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ATOA CAE Multiphysics and Multimaterial Design With COMSOL Webinar P

3D Printing is projected as the next industrial revolution and it can potentially influence almost every aspect of our daily life in some way. For an individual innovator, 3D printing enables product ideas to come alive! For CAD/CAE Engineers, it is dream come true to make, touch and feel the virtual designs, right next to their workstation as a functional product. The missing link or bottle neck in computer aided product development is prototyping or Product manufacturing. Currently, Conceptual drawing to Engineering design is executed in a digital environment with teams collaborating across the globe. But the final prototyping needs to be done using traditional methods, which is a bottle neck and slows down the entire product development process. But, 3D printing transports the prototyping or manufacturing into the digital environment. Now, from concept to CAD to CAE to CAM can be done under digital environment. Product development in a digital environment is a great enabler and allows us to do the design iterations and development virtually for cost effective and faster product development. Digital product development and 3D printing, coupled with Multiphysics CAE opens up all new possibility of product development. New development in 3D printing such us digital material takes the new product development to newer heights. Functional 3D products with complex shapes for novel functionality can be manufactured right at your desktop. Self-replicating 3D printing machines can revolutionize the industrial manufacturing from linear to nonlinear growth. For end customers, 3D printing technology enables complex, intricate design and high cost production products, custom made. This webinar will start with an overview of 3D printing Technology. The parametric CAD model design methodology in COMSOL for 3D printing will be given. Material modelling for evaluating various materials such as polymers, composites, metals, ceramics and hybrid materials, suitable for 3D Printing will be detailed. Resistive, laser and inductive heating simulations for effective Thermal processing will be highlighted. A wide range of 3D printed products from molecular models to consumer products which are engineered using Multiphysics CAE will be showcased.
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
0% found this document useful (0 votes)
125 views31 pages

ATOA CAE Multiphysics and Multimaterial Design With COMSOL Webinar P

3D Printing is projected as the next industrial revolution and it can potentially influence almost every aspect of our daily life in some way. For an individual innovator, 3D printing enables product ideas to come alive! For CAD/CAE Engineers, it is dream come true to make, touch and feel the virtual designs, right next to their workstation as a functional product. The missing link or bottle neck in computer aided product development is prototyping or Product manufacturing. Currently, Conceptual drawing to Engineering design is executed in a digital environment with teams collaborating across the globe. But the final prototyping needs to be done using traditional methods, which is a bottle neck and slows down the entire product development process. But, 3D printing transports the prototyping or manufacturing into the digital environment. Now, from concept to CAD to CAE to CAM can be done under digital environment. Product development in a digital environment is a great enabler and allows us to do the design iterations and development virtually for cost effective and faster product development. Digital product development and 3D printing, coupled with Multiphysics CAE opens up all new possibility of product development. New development in 3D printing such us digital material takes the new product development to newer heights. Functional 3D products with complex shapes for novel functionality can be manufactured right at your desktop. Self-replicating 3D printing machines can revolutionize the industrial manufacturing from linear to nonlinear growth. For end customers, 3D printing technology enables complex, intricate design and high cost production products, custom made. This webinar will start with an overview of 3D printing Technology. The parametric CAD model design methodology in COMSOL for 3D printing will be given. Material modelling for evaluating various materials such as polymers, composites, metals, ceramics and hybrid materials, suitable for 3D Printing will be detailed. Resistive, laser and inductive heating simulations for effective Thermal processing will be highlighted. A wide range of 3D printed products from molecular models to consumer products which are engineered using Multiphysics CAE will be showcased.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Multiphysics and Multimaterial

Design with COMSOL


Dr Raj C Thiagarajan, PhD
ATOA Scientific Technologies Pvt Ltd
05 APR 2013

Visit
http://www.comsol.co.in/events/953/multiph
ysics-and-multimaterial-design-with-comsol/
ATOA Scientific Technologies
Multiphysics CAE for Innovation TM
[email protected]
• Raj C Thiagarajan, MD of ATOAST,
Currently providing Multiphysics
CAE Design Services for Industrial
Innovation.

• Computational mechanics and http://in.linkedin.com/in/ctraj


composite product development
since 1988

• ATOA Scientific Technologies is a


leading Multiphysics CAE Solution
provider
www.atoa.com

• First COMSOL certified Consultant


from India.
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 2
INTRODUCTION
Engineering is Conversion of Material into Useful Product
Industrial Drivers: Cost, Weight and Performance
CAE product development for first time right
Multimaterial and Multiphysics for Optimal Design

Engineering
Design

Multimaterial Multiphysics

Innovative
Product
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 3
Overview
 Multiphysics Product Design
Multiphysics
Product Engineering
 Materials
• Engineering Materials
• Materials in product design
Material Design/
Mechanics
 Multiphysics design of Material
• Composite mechanics
• Examples: CFRP
Composites Multimaterials
 Focus: Product and Material
Design Link
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 4
Nature & Multifunctional Composites
• Nature uses simplest material in optimal
form for efficient function.

• Composites are used for single


functionality ~ 80% structural

• The future growth is expected from


multifunctional composites.

• The availability of Multiphysics modeling


capability will