Multi-Scale Modeling of Reinforced Plastic Parts with
Digimat to RADIOSS
Roger Assaker, Thibault Villette, e-xstream
Fast and cost efficient design of higher quality, lighter
and more energy efficient vehicles is one of the key success
factors for today’s automotive industry. Predictive
CAE and the use of composites materials, offering
good weight to mechanical performance ratio, are two ingredients
that
will help the industry moving forward profitably.
The nonlinear Finite Element Analysis (FEA)
of automotive parts using homogeneous isotropic
materials like steel is challenging but has
become today a standard
step in any modern design process. The FEA
of metallic parts is very well performed using
one of the leading FEA packages
on the market today.
The nonlinear FEA of injection molded parts
using fiber-reinforced plastics is much more
challenging and still suffers from a lack
of modeling tools, simulation procedures
and the material data that are needed to
deal with the local, process-dependent, anisotropic,
nonlinear and strain rate
dependent behavior of the reinforced plastics.
In this presentation, we will introduce the
nonlinear micromechanical modeling technology
that can be used to predict the nonlinear behavior
and failure of a multi-phase
materials, based on their underlying microstructure
(e.g. fiber content, fiber orientation, fiber
length, …).
The multi-scale material modeling process,
used to model the reinforced plastic part, will then be presented.
This process
uses RADIOSS as the structural FEA package
at the part level coupled to nonlinear micromechanically-based
material models,
taking into account the fiber orientation induced
by the injection molding of the part.
Nonlinear multi-scale modeling technology,
including mean-field homogenization methods
(e.g. Mori-Tanaka), advanced material models
(e.g. Elasto-Viscoplastic and Micro
Failure), realistic microstructures (e.g.
complex fiber orientation and fiber length
distribution) and strong coupling to the
major injection molding and to RADIOSS is
implemented in the DIGIMAT software platform.
The industrial use of nonlinear multi-scale
modeling technology will be illustrated
using an automotive plastic part subject to impact
loading conditions.
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