Booklet Digimatum10

DIGIMAT USERS’ MEETINGOCTOBER 5-7, 2010 - LUXEMBOURG

THE MATERIAL MODELING CONFERENCE

pROGRAM

2010 DI GI MAT U s ers ’ Meet ing - T he Ma ter ia l Mod el ing Conf erence1

S I M U L A T I O N S O F T W A R E & E N G I N E E R I N G S E R V I C E S 1 0 0 % F O C U S E d O N A d V A N C E d M A T E R I A L M O d E L I N G

WELCOME TO ThE 2010 dIGIMAT USERS’ MEETING

After Brussels and Nice, this year’s edition is taking place in Luxembourg, the second home country of e-Xstream. This year, we are expecting over 100 attendees, 30 presentations from customers, partners and e-Xstream’ staff. We also have the pleasure to welcome an invited lecture about bio-medical engineering of orthopedic implants.

The highlights of this conference are the opening of our 1st North American office in Plymouth, Michigan, the release of DIGIMAT 4.1 and the continuous strengthening of the team.

Today, one of the many challenges facing all industries is the need to develop green products without sacrifying the product performance or value for money. Advanced materials are key enablers for facing the performance challenge. However, the economic challenge can only be addressed thanks to an optimal use of the “right materials”. If we consider composites as an example, the “right material” can either have a thermoplastic or a thermoset matrix reinforced with continuous or chopped fibers that is molding or forming the final product. The efficient engineering of such materials and products can only be done thanks to an extensive use of predictive CAE technologies and tools.

e-Xstream’s vision is to position DIGIMAT as the unique and central material modeling platform to enable computer aided material and structural engineering.

This meeting is dedicated to exchanging material modeling ideas and best practices across industries, materials and CAE tools. It is before all for us a great opportunity to learn about your needs; the main driver for DIGIMAT developments. I thank you for making this event productive and enjoyable and look forward to discussing with each one of you during the next couple of days.

dr Roger AssakerCEO e-Xstream engineering

2 0 1 0 D IG IM AT U s ers ’ Meet ing - T he Ma ter ia l Mod el ing Conf erence 2

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2010 dIGIMAT USERS’ MEETING IS SpONSOREd by

PREMIUM SPONSORS

SPONSORS

Thank you



08:00 – 08:30 Registration & Welcoming Coffee Sponsor Areas

08:30 – 09:00 Roger Assaker - e-Xstream engineeringe-Xstream Status & Outlook

Conference A&B

09:00 – 09:30 Laurent Hazard, Guy Van Meulebeke, Luc Dewez, Vito Leo - SOLVAY ADVANCED POLYMER Troubleshooting Fatigue Failure of Injection Molded Bow Limbs, using DIGIMAT and Experimental Fatigue Measurements

Conference A&B

09:30 – 10:00Dariusz Bednarowski, Lukasz Malinowski, Przemyslaw Laskos - ABB CORPORATE RESEARCH CENTER Modeling of Reinforced Thermoplastics’ Mechanical Performance with Use of Failure Indicators

Conference A&B

10:00 – 10:30 Jan Seyfarth - e-Xstream engineeringDIGIMAT 4.1

Conference A&B

10:30 – 11:00 Coffee Break & Partners Exhibition** Sponsor Areas

11:00 – 11:30 Lucien Douven - DSM ENGINEERING PLASTICS Modeling of Failure of Short Glass Fiber Filled Thermoplastics with DIGIMAT

Conference A&B

11:30 – 12:00 Warden Schijve - SABIC Long Fiber Reinforced PP. Material Characteristics & Modeling Needs

Conference A&B

12:05* – 12:35 1. Partner Presentation: SIMULIA 2. Partner Presentation: ANSYS 1. Conference A 2. Conference B

12:35 – 13:55 Lunch Break** Le Cube

13:55 – 14:25* 3. Partner Presentation: AUTODESK 4. Partner Presentation: ALTAIR 3. Conference A 4. Conference B

14:30 – 15:00 Noriyo Ichinose - JSOL CORPORATIONMulti-Scale Approach for CFRP Composite Simulation by JSTAMP/NV

Conference A&B

15:00 – 15:30 Joscha Sehnert - SIMPATEC GmbHCoupled Analysis of Bicycle Brake Made of Glass Fiber Reinforced Polyarylamide

Conference A&B


16:00 – 16:30 Laurent Adam - e-Xstream engineering Beyond DIGIMAT 4.1

Conference A&B

16:30 – 17:00Walid Zerguine - ARKEMATowards the Modeling of Continuous Reinforced Thermoplastics by DIGIMAT Conference A&B

17:00 – 17:45 DIGIMAT Open Q&A Session Conference A&B

17:45 – 18:15 Pr Richard Assaker - CHRU Lille, Cervical Arthorplasty Design RationaleDr Philippe Maxy - Medtronic, Designing Orthopedic Implants with Biomedical Materials

Conference A&B

19:00 – 23:30 Gala Evening (see invitation flyer) Le Sud

TUESDAY, OCTOBER 5

* 5 minutes are required to set up partners’ session and transfer rooms** SIG (Special Interest Groups) can be organized during coffee & lunch breaks in conference room C


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08:00 – 08:30 Registration & Welcoming Coffee Sponsor Areas

08:30 – 09:00 Eric Marechal - TECHSPACE AERONumerical Simulation of Short Carbon Fibers Reinforced Thermoplastics in Aircraft Engine Application

Conference A&B

09:00 – 09:30Olivier Moulinjeune - RHODIA POLYAMIDEFirst Use of First Pseudo-Grain Failure Model Conference A&B

09:30 – 10:00 Anne Paquin - GOODYEAR INNOVATION CENTER LUXEMBOURGMulti-Scale Modeling of Fiber Reinforced Rubber Composites

Conference A&B


10:30 – 11:00 Masahiro Seto - KANAZAWA INSTITUTE OF TECHNOLOGY, S. kijima, Y. Kanki – UES Software The Prediction of the Stiffness of Formed Plastic with Homogenization and Microstructure Optimization

Conference A&B

11:00 – 11:30 Massimo Nutini - BASELL POLIOLEFINE srl, Consuelo Garcia Rascon – BASELL POLIOLEFINAS Co. Fiber Orientation Prediction for Reliable Simulations of Glass-Reinforced, Polypropylene-based Components using DIGIMAT

Conference A&B

11:30 – 12:00Frank Braymand - L&L PRODUCTS, Lucien Douven - DSM, Laurent Adam - e-Xstream engineeringCoupling of Digimat to Radioss Bulk and Radioss Block : Improved Physical Property Prediction of Short Fiber Reinforced Polyamide by Utilizing Fiber Orientation

Conference A&B

12:05* – 12:35 1. Partner Presentation: SAMTECH 2. Partner Presentation: DYNAMORE 1. Conference A 2. Conference B

12:35 – 13:55 Lunch Break ** Le Cube

13:55 – 14:25* 3. Partner Presentation : LMS 4. Partner Presentation : MATERIALISE 3. Conference A 4. Conference B

14:30 – 15:00 Manuel Laspalas, I. Viejo, J-M. Bielsa, A. Escolan, J. Gomez - INSTITUTO TECNOLOGICO DE ARAGONSimulation of a Short Fiber Reinforced Composite and a Nano Reinforced Composite with Digimat-FE

Conference A&B

15:00 – 15:30 Kevin Brown, Richard Brooks - UNIVERSITY OF NOTTINGHAM Meso-scale Modeling of the Dynamic Response of Cellular Glass Particle-Reinforced Composites with Digimat-FE

Conference A&B


16:00 – 16:30 Utku A. Ozden, Geng Chen, Alexander Bezold, Christoph Broeckmann - IWM RWTH AACHENHomogenization of WC-Co Hard Metal Materials Elasticity with Digimat-MF and other Analytical Mean-Field Methods

Conference A&B

16:30 – 17:00Martin Reiter, Franz Hiptmair, Zoltan Major - JOHANNES KEPLER UNIVERSITY OF LINZSimulation of the Deformation Behavior of Digital Materials by Digimat-MF and Digimat-FE Conference A&B

17:00 – 17:15Roger Assaker - e-Xstream engineeringClosing Remarks & Adjourn Conference A&B

DIGIMAT Users’ e-Xstream Invited Lecture Partners

WEDNESDAY, OCTOBER 6



DATE: October 5, 2010TIME: 09.00 - 09.30ROOM: Conference A&B

Laurent hazardCAE Senior SpecialistSolvay Advanced Polymer

Co-authorsGuy Van Meulebeke, Luc Dewez & Vito Leo, Solvay Advanced Polymer

BIOGRAPHY

Laurent Hazard was trained as a civil engineer. He has more than 15 years of experience in vari-ous CAE-related jobs, mainly in the automotive world. After working for Solvay Automotive for 5 years, he completed his curriculum with a PhD in structural dynamics & acoustics. He is now working in the Technical-Marketing team of Solvay Advanced Polymers, where his primary focus is on helping customer design better plastic products using high performance polymers.

