Company:

JSOL Corporation

Products:

Digimat

Industries:

Automotive

JSOL Corp. - Engine Backfire in an Air Intake Manifold

Overview:
“Fiber reinforced plastic becomes major material for intake manifold because of lightweight and heat resisting properties. Detecting the correct high stress concentration area is important to predict fatigue properties of manifold. DIGIMAT helps us to predict correct stress distribution by taking into account the fiber orientation coming from injection molding. "
Challenge:
  • To comply to the environmental needs of automotive industry and deliver greener technology by weight saving
  • To support the process of design of under-­-the hood plastic parts reinforced with glass fibers
Solution:
  • Calibration of an elasto-plastic DIGIMAT material
  • Simulation of the load case with Digimat-CAE/LS-DYNA interface based on fiber orientations coming from injection molding
  • Comparison of maximum principle stresses of the composite material with an isotropic calculation
Results Validation:
"Fiber reinforced plastic becomes major material for intake manifold because of lightweight and heat resisting properties. Detecting the correct high stress concentration area is important to predict fatigue properties of manifold. DIGIMAT helps us to predict correct stress distribution by taking into account the fiber orientation coming from injection molding. " Noriyo Ichinose, Sales engineer, JSOL Corporation, Japan
Benefits:
  • For the high pressure peak (t1 = 8 ms) and the low pressure region (t1 = 12 ms) significant differences in the stress distribution are observed compared to the simulation using isotropic material
  • The fiber reinforced part shows lower stresses than the isotropic case pointing out an over-designed part
  • Potentially further weight can be saved on the part by introducing DIGIMAT in the design cycle

 
DOWNLOAD

Company:

Ticona GmbH

Products:

Digimat

Industries:

Automotive

Ticona - Force Response of a Sun Roof Bearing

Overview:
Digimat was used to model the plastic injection of a sun roof bearing part, taking into account fiber orientations predicted by injection molding. There existed very good correlation with experimental failure data. Digimat was able to predict critical failure location in the part.
Challenge:
  • To correctly model fiber reinforced plastic parts
  • To have quantitative and predictive results from FEA
  • To use a unique material description valid for all kind of different load cases
Solution:
  • Calibration of an elastoplastic micromechanical DIGIMAT model based on dumbbells from a plate cut 0° and 90° with respect to highly oriented fibers
  • Setup of two different load cases (global & local) with different isotropic approaches and via DIGIMAT multi-scale modeling
Results Validation:
"Ticona’s intent is to provide solutions to our customers. Speed and quality of CAE predictions are key factors when we work on new components. Customers expect working solutions based on detailed structural response predictions and optimized mold design. From the results of our practical tests, the use of DIGIMAT to link Moldflow with Ansys structural analysis proved to be a very good way to fulfill these customer needs." Ulrich Mohr­-Matuscheck, Leader Design CAE, Ticona GmbH
Benefits:
  • With the scaling approach two different factors have to be applied to match the experimental force displacement curve of the global and local load case
  • Only the micromechanical DIGIMAT model describes correctly both load cases based on one unique material model taking into account fiber orientations predicted by injection molding simulation
  • In good correlation with experimental failure DIGIMAT per-­-phase results point out the critical location in the part

 
DOWNLOAD

Company:

Sovitec

Products:

Digimat

Industries:

Consumer Products

Sovitec - Material Design for Particle Reinforced Polyamide

Overview:

This study allowed Sovitec to obtain the arguments necessary in order to be more effective in the prospection of new markets, but also to consolidate its image of serious in the presentation of technical results in the plastic industry. Clearly a Plus.

Challenge:
  • Replace existing glass fiber reinforcement technology by solutions based on glass beads
  • Provide equal or improved material performance with the new solution
  • Reduce cost of material production
Solution:
  • Calibration of micromechanical material models for PA6/GF30 and PA6/GB30 based on experimental results
  • Virtual compounding of new material mixture in Digimat-MF
  • In-depth micro investigation of promising candidates by Digimat-FE
  • PA6/GF15/GB15 provides same composite stiffness in fiber direction and transverse to fiber direction
  • 15% of glass beads lead to an isotropisation of thermal properties
  • 15% of glass beads lead to an improvement of failure strength
Results Validation:
"This study allowed Sovitec to obtain the arguments necessary in order to be more effective in the prospection of new markets, but also to consolidate its image of serious in the presentation of technical results in the plastic industry. Clearly a Plus." Frederic Juprelle, Business Unit Manager, Sovitec
Benefits:
  • 20% price per produced part
  • 29% cycle time per part
  • 4% part reject rate
  • Machine durability

