*mat 4a micromec micro mechanic based material model

© 4a engineering GmbH, all rights reserved

*MAT_4A_MICROMEC

micro mechanic based material model

P. Reithofer1, A. Erhart2, A. Fertschej1, S. Hartmann2, B. Jilka1

14a engineering GmbH, 2Dynamore GmbH

4a engineering GmbH

Industriepark 1

A-8772 Traboch

[email protected]

++43 (0) 664 80106 6015. – 6. April 2017, Hanau

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Autor: Peter Reithofer, Artur Fertschej, Bernhard Jilka

Datum: 170406

Titel: rep_17040601_pr_afer_bj1a_gga_MAT215.ppt


Content

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▪ Introduction

▪ Simulation process chain

▪ Constitutive material models in LS-DYNA

▪ *MAT_215 - *MAT_4A_MICROMEC

▪ mean field homogenization

▪ Keyword format

▪ verification

▪ validation

▪ CPU time

▪ Case studie

▪ Conclusion


Introduction4a engineering GmbH

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polymer and materials science

numerical simulation methods

fiber reinforced plastics and composites

method and software development

material characterization

product development

strut bar:

LH2 – tank mounting:


Introductionplastics in typical automotive applications

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Exterior [1] Interieur [2]

PBTGF30PA6GF30 PPGF30 PPLGF30


longitudinal

1 m/s

0.001 m/s

perpendicular

1 m/s0.001 m/s

Raw material data

provided by Celanese

e.

Raw material data


a11

longitudinal

diagonal

perpendicular

1 m/s

Raw material data


jPP GF50

PP GF40

PP GF30

1 m/s

-30 C

+23 C

+80 C

Raw material data


T

1 m/s

Introductiontypical behavior – bending test

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Introductiontypical SFRT

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average orientated

Back door [3]

02,000

011,00

0087,0

ija

02,000

032,00

0066,0

ija


Material models in LS-DYNAconstitutive approach

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*MAT_024

▪ quick & dirty

▪ Mises plasticity

*MAT_187 (*MAT_124)

Plastics

SHELL or TET10

*MAT_022/

*MAT_054/058

▪ orthotropic elastic

▪ Damage

Composite

a

COMPOSITE (PLY)

*MAT_002

▪ orthotropic elastic

*MAT_157

▪ orthotropic

▪ elastic viscoplastic

▪ Hill plasticity

SFRT / LFRT

a

aa

INITIAL_STRESS

a – orientation dependent


Simulation process chain For injection molded parts

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fiber orientation

02,000

032,00

0066,0

ija

Injection molding (Moldflow, Moldex, …)

micromechanic modeling(4a micromec, …)

anisotropy

Mapping(4a fibermap, …)

Mapping in thickness direction

In plane mapping

Crash Simulation(LS-DYNA)

orientations

standard material models

*ELEMENT_SHELL_BETA

*MAT_(ANISO)TROPIC_ELASTIC

*ELEMENT_SHELL_COMPOSITE

*INITIAL_STRESS_SHELL(SOLID)

*MAT_ANISOTROPIC_ELASTIC_PLASTIC

Str

uc

tura

l S

imu

lati

on

Material ModelMean Field

homogenization

MFC

jj 1

*MAT_215

Standard Material

Model

Hill Plasticity

a

*MAT_157a


Standalone product

*MAT_215 - *MAT_4A_MICROMECmean field homogenization

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MFC

jj 1

C...composite, F...fiber, M...matrix

Comparison by University of Leoben [4]

since 1999


Library


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Standalone product

MFC

jj 1


*MAT_157

calculate parameter for

constitutive law



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Library4a impetus

Standalone product

usermaterial

MFC

jj 1


assumption elliptical inclusion

(Eshelby Tensor )

Main FrameworkMori Tanaka Mean Field Theory

Composite stresses, strains (i)

Matrix stresses, strains

Fiber stresses, strains

Failure, Damage Criteria

Composite stresses, strains (i+1)

Yield condition J2 PlasticityIsotropic Harding

Table Lookup or

Parameter Setup

plug ablepossible extensions

other plasticity formulations, ....