PRESENTATION SUMMARY

Solvay’s Advanced Polymers are devoted to highly technical applications (aircraft, medi-cal, aerospace, automotive,...). Reinforcements such as glass or carbon fibers are typical for these high performance polymers. A key factor for accurate CAE prediction of the mechanical behavior of products is to consider the effect of these fillers on the rheological & mechanical properties of the polymers. Companies like e-Xstream engineering have largely contributed to the spreading use of micro-mechanical mean-field approaches to interface flow results (like glass fiber orientation predictions) with nonlinear stress analysis codes. We will illustrate this approach with the troubleshooting of an original application: injection molded bow limbs for sport archery. A new design, targeting “expert” users, was failing the fatigue testing. Isotropic simulation could not explain the breakage. The use of injection molding simulation, mechanical analysis based on an anisotropic DIGIMAT material law, and experimental fatigue measurements helped us understand the root causes behind failures and propose a solution. This original case will emphasize the tight link between the part design, the gating choice, the flow pattern and the durability of the final product.

Go to the Survey Section to rate this presentation and participate to our draw to win the new iPod Touch!

TROUbLEShOOTING FATIGUE FAILURE OF INjECTION MOLdEd bOW LIMbS, USING dIGIMAT ANd EXpERIMENTAL FATIGUE MEASUREMENTS

Deformation of a half bow limb made of Ixef, under full rope extension


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MOdELING OF REINFORCEd ThERMOpLASTICS’ MEChANICAL pERFORMANCE WITh USE OF FAILURE INdICATORS

dariusz bednarowskiResearch ScientistABB Corporate Research Center

Co-authorsŁukasz Malinowski, Przemysław Laskos, ABB Corporate Research Center

BIOGRAPHY

Dariusz Bednarowski graduated in 2001 from Cracow University of Technology, Poland. He specializes in Computational Mechanics (FEA, FDM – theory and application, new materials, programming etc.). Since 2000 he has been working at the ABB Corporate Research as a research scientist. He mainly works with CAD and CAE tools aiming the improvement of product manufac-turing processes.


Presented work is focusing on numerical simulation of short glass fibers reinforced thermoplas-tic composites produced with injection molding technology. A combination of leading software packages for: injection molding analysis (two leading systems), material modeling (DIGIMAT) and structural analyses (Abaqus) enables computer simulations of mechanical behavior incor-porating information on fibers’ distribution. Such approach allows prediction of mechanical response much closer to reality. A series of tensile tests on injection molded samples prepared according to ISO standard as well as for «real» product were conducted in order to compare simulation approach with reality.



Medium voltage embedded pole



dIGIMAT 4.1

dr jan SeyfarthProduct Managere-Xstream engineering

BIOGRAPHY

Jan Seyfarth owes a PhD thesis in theoretical inorganic chemistry from the Ludwigs Maximilians Universität in Munich and University Bayreuth. After 8 months working for CADFEM GmbH as free-lancer, supporting the introduction of innovative material simulation software, he integrated the company in September 2007 being responsible for the topic of multi-scale material modeling and product management for the material simulation software DIGIMAT from e-Xstream engi-neering. On September 2010 he joined e-Xstream engineering as Product Manager of DIGIMAT.


The presentation will give an overview over the new capabilities of DIGIMAT 4.1.1, the ver-sion soon to be released. In this software nonlinear thermo-mechanical material models (TEVP,TEP,...) are available to the Digimat-MF user. In Digimat-MX the possibilities for ad-vanced reverse engineering have been enhanced and failure indicators have been added to the range of stored data. With Digimat to Hypermesh and Digimat to Optistruct two new possibilities of coupling have entered the code and will further increase the DIGIMAT community in the future. A completely new capability is the output project. Here the user is given the possibility to select his own choice of output from Digimat-MF in Digimat to CAE. Results like principle strain or stress on micro level are therefore now available. In Digimat-FE a set of useful tools for pre- and post-processing simplifies life for the user. The created RVE can thoroughly be analyzed to see whether it fulfills the input constraints.



Detailed of a ribbed beam (PA6 GF30%) deformed in a 3-point

bending test


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MOdELING OF FAILURE OF ShORT GLASS FIbER FILLEd ThERMOpLASTICS WITh dIGIMAT

dr Lucien douvenDesign Engineer - EPDSM Engineering Plastics

BIOGRAPHY

Lucien Douven owes a Master of Science and a PhD in Mechanical Engineering from the Eindhoven University of Technology on the field of Computation of properties of injection molded products. He worked for 3 years at TNO as research scientist in the area of resin transfer molding. Afterwards he worked for 7 years at Philips Research as research scientist in the field of bio-mechanics of the skin and an additional 7 years at Philips Display Components as senior development engineer in the field of glass processing. Since 2006 he works at DSM Engineering Plastics, Material Science Centre as design engineer with an expertise in computational methods for engineering plastics, concentrating on integrative simulation techniques.


Over the last few years large steps have been taken in the development and application of homogenization methods for the modeling of materials with a complex microstructure. At DSM we apply these methods for short glass fiber filled thermoplastics, where the microstructure of the part is governed by the flow during injection molding. With DIGIMAT, material non-linearity (plasticity, strain-rate dependency, etc.) can be taken into account by the homogenization methods.

First developments were aimed at applying the DIGIMAT approach to model the mechanical behavior of parts, where we focus on the overall part response (e.g. force-displacement curve) and try to identify critical areas in the part design. In our opinion the added value of DIGIMAT is in the more accurate identification of critical areas in parts that are highly loaded. Thus the next step in the integration of DIGIMAT in our CAE methods is to incorporate the modeling of the material failure. In this way we will not only be able to identify critical areas but also predict the overall load level at which failure will occur.

In the presentation we will give an overview of the use of several failure criterions, already implemented in DIGIMAT. Another topic will be the analysis of the stress-strain behavior of so-called RVE’s (Digimat-FE) that we will use to better understand the various failure modes of glass filled engineering plastics.


Detailed of a ribbed beam (PA6 GF30%) deformed in a 3-point

bending test



LONG FIbER REINFORCEd pOLypROpyLENE. MATERIAL ChARACTERISTICS & MOdELING NEEdS

Warden SchijveExpertise Manager STAMAXSABIC Innovative Plastics

BIOGRAPHY

Warden Schijve studied Aerospace technology at the Delft University. He worked for 11 years in the design and process development of composite materials at Fokker Aircraft. Afterwards he worked for 14 years as project leader and expertise manager for material, process andapplication development for STAMAX long glass PP, at SABIC (previously DSM). He is currently the Expertise Manager of STAMAX at SABIC Innovative Plastics.


Specific aspects, determining mechanical behavior for long glass fiber reinforced polypropylene will be discussed. They are:1. Fiber orientation2. Fiber length distribution3. Fiber dispersion

It will be explained that especially fiber dispersion needs a different modeling of micromechanical behavior compared to e.g. short glass fiber reinforced materials. It will also be explained how to deal with above three items in mechanical simulations.



Ashed long fibre sample, showing bundles


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REALISTIC SIMULATION AS AN INTEGRAL bUSINESS pRACTICE

Gaetan Van den berghSales EngineerSIMULIA

BIOGRAPHY

Gaetan Van den Bergh studied Aerospace Engineering at the TUDelft in the Netherlands. In 2004 he started working as a pre-sales engineer for Noesis Solutions, a spin-off of LMS International. He was involved in Process Automation and Design Optimization. In 2008 he joined SIMULIA Benelux as a sales engineer. He is responsible for Belgium and Luxembourg.


SIMULIA is the Dassault Systèmes brand that delivers a scalable portfolio of Realistic Simulation solutions including the Abaqus product suite for Unifi ed Finite Element Analysis, multi-physics solutions for insight into challenging engineering problems, and SIMULIA SLM for managing simulation data, processes, and intellectual property.

In this presentation we will focus on the different possibilities to couple DIGIMAT to Abaqus and what are their advantages. To demonstrate this coupling we will use a composite hull example. A brief overview is given which introduces the problem, the required solvers and how to setup the coupling itself. From the presentation you will see that DIGIMAT and Abaqus are tightly integrat-ed and the perfect solution to solve accurately your nonlinear implicit and explicit FEA problems of composite structures.

