layup, Spray up, Resin Transfer Molding, Autoclave Molding, Filament, Tape Winding, Pultrusion, Compression Molding, Injection Molding, Thermoforming.

Co

mp

osit

e A

pp

lica

tio

ns

Aerospace

Automobile

Transportation

Consumer

Industrial

Medical

Packaging

Oil and Gas

Energy

Electronics

Infrastructure

Mining

Aft

er

Se

rvic

e

Smart Structural health monitoring,

Condition monitoring

maintenance,

Repair,

Retrofitting of composite products

Composite Industry Value Chain

• Simulation tools are use at every stage of value chain

• We shall focus on the Material Design of composite products

Reinforcement

Matrix

Semi-Finish Intermediate

Design

Processing

Composite

Products

After

Service

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Type of Composites

• Particulate Composites

• Short Fiber Reinforced

composites

• Long Fiber Reinforced

composites

• Continuous Fiber reinforced

composites

• Multimaterial

Pe

rform

ance

Param

eter (Stre

ngth

, Stiffne

ss..)

Typical P

roce

ssing co

st

Macro Composites Metal polymer hybrids Sandwich structures Metal hybrid picture from Injection molding,

www.plastictechnology.com, pp11.

Constituents Form Physics Load: Static Dynamic Time Results: Singlepoint Multipoint

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Material Design/Property Prediction

11

• Additive

• Product

• Super

– Stiff and tough

– Ultra low weight

• Meta

– Beyond Nature

Nano

Micro

Macro

After US 7838108

Vf

No

rmal

ized

Pro

per

ty

Material 1 Material 2

Metamaterials


COMPOSITE Material Modeling

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• Analytical

– Rule of Mixtures

• Micromechanics

– 2D/3D

• Lamination Theory

– Ply, Laminates

• Product performance

– Multiphysics

• Failure mechanics

– Damage, progressive failure

• Analytical tools

• Micromechanics codes

• Classical Lamination Theory

• General purpose FEA

software

• COMSOL for composite modeling


COMSOL Example CFRP Composites

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• Structure

• Part

• Laminate

• Fiber

• Matrix

• Molecular

• ATOMIC

0.3345 nm

0.142 nm

0.669 nm

c

ba

• Carbon T300 / Epoxy 914

• Multiphysics – Structural+ Electrical

– Structural + Thermal

– Damage Mechanics

– Structural Health Monitoring

• Micromechanics – UD composites

– Particulates

– Laminates

• Constituent – Graphene Sheet

– Carbon fiber


Structural

Thermal

Electromagnetic

Acoustic

COMSOL Modeling Steps

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• Select a suitable physics (Governing, Constitutive equation)

• Model a representative volume with periodic boundary condition

• Develop Global/macro and Local/ micro relationship (Virtual Testing)

• Solve and post process for Material property prediction.

Eε ε jEω) ε ε (σJ '

r0

"

r0 t

H

t

EE

Ex Hx


Micromechanics

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• Continuum Micromechanics based on homogenization theory

• Aims at finding a volume elements (Representative Volume Element – RVE, periodic Micro field- PMA response to prescribed macro response)

• Prediction of macro properties from micro structure and constituents.

Localization relationship

Micro fields

Macro fields

Homogenization relationship Where,

W volume, G-surface,

u(x)– deformation vector t(x)– surface traction vector nG – surface normal vector

Homogenization Theory/ Methods

• Mean Field Theory

• Variational Bounding methods

• RVE (Representative Volume Element) or PMA ( periodic Micro field)

• Generalized Method of Cells

• Embedded Cell

• Windowing Approach

• Variational Asymptotic Method

• Multiscale Models


Representative Volume

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• Square Array

• Hexagonal Array

• Random

Micrograph -> Image map -> Material properties


Numerical Implementation 2D

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• Periodic boundary condition

• u xl= u x0 + ex

• v yl= u y0 + ey

• Load

• Body force

• Global (macro) vs local (micro) stress and strain

• Integration of variables

• Parametric model to predict the stress strain behavior


2D Results

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• Isotropic property prediction

• Polymer composite anisotropic property prediction

• Macro performance

• Micro mechanical exploration for novel materials


2D Results CFRP

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• T300, Epoxy914, Vf 60%

• Quarter segment

• Periodic BC

• Global vs Local

• Transverse Modulus

• Experiments :

8.96+0.06 GPa

• COMSOL:

9.127 GPa

T300 Carbon Fiber

Matrix Epoxy

914


2D Random Results

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2D: Thermo Elastic Performance

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• Design of a Dynamic Thermal conductivity Material

• Thermal Insulator to conductor

• Coupled Thermo elastic Analysis + DoE: Commercial Materials, Vf, packaging

• Virtual Design of novel Thermal material

0 80

100


3D RVE

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• Reinforcement shapes

– Fiber

– Whiskers

– Flakes

– Platelets

– Spherical Particles

• Regular or Random

• Create your own 3D RVE using geometrical modeling tools


3D Results

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• CFRP UD: 60% Vf

• T300 /Epoxy 914

• Longitudinal Modulus

• Experiments :

140+1.2 GPa

• COMSOL:

139.04 GPa

• Transverse Modulus

• Experiments :

8.96+0.06 GPa

• COMSOL:

9.095 GPa


Nonlinear Performance

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• Elasto Plastic Performance polymer matric composites

• Polycarbonate + Glass

Strain

Stre

ss


COMPOSITE Damage Mechanisms

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• Self sensing of Carbon fiber composites

• Good Thermal and Electrical Conductor

• Fiber

• Fiber breaks

• Matrix

• Matrix crack

• Interface

• Delamination

• cracks

(d)

(a)

(b)

(c)


Numerical investigation

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• The electrical conduction mechanism and the effect of damage in CFRP composites were simulated in COMSOL using AC/DC Electric Currents Interface.

• Homogeneous composite model with effective properties

• Micromechanical model with constituent properties


Results : Fiber breaks

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• UD composites

• Electrode on edge

• Resistance change vs fiber breaks

• Parallel resistance model behavior

• Very sensitive to fiber breaks.


Results: Matrix Cracks

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• Matrix crack density vs change in resistance

• Can detect matrix cracks also


Results : Delamination

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• Delamination length vs resistance change.

• Delamination growth between fibers


Negative refraction

Electrostatic resonance

Composite cloaks

Acoustic super lens

Summary

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• Materials, Multiphysics product design

• Micromechanical modeling with COMSOL

• 2D and 3D modeling method and results

• CFRP Simulation vs Experiments -> good

• Design for Multiphysics and Multimaterial is the way forward for First time Right Product Design

• Refer COMSOL CONFERENCE PAPERS for more

• Visit for the Presentation @

• http://www.comsol.co.in/events/953/multiphysics-and-multimaterial-design-with-comsol/














Abstract

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• Engineering structures are inherently multimaterial and multiphysics in nature. However, they are usually designed for dominant physics. Recent development at PDE level model and software allows us to design for Multiphysics and Multimaterial. This webinar will give an overview of multiphysics and multimaterial mechanics. The computational design of material and prediction of structural, thermal, acoustics, and electromagnetic properties will be detailed. The macro, micro, and nano scale effects of composites will also be highlighted. The link between multiphysics engineering application and the design of material will be detailed.

atoast multiphysics multimaterial and or composite cae design

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