Labor Finite-Elemente-Methode (FEM)
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finite element simulation of sheet metal forming, shell elements are widely used. The limits of applicability of the shell elements are sometimes disregarded, which leads to an error in predictions of important values such as springback geometry. The underlying kinematic assumptions of the shell elements do not hold where the thickness of In the metal sheet approaches the value of the radius of curvature. Complex three-dimensional material behavior effects cannot be represented precisely as the result of the simplified kinematics. Here we present a model adaptivity scheme based on a model error indicator. The model-adaptive technique presented in this paper aides to resolve only the critical areas of the structure with a three-dimensional discretization while keeping reasonable computational cost by utilizing shell elements for the rest of the structure. The model error indicator serves as a guide for subsequent automatic adaptive re-meshing of the work-piece followed by a model-adaptive finite element analysis. The accuracy of the approximation obtained by the model-adaptive technique coincides well with that of a more expensive solution obtained with solid elements only.
A Graphical User Interface for Simulating Resin-Transfer-Molding Combining LS-DYNA and OpenFOAM
(2015)
The paper describes parts of the joint research project Swim-RTM including several industrial and academic partners. Its goal is to combine LS-DYNA and the open-source CFD solver OpenFOAM to simulate the production process of continuous fiber-reinforced plastics, particularly the resin-transfer-molding (RTM) process, in which the layers of dry fabric (unidirectional or woven) are formed in the mold (draping) and then filled with liquid resin with high pressure at injection points. Through a combined analysis of both the structural mechanical and the fluid dynamical phases, a better prediction and thereby optimization of the textile components properties as well as injection points can be achieved, improving the manufacturing process. The draping simulation of the fabric layers is carried out with LS-DYNA, while the injection simulation of the matrix material is performed in full 3D with OpenFOAM. A key question in this research project is how local porosities can be derived from the structural computation in the draping step. The purpose of the presented subproject is to develop a graphical user interface (GUI) to enable the simulation of the entire RTM process of long-fiber-reinforced components including the transfer of results between the draping and injection phases. The complete simulation task is relatively complex and involves several software packages, meaning a high effort for the user to get familiarized with. To circumvent this, the GUI aims at requiring from the user only the minimum necessary input data, creating and running the simulation and mapping tasks in the background, and showing graphically all demanded intermediate and final results. For the draping step several current fabric materials such as *MAT_034, *MAT_234, *MAT_235, *MAT_249 are available. Several modelling techniques for the composite setup are also conceivable, including a workflow similar to metal forming applications. In the injection step the fabric is modelled as a porous medium and different transport models and liquid resin types are at hand. For the data transfer between the draping and injection models, i.e. the mapping of data between shell and volume meshes within the developed GUI, first the OpenFOAM volume mesh is converted to LS-DYNA format and the necessary passing parameters are extracted from the output files, then the mapping tool DYNAmap [3] from DYNAmore GmbH is invoked, and finally the OpenFOAM command files are created. After the injection simulation is started and successfully terminated, information, such as the distribution of air inclusions or the shear stress distribution to analyze the reorientation of component fibers, is available and can be transferred from the 3D fluid mesh to an LS-DYNA shell mesh for further computations, for instance a crash simulation. This backward data mapping between volume and shell meshes can then be performed inside the GUI.
Structural mechanic properties of fiber reinforced plastics depend on the single components’ properties, namely matrix and fiber [5]. Simple micromechanic homogenization theories reach a limit when a laminate consists of fabric reinforced layers instead of unidirectional layers. The ondulations of warp and fill yarn caused by the textile semi-finished product are the reason why the mesoscopic scale, which is in between the microscopic and the macroscopic scale, has to be taken into account when mechanically characterizing fabric reinforced composites [3]. In this scale a mesomechanic kinematic can be derived analytically. Especially, when considering free damped vibrations of structures the repeated acting of the kinematic correlation significantly affects the damping behaviour to higher values compared to theoretically predicted damping ratios. The model is investigated using Finite-Element-Analyses and basically validated experimentally.
Finite element (FE)–based studies of preoperative processes such as folding,pleating, and stent crimping with a comparison with experimental inflation tests are not yet available. Therefore, a novel workflow is presented in which residual stresses of balloon folding and pleating, as well as stent crimping, and the geometries of all contact partners were ultimately implemented in an FE code to simulate stent expansion by using an implicit solver. The numerical results demonstrate that the incorporation of residual stresses and strains experienced during the production step significantly increased the accuracy of the subsequent simulations, especially of the stent expansion model. During the preoperative processes, stresses inside the membrane and the stent material also reached a rather high level. Hence, there can be no presumption that balloon catheters or stents are undamaged before the actual surgery. The implementation of the realistic geometry, in particular the balloon tapers, and the blades of the process devices improved the simulation of the expansion mech-anisms, such as dogboning, concave bending, or overexpansion of stent cells. This study shows that implicit solvers are able to precisely simulate the mentioned preoperative processes and the stent expansion procedure without a preceding manipulation of the simulation time or physical mass.