DATE: October 5, 2010TIME: 12.05 - 12.35ROOM: Conference APARTNERS SESSION

Displacement in composite yacht hull calculated with a combination of Abaqus and DIGIMAT solutions



dr Thierry MarchalIndustry DirectorANSYS, Inc.

ENSURING pROdUCT INTEGRITy ThROUGh ENGINEEREd MATERIALS

BIOGRAPHY

Thierry Marchal received his degree in Mechanical Engineering from the University of Louvain in Belgium in 1990 and joined the Polyfl ow group in 1991 before completing his training with a MBA in marketing in 1993. He became the POLYFLOW Product Manager in 1996. Thierry enlarged his industry focus as Global Market Segment Manager for the Materials industries with Fluent in 2004. He was appointed Global Industry Director for the Healthcare, Construction and Consumer Product Industries in ANSYS in 2006. Thierry is the author of numerous technical and business papers covering polymer, glass, food, healthcare and construction applications.


Ensuring product integrity means designing products that perform superbly and meet both manufacturer and customer expectations in every respect: customers demand safety, reliability, low environmental impact and, high quality while manufacturers strive to minimize risk, time and cost to market. There is not one design aspect that can be sacrifi ced for another and an enterprise that wants to propel itself into the future must meet all expectations.

And, the truth is that to succeed in this economic climate you cannot conduct business as usual. Getting designs right the fi rst time comes from being able to predict – early in the design process - how a product will behave in real-world situations. Innovative companies that are integrating new composite materials into smart products are adopting virtual design and rapid prototyping to engineer their materials to precise design requirements.

Necessary Rapid Design Solution is suggested through seamless workfl ow involving manufactur-ing codes, DIGMAT and ANSYS software leading to Smart Product with Integrity.

DATE: October 5, 2010TIME: 12.05 - 12.35ROOM: Conference BPARTNERS SESSION

Average fi ber orientation


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dr hugues AlglaveExperta Calculation SimulationAutodesk Moldfl ow

BIOGRAPHY

Hugues Alglave is engineer in Material Sciences and PhD of the University of Strasbourg, special-ized in the fi eld of applied simulation for the modeling of plastic materials. During his career he worked for companies such as Total Chimie, Hutchinson and Moldfl ow Corp. Since the acquisi-tion of Moldfl ow Corp. by Autodesk in June 2008, Hugues Alglave works at Autodesk as Expert Calculation & Simulation in the Manufacturing Division, where he provides technical support to customers. He is also the R&D contact for the Moldfl ow products.


With the acquisition of Moldfl ow by Autodesk, the Moldfl ow products are entering a new era. The industry leading Moldfl ow products now have access to state of the art technology avail-able within the Autodesk portfolio of products, and advances in product development are made faster than ever before! One important focus area is the development of new and improved fi ber orientation capabilities. In the Autodesk Moldfl ow Radium Technology Preview, we made two important improvements available to the Moldlfow customers. More accurate fi ber orientation results can improve predictions of process-induced mechanical properties that can be used by structural FEA analysis through the use of products like DIGIMAT. Reduced Strain Closure Model for Short Fiber reinforced plasticsThe Forgar-Tucker equation is the basis for the default fi ber orientation mode used for fi ber orientation calculations in Autodesk Moldfl ow and other injection molding simulation software. Recent research has indicated that the standard Folgar-Tucker model over-estimates the fi ber orientation develops orientation too quickly compared to experimental data. The new Reduced Strain Closure model (RSC model) has been developed to capture the slower orientation dynamics and preserve objectivity in calculating fi ber orientation, and is available for Midplane, Dual Domain and 3D models. This development was done in collaboration with Pro-fessor Tucker at the University Illinois, and Delphi (an industrial partner). Delphi Technologies, Inc. (Tucker et al., 2007) holds the United States Patent on the Reduced Strain Closure model, and Autodesk holds an exclusive license for use of this model.Long Fiber Orientation ModelFibers having an initial length longer than 1 mm are generally considered as long fi bers. Long fi ber fi lled plastics are becoming increasingly popular, in particular in the Automotive industry where their light and the way they orient themselves during the injection molding process can substantially differ from the way short fi bers orient. A new fi ber orientation model called the anisotropic rotary diffusion (ARD) model was developed in collaboration with the US Depart-ment of Energy and Pacifi c North West Labs (PNNL) to predict the fi ber orientation for long fi ber reinforced injection molded plastics, and can be used in Midplane, Dual Domain and 3D models. For Both short and long fi bers, the new models and experimental validations are presented in

COMpARISON OF RECENT FIbER ORIENTATION MOdELS WITh MEASUREd FIbERORIENTATION dATA IN AUTOdESk MOLdFLOW INSIGhT


Average fi ber orientation




haroun MokdadDirector Product DesignAltair product Design

BIOGRAPHY

Haroun Mokdad owes a Master of Science from the Ecole polytechnique de Lausanne. In 2002 he carried out a Master Degree in Structural Engineering at Supaero. In 2003 he started working at Mecalog Group, in Paris, first as structural engineer and then as Project Manager in 2005. In 2008 he has joined Altair France as Manager Product Design Team. He is currently Director Product Design France.


Experimental studies show that the microstructure of a composite material has a strong influ-ence on its macroscopic response. The multi-scale material modeling approach implemented in DIGIMAT allows one to numerically account for the composite microstructure properties in the computation of its effective properties. In this presentation, we give an insight into such influ-ences by illustrating them with simple applications, using the HyperStudy module from Altair to pilot Digimat-MF.

Three examples will be presented:

- Calibration of Digimat-MF electrical percolation model against experimental data using the built-in optimization capability of HyperStudy.- Analysis of a GFRP’s sensitivity to the aspect ratio and the content of its reinforcing phase (glass fibers), via a design of experiment procedure.- Identification of the aspect ratio equivalent to an aspect ratio distribution based on a GFRP’s mechanical response.


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Noriyo IchinoseSales EngineerJSOL Corporation

MULTISCALE AppROACh FOR CFRp COMpOSITE SIMULATION WITh jSTAMp/NV ANd dIGIMAT

BIOGRAPHY

Noriyo Ichinose carried studies at the Graduate School of Engineering Science of Osaka Univer-sity and owes a Master of Engineering in Mechanical Engineering from that university. Since April 2001 he works in the Engineering Division of JSOL Corporation as Consultant and Technical sales for simulation software. He owes 2 years experience in the automotive design to improve crush capability, performing consulting projects for Japanese automotive companies, pre and post sales activities for LS-DYNA and DIGIMAT, developing the technique for high accurate plastic simulation.


In the automotive industry, CFRP is becoming the essential material because of the lightweight property and the stiffness. Some automotive companies try to use the CFRP instead of metal panel in low price vehicle. A press forming is used to reduce the production time and cost of CFRP parts.

In the metal forming simulation, we have 15 years of experience and are developing the inte-grated forming simulation system named “JSTAMP/NV”. To adapt JSTAMP/NV to “CFRP forming simulation”, we made the simple interface between DIGIMAT and JSTAMP/NV.

In this presentation, we will introduce JSTAMP/NV with DIGIMAT and show some examples for CFRP forming simulation. Furthermore the crush simulation considering the forming effect will be shown.


Formability evaluation of CFRP panel



CALCULATION OF A bICyCLE bRAkE COUpLEd WITh MOLdEX3d ANS AbAqUS

joscha SenhertAccount ManagerSIMPATEC GmbH

BIOGRAPHY

Joscha Senhert owes a Diploma in Applied Sciences from the University of Rosenheim. He started as Managing Director of PlastSim GmbH in 2003. In January 2009 he started working as sales for DIGIMAT at CADFEM GmbH. Since August 2010 he works at Simpatec GmbH as Account Manager for Moldex3D and more.


Fast and cost efficient design of higher quality, lighter and more energy efficient part for bicycles are one of the key success factors for this high engineered bicycle brake industries. Predictive CAE and the use of fiber reinforced materials, offering good weight to mechanical performance ratio. The nonlinear Finite Element Analysis (FEA) of bicycles parts using anisotro-pic 50 % fiber reinforced Polyamids materials has become today a standard step in any modern design process.

