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Engineering Plastics
Stamping Process Integration of
Composites in Crash Analysis
Solvay Engineering Plastics
Expert in crash simulation
Technyl Innovation Center
Cécile DEMAIN
ATC – 23 et 24 avril 2013
Summary
• SOLVAY / RHODIA
• EVOLITE Offer:
• composite TP with continuous reinforcement
• process
• Stamping process integration in crash analysis
• the stamping simulation
• Crash analysis
• Comparison between standard and integrative approach
• Example composite post-processing
• Ply orientation
• Number of plies failed
• Conclusion
ATC – april 2013 2
Creating a major Chemistry player
September 2011, SOLVAY acquired Rhodia
Offering a broad range of products that
contribute to improving quality of life and
the performance of its customers
World leader with 90% of sales in markets
where it is among Global Top 3
A strong commitment to sustainable
development with a clear focus on
innovation and operational excellence
Diversified end-use markets
Global Top 10 Chemical company
29,000 EMPLOYEES
€12.7bn NET SALES
110 MAJOR
INDUSTRIAL
SITES
€2.1bn REBITDA
€825m NET INCOME
ATC – april 2013 3
Developing sustainable solutions for the future
Research and development
Strengthening our innovative capabilities
External partnerships
Academic, start-ups and venture capital
funds to create synergies
Guaranteeing a seamless link between
fundamental and applied research
6 major innovation themes aligned
with megatrends:
sustainable energy solutions
renewable chemistry
nanotechnology & advanced materials
eco-efficient processes
organic electronics
consumer chemicals
1,700 R&D
EMPLOYEES
322 NEW PATENTS
IN 2011
12 MAJOR
R&D CENTERS
€54m IN
VENTURING
€274m R&D
ATC – april 2013 4
Over 40% of sales from high-growth
countries
North
America
17% 25 PRODUCTION
SITES
5 R&D
SITES
Western
Europe
43% 40 PRODUCTION
SITES
11 R&D
SITES
Latin
America
14%
10 PRODUCTION
SITES
1 R&D
SITE
Asia-Pacific
26% 35
PRODUCTION
SITES
3 R&D
SITES
based on 2010 pro forma figures
110 production sites
A global leader with a sustainable and profitable growth
strategy
ATC – april 2013 5
Stronger together / a complementary product offer
Solvay Specialty Polymers
Engineering Plastics
Solvay Vinyls
ATC – april 2013 6
Today’s applications Mid- to long-term potential applications
Mature Growing Breakthrough
Car Structure Seat Structure
Fuel Tank
Pedals
Air Intake Manifold
Front End Engine Support
Oil Pan Fuel Filler Pipe
*Source: A2Mac1 / Rhodia estimates
CO2 reduction through lightweight solutions
Recyclability
Cost-efficiency
Why using composite TP ? Polyamide: a proven technology to save weight
ATC – april 2013 7
130g CO2/km under homologation
Target 95g
CO2/km >100kg weight saving
PA composites PA compounds
Why using composite TP ? EvoliteTM – Solvay’s answer to breakthrough weight reduction
Solvay polyamide
tailored for
composites
Glass or Carbon
ATC – april 2013
8
Parts
Automatic UD tapes
positioning in a mold (robot)
Filament winding
Stamping
Thermoforming Process
With partnership
• Thermoforming examples
ATC – april 2013 9
Process of a composite TP
ATC – april 2013 10
Process of composite TP
• Stamping process
• 1. Heating: the material is softened so that its shaping.
• 2. Transfer: The product is then transferred to the press.
• 3. Forming: The plate is hot-pressed, and is in contact with the mold.
• 4. Cooling: The room is cooled under pressure to ensure dimensional
stability.
• 5. Release: The part is then removed from the mold and continues to
be cooled to the ambient temperature
1 2 3 4+5
ATC – april 2013 11
Process of a composite TP consequence
• Why simulate the stamping process?
