w w w . a u t o s t e e l . o r g

Web-Based Materials Property Database

Presentation for “Great Designs in Steel”February 18, 2004By Dale C. Wetzel

w w w . a u t o s t e e l . o r g

Presentation Overview

Why did we wish to build a Materials Property Database (MPD)?Who will use it and why?What Material Properties are Needed and Why?Details of the Database and rational reasons for the methodology.

w w w . a u t o s t e e l . o r g

Background – Why did we wish to build a MPD?

Enabler to the Chrysler Development System (CDS)- Provide innovation - Improve quality- Cut redesigns (time) - Cut costsWill be a foundation for one global location for materials property data- Within: DCAH, DCS, Freightliner, etc.- Also partners: MMC, HyundaiFoundation for material commonization- Purchasing power thru bulk lower costs

w w w . a u t o s t e e l . o r g

Background – Who will use it and why?

CAE for accurate design simulationMaterials engineers for quality propertiesProduct development engineers for material choice

w w w . a u t o s t e e l . o r g

Background – Who’s Database Shell?

We chose MSC Software (Mvision)Compatibility

w w w . a u t o s t e e l . o r g

Background - What Material Properties are Needed?

This Depends Very Much on the User!Generally Properties of the Categories:- Monotonic Properties- Cyclic Properties- Characteristic Properties

w w w . a u t o s t e e l . o r g

Background - What Material Properties are Neded? CAE might desire:

Monotonic Properties- Data from Engineering Stress / Strain Curve- Data from True Stress / Strain CurveCyclic Properties- Data from Cyclic Stress / Strain Curve- Data from Strain / Life Curve

w w w . a u t o s t e e l . o r g

Background - What Material Properties are Needed? Materials Engineer might desire:

Monotonic Properties- Numeric Property Values (UTS, YS, E, etc.)Cyclic Properties- Fatigue Life or LimitMicrostructureChemical Composition

w w w . a u t o s t e e l . o r g

Background – Why are these Material Properties Needed?

Monotonic Properties- Design to an ultimate and yield strength- A small number of failures are do to overloadsCyclic Properties- Design for fatigue resistance- 90% of mechanical failures are attributed to fatigue

w w w . a u t o s t e e l . o r g

Fatigue Life Prediction Models

Component load-life modelNominal stress-life modelLocal strain-life model

w w w . a u t o s t e e l . o r g

Local Strain-Life Method

Produce Strain – Controlled Fatigue DataProduce Material Strain/Life CurveExtract Data for Models and Computations

Vinay Kumar – TCC/CAE, Girish Kulkarni - SVPT/CAE, John Hirshey - TCC/CAE, Sudheendra Rao, Fred Zweng – PVPT/CAE04/03/2003

DCAH CAE ProcessDCAH CAE Process

Supplier FE models

CATIA

Archive data

Parametric Geometry & welds (KBE)

P/T & Chassis “Chunky”

Components -3D Modeling

BIW Meshingand Assembly

Closures modeling and

assembly

Quality gates (Milestone Data)

Solvers/OptimizationNASTRANDYNAABAQUSFE-Fatigue, etc.

Component & Subsystem libraries•Road load data•Modal components (tires, etc.)•Bushing data•Stamping data•Crash dummy models•DMIG components, etc.

Targets & Testdata

DESKTOP (LMS)• Trimmed BIW assembly• Full vehicle assembly• Loads/BC’s• Post process• Optimization

Geometry/ConnectionAssociativity

MVISION

Connections (ABF)

ENVIRONMENTMVISION

w w w . a u t o s t e e l . o r g

Details of the Database

Screen Shots to Show Methodology

w w w . a u t o s t e e l . o r g

Select Database

w w w . a u t o s t e e l . o r g

Search for a Material

w w w . a u t o s t e e l . o r g

Search for Material

w w w . a u t o s t e e l . o r g

Display of Material Search

w w w . a u t o s t e e l . o r g

Search for Property Desired

w w w . a u t o s t e e l . o r g

Display of Search

w w w . a u t o s t e e l . o r g

Chemical Composition

w w w . a u t o s t e e l . o r g

Monotonic Properties

w w w . a u t o s t e e l . o r g

Stress / Strain Curve

w w w . a u t o s t e e l . o r g

Cyclic Properties

w w w . a u t o s t e e l . o r g

Stress Amplitude vs Strain Amplitude

w w w . a u t o s t e e l . o r g

Stress Amp. Vs. Plastic Strain Amp.

w w w . a u t o s t e e l . o r g

Stress Amp. Vs. Fatigue Life Reversals

w w w . a u t o s t e e l . o r g

Elastic Strain Amp. Vs. Fatigue Life Reversals

w w w . a u t o s t e e l . o r g

Plastic Strain Amp. Vs. Fatigue Life Reversals

w w w . a u t o s t e e l . o r g

Total Strain Amp. Vs. Fatigue Life Reversals

w w w . a u t o s t e e l . o r g

Material Microstructure

w w w . a u t o s t e e l . o r g

Criteria Search

w w w . a u t o s t e e l . o r g

Select Options

w w w . a u t o s t e e l . o r g

Options

w w w . a u t o s t e e l . o r g

Specific Results

w w w . a u t o s t e e l . o r g

Advanced Search

w w w . a u t o s t e e l . o r g

Search Results

w w w . a u t o s t e e l . o r g

Deeper Search

w w w . a u t o s t e e l . o r g

Results of Added Criteria

w w w . a u t o s t e e l . o r g

Cyclic Comparison of Two Materials

w w w . a u t o s t e e l . o r g

Comparison Continued

w w w . a u t o s t e e l . o r g

Comparison of Two Material Curves

w w w . a u t o s t e e l . o r g

Conclusions

A Materials Property Database is an important enabler to the design process.A web based Materials Property Database is one central location to house accepted quality data. A Materials Property Database is a tool to help cut costs!

w w w . a u t o s t e e l . o r g

Materials Property Database Wrap-up

Thank You!Any Questions?

w w w . a u t o s t e e l . o r g

w w w . a u t o s t e e l . o r g

Sponsored by: American Iron and Steel Institute