This presentation will show the differences between linear elastic analysis of an Magura hand brake system and calculations using interfaces from injection molding simulations. It will show the results of linear elastic anisotrop calculations compared with anisotrop non linear elasto-plastic simulations with DIGIMAT. Linear simulations are just able to show geometric dependent behavior forced by a load just in time for one temperature and without any effect of plasticity. It is mostly no tool to predict the location of the failure of a part. To include the anisotrop behaviour is one tool further to predict the areas that are concentrating the stresses and strains. But this results are jumping from element to element in very huge area. Just the aniso-tropic elasoplastic (non linear) material characterization that let the forces flow through the part is able to predict precisely the location of the part failure under load.



Mechanical analysis of a Magura brake


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bEyONd dIGIMAT 4.1.

dr Laurent AdamR&D Team Leadere-Xstream engineering

BIOGRAPHY

Dr Laurent Adam is Physicist Engineer in Solid Mechanics from the University of Liège. From 1998 to 2003 he was a Ph.D. student at LTAS – Department of Thermomechanics from the University of Liège. In 2003 he started working as researcher and teaching assistant at the University of Liège, Department of Fracture Mechanics and Department of Structural and Multidisciplinary Opti-mization. He started at e-Xstream engineering in 2004 as Development & Application engineer (R&D team). Since 2006 he is Team Leader Software Development at e-Xstream engineering.


The presentation will focus on three of the major topics being part of the DIGIMAT technological roadmap, namely:

• Modeling of long fiber reinforced plastics: e-Xstream starts working on the modeling of such materials in order to account for their micro structural specificities like bended fibers.

• Modeling of fatigue behavior of fiber reinforced materials: The theoretical framework that will be the basis of this new set of capabilities will be described.

•Modeling of unidirectional composites: This targets two objectives: 1. The link with composite manufacturing modeling software to take into account

the real fiber orientation in the final part. 2. The development of new modeling techniques both based on finite element like

or mean field homogenization, in order to describe the damaging and failure of laminates.




CERVICAL ARThROpLASTy dESIGN RATIONALE

BIOGRAPHY

Richard Assaker graduated as Medical Doctor from the Liege Medical University in 1983. He finalized his PhD Thesis, focused on biothecnology, at the Université du Droit et de la Santé de Lille II in April 2001. Afterwards, he obtained qualification for research direction and started teaching neurosurgery in 2002. Pr Richard Assaker is within other: President of the French-speaking Neurosurgical Spine Society, Member of the board of the French Surgical Spine Society, Vice president of the French Surgical Spine Society (June 2010), President of the French Surgical Spine Society, Member of the board of the Spine committee at EANS (European Association of Neurosurgical Societies), Member of the French Neurosurgical Society, ...

PRESENTATION SUMMARY Cervical disc herniation and/or spondylosis leads to radicular pain and myelopathy. If surgery is required, anterior and /or posterior decompression could be the adequate treatment. Over the last 50 years, various combinations of anterior and posterior instrumented surgeries have been devised and refined and continue to be used. The most frequent decompression technique considered as the “gold standard” still the arthrodesis. The problem with interbody cervical fusion is that typically a reduction in effective motion occurs. As a consequence, the iatrogenic rigidification of a mobile cervical segment leads to an adjacent disc disease, requiring reop-eration. This has been quoted as being as high as 3% per year. To avoid the side effect of the arthrodesis, a functional restoration, arthroplasty, has been designed in order to preserve the motion and protect the adjacent segment. avoid deformity, reduce adjacent segment stresses, and allow for an adequate decompression without having to use bone graft. The authors will expose the medical needs, the rationale and limitations of motion preservation technology in the cervical spine.


pr Richard AssakerCHRU de Lille, Hôpital SalengroPôle de neurochirurgie

DATE: October 5, 2010TIME: 17.45 - 18.15ROOM: Conference A&BINVITED LECTURE


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ORThOpEdIC IMpLANTS REqUIRE A TREMENdOUS dIVERSITy OF MATERIALS

BIOGRAPHY

Philippe Maxy has a M.S. in Mechanical Sciences from the Ecole Nationale Supérieure des Arts & Métiers of Paris. In 1993, he started as Product Development Engineer for Sofamor, a company specialized in the manufacturing of orthopedic devices. He was involved in the development of various spinal devices, dealing with deformations, fractures or degeneration treatments. Since joining Medtronic in 1999, he had various assignments within the Medtronic Spinal R&D organi-zation. He began as Research Manager, working mainly on Finite Element studies and implants design optimization. Most recently he was designated as Principal Scientist, responsible for the initiation, design, development, execution, implementation and promotion of scientific research projects.


Since three decades now, rigid materials are used as constructive support in applications such as hip and knee arthroplasty, as well as in devices for spinal stabilization or fixation. Histori-cally, as well as today, metals have been the material of choice. Metals such as titanium offer superb strength and stability. However sometimes too much is really too much. A phenomenon called stress shielding is often quoted with respect to rigid implants: bone growth is influenced by the amount of stress that is placed on it. Like many tissues in nature, bone grows in accor-dance with its needs. When too strong, stiff metal constructs take over the function of the bone, it simply loses its strength. One of the solutions is to use materials that have an elastic modulus much closer to that of bone. In recent years, significant progress have been made by the use of new materials like PEEK (PolyEther Ether Ketone) as a substitute for titanium in certain devices such as vertebral inter body disc spacers, bringing the implants stiffness a step closer to that of bone. Finally, the use of more elastomeric materials is gaining ground. Silicone polymers have been used for a very long time, being applied in many cardiovascular applications as well as in the use of joints. Elastomeric materials may have the potential to mimic the soft tissues of the human body in the way that rigid materials can mimic bones. In the spine, some elastomers have similar damping characteristics as the real human disks and should therefore be a suit-able material to develop replacements for the real tissues. Characteristics of such materials, in combination with the implant design, may provide 3D motion that mimics the spine’s natural biomechanics. Today, medical companies focus on new materials, particularly in polymer tech-nologies to make new and improved treatments. On their side, the material manufacturers must face important challenges in so far as materials for orthopedic implants are selected based on biocompatibility, mechanical match, corrosion resistance, friction and wear resistance, osteo-integration capabilities, toxicity, longevity, ease of installation, etc.


dr philippe Maxy Principal ScientistMedtronic

DATE: October 5, 2010TIME: 17.45 - 18.15ROOM: Conference A&BINVITED LECTURE



NUMERICAL SIMULATION OF ShORT FIbERS REINFORCEd ThERMOpLASTICSIN AIRCRAFT ENGINE AppLICATIONS

BIOGRAPHY

Eric Marechal graduated from the University of Liège as Electro-mechanical engineer in Aero-nautics with a specialization in structural analysis, numerical methods and compositematerials mechanics. He worked for 4 years as Research Engineer at the Aerospace Laboratory of the University of Liège. Afterwards, he worked for 3 years in the Tire Vehicle Engineer depart-ment at Goodyear S.A. Luxembourg Technical Centre. From 1988 to 2006 he worked as Composite Materials Engineer at SAMTECH S.A. contributing to the development of composite analysis functionalities in the Samcef software suite. From 2006-2008 he worked as freelance consult-ing engineer at SONACA SA. (A400M /A330/A340 programs). Since 2008, he works as freelance consulting methods engineer at Techspace-Aero.

PRESENTATION SUMMARY In the general framework of the “Plan Marshall” R&D program, launched by the Walloon Region in December 2006, the APC project aims at promoting more intensive usage of polymer matrix composites for aeronautical applications within aero structures or engines.

A particular work package is dedicated to the development of a computational optimization chain of short fibers reinforced thermoplastics parts, connecting different disciplines i.e. injec-tion molding simulation, material characterization and Finite Element based structural analysis. This presentation focuses more particularly on the benefit of using Digimat-MF, Map and Digi-mat to CAE solutions allowing taking the local orthotropic nature of the material into account in the Finite Element simulation. Static and modal analyses of a thermoplastic part reinforced with short carbon fibers are presented and comparison is made between standard global homo-geneous isotropic and DIGIMAT based local orthotropic approaches. Comparison with experi-mental observations is also presented.


Eric MarechalDT Stress AnalysisTechSpace Aero


GenX-1B thermplastic inner shroud sectorDIGIMAT view of fibers orientation

GenX-1B thermplastic inner shroud sector vibration testing device


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Olivier MoulinjeuneExpert SimulationRHODIA Engineering Plastics

FIRST USE OF FIRST pSEUdO-GRAIN FAILURE MOdEL

BIOGRAPHY

Olivier Moulinjeune works as Expert Simulation in the Laboratoire de Simulation & Développe-ment Applicatif of the R&D department at Rhodia Engineering Plastics in Lyon. He coordinates the software tools selection and expansion of the CAE efficiency worlwide. Olivier is currently involved in the development of the MMI ConfidentDesign® Technology, which aims at improving the simulation tools provided to customers. Previously, Olivier Moulinjeune has successively worked as simulation engineer, then simulation support manager for France, Spain and Portugal, to finally manage the Simulation Department at Rhodia Engineering Plastics.