Main FrameworkMori Tanaka Mean Field Theory

Composite stresses, strains (i)

Matrix stresses, strains

Fiber stresses, strains

Failure, Damage Criteria

Composite stresses, strains (i+1)

MC

Mi

F

T

Mi

Mpl

MT

M

M

C

i

M

FMC

IA

CBSA

dlEfofB

E

IB

jj

ee

ejj

e

eee

1

,,

,,

1

1

,

1

)4(1

matrix

fiber



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Library4a impetus

Standalone product

usermaterial

*MAT_4A_MICROMEC *MAT_215

matrix:

▪ isotropic elastic

fiber:

▪ transversal

isotropic elastic

Composite

COMPOSITE (PLY)

*MAT_215

matrix:


viscoplastic

(like *MAT_024)

fiber:


SFRT / LFRT

INITIAL_STRESS


*MAT_215 - *MAT_4A_MICROMECKeyword format

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CARD 1: General Options / Parameter

CARD 2-3: Element orientation*

q1

q2

CARD 4: Composite Buildup*Card 4 1 2 3 4 5 6 7 8

FVF FL FD A11 A22

PP GF30 -0.3 200.0 10.0 0.7 0.25

PP LGF50 -0.5 1000.0 20.0 0.65 0.30

PA6 GF45 -0.45 250.0 10.0 0.8 0.15

Carbon UD 0.6 10000.0 10.0 1.0 0.0

*may be overwritten by *INITIAL_STRESS_SHELL/SOLID

analog to LSDYNA standard anisotropic material cards

FVF > 0: fiber volume fraction Composite

FVF < 0: fiber mass fraction SFRT/LFRT

exemplary values without any warranty



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CARD 5: fiber material

Card 5 1 2 3 4 5 6 7 8

FIBER ROF EL ET GLT PRTL PRTT

UNITS kg/mm³ GPa GPa GPa - -

glass 2.59E-6 70.0 70.0 28.8 0.217 0.217

T400 1.76E-6 218.8 28.0 50.0 0.02943 0.390

Standard values from literature

glass fiber (isotropic) T400 (transversal isotropic)




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CARD 7-8: matrix material

Card 7 1 2 3 4 5 6 7 8

Matrix ROM E PR

Units kg/mm³ GPa -

PP 0.9E-6 1.5 0.4

PA6 dry 1.2E-6 3.2 0.35

PA6 cond. 1.2E-6 2.0 0.35

from material characterization (e.g. 4a impetus MPIP)

Card 8 1 2 3 4 5 6 7 8

Matrix SIGYT ETAN EPS0 C

Units GPa GPa - 1/ms -

PP 0.015 0.5 1.E-6 10

PA6 dry 0.06 1.0 1.E-6 15

PA6 cond. 0.04 0.8 1.E-6 10


visco

plasticity

Bilinear

+ Johnson

Cook

elasticity



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CARD 9: matrix material tablesCard 9 1 2 3 4 5 6 7 8

Variable LCIDT LCDI UPF

Type F F F

Default 0 0 0.0

h

ef

ep

vm

Hardening Damage Initiation

LCIDT Effective stress (Table)

LCDI Damage initiation (Table)

UPF Damage evolution parameter

h

upf

Damage Evolution


100% fiber ✓

100% matrix ✓

100% fiber ✓

✓60% fiber

*MAT_215 - *MAT_4A_MICROMECVerification – 1-Element tension test

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x

y

y

x

x,y

uxa



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x

y

y

x

x,y

uxa

a 0°✓

a 90°✓

✓ ✓



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x

y

y

x

x,y

uxa

DOE with LS-OPT: MATRIX: PP

FIBER: GLASS

FVF: -0.05;-0.15;-0.20;-0.25;-0.30;-0.35;-0.40;-0.50;-0.60

FL: 100;200;500;1000

A11: 0.6;0.7;0.8;0.9

a: 0 ;15 ;30 ;45 ;60 ;75 ;90

✓RUNS without an Error


*MAT_215 - *MAT_4A_MICROMECMaterial characterization

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sta

tic

dynam

ic

dynam

ic

sta

tic

dynam

ic

sta

tic

dynam

ic

sta

tic

dynam

ic

comment

*MAT_024Materialcard for each

direction

*MAT_157

*MAT_215µCT

validationtension puncturebending

tension

dominated

bending

and/orv, mp

h

ef

ep

vm

Upcoming ISO

Plate 120 x 80 x 2 mm

injected samples

component validation

a 0/45/90

h

ef

ep

vm

q1

q2



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a 0/45/90

h

ef

ep

vm

q1

q2

Puncture

Bending



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Bending 2m/s

longitudinal

diagonal

transversal

···· averaged test curves

result of simulation


a 0/45/90

h

ef

ep

vm

q1

q2


Case study DoublecrossribUsing *MAT_215

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*MAT_215 - *MAT_4A_MICROMECCPU TIME per integration point (SMP 1 CPU)

