JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 33

Fully coupled process-structure analysis for automotive center floor panel

Homogenization technique (DigimatMF). After creating a material model,
calibrations using tensile test results
from machined-cut specimens are
conducted
(Digimat-MX).
This
calibration process is called Reverse
Engineering (RE), which includes
iterative optimization processes aimed
at finding optimal values of design variables (e.g. material law parameters)
that minimize the difference between
model prediction and experimental
measurements (Figure 3).

-	 FEA simulations were conducted
for the load case to validate static
performance with/without fibre reorientation. Isotropic modelling assumes
that fibre directions are projected onto
the part in respect to the global x-axis.
Process-induced fibre reorientation is
not accurately involved in the isotropic model. A comparison of the stress
contour computed by the isotropic
and anisotropic model at the load case
are shown that involving process induced fibre reorientation (anisotropic
model) has less than one tenth of the
vertical stress in the Y-axis(S22) of the
Global Coordinate System compared
to the isotropic model (Figure 5). If
fibre reorientations are not carefully
considered, an unexpected failure may
occur if local features are in highly
loaded area.
Conclusion
All primary design decisions for automotive center floor panels made of 55% vol.
of unidirectional carbon fibre reinforced
epoxy are made based on the isotropic
model calculated for each design iteration. This model can be used to quickly
evaluate the internal structure and general design considerations. Model stiffness
is then calibrated based on anisotropic
coupled analysis to obtain reliable and to
validate design features from the isotropic
model. Anisotropic coupled analysis involves the combination of manufacturing
process, microstructure, and structural
simulation. In addition, mechanically significant details and features are designed
based on the anisotropic model.

-	 After submitting FEA jobs, it allows
you to start generation of the coupled
analysis files including the input deck
associated to the structural model,
modified with the specified Digimat
materials and manufacturing data,
each Digimat material used in the
AAFF-T_JEC
14/5/18 will
10:12
This1 approach
be able to support
analysis and
a copyCOMPOSITES_2018_Juny2018.pdf
of relevant manu-

finding alternative material selections or
manufacturing process configurations
prior to the actual process implementation, which will avoid unnecessary, costly
modifications.
More information:
www.c2eskorea.com
knowledgments
This work was supported by Korea
Institute of Industrial Technology
(KITECH).
References
[1] Compositesworld.com. 2020.
Thermoplastic Door A First for
Automotive Composites. [online]
Available at:  [Accessed 25 June 2020].
[2] Reiter, M., Pröll, A., Thurmeier, M. and
Major, Z., 2020. DESIGN METHODOLOGIES
FOR AUTOMOTIVE COMPONENTS
MADE FROM SHORT CARBON FIBER
REINFORCED THERMOPLASTIC
MATERIALS. [online] Iccm-central.org.
Available at:  [Accessed 25 June
2020].
[3] Hartl, A., Jerabek, M., Freudenthaler,
P. and Lang, R., 2015. Orientationdependent compression/tension
asymmetry of short glass fiber reinforced
polypropylene: Deformation, damage
and failure. Composites Part A: Applied
Science and Manufacturing, 79, pp.14-22.
[4] Hartl, A., Jerabek, M., Freudenthaler,
P. and Lang, R., 2015. Orientationdependent compression/tension
asymmetry of short glass fiber reinforced
polypropylene: Deformation, damage
and failure. Composites Part A: Applied
Science and Manufacturing, 79, pp.14-22.

C

M

Y

CM

MY

CY

CMY

K

N°137 November - December 2020

/ jec composites magazine

Feature Automotive

-	 Manufacturing
mesh
including
fibre orientations from compression
moulding analysis can be exported by
FEA interface feature from AniForm
PrePost. The input deck file for
structural analysis (Abaqus) includes
solid mesh, load cases and boundary
conditions.
-	 Digimat-MAP is used to map the
manufacturing process data (Fibre
orientation) to the structural analysis
model by connecting two interfaces,
compression moulding and structural
simulation. Proper overlapping of the
two meshes with scaling, transformation and rotation is required to send
manufacturing data to the component
mesh (Figure 4). Digimat-CAE provides material properties in the form
of subroutines for the desired FEA
solver.

facturing data files.

33


http://www.c2eskorea.com http://www.Compositesworld.com https://www.compositesworld.com/articles/thermoplastic-door-a-first-for-automotive-composites http://www.Iccm-central.org http://www.iccm-central.org/Proceedings/ICCM21proceedings/papers/4126.pdf http://www.intermas-industry.com

JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020

Cover
Edito
“We can change the way we envision global shipping overall”
Contents
NEWS
In brief
Agenda
BUSINESS
Human ressources - Skills requirements in the composite materials sector – the French example
Startup - Make lightness and performance affordable without compromising the environment
Offshore - GWEC: Asia Pacific to become the largest offshore wind market by 2030
MANUFACTURING
Additive manufacturing - The METHOD platform expands to support more materials,applications, and markets
Automation - One-shot manufacturing of cylindrical lattice structures for satellite applications
Recycling - World’s first fully-recycled thermoplastic composite application in aerospace
Additive molding - From large-scale continuous thermoplastic composites to mass production
FEATURE AUTOMOTIVE - Is it possible to do better?
FRP - Fully coupled processstructure analysis for automotive center floor panel
Honeycomb - Composite materials for lighter vehicles
Additive manufacturing - Transforming composite production processes with FDM additive manufacturing
EV - All-composite EV wheel moves to next development phase with pilot production
Security - The world’s fastest armoured car
Natural fibre - Sustainable composite solution for new Toyota LQ concept car
SOLUTIONS
Defence - Drones as wingmen
City - Composites for tomorrow’s cities
Maintenance - Degradation mechanism and maintenance of GFRP hydrochloric acid storage tanks
TECHNOLOGY
Bonding - Adhesion properties of bonded composite-to-aluminium joints using peel tests
Inside the lab - The University of Southern Queensland - Centre for Future Materials
Method - Weight and cost reduction with double-double laminates
Index
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JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - “We can change the way we envision global shipping overall”
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Human ressources - Skills requirements in the composite materials sector – the French example
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 12
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 13
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Startup - Make lightness and performance affordable without compromising the environment
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 16
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Offshore - GWEC: Asia Pacific to become the largest offshore wind market by 2030
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 18
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive manufacturing - The METHOD platform expands to support more materials,applications, and markets
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 20
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Automation - One-shot manufacturing of cylindrical lattice structures for satellite applications
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 22
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Recycling - World’s first fully-recycled thermoplastic composite application in aerospace
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 25
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 26
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive molding - From large-scale continuous thermoplastic composites to mass production
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 28
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 29
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - FRP - Fully coupled processstructure analysis for automotive center floor panel
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 31
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 32
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 33
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Honeycomb - Composite materials for lighter vehicles
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 35
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 36
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive manufacturing - Transforming composite production processes with FDM additive manufacturing
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 38
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - EV - All-composite EV wheel moves to next development phase with pilot production
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 40
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Security - The world’s fastest armoured car
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 42
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 43
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Natural fibre - Sustainable composite solution for new Toyota LQ concept car
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 45
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 46
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Defence - Drones as wingmen
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 48
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - City - Composites for tomorrow’s cities
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 51
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Maintenance - Degradation mechanism and maintenance of GFRP hydrochloric acid storage tanks
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 53
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Bonding - Adhesion properties of bonded composite-to-aluminium joints using peel tests
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 56
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 58
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 59
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Inside the lab - The University of Southern Queensland - Centre for Future Materials
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Method - Weight and cost reduction with double-double laminates
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 68
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