Modeling of fiber reinforced polyamide is continuously and rapidly improving. Mechanical simulation taking into account short glass fiber is about to become a standard. With a finer representation of the material, usual criteria like stress or strain maximum cannot be used anymore. Results interpretation is becoming more complex. Hopefully, the introduction of FPGF failure criteria is bridging the gap between lab experimentations and industrial application. We will show first results obtained using this method and what are the next steps required to make it even better.





dr Masahiro SetoPostdoctoral FellowResearch Laboratory for Integrated Technological SystemsKanazawa Institute of Technology

Co-authors: Dr. Masashi Yamabe, Kanazawa Institute of Technology, Shuya Kijima, Yasufumi Kanki, UES Software Asia

ThE pREdICTION OF ThE STIFFNESS OF FORMEd pLASTIC WITh hOMOGENIzATION ANd MICROSTRUCTURE OpTIMIzATION


BIOGRAPHY

Masahiro Seto has a Ph.D. in Material Design Engineering from the Kanazawa Institute of Technology in Japan. From 2005-2007 he worked as a Research Engineer at the R&D Center of the Nippon Light Metal Company Ltd. Since 2007, Dr Seto is a Postdoctoral Fellow at the Research Laboratory for Integrated Technological Systems at the Kanazawa Institute of Technology. His research topics include: Visualization of Resin Flow Behavior during Injection Molding, Study of Heat Transfer between Resin and Mold during Injection Molding, Study of Prediction of Warpage in Injection Molded Article, Design of Impact Absorption Parts using Numerical Simulations, Simulation of Automotive Dynamics.

PRESENTATION SUMMARY Recently, foamed plastic is beginning to be used for the inner package material of a car and is considered that demand continued to increase for a weight saving. Foamed plastic is divided into two layers. The surface is skin layer of only a plastic, and an inside is foaming layer. The stiffness reduction can be constrained with weight saving, since it can be controlled the thick-ness of the skin layer and a foaming layer, the foaming amount. However, the actual condition is asking the optimal material structural design in the experiment of trial and error. Furthermore, when the composite material containing a foaming layer is analyzed by conventional FEM, it becomes a large-scale model, and execution time is taken too much and is not made easily.

This report examined how to presume the material characteristics of the foamed plastic by Digimat-MF. The used foamed plastic is mixed 4% of the foaming agent in PP. The test piece is formed by injection molding and the thickness is 3mm. Examination and analysis were conduct-ed by the following procedure: 1. Make test pieces of PP, Foaming Part and composite, examine the tensile test and draw

up the S-S curves. 2. Observe the microstructure, the thickness of the skin layer and the distribution of

voids, void size, etc. 3. Identify mechanical constants from S-S Curve by Digimat-MF. 4. Make a test piece of the formed plastic for the bending test, do the test, and measure

the deformation. 5. Calculate the bending test model by FEM using the stiffness from Digimat-MF and

examine the deformation with the experimental result. 6. Examine the stiffness change by the thickness change of skin layer and by the

Amount of Voids, and an optimal microstructure.

By this research, the parameters which determine the material characteristics of foamed plastic by Digimat-MF became clear and it turned out that optimization of microstructure is possible.


Foamed injection molding product


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dr Massimo NutiniResearcher & CAE EngineerBasell Poliolefine

Co-authorConsuelo Garcia Rascon, Basell Poliolefinas Co. Española

FIbER ORIENTATION pREdICTION FOR RELIAbLE SIMULATIONS OF GLASS-REINFORCEd, pOLypROpyLENE-bASEd COMpONENTS USING dIGIMAT


BIOGRAPHY

Massimo Nutini is graduated in Nuclear Engineering (1992) and Ph.D. Mechanical Engineering / Energetics (1996) from the Polytechnic of Milan, Italy. His lines of specialization include numer-ical methods applied to engineering, (F.E., CFD, Monte Carlo, Soft Computing). He has worked as researcher at Pirelli Cavi from 1996 to 2002, authoring several international Patents (European and US). Since 2003 he works as Researcher and CAE Engineer at Basell Poliolefine srl, developing new methods for Polymers Mechanical characterization and numerical simulation, finalized to increase the reliability of Finite Elements analysis.


The accuracy of a structural simulation of glass-reinforced, polypropylene-based components is contingent on the prediction of the fiber distribution in the part, which is the basic informa-tion resulting from the process simulation. In the injection molding process, the fiber distribu-tion is usually determined by using the Folgar-Tucker equation, as in the Moldflow code. In this instance, we examine the main parameters that are to be set and fine-tuned to show their impact on the final results in a very simple benchmark test using an injection-molded plaque. An industrial component application is also shown.




dr Frank braymandMaterial & CAE Technical ExpertL&L Products

Co-authorsLucien Douven, DSM Engineering Plastics, Laurent Adam, e-Xstream engineering

COUpLING OF dIGIMAT TO RAdIOSS bULk ANd RAdIOSS bLOCk: IMpROVEd phySICAL pROpERTy pREdICTION OF ShORT FIbER REINFORCEd pOLyAMIdE by UTILIzING FIbER ORIENTATION

BIOGRAPHY

Frank Braymand owes a PhD thesis from the INSA Lyon on the hammer drilling of concrete materials. His first crash simultations applied on heterogeneous materials. Frank has worked during 4 years at PSA, dedicated to design automotive structure to fullfill crash requirements using steel and aluminum. For 10 years now, he has been working at L&L Products, introducing structural reinforcements made of polymers into the automotive industry. His first, and not last, DIGIMAT simulations applied on polymers; How to improve Reliabilty, Weight Saving, Cost efficiency in the design.


Lightweight structural applications using polymers reinforced with short fibers, processed by injection molding, are well known in many technical fields. The main interest in using such mate-rials is the design freedom, the high mechanical material properties with respect to the density, the capabilities to produce parts for high volumes. On one hand, one of the main characteristics of these materials is a strong anisotropic behavior. These materials are also known to be visco-plastic, strain rate dependent and sensitive to damage. The fiber orientation along the part, the intrinsic matrix and fiber materials properties are the most influent factors.

However, in the CAE process, the assumption of a global isotropic material model is generally used by default. As a consequence, the application is then over-designed to guarantee a func-tional and robust output.

This presentation will show how to implement the fiber orientations and other material specifici-ties into the CAE process, using DIGIMAT coupled to Radioss bulk (Optistruct) and Radioss block. The study is based on a real and industrial application. The improvement of predictions, induced by the coupling of Digimat to Radioss bulk (NVH applications) and Radioss block (crash appli-cations), will be highlighted. And with an improved predictivity, optimal and robust lightweight design is then possible.



Anisotropic simulation using DIGIMAT - Radioss Bulk strain energy density on 4th

modal shape


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jean-pierre delsemmeR&D Senior EngineerSAMTECH

EXTENSION OF dIGIMAT – SAMCEF COUpLING TO dIGIMAT-FE

BIOGRAPHY

Jean-Pierre Delsemme was graduated as Civil Engineer in Electro-Mechanics from the Univer-sity of Liège, in 1981. In 1982, he joined Cockerill Mechanical Industries as engineer on nuclear equipments. In 1984, he worked for SONACA in the aeronautics and joined in 1985 the University of Liège as Research engineer. He also took part to SAMCEF development and support. Jean-Pierre Delsemme joined SAMTECH in 1986 to develop further in SAMCEF analysis modules and to bring a technical assistance for sales, studies and customers…He is now R&D Senior Engineer and is currently involved in several research projects dedicated to composite material simula-tion.


During the APC project (Avion Plus Composite, More Composite Aircraft) supported by the Walloon Region in the context of SKYWIN Pole of Competitiveness, a fi rst coupling between SAMCEF and Digimat to CAE has been initiated. This fi rst version opened the door to DIGIMAT material models within SAMCEF FE software and, in particular, the possibility to simulate short fi ber composites produced by injection process, in industrial stress analyses.