 
DOWNLOAD

Company:

RHODIA

Products:

Digimat

Industries:

Consumer Products

Rhodia - Impact on a beam

Overview:
Being predictive in crash simulation is the dream of CAE engineers. The use of short fiber reinforced materials was putting this target out of range, because such materials have a variable anisotropy all over the part, associated to complex matrix behavior. No material model implemented in a code is able to capture this complexity level. Digimat to LS DYNA does. Associated with the Rhodia material database MMI confident Design™, Digimat CAE/LS DYNA is providing the best predictability level available on the market today.
Challenge:
  • To support their customers in the design of polyamide parts
  • To take into account the influence of fiber orientation for reinforced polyamide material
  • To provide the best material data possible to support simulation technologies
Solution:
  • Calibration of a strain rate dependent elasto-viscoplastic DIGIMAT material model sensitive to fiber orientation
  • Coupling to fiber orientation from Moldflow injection molding analysis by using the Digimat-CAE/LS-DYNA interface
Results Validation:
"Being predictive in crash simulation is the dream of CAE engineers. The use of short fiber reinforced materials was putting this target out of range, because such materials have a variable anisotropy all over the part, associated to complex matrix behavior. No material model implemented in a code is able to capture this complexity level. Digimat to LS-­-DYNA does. Associated with the Rhodia material database MMI confident Design™ , Digimat-­-CAE/LS-­-DYNA is providing the best predictivity level available on the market today. Rhodia is proud to offer this reliability to its customers." O. Moulinjeune, Simulation Expert at Rhodia Engineering Plastics
Benefits:
  • The Digimat-CAE/LS-DYNA analysis correlates very well with the experimental results
  • The peaks’ maximum force as well as their occurrence in time is matched well
  • It is crucial to take the fiber orientation into account when simulating fiber reinforced plastic parts

 
DOWNLOAD

Company:

bime

Products:

Digimat

Industries:

Aerospace
Energy

Bime - Damage Behavior of Highly Porous Ceramics

Overview:
The application of Digimat MF and Digimat FE gave insight into the influence of microstructure on the overall mechanical and brittle damage behavior of highly porous sound absorbing ceramics. Digimat gave the engineers at bime key in-sight into the elastic properties of these porous sound absorbing ceramics, that was necessary to reduce production cost and increase the material's strength.
Challenge:

 

  • In-depth investigation aiming at material design
  • Prediction of elastic properties of porous sound absorbing ceramics
  • Prediction of pure brittle damage with respect to microstructure
Solution:
  • Reverse engineering of the unknown material properties based on experimental results
  • Virtual compounding of different porous ceramics in Digimat-MF
  • In-depth micro investigation of porous ceramics by Digimat-FE
  • Numerical investigation of pure brittle damage at both micro and macro scales on the porous ceramics
Results Validation:
"The application of Digimat-­-MF and Digimat-­- FE paved the way for me to give an insight into the influence of microstructure on the overall mechanical and brittle damage behavior of highly porous sound absorbing ceramics. I was able to contribute to the improvement of material strength by new material design while keeping the good sound absorption." Reza Malekmohammadi Research Assistant, bime
Benefits:
  • Reduced cost of material production and characterization
  • Increased material strength with improved material design
  • Boosted cooperation between ceramic developer and acoustic user

 
DOWNLOAD

Company:

European Space Research and Technology Center

Products:

Digimat

Industries:

Aerospace

ESA/ESTEC - Thermo-mechanical Design of an Ultra-light Satellite Antenna

Overview:
Digimat offered the engineers at the European Space Research and Technology Center the tools they needed to bridge the gap between the Micro world and the Macro world. Using Multi scale modeling of advanced woven composite material Digimat can support a virtual design of an ultra light satellite antenna.
Challenge:
  • Satellite antennas have to be designed in a sturdy and reliable manner
  • There is no easy way to repair a satellite once it breaks down
  • The extreme sensitivity of the structure towards thermal loads has to be investigated under environmental conditions
Solution:
  • Multi-scale modeling of advanced woven composite material on 3 scales
  • Carbon/epoxy composite: homogenization of yarn properties
  • Triaxial woven fabrics (TWF): detailed analysis of a representative cell
  • Satellite antenna: simulation of the full structure based on an equivalent multi-layer shell model representative for TWF
Results Validation:
“DIGIMAT is able to bridge the micro to the Macro world. A great example of high-­-quality european know-­-how” Dr Julian Santiago Prowald, TEC-­-MSS Structures Section ESA/ ESTEC
Benefits:
  • Mean-field homogenization gives high quality prediction of yarn properties (stiffness & CTE)
  • Yarn properties used to compute accurate results for stiffness & CTE for TWF
  • Good prediction of displacement behaviour of the satellite antenna due to thermal loading

 
DOWNLOAD

Company:

L&L Products

Products:

Digimat

Industries:

Automotive

L&L Products - Impact on a Stiffener for Lower B-Pillar

Overview:
Digimat provides L&L Products with state of the art simulation methods which aid engineers in product development. The key advantage provided by Digimat coupled to Radioss and other CAE software is a drastic predictability improvement for glass filled polyamide materials. With an improved predictability, optimal and robust lightweight design is possible in the future.
Challenge:
  • To move towards greener technology by replacing classical metal design by composite structures
  • To use the outstanding performance of composite materials whilst tackling all additional difficulties arising from the injection molding process
  • High quality prediction of impact on a short fiber reinforced stiffener beam
Solution:
  • Strain rate dependent micromechanical material model for AKULON K224 HG7 supplied by DSM
  • Mapping of MOLDFLOW fiber orientations onto the structural mesh
  • Solution of a nonlinear multi-scale analysis with DIGIMAT coupled to RADIOSS
Results Validation:
"The key advantage provided by DIGIMAT coupled to Radioss and other CAE software is a drastic predictivity improvement for glass filled polyamide materials. With an improved predictivity, optimal and robust lightweight design is possible in the future." F. Braymand, Simulation Manager at L&L Products
Benefits:
  • Excellent correlation on the force-­-displacement curve with experiment
  • Excellent correlation on the failure location compared to experiment
  • Drastic improvement of predictivity enables robust and lightweight design focusing on cost efficiency based on advanced DIGIMAT CAE technology

 
DOWNLOAD

Company:

Integrative Simulation and Engineering of Materials and Processes

Products:

Digimat
Marc

Industries:

Aerospace

ISEMP - Curing of Carbon Fiber Reinforced Plastics (CFRP)

Overview:
“Digimat enables the engineers at ISEMP to perform in-depth studies of complex and realistic microstructures. As they continue to invest into the future they now base their simulation approach on the Digimat software, improving their own research method as well as the education of a new generation of simulation engineers."
Challenge:
  • Processing of CFRP results in residual stresses in the material
  • Residual stresses lead to micro-­-damage & failure of CFRP
  • Goal is to simulate residual stresses of a carbon fiber composite material at the micro scale with realistic topology
Solution:
  • Generation of RVE with continuous fibers and layered microstructure
  • Realistic RVE with stochastically distributed fibers
  • CAD geometry of RVE to be used with external solvers
Results Validation:
"DIGIMAT enables us to perform in depth studies of complex and realistic microstructures. As an invest into the future we base our simulation approach on the DIGIMAT software, both for our research and the education of a new generation of simulation engineers who will be experts in the modeling of materials." Prof. Vasily Ploshikhin, Airbus endowed chair for Integrative Simulation and Engineering of Materials and Processes
Benefits:
  • The FE-­Simulation of laminate layers with inhomogeneous properties enables a detailed analysis of stress distribution and possible origins for different types of micro defect formation
  • Highest stresses can be found at the fiber matrix interface
  • Matrix areas between very close fibers are under higher load
  • Fiber matrix interface between differently oriented laminate layers shows higher stresses

 
DOWNLOAD

Company:

CADF

Products:

Digimat

Industries:

Energy

CADFEM - Continuous Fiber Reinforcement in Wind Turbine Rotor Blades

Overview:
Digimat assisted the engineers at CADFEM to develop a more efficient wind turbine by closing the gap between advanced modeling of heterogeneous anisotropic and nonlinear materials. The possibility of taking into account the micromchanical properties of fiber reinforced plastics in wind turbines is another area Digimat can aid in the production process of green energy.
Challenge:
  • Design of bigger turbine blades with low weight & high rotational inertia
  • Optimal use of expensive high-­-end composite materials
  • Flexible & realistic simulation approach to investigate design concepts
Solution:
  • Multi-scale analysis based on ANSYS Composite PrepPost™ model
  • Describe GFRP and CFRP composites via a unique material modeling approach using the mean field homogenization on the microscopic scale in DIGIMAT
  • Fiber description taking into account isotropic or transversely isotropic properties
  • Systematic analysis of failure directly in the Epoxy and the fiber phases
Results Validation:
"DIGIMAT enhances our product portfolio and closes the gap towards advanced modeling of heterogeneous anisotropic and nonlinear materials. We see a large potential for taking into account the micromechanical properties of fiber reinforced plastics." Martin Kracht, Product Manager DIGIMAT at CADFEM GmbH - ANSYS Competence Center FEM in Germany
Benefits:
  • Failure indicators are in general much lower for carbon fiber than for glass fiber reinforcement Carbon fiber reinforced blade fails on different ply level compared to the glass fiber design
  • The usage of a transversely isotropic description for the carbon fibers is critically important for a realistic simulation approach

 
DOWNLOAD

Company:

SOLVAY Speciality Polymers

Products:

Digimat

Industries:

Consumer Products

Solvay - Fatigue Failure of Injection Molded Bow Limbs

Overview:
By using DIGIMAT the engineers at Solvay could clearly demonstrate the tight link between geometry, flow of material, fiber orientation and mechanical behavior. They successfully used the approach to evaluate the endurance of a number of different bow limb designs.
Challenge:
  • A manufacturer injection-molded plastic bows set the goal to produce the best bows for recreational archery on the market based on SOLVAY material
  • A new and apparently improved design of the bow limbs showed a reduced fatigue lifetime as compared to an existing geometry
  • The question arose whether the premature failure of the new design is directly connected to the change in the processing of the bow limbs
Solution:
  • Reverse engineering of an elasto-plastic DIGIMAT material model
  • Computation of 1st principles stresses for preload and load cases based on fiber orientation data coming from Moldflow
  • Life time prediction using a Haigh diagram
  • Comparison between the two different designs for the bow limbs
Results Validation:
"By using DIGIMAT we could clearly demonstrate the tight link between geometry, flow of material, fiber orientation and mechanical behavior. We successfully used the approach to evaluate the endurance of a number of different bow limb designs." Laurent Hazard, CAE Senior Specialist, SOLVAY
Benefits:
  • The lifetime in fatigue of the original design should be slightly longer than the new design
  • The higher stress level for the new design could be connected to a higher local stiffness in the critical region in the bow limb
  • The higher local stiffness could be explained by a “better” fiber orientation due to a change in the melt flow in the processing step (combination of two “converging” flows)

 
DOWNLOAD

Company:

Optimec Consultants

Products:

SimXpert

Industries:

Machinery

Optimec Consultants

Overview:
Based in the Greater Montreal area in Quebec, Canada, Optimec Consultants is an advanced engineering consulting firm offering Computer Assisted Engineering (CAE) services and complete Finite Element Analysis (FEA) solutions, and is a certified reseller of the MSC Software product line. For the past year, major efforts have been directed towards maximizing the potential uses of templates for building and analyzing FEA models. Templates are powerful macros that allow automation and improve productivity. Template building is a very promising capability within the MSC SimXpert multidisciplinary simulation environment. The goal of developing templates is to use them internally and to offer personalized simulation solutions to existing clients and new industries looking to implement the Finite Element Method in their design process. This case study presents four key templates that have been developed specifically for the large machinery industry and for work in future developments.
Challenge:
Automating the modeling and analysis of large FEA models.
Solution:
The SimXpert template building capability permits the creation of templates aimed at automating repetitive processes. Building templates can be done using actions library or via macro recording. Specific scripts can also be coded using Python programming language. SimXpert’s main advantage over its competitors is its ease of use and straightforward interface.
Benefits:
  • Quick verification of results
  • Shorter analysis time
  • Ease of use

     
    DOWNLOAD

    Company:

    Patrick Air Force Base

    Products:

    Adams

    Industries:

    Aerospace
    Defense

    Patrick AFB

    Overview:
    Ejection seats must work perfectly every time they are used in an enormously wide range of altitudes, aircraft motion profiles, wind conditions and pilot weights while at the same time taking manufacturing variation into account. Physical testing of course plays a pivotal role in ejection seat design but time, cost and safety limit the number of situations that can be tested to far fewer than the number of potential ejection scenarios. Analysts at the Naval Surface Warfare Center (NSWC) at Indian Head, Maryland, and the 45th Space Wing at Patrick Air Force Base, Florida, have developed a model of an ejection seat using MSC Adams rigid body simulation software. During the model’s initial 5-year joint-force development process, Adams was the first professional dynamics software used to completely model the complex physics involved in the deployment of an ejection seat.
    Challenge:
    Improve ejection performance and safety.
    Solution:
    Adams was used to model the complex physics involved in the deployment of an ejection seat.
    Benefits:
    • Accurate Simulation
    • Reliable Analysis
    • Improved Design Process

     
    DOWNLOAD

    Company:

    Setforge Engineering

    Products:

    Patran

    Industries:

    Aerospace
    Automotive
    Heavy Equipment

    Setforge - Simulating the Electro-upsetting Process During Metal Forging

    Overview:
    When Setforge joined the group, Farinia took the opportunity to review its simulation resources. Nicolas Behr, Chief Project Engineer at Setforge Engineering explains: “We realized the limits of the tools we were using and that their maintenance cost was too high relative to their capacities. What’s more, because of some of the methods used by the group – especially electro-upsetting – we had to model and simulate the nonlinear multiphysics phenomena that characterize these technologies.”
    Challenge:
    Simulate the electro-upsetting process used to make very long sectional parts
    Solution:
    • Patran to develop simulation model.
    • Marc to simulate the nonlinear multiphysics phenomena that characterize electro-upsetting technologies.
    Benefits:
    • Achieve Best Cost/Performance Ratio
    • Process Optimization

     
    DOWNLOAD

    Company:

    Achates Power

    Products:

    Adams
    Patran

    Industries:

    Automotive

    Achates Power

    Overview:
    Achates Power, Inc. is developing a lightweight, low-emissions and low fuel consumption two-stroke, opposed-piston diesel engine designed as a modular and scalable mechanism termed A40. Achates Power places heavy emphasis on modeling and simulation through state-of-the-art analytical tools and methods. Within the structural dynamic analysis arena, the focus is on overall dynamics, such as torsional and bending vibrations, including torsional vibration damper (TVD) and flywheel layouts, as well as (hydrodynamic) bearing analysis. The emphasis is on identifying areas of conceptual, structural and dynamic improvement with regard to overall dimensions and weight. A hybrid approach is utilized, thus combining the advantages of multi- body simulation (MBS) and finite element analysis (FEA).
    Challenge:
    Develop a light-weight, low-emissions, and low fuel-consumption diesel engine
    Solution:
    MSC Adams with FEV Virtual Engine powered by Adams
    Benefits:
    • Confirmed structural integrity
    • Optimized components
    • Weight reduction

     
    DOWNLOAD

    Company:

    Kosme

    Products:

    Adams
    MSC Nastran

    Industries:

    Machinery
    Packaging

    Kosme - Design and optimization of packaging machines

    Overview:
    Kosme produces a full range of turnkey filling, labeling, capping, packaging and conveying solutions for beverage products including soft drinks, water, beer, wine, and spirits, as well as personal care products.
    Challenge:
    In developing custom solutions for customers, Kosme is frequently asked to develop machines that will operate faster and more reliably than their predecessors. Increasing the speed of machines raises inertial loads, creating the potential for vibration and resonances that could substantially reduce the life of the machines and cause breakdowns. In the past, Kosme engineers used hand calculations to estimate the performance of components and built physical prototypes to evaluate system performance. Problems were frequently discovered during the prototype stage. These problems often required many iterations of revisiting the design and modifying and re-testing the prototype.
    Solution:
    MSC Nastran and Adams simulation software made it possible for Kosme to design, optimize and visualize packaging machines prior to the prototype stage. The result is that the company is able to engineer substantial performance improvements while getting the design right the first time.
    Benefits:
    Simulation makes it possible for Kosme to design, optimize and visualize packaging machines prior to the prototype stage. The result is that the company is able to engineer substantial performance improvements while getting the design right the first time.
    • Increase the processing speed of bottling machines by 50%
    • Reduction of vibration levels
    • Reduction of mass of critical moving components by 20% to 30% while reducing stress levels.

       
      DOWNLOAD

      Pages