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0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

*MAT_024 *MAT_SAMP-1 *MAT_157 *MAT_215

1.0

2.2

1.6

3.2

1.7

1.91.9

3.2

1.6

2.1 2.1

4.2Shell TYP16 9 IP 2mm

Solid TYP16 2 LAYER 2 mm

Solid TYP16 5 LAYER 1 mm

▪ *MAT_215 - possible improvements

▪ timestep calculation (conservative implementation)

▪ compiler options – Optimizations for Cluster

▪ …

TET10

TYP16

5 LAYER

TET10

TYP16

2 LAYER

SHELL

TYP16

Actual

tests

Current

implementation


Summary

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*MAT_157 *MAT_215

Solverimplicit/explicit

R9/R8

Explicit

R10

CPU TIME vs.

*MAT_0242x slower

4x slower

ongoing improvement (2x)

Material model Composite (HILL)Mean Field

Homogenization

Material model

parametersat least 20 at least 10

Failure/DamageComposite

properties

Matrix and

Fiber criteria

Mapping Material propertiesFiber orientation &

content, aspect ratio

Ease to use -* +

* Check input not really possible


Outlookongoing testing / validations

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and hopefully many of your applications …

Nutini Box [4] [5]

Hirtenberger Automotive

Safety GmbH & Co KG

Bosch Automotive Products

(Suzhou) Co., Ltd


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„in physics we trust”

Thank you for your attention!


Literature

[1] R. Luijkx - Kunststoffmaterialien in der Interieur Funktionsauslegung bei Audi AG, 4a

Technologietag 2010 (Link)

[2] H. Staack, A. Koukal (Audi AG) – Anforderungsgerechte Materialund Bruchmodellierung für

die Fahrzeugsicherheit, 4a Technologietag 2016 (Link)

[3] P. Reithofer, B. Jilka, A. Fertschej (4a engineering GmbH) – 4a micromec für die integrative

Simulation faserverstärkter Kunststoffe, NAFEMS Deutschsprachige Konferenz 2014,

Bamberg (Link)

[4] Ch. Bodor¹, R. Brunner², R. Jördis², D. Tscharnuter³, H. Erlach4; (1Lehrstuhl für Spritzgießen,

Montanuniversität Leoben, ²Materials Center Leoben, ³PCCL GmbH, Leoben, 4Mahle

Filtersysteme Austria GmbH) - Kopplung μCT und FEM Berechnung, 4a Technologietag 2014

(Link)

[5] R. Jennrich, M. Roth, Prof. S. Kolling (Technische Hochschule Mittelhessen),

C. Liebold (DYNAmore GmbH),G. Weber (Celanese GmbH) –

Experimentelle und numerische Untersuchung eines kurzglasfaserverstärkten Kunststoffes,

13. LS-DYNA Forum 2014, Bamberg (Link)

[6] P. Reithofer , B. Jilka, S. Hartmann (4a engineering GmbH), T. Erhart, A. Haufe (DYNAmore

GmbH) - Short and long fiber reinforced thermoplastics – material models in LS-DYNA, 10th

European LS-DYNA Conference 2015, Würzburg (Link)

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http://technologietag.4a.co.at/images/tt2010/08_Luijkx.pdf

http://technologietag.4a.co.at/images/tt2016/tt16_t1_v04.pdf

http://impetus.4a.co.at/images/downloads/events/04_rep_14060301_pr_afer_bj1a_gga_MICROMECNAFEMS2014.pdf

http://technologietag.4a.co.at/images/tt2014/s5av2_Bodor.pdf

http://www.dynamore.de/de/download/papers

http://impetus.4a.co.at/images/downloads/events/16_15072101_afer_pr_gga_DynaforumFIBERPresentation+Longversion.pdf

*mat 4a micromec micro mechanic based material model

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