With Autodesk Advanced Material Exchange and Abaqus to precise results of structural FEM for fiber reinforced materials

Fibre reinforced materials are an excellent alternative to light metals and sheet metal in the constant strive for reduction of mass for critically loaded components, such as eg. oil filter housings and engine brackets. However, with structural FEM classic material data fails as it doesn't include fibre orientation effects. Since latter cause substantial anisotropy in material, we must calculate on the safe side if we don't know the actual fibre orientation.

 

Slika4 napetostiProblem Definition

From the usage point of view:

  • bad precision of standard FEM due to inaccurate material data (fibre orientation not included in calculation)
  • large safety factor at dimensioning and design
  • lack of knowledge of actual component strength

From the used method point of view:

  • checking of results precision of the method (i.e. FEM-analysis including fibre orientation)

 

Solution

We performed several analyses with Abaqus software with different methods and material data/models. For precise analysis we coupled structural analyses in Abaqus with injection moulding simulations in Autodesk Moldflow Insight, which predicted true orientation of fibres in the component. The orientation was later exported to Abaqus and used for the precise calculation.

We used PA6 Durethan BKV 30 H2.0 material with 30% of glass fibres.The specimen was injected from two different locations (gate A - longitudinal and gate B - perpendicular to the long axis), which incorporated two different orientations of fibres in the component and consequently different material data.

Some important remarks:

  • alltogether we performed an analytical calculation, 4 FEM analyses with 4 different material data and an experiment - everything for two variations of runner system
  • the samples were injected with identical parameters as those used in Moldflow study
  • tensile test was used to determine force at break
  • comparisson of results for various methods was used

 

Purpose and Benefits for End Customer

  • actual strength and stress state of the product
  • lower weight due to better material usage
  • reliable solution, double checked with calibration through experiment
  • lower risks in the design phase and later in product life

 

Table and Figure below show the comparisson of the results of 6 various approaches using different material models and analyses types versus experimental data. One can clearly observe the advantage of using method 5, which was coupled Moldflow and Abaqus analysis.

tabela1 rezultati en

 

slika3 primerjava-rezultatov EN

Detailed information can be found in the attached document.

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