In order to extend further the DIGIMAT - SAMCEF integration, a coupling with Digimat-FE will also be initiated. In a fi rst step, the import of geometry in SAMCEF Field CAD based pre- and post-processor will be automated. Meshing of solids will be made as robust as possible. Periodic boundary conditions will be introduced with the help of existing SAMCEF capabilities. The FE Analyses accounting for the DIGIMAT - SAMCEF coupling will be linear static (within the SAMCEF Asef module) and non-linear static (within the SAMCEF Mecano module). Finally, the obtained numerical results will be sent back to DIGIMAT for post-processing.




dr Andre haufeProcess Simulation ManagerDYNAmore GmbH

MATERIAL MOdELS FOR pLASTIC COMpONENTS IN CRAShWORThINESS SIMULATIONS IN LS-dyNA

BIOGRAPHY

Dr. André Haufe studied civil engineering with emphasis in structural mechanics, mechanics of materials as well as statics and dynamics at the Universities of Stuttgart (Germany) and Calgary (Canada). He received his Ph.D. in 2001 from the University of Stuttgart (Institute of Structural Mechanics) and spent his post-doctorate as scholar of the German Academic Exchange Service (DAAD) at the University of Calgary. In 2002 he joined DYNAmore GmbH and was responsible henceforth for constitutive models, ALE, airbags and modeling of connection techniques. Since 2006 he manages the process simulation group within DYNAmore. Furthermore Dr. Haufe is lecturing the course “Theory and Application of explicit Finite Elements” at the University of Stuttgart.


During the past years polymer materials have gained enormous importance in the automotive industry. Especially their application for interior parts to help in passenger safety load cases and their use for bumper fascias in pedestrian safety load cases had driven the demand for much more realistic finite element simulations. In order to not only predict the deformations but also localized damage and failure correctly, the locally varying constitutive properties of parts and components need to be taken into account. It is obvious that the production history of the part play a major role herein. This trend of needing a much better understanding of the local properties of materials has lead to new approaches in the produceability-to-serviceability process chain in numerical simulations – not only for plastics but also for other materials.

As one of the industry leading general purpose finite element codes LS-DYNA provides a number of interfaces to interact with the internal structures of the finite element code. Besides provid-ing the ability to link individual element types, contact handling subroutines and failure models, also user-defined constitutive models may be linked with any executable of LS-DYNA. Hereby the possibility to interface with other software codes, as for instance DIGIMAT, that deliver or include results from produceability studies (i.e. mould filling simulations but also sheet metal

forming or casting simulations of iron) and that enhance the predict-ability of crash simulations by state-of-the-art material formula-tions, is given.

The presentation will focus on the need of closing the gap between produceability and serviceability simulations. Here a number of theo-retical approaches to take spatial constitutive variance of material properties into account may be fruitful. Benefits as well as downsides will be discussed in the context of crashworthiness simulations with LS-DYNA including the DIGIMAT constitutive model. Furthermore necessary steps to generate needed model parameters will be high-lighted.



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dr Michael hackProduct ManagerLMS International

Co-authorChristophe Liefooghe, LMS International

UNIFIEd pARAMETRIC MOdELING & MULTI-ATTRIbUTE SIMULATION WITh LMS VIRTUAL.LAb INCL. AN OUTLOOk TO EXTENd IT IN COMbINATION WITh dIGIMAT TOWARdS COMpOSITES FATIGUE ANALySIS


BIOGRAPHY

Michael Hack owes a master degree in Industrial Mathematics including a Certifi cate of the Eu-ropean Consortium for Mathematics in Industry (ECMI). He started working at TechMath / LMS in 1995 as method development engineer for fatigue life prediction software. In 1996 he presented a PhD thesis on damage based hysteresis fi ltering. On 1998 he integrated LMS as project leader LMS FALANCS development, to become product manager of LMS Durability CAE products in 2000. Since 2006 he works as product line manager for LMS Durability Solutions – CAE.


More than ever before, the automotive industry operates in a highly competitive environment. Manufacturers must deal with competitive pressure and with confl icting demands from custom-ers and regulatory bodies regarding the vehicle functional performance, which forces them to develop products of increasing quality in even shorter time. To address these challenges and deliver optimal collaboration between design and engineering, the integration between CAD and CAE is key.

Through a strong link between CAD and CAE, along with the integration of all simulation steps in one environment, new methodologies are developed, allowing the full utilization of parametric geometry based analysis, enabling quick “what if” scenarios simulation, and thus front-loading design with simulation. LMS Virtual.Lab is fully integrated with Dassault System CATIA V5, and therefore seamlessly linking CAD with CAE. With increasing awareness towards reducing CO2 emission, polymer composites are being increasingly looked at as an alternative to conventional engineering materials. Besides being extremely light weight, random fi ber composites are also easy to manufacture and have numer-ous other advantages over conventionally used metals. Despite all the promises held by random fi ber composite materials, their use in industry today is rather limited.

This can be ascribed to a large extend to the reason that methods which are both reliable and computationally inexpensive are unavailable in market. The development time of vehicles which use conventional engineering materials has come down drastically and even durability analysis has been systematically incorporated in the design cycle trough FE-based numerical simulation methods. LMS and e-Xstream therefore suggest now a reliable and computationally inexpensive method to study durability in Random fi ber composite materials. Besides being computation-ally inexpensive the proposed method will also determine the critical areas and achieve similar prediction accuracy as is possible for metals.

Generic assembly model in LMS Virtual Lab



FROM SCAN TO FINITE ELEMENTS USING ThE MIMICS INNOVATION SUITE


pieter-jan CorthoutsApplication EngineerMaterialise

BIOGRAPHY

Pieter-Jan Corthouts started his carrier after studying Master of Science in Mechanical Engineer-ing at the KULeuven as a researcher at the same university. His research domain at that time was dimensional metrology. Since this research was in cooperation with Metris –a company specialized in 3D metrology equipment- the logical step was working at Metris fi rst as produc-tion specialist, fi nally as CT-scanning specialist. Currently he holds a position at Materialise where he is responsible for the Micro- and TechCT business. At Materialise he wants to innovate this business and further develop this domain.


Materialise Industrial Software develops innovative software applications for enabling and optimizing the advanced use of rapid prototyping (RP), tooling and manufacturing techniques. Whether it’s STL fi le handling and manipulation, preparation for rapid prototyping, tool design, 3D CAD communication, design optimization or even reverse engineering, our software equips customers to accomplish their most challenging tasks with ease. Materialise Software offers a wide range of activities applicable in a variety of markets and industries. Its SDS department develops customized, integrated software applications. Our highly automated solutions boost effi ciency and reduce lead-times, resulting in increased productivity within entire processes.

Improved mesh of a pyrite and Calcite structure


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Manuel LaspalasProject ManagerInstituto Tecnologico de Aragon

Co-authors: I. Viejo, J.M. Bielsa, A. Escolan, J. Gómez, Instituto Tecnológico de Aragón (ITA)

SIMULATION WITh dIGIMAT-FE OF A ShORT FIbER REINFORCEd COMpOSITE ANd A NANO REINFORCEd COMpOSITE

BIOGRAPHY

Manuel Laspalas owes a Master of Engineering degree and works as a RTD researcher at ITA since February 1999. His lines of specialization include material characterization, models development and simulation for different types of materials: metals, plastics, elastomers... He has worked in around 50 projects, both for the private sector and in public funded research at national and international level. He is currently acting as a project manager in ITA strategic projects.


ITA is currently carrying out several investigations on different heterogeneous materials. The purpose of this presentation is to show some examples where we are evaluating the capabilities of DIGIMAT to predict effective properties of different materials.

The fi rst example is the study of a thermoplastic (PET) reinforced with glass fi bers. Taking as an input data the fi ber orientation measurements performed on material samples, an analysis of the proper RVE size is performed. As the fi ber orientation has preferential directions, a RVE with different length, height and width dimensions is more suitable to allocate the required fi ber content percentage. The dimensions are made dependent on the components of the second rank orientation tensor. The calculations are done using Abaqus.

The next example shows a methodology for development of 3D RVE model of spherical nano-sized particles. This methodology was applied to a PCL (poly-caprolactone) matrix reinforced with PEGylated silicata nano-sized particles. RVEs were built up from the morphological proper-ties studied by using TEM. In order to obtain an optimized mesh and an accurate prediction, a convergence study of RVEs and a sensitive analysis of boundary conditions and RVE-size were carried out, respectively. The FE approach was compared with mechanical properties. Results revealed that the interface formed between matrix and nano-particles in the functionalization procedure has to be taken into account. Finally, this interface was modeled in the RVE, improving signifi cantly the numerical predictions.



