integrated tool for simulation of textile composites · behaviour crash behaviour static behaviour...

Marinus Schouten 06-2006 EADS-Corporate Research Centre 1

Integrated Tool for Simulation of Textile Composites

SIXTH FRAMEWORK PROGRAMMEProposal no.: 516146

Aerodays Vienna June 2006

ITOOLIntegrated Tool for Simulation of Textile Composites


General objectives

• Objectives– Development of an adequate integrated simulation tool for braids,

advanced engineering textiles, weaves and stitched textiles– Simulation along the process line – Establish a virtual manufacturing chain

• Approach– Linking and integration of different stand-alone solutions – Open flexible interface for fluent data exchange and communication – Set up a standard for testing, modeling and simulation – Application/validation examples in Aeronautics – Summarized in guidelines, design rules and educational tools



• EADS Germany• Alenia Aeronautica S.p.A.• Cranfield University• Dassault Aviation• German Aerospace Center• EADS Corporate Research

Center France• ESI Software• University of Stuttgart• University of Aachen• University of Leuven• INSA University Lyon• SISPRA• University of Zaragoza

Partners involved

IFB



Simulation chain

Micro Meso

Modelling

Braiding

Stitching

Draping Impregnation Curing

Spring backImpact

BehaviourCrash

behaviour

Static

BehaviourToolingHandling

Repair

Textile Process Textile Integration Impregnation Curing Loading

Micro Meso

Modelling

Braiding

Stitching

Draping Impregnation Curing

Spring backImpact

BehaviourCrash

behaviour

Static

BehaviourToolingHandling

Repair

Textile Process Textile Integration Impregnation Curing Loading



Project overview

I/O interface Tool interface GUI

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WP5: Integration


WP5: IntegrationWP1

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Current project status: WP1: Material Characterisation / DataTool• WP1: Material characterization

– Selection of relevant data for:Dry textilesImpregnated composites

– Data ToolDescription of the Data Tool Implementation of example cases in the Data Tool

– Sub tasks1.1 Selection of relevant data1.2 Structure of the Data Tool1.3 Collection of data



Current project status: WP2: 3M mechanics

• WP2: 3M mechanics– Development of the models on Micro and Meso

levelGeometry of fiber and yarn placement in 3d reinforcementsHomogenized mechanical properties of the unit cell of textile compositeDamage initialization and development

– provide input to models of textile deformability and external loading behavior of composite part



Current project status: WP2: 3M mechanics (cont.)

• WP2.2 Meso level geometrical models– 3D braids

Braid3DTex tool development– Structural stitching

model development• WP2.3 Micro – Meso Homogenization

– models are selected and being implemented in FE

• WP2.4 Meso – Macro Homogenization– theoretical foundations ready



Current project status: WP3: Process Simulation

CABRun example

• WP3: Process Simulation– ‘virtual manufacturing’ chain

for textile composites process simulation = central task

– Main targetsdrapability behavior Impregnation simulation

– Sub tasks3.1 Development of concepts for a process simulation for NCF, sewing/stitching, 2d-braiding.



Current project status: WP3: Process Simulation (cont.)

• WP3.2 : Draping simulation– Identification of meso-macro mechanical

behaviour (LaMCoS)biaxial tension experimentsin-plane shearing experimentsvirtual experiments (FE)

– Definition of numerical tools and specific finite elements for fabric forming simulation (LaMCoS)

continuum and formulation approaches

– Simulation of forming behaviour of a deformed dry textile ongoing (CCR)

• WP3.3 : Mould filling simulation– Development and test of some new

computational methods (ESI)



Current project status: WP4: External loading behaviour– On macroscopic level

structural behaviordeformationstress and failure modeling WP4.1 Stress analysis and quasi-static failure criteria

– Failure model for 2D triaxial braided composites (ALA)

– Experimental failure and damage analysis of UD-braids (EADS-G)

– implementation of homogenisation and damage routines in MSC.Marc (EADS-G)

– Development of validation procedure for a failure criterion for 3d reinforced textile composites (DLR)

• WP4.2 Impact and crash simulation– Development of new test procedures for dynamic material

data collection + simulation of these test procedures (CRAN)

UD-braid



Current project status: WP5: Integration

• WP5: Integration

– Main ITOOL concept = integration

– TargetEnsure the fluid interaction of the different WP solutionsminimize user interferenceData interchanging has to go with minimum friction and critical data loss

– Sub tasks5.1 Evaluation of the different tools5.2 Data handling5.3 Design of a graphical user interface for the ITOOL



Current project status: WP6: Industrial validation / TestDAS

ALA

EADS-G

• WP6: Industrial validation / Test– “industrial" acceptance of the integrated

simulation tool – test the whole simulation chain on a finished

composite partsimulation of the textile production prediction of meso/macro propertiesdrapability behaviorimpregnation FE-analysis

– Sub tasks6.1 Specification of test cases6.2 Manufacturing of the parts and testing6.3 Tool chain proof on defined test cases6.4 Cost benefit analysis



Current project status: WP7: Design guidelines / standardizations

• WP7: Design guidelines / standardizationsObjectives– allow textile and composite engineers to evaluate

major factors of influence and to design optimized structures.

– Development of philosophies for a standardization of test procedures and textile processes

– Bases on realistic, exemplary components.

Sub tasks– 7.1 Definition of structural elements – 7.2 Analysis of potential and limitations of textile

processes – 7.3 Development of design guidelines – 7.4 Evaluation based on realistic applications– 7.5 Generation of philosophies for standardization



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integrated tool for simulation of textile composites · behaviour crash behaviour static behaviour...

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