Stamping Process Integration of Composites in Crash Analysis

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


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


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


Stronger together / a complementary product offer

Solvay Specialty Polymers

Engineering Plastics

Solvay Vinyls


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


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


Process of a composite TP


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


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 ?


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


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


with


Second step – stamping process

Process

Initial position Final position

• Preprocessing

• Fixed matrix, moved punch

• Stamping direction in Y

• Symmetry condition in YZ plane


En collaboration avec


Second step – stamping process

Process

• Stress

• Glass – eighth layer oriented in

45°

• Strain

• Glass – eighth layer oriented in

45°


with


Third step – stamping process

mapping

• Thickness • Orthotropy direction:

• Ply 1: 0°

• Orthotropy direction:

• Ply 2: 45°


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


Crash analysis stress results

• With stamping process

• Without stamping process


with

Thickness from

stamping

process

• See the difference

• Localization of the failure

• Level of stress

Constant thickness of 2 mm


Crash analysis example of post-processing

• Material orientation • Plies orientation visualization


• 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


with stamping

Plastic Work

without stamping

Eps 11

Eps 12


with stamping without stamping

Number of plies failed

Timing rupture due to

plastic work

Timing rupture

due to strain 11



• Comparison between with and without stamping process

Crash analysis internal energy

Difference due to the failure area


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


• 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

Stamping Process Integration of Composites in Crash Analysis

Technology

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