RVE of short fi ber thermoplastic composite

(highly aligned)

RVE of nano reinforced composite with particle coating



dr kevin brownResearch Fellow Polymer Composites Research groupUniversity of Nottingham

Co-authorRichard Brooks, University of Nottingham

MESO-SCALE MOdELING OF ThE dyNAMIC RESpONSE OF CELLULAR GLASS pARTICLE-REINFORCEd COMpOSITES WITh dIGIMAT-FE


BIOGRAPHY

Dr Kevin Brown is currently a Research Fellow at the University of Nottingham in the Polymer Composites Research Group. His current research work is on developing meso-scale compu-tational models for novel particulate-reinforced composites. He has developed advanced finite element models for simulating the complex damage modes and deformation behavior of composites, foams and sandwich structures under static and dynamic impact loading. Kevin has worked as a consultant on the application of composites in the transportation sector while on assignment at Network Rail, Bombardier Transport and the Highways Agency. Kevin earned a Masters (MEng Hons) in Mechanical Engineering and a PhD in Mechanical Engineering from the University of Nottingham.


There is increasing interest in developing novel cellular particulate composite materials for high energy absorbing applications in the defense and automotive industry. However such materials have high heterogeneous microstructures and their behavior under dynamic loading is complex. The aim of this study is to gain a deeper understanding of the influence of the constituent mate-rials on the macroscopic properties of the composite through multi-scale modeling.

In this paper the Digimat-FE software is used to generate two-dimensional (2D) and three dimensional (3D) meso-scale representative volume element (RVE) geometrical models for a particulate composite system comprised of randomly distributed cellular glass balls embedded in a polymer matrix. The generation process is based on the random placement of glass balls of a specified size range and volume fraction into the matrix material. The geometrical models are then meshed using the Hypermesh software. The meso-scale RVE models are analyzed under dynamic compression loading using the LS-DYNA explicit finite element code. The progressive damage and fracture of the cellular glass balls is modeled with the Johnson-Holmquist elastic-plastic damage model. The stress-strain response and damage obtained from the simulations shows good agreement with experimental results over a range of strain rates. The models are used to investigate the influence of volume fraction, strain rates, voids and clustering on the energy absorbing capabilities of the material.


Stress distribution in a cellular particulate composite under dynamic loading

Comparison of Homogenized Elastic Modulus for a Co Based WC-Co Hard Metal Material obtained

from various Homogenization Schemes


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dr Utku A. OzdenPh.D studentIWM, RWTH Aachen

Co-authorsGeng Chen, Alexander Bezold, Christoph Broeckmann IWM, RWTH-Aachen

A STUdy ON ThE hOMOGENIzATION OF WC-CO hARd METAL MATERIAL’S ELASTICITy WITh dIGIMAT-MF ANd OThER ANALyTICAL MEAN-FIELd METhOdS

BIOGRAPHY

Utku Ahmet Özden (M.Sc.), Ph.D. student and member of the IWM-RWTH Aachen material applications simulation group since 2009, has conducted his B.Sc. and M.Sc. studies in Middle East Technical University (METU-Turkey) Geological Engineering Department. He has solid knowledge on the degradation and mechanics of brittle materials and has about 8 years of experience in numerical simulation applications. Moreover he has several publications related to the subject in refereed international and national journals and congress proceedings.


Tungsten carbide-cobalt (WC-Co) hard metals have high hardness as well as high wear resis-tance, and hence are widely used as machining tools and structural parts [Aok96]. By nature WC-Co hard metals are genuinely heterogeneous materials since they are composed of dissimi-lar materials. Nevertheless, in macroscopic level the composite demonstrates homogeneous properties. Generally experimental work is conducted in order to determine such macroscopic properties however the commercial software Digimat-MF offers a robust homogenization func-tion in order to determine properties such as elastic modulus which would decrease the need for experimental work. The main objective of this study is to evaluate the consistency between the results obtained from Digimat-MF and different analytical homogenization methods. Analyti-cal homogenization methods mainly based on mean-field theory comprise an important cluster of homogenization methods. Most methods in this category depending on Eshelby’s research in 1960s [Esh57] are rooted in a very precise mechanics background, although due to the dif-ficulty of modeling they far or less have to make some compromises and impose several strongly constrained conditions. However, they are capable to offer a prediction of satisfactory accuracy with minor computational effort. In addition to Digimat-MF, mean-field theory based homog-enization schemes such as Mori-Tanaka, dilute, self-consistent and differential methods are applied to study the WC-Co material [Hil65; Mor73; Nor85]. On the other hand, based on Hill’s theorem [Hil63], theoretical prediction bands acquired from Voigt and Reuss scheme are also applied for the further validation of the homogenization results [Reu29]. The analytical homog-enization theorems were implemented to commercial software MATLAB for the modeling and cal-culations. The results obtained from the different schemes are plotted indicating the change of normalized elastic modulus (E/Eco) with respect to increasing inclusion volume content (VolWC) and the trend lines were compared. Except the homogenized elastic modulus values resulted from dilute method, prediction from all mean-field theory based homogenization scheme differ slightly and has a nice agreement with the results of Digimat-MF. Meanwhile, these predictions lie inside the bounds posted by Voigt and Reuss scheme.



Comparison of Homogenized Elastic Modulus for a Co Based WC-Co Hard Metal Material obtained

from various Homogenization Schemes


S I M U L A T I O N S O F T W A R E & E N G I N E E R I N G S E R V I C E S 1 0 0 % F O C U S E d

Martin ReiterAssistant Institute of Polymer Product EngineeringJohannes Kepler University Linz

Co-authorsFranz Hiptmair, Zoltan Major,Institute of Polymer Product Engineering, Johannes Kepler University Linz

SIMULATION OF ThE dEFORMATION bEhAVIOR OF dIGITAL MATERIALS WITh dIGIMAT-MF ANd dIGIMAT-FE

BIOGRAPHY

Martin Reiter obtained a Master in material science from the Montanuniversity Leoben in 2007. From 2007 to 2009 he has worked at the Polymer Competence Center Leoben GmbH as Researcher in the field of dynamic material characterization and simulation. Since 2009 he is Assistant at the Institute of Polymer Product Engineering at Johannes Kepler University Linz. Research fields: Characterization of the material behavior of polymers under static and dynamic loading; Mate-rial modeling for finite element based structural simulation; Investigation of macroscopic as well as micromechanics based material models.

PRESENTATION SUMMARY Recently, a novel PolyJet prototyping device (Objet Geometries Ltd, Israel) for 3D multi-material printing was introduced. In addition to the conventional application of this device, the rapid prototyping of various components and products in the design phase, a novel application was developed and implemented and partly described in this paper.

Due to the special capabilities of this machine, the virtual microcells created in Digimat-FE can be produced by using various model materials. The company provides materials over a wide elastic modulus range from approx. 1 MPa up to 3500 MPa. While the low modulus materials (1 to 5 MPa) correspond to the mechanical behaviour of elastomers, the high modulus materials can be used to simulate the deformation behaviour of more stiff thermoplastic polymers. Further-more, these materials reveal significantly different deformation and failure behaviour over a wide strain range which is reflected in the wide variety of their stress-strain curves.

Micromechanical modeling of both elastomer matrix (soft) based and thermoplastic matrix based compounds was performed using elastic, hyper elastic and elastic-plastic models in Digimat-MF and Digimat-FE. While, for soft matrix the filler particles were modeled by stiff thermoplastic particles in the size range of 0.5 to 2 mm revealing different aspect ratios and ori-entation, for hard matrix the soft materials were used as fillers. To determine adequate material data, tensile tests were carried out with additional full-field strain analysis.

The microcells were realized of thin tensile specimens with nominal thickness of less than 1 mm and 5x5x5 mm3 cubes. Tensile and compressive test were performed and both the global force-displacement curves and the local strain distributions determined by the experiments and by the simulations were compared. The digital compounding provides novel perspectives for a rapid material development by combining material prototyping and micromechanical modeling.



A real production of a periodic Digimat-FE microcell built with a multi

material 3D printer (Connex350 by Objet)

O N A d V A N C E d M A T E R I A L M O d E L I N G

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pRESENTATIONS

1. e-Xstream Status & Outlook, Roger Assaker – CEO of e-Xstream engineering

On a scale from 1 to 5, where 1 represents “very low” and 5 “very high”, please rate the interest of this presentation for you:

1 2 3 4 5 Why? ................................................................................................................................

2. Troubleshooting Fatigue Failure of Injection Molded Bow Limbs, using DIGIMAT and Experimental Fatigue Measurements, Laurent Hazard - SOLVAY ADVANCED POLYMER


1 2 3 4 5 Why? ................................................................................................................................

