Injection-molded fiber-reinforced thermoplastics show a high potential for cost-effective weight reduction in the automotive area. However these materials feature a complex mechanical behavior which is dependent on the injection-molding process. Local microstructure and fiber orientation / distribution, which exert a great influence on elasto-plastic and fracture characteristics, are defined by the manufacturing process. To improve the crash simulation quality of injection-molded fiber-reinforced parts an integrative simulation approach seems to be inevitable. Ford Research and Advanced Engineering in cooperation with the companies MATFEM Partnerschaft Dr. Gese & Oberhofer and SIGMA Engineering GmbH have developed a methodology for coupling injection simulation with crash simulation which can be used in the development process at Ford Motor Company. The MF-GenYld+CrachFEM material model is used within RADIOSS® and LS-Dyna® by taking into account the injection-molding manufacturing process results delivered by SIGMASOFT®. Automotive prototype parts have been manufactured and subjected to various load cases to validate the advanced methodology by correlating the CAE models with the test data in terms of measured force-deflection curves and observed material failure. The integrative simulation approach leads to a much better correlation in terms of deflection, deformation and fracture behavior compared to conventional approaches.
Integrative simulation of fiber-reinforced plastics for crash applications
2013
12 Seiten, 8 Bilder, 5 Quellen
Aufsatz (Konferenz)
Englisch
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