• To verify the faisability of the stamping process in a composite part
• To avoid « wrinkles »
• To know the story of the part before the mechanical sollicitation (crash
test)
• Consequence of stamping process:
• Apparition of defects
• "wrinkles" fiber mats inside radius
• Mass matrix due to the flow of the matrix to fill empty
• Nonuniform thicknesses
• Modification of fibre orientation in the fillets
• Residual constraints
How to take into account the process in a crash analysis ?
ATC – april 2013 12
Mechanical simulation integrating process
Advanced database on
polyamide composite
mechanical behavior
• Objective:
• To take into account the material heterogeneities issued from the
stamping process of a thermoplastic composite part
Mapping results
from stamping mesh
to structure mesh
•Mechanical simulation
•Static and dynamic / Impact / Creep
Hyperform
Material Database
Stamping simulation
ATC – april 2013 13
First step – stamping process
Preprocessing
• geometry of tools and final part
Tools Part in its tooling
(end of the stamping process)
Innovation Intelligence®
with
• Behavior of the molten polymer: In shear
with Bias Test
ATC – april 2013
14
First step – stamping process
Mesh
Positionning of tools and plate • Stamping modelling
• Mesh of tools and plate (part before stamping)
• Part modelling in composite with continuous fiber with 2
materials:
• 1 material for the fiber (9 layer with different orientations)
• 1 material for the resin (liquid/viscous)
• Tools modelling:
• Shell mesh
• Rigid body
Innovation Intelligence®
with
ATC – april 2013 15
Second step – stamping process
Process
Initial position Final position
• Preprocessing
• Fixed matrix, moved punch
• Stamping direction in Y
• Symmetry condition in YZ plane
Innovation Intelligence®
En collaboration avec
ATC – april 2013 16
Second step – stamping process
Process
• Stress
• Glass – eighth layer oriented in
45°
• Strain
• Glass – eighth layer oriented in
45°
Innovation Intelligence®
with
ATC – april 2013 17
Third step – stamping process
mapping
• Thickness • Orthotropy direction:
• Ply 1: 0°
• Orthotropy direction:
• Ply 2: 45°
ATC – april 2013 18
Crash analysis
• With stamping
• Orthotropy direction in the first layer
• Dynamic solicitation
• A mass of 7 kg impact the part
• With the speed of 3.5 m/s
• Comparison between the two approaches
• With stamping process simulation: to take into account orthotropy
directions after stamping
• Without stamping process simulation : reference case : fibers direction
defined in X direction (manually all over the geometry)
• Without stamping
• fibers direction defined in X
ATC – april 2013 19
Crash analysis stress results
• With stamping process
• Without stamping process
Innovation Intelligence®
with
Thickness from
stamping
process
• See the difference
• Localization of the failure
• Level of stress
Constant thickness of 2 mm
ATC – april 2013 20
Crash analysis example of post-processing
• Material orientation • Plies orientation visualization
ATC – april 2013 21
• Stress and strain tensor are
expressed in local element system.
• Use the Expression Builder to
express tensor in the ply direction
Expression Builder
under HyperView
Crash analysis example of post-processing
with stamping
Plastic Work
without stamping
Eps 11
Eps 12
ATC – april 2013 22
with stamping without stamping
Number of plies failed
Timing rupture due to
plastic work
Timing rupture
due to strain 11
Crash analysis example of post-processing
ATC – april 2013 23
• Comparison between with and without stamping process
Crash analysis internal energy
Difference due to the failure area
ATC – april 2013 24
conclusion
• Data transfert from the simulation of stamping process to a
crash simulation
• Thickness/fiber orientation
Future: residual stresses
• Difference between the 2 approaches (in simulation):
• Failure area
• Stress level
• Internal energy
ATC – april 2013 25
• Composite post-processing
• Ply orientation
• Strain in ply direction
• Number of plies failed
• Rupture due to plastic work/strain11/strain22/strain12
Future: validation in real tests