Dr Gasser Abdelal

VEC Workshop 2011

25/26 October 2011

VEC Workshop 2011

PRODUCTION PROCESS SIMULATION

VEC Workshop 2011

COMPOSITES

VEC Workshop 2011

Objectives of Composite Manufacturing Simulation Early estimation of Mechanical and Thermal properties. Optimize the manufacturing process and/or (fibre matrix weave layout) to improve strength, fatigue, weight. Theoretical and Numerical Tools: Micromechanics theory [homogenization Finite element]. TEXGEN [2D & 3D Weave CAD]. ABAQUS [FE tool] + Material Subroutines. Multi-Scale Finite Element [Macro Micro (RVE)].

Virtual Manufacturing - Composites

VEC Workshop 2011

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 weave composites laminates using RVE (Representative Volume Element). TEXGEN + ABAQUS (using Python to apply Periodic boundary conditions).

Case 3

Applying Multi-Scale (Macro-Micro) Finite Element method to estimate properties of 3D complex composite structure (landing gear). Autoclave cure of 2D woven composites applying Multi-Scale FE.

Virtual Manufacturing - Composites

VEC Workshop 2011

We need Real Test Cases to verify our numerical approach

VEC Workshop 2011

METALLIC - PLASTICS

VEC Workshop 2011

Objectives of Metallic-Plastics Manufacturing Simulation Choose between different design variants to fit both your criteria and your cost. Optimize the manufacturing process to improve strength, fatigue, weight, and reduce cost. Theoretical and Numerical Tools: ABAQUS [FE tool] + Material Subroutines. Isight v5 for Surrogate, Sensitivity analysis, and Optimization. Multi-Scale Finite Element [Macro Micro (RVE)]. HPC for high speed computing.

Virtual Manufacturing Metallic

VEC Workshop 2011

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 or Design Parameters]. 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 2 MAST

Case 3 CGYNET

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

Case 4 VEC

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 process develop a Surrogate.

Virtual Manufacturing - Metallic

VEC Workshop 2011

WHY COME TO VEC ?