Marinus Schouten 06-2006 EADS-Corporate Research Centre 1
Integrated Tool for Simulation of Textile Composites
SIXTH FRAMEWORK PROGRAMMEProposal no.: 516146
Aerodays Vienna June 2006
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 2
General objectives
• Objectives– Development of an adequate integrated simulation tool for braids,
advanced engineering textiles, weaves and stitched textiles– Simulation along the process line – Establish a virtual manufacturing chain
• Approach– Linking and integration of different stand-alone solutions – Open flexible interface for fluent data exchange and communication – Set up a standard for testing, modeling and simulation – Application/validation examples in Aeronautics – Summarized in guidelines, design rules and educational tools
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 3
• EADS Germany• Alenia Aeronautica S.p.A.• Cranfield University• Dassault Aviation• German Aerospace Center• EADS Corporate Research
Center France• ESI Software• University of Stuttgart• University of Aachen• University of Leuven• INSA University Lyon• SISPRA• University of Zaragoza
Partners involved
IFB
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 4
Simulation chain
Micro Meso
Modelling
Braiding
Stitching
Draping Impregnation Curing
Spring backImpact
BehaviourCrash
behaviour
Static
BehaviourToolingHandling
Repair
Textile Process Textile Integration Impregnation Curing Loading
Micro Meso
Modelling
Braiding
Stitching
Draping Impregnation Curing
Spring backImpact
BehaviourCrash
behaviour
Static
BehaviourToolingHandling
Repair
Textile Process Textile Integration Impregnation Curing Loading
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 5
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 6
Project overview
I/O interface Tool interface GUI
WP5: IntegrationWP1
: Mat
eria
l Cha
ract
eris
atio
n
Mat
eria
l cha
ract
eris
atio
nD
ataT
ool
WP2
: 3M
Mec
hani
cs
Mic
roM
eso
Mac
ro
WP3
: Pro
cess
Sim
ulat
ion
Text
ile P
roce
ssD
rapi
ngIn
filtra
tion
WP4
: Ext
erna
l Loa
ding
Beh
avio
ur
Failu
reS
tatic
S
treng
thIm
pact
&
Cra
sh
WP6
: Ind
ustr
ial v
alid
atio
n / t
est
WP7
: Des
ign
Gui
delin
es /
Stan
dard
isat
ion
I/O interface Tool interface GUI
WP5: Integration
I/O interface Tool interface GUI
WP5: IntegrationWP1
: Mat
eria
l Cha
ract
eris
atio
n
Mat
eria
l cha
ract
eris
atio
nD
ataT
ool
WP1
: Mat
eria
l Cha
ract
eris
atio
n
Mat
eria
l cha
ract
eris
atio
nD
ataT
ool
WP2
: 3M
Mec
hani
cs
Mic
roM
eso
Mac
ro
WP2
: 3M
Mec
hani
cs
Mic
roM
eso
Mac
ro
WP3
: Pro
cess
Sim
ulat
ion
Text
ile P
roce
ssD
rapi
ngIn
filtra
tion
WP3
: Pro
cess
Sim
ulat
ion
Text
ile P
roce
ssD
rapi
ngIn
filtra
tion
WP4
: Ext
erna
l Loa
ding
Beh
avio
ur
Failu
reS
tatic
S
treng
thIm
pact
&
Cra
sh
WP4
: Ext
erna
l Loa
ding
Beh
avio
ur
Failu
reS
tatic
S
treng
thIm
pact
&
Cra
sh
WP6
: Ind
ustr
ial v
alid
atio
n / t
est
WP7
: Des
ign
Gui
delin
es /
Stan
dard
isat
ion
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 7
Current project status: WP1: Material Characterisation / DataTool• WP1: Material characterization
– Selection of relevant data for:Dry textilesImpregnated composites
– Data ToolDescription of the Data Tool Implementation of example cases in the Data Tool
– Sub tasks1.1 Selection of relevant data1.2 Structure of the Data Tool1.3 Collection of data
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 8
Current project status: WP2: 3M mechanics
• WP2: 3M mechanics– Development of the models on Micro and Meso
levelGeometry of fiber and yarn placement in 3d reinforcementsHomogenized mechanical properties of the unit cell of textile compositeDamage initialization and development
– provide input to models of textile deformability and external loading behavior of composite part
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 9
Current project status: WP2: 3M mechanics (cont.)
• WP2.2 Meso level geometrical models– 3D braids
Braid3DTex tool development– Structural stitching
model development• WP2.3 Micro – Meso Homogenization
– models are selected and being implemented in FE
• WP2.4 Meso – Macro Homogenization– theoretical foundations ready
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 10
Current project status: WP3: Process Simulation
CABRun example
• WP3: Process Simulation– ‘virtual manufacturing’ chain
for textile composites process simulation = central task
– Main targetsdrapability behavior Impregnation simulation
– Sub tasks3.1 Development of concepts for a process simulation for NCF, sewing/stitching, 2d-braiding.
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 11
Current project status: WP3: Process Simulation (cont.)
• WP3.2 : Draping simulation– Identification of meso-macro mechanical
behaviour (LaMCoS)biaxial tension experimentsin-plane shearing experimentsvirtual experiments (FE)
– Definition of numerical tools and specific finite elements for fabric forming simulation (LaMCoS)
continuum and formulation approaches
– Simulation of forming behaviour of a deformed dry textile ongoing (CCR)
• WP3.3 : Mould filling simulation– Development and test of some new
computational methods (ESI)
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 12
Current project status: WP4: External loading behaviour– On macroscopic level
structural behaviordeformationstress and failure modeling WP4.1 Stress analysis and quasi-static failure criteria
– Failure model for 2D triaxial braided composites (ALA)
– Experimental failure and damage analysis of UD-braids (EADS-G)
– implementation of homogenisation and damage routines in MSC.Marc (EADS-G)
– Development of validation procedure for a failure criterion for 3d reinforced textile composites (DLR)
• WP4.2 Impact and crash simulation– Development of new test procedures for dynamic material
data collection + simulation of these test procedures (CRAN)
UD-braid
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 13
Current project status: WP5: Integration
• WP5: Integration
– Main ITOOL concept = integration
– TargetEnsure the fluid interaction of the different WP solutionsminimize user interferenceData interchanging has to go with minimum friction and critical data loss
– Sub tasks5.1 Evaluation of the different tools5.2 Data handling5.3 Design of a graphical user interface for the ITOOL
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 14
Current project status: WP6: Industrial validation / TestDAS
ALA
EADS-G
• WP6: Industrial validation / Test– “industrial" acceptance of the integrated
simulation tool – test the whole simulation chain on a finished
composite partsimulation of the textile production prediction of meso/macro propertiesdrapability behaviorimpregnation FE-analysis
– Sub tasks6.1 Specification of test cases6.2 Manufacturing of the parts and testing6.3 Tool chain proof on defined test cases6.4 Cost benefit analysis
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 15
Current project status: WP7: Design guidelines / standardizations
• WP7: Design guidelines / standardizationsObjectives– allow textile and composite engineers to evaluate
major factors of influence and to design optimized structures.
– Development of philosophies for a standardization of test procedures and textile processes
– Bases on realistic, exemplary components.
Sub tasks– 7.1 Definition of structural elements – 7.2 Analysis of potential and limitations of textile
processes – 7.3 Development of design guidelines – 7.4 Evaluation based on realistic applications– 7.5 Generation of philosophies for standardization
ITOOLIntegrated Tool for Simulation of Textile Composites
Marinus Schouten 06-2005 EADS-Corporate Research Centre 16
Visit us on:
www.itool.eu
Thank you