3. Modeling of Reinforced Thermoplastics’ Mechanical Performance with Use of Failure Indicators, Dariusz Bednarowski - ABB CORPORATE RESEARCH CENTER


1 2 3 4 5 Why? ................................................................................................................................

4. DIGIMAT 4.1, Jan Seyfarth - Product Manager, e-Xstream engineering


1 2 3 4 5 Why? ................................................................................................................................

5. Modeling of Failure of Short Glass Fiber Filled Thermoplastics with DIGIMAT, Lucien Douven - DSM ENGINEERING PLASTICS


1 2 3 4 5 Why? .................................................................................................................................

6. Long Fiber Reinforced PP. Material Characteristics & Modeling Needs, Warden Schijve - SABIC


1 2 3 4 5 Why? ................................................................................................................................

7. Multi-Scale Approach for CFRP Composite Simulation by JSTAMP/NV, Noriyo Ichinose - JSOL CORPORATION


1 2 3 4 5 Why? .................................................................................................................................

8. Coupled Analysis of Bicycle Brake Made of Glass Fiber Reinforced Polyarylamide, Joscha Sehnert - SIMPATEC GmbH


1 2 3 4 5 Why? .................................................................................................................................

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9. Beyond DIGIMAT 4.1, Laurent Adam – e-Xstream engineering


1 2 3 4 5 Why? ................................................................................................................................

10. Towards the Modeling of Continuous Reinforced Thermoplastics by DIGIMAT, Walid Zerguine - ARKEMA


1 2 3 4 5 Why? .................................................................................................................................

11. Designing Orthopedic Implants with Biomedical Materials, Richard Assaker - CHRU Lille, Philippe Maxy - Medtronic


1 2 3 4 5 Why? ................................................................................................................................

12. Numerical Simulation of Short Carbon Fibers Reinforced Thermoplastics in Aircraft Engine Application, Eric Marechal - TECHSPACE AERO


1 2 3 4 5 Why? .................................................................................................................................

13. First Use of First Pseudo-Grain Failure Model, Olivier Moulinjeune - RHODIA POLYAMIDE


1 2 3 4 5 Why? .................................................................................................................................

14. Multi-Scale Modeling of Fiber Reinforced Rubber Composites, Anne Paquin - GOODYEAR INNOVATION CENTER


1 2 3 4 5 Why? .................................................................................................................................

15. The Prediction of the Stiffness of Formed Plastic with Homogenization and Microstructure Optimization, Masahiro Seto - KANAZAWA INSTITUTE OF TECHNOLOGY


1 2 3 4 5 Why? ................................................................................................................................

16. Fiber Orientation Prediction for Reliable Simulations of Glass-Reinforced, Polypropylene-based Components using DIGIMAT, Massimo Nutini - BASELL POLIOLEFINE srl


1 2 3 4 5 Why? .................................................................................................................................

17. Coupling of Digimat to Radioss Bulk and Radioss Block : Improved Physical Property Prediction of Short Fiber Reinforced Polyamide by Utilizing Fiber Orientation, Frank Braymand - L&L PRODUCTS


1 2 3 4 5 Why? .................................................................................................................................

18. Simulation of a Short Fiber Reinforced Composite and a Nano Reinforced Composite with Digimat-FE, Manuel Laspalas - INSTITUTO TECNOLOGICO DE ARAGON


1 2 3 4 5 Why? .................................................................................................................................

19. Meso-scale Modeling of the Dynamic Response of Cellular Glass Particle-Reinforced Composites with Digimat-FE, Kevin Brown – University of Nottingham


1 2 3 4 5 Why? .................................................................................................................................

20. Homogenization of WC-Co Hard Metal Materials Elasticity with Digimat-MF and other Analytical Mean-Field Methods, Utku A. Ozden - IWM RWTH AACHEN


1 2 3 4 5 Why? ................................................................................................................................

21. Simulation of the Deformation Behavior of Digital Materials by Digimat-MF and Digimat-FE, Martin Reiter - JOHANNES KEPLER UNIVERSITY OF LINZ


1 2 3 4 5 Why? ................................................................................................................................

dIGIMAT USERS’ MEETING

22. What are your top 3 reasons to come to the conference?

TOP 1 ................................ TOP 2 ..................................... TOP 3 ..........................................

23. In terms of your TOP 3 reasons, how is the level of your satisfaction about the conference?

Excellent ❏ Good ❏ Fair ❏ Poor ❏

24. Overall, what do you think about:

Excellent Good Fair Poor

Conference Location ❏ ❏ ❏ ❏

Conference Hotel ❏ ❏ ❏ ❏

Presentations Content ❏ ❏ ❏ ❏

Gala Evening ❏ ❏ ❏ ❏

Overall Organization ❏ ❏ ❏ ❏

General Communication ❏ ❏ ❏ ❏

SUR

VEY

25. As to you, what could we improve for coming Users‘ Meeting?

TOP 1 .........................................................................................

TOP 2 .........................................................................................

TOP 3 .........................................................................................

26. Are you planning to participate to the 2011 DIGIMAT Users’ Meeting?

Yes ❏ No ❏ Don’t know ❏

dIGIMAT SOFTWARE (pLEASE dO ONLy FILL IN ThIS SECTION IF yOU ARE dIGIMAT USER)

27. What version of DIGIMAT do you use?

3.0.1 ❏ 3.2 ❏ 4.0.1 ❏ 4.0.2 ❏

28. What modules of DIGIMAT do you use?

Digimat-MF ❏ Digimat-MX ❏ Digimat-FE ❏ Digimat to CAE ❏ Map ❏ Micross ❏

29. What is the application of DIGIMAT in your company?

.......................................................................................................................................................................................................

.......................................................................................................................................................................................................

30. What are the TOP 3 points you like best in using DIGIMAT?

TOP 1 .........................................................................................

TOP 2 .........................................................................................

TOP 3 .........................................................................................

31. What are the TOP 3 points we can improve in the DIGIMAT material modeling platform?

TOP 1 .........................................................................................

TOP 2 .........................................................................................

TOP 3 .........................................................................................

32. What are TOP 3 developments you would like to see in the coming versions of DIGIMAT?

TOP 1 .........................................................................................

TOP 2 .........................................................................................

TOP 3 .........................................................................................

pARTNERS EXhIbITION (pLEASE dO ONLy FILL IN ThIS SECTION IF yOU ARE A SpONSOR AT ThE 2010 dIGIMAT USERS’ MEETING)

33. Were you exhibiting for the first time at the DIGIMAT Users’ Meeting?

Yes ❏ No ❏

34. How would you rate your overall experience at the DIGIMAT Users’ Meeting?


35. How would you rate the value of your exhibition booth at the DIGIMAT Users’ Meeting?


36. Overall, what do you think about:

Excellent Good Fair Poor

Number of attendees ❏ ❏ ❏ ❏

Quality of attendees ❏ ❏ ❏ ❏

Exhibiting space ❏ ❏ ❏ ❏

Number of sales leads ❏ ❏ ❏ ❏

Advertising Opportunities ❏ ❏ ❏ ❏

Event website ❏ ❏ ❏ ❏

37. Do you plan to participate as sponsor to the next DIGIMAT Users’ Meeting ?

Yes ❏ No ❏ Don’t know ❏

38. We are always looking for ways to improve your experience at the DIGIMAT Users’ Meeting. Please provide us with any comments or feedback: ............

.......................................................................................................................................................................................................

.......................................................................................................................................................................................................

.......................................................................................................................................................................................................

.......................................................................................................................................................................................................

2 0 1 0 D IG IM AT U s ers ’ Meet ing - T he Ma ter ia l Mod el ing Conf erence

NO

TES

2010 DI GI MAT U s ers ’ Meet ing - T he Ma ter ia l Mod el ing Conf erence


NO

TES

2010 DI GI MAT U s ers ’ Meet ing - T he Ma ter ia l Mod el ing Conf erence


NO

TES

Copyright © e-Xstream engineering, 2010. e-Xstream engineering, eX, eXdigimat and their derivates are regis-tered trademarks of e-Xstream engineering SA. All other brand, product, name or trademark are the property of their respective owners.

INFO [email protected]

TEChNICAL [email protected]

www.e-Xstream.com

e-Xstream engineering S.A.Rue du Bosquet 7L-1348 Louvain-la-NeuveBelgium

e-Xstream engineering S.a.r.lZ.I. Bommelscheuer L-4940 BascharageLuxembourg

e-Xstream engineering LLCSuite 390 14492 Sheldon RoadPlymouth TownshipMI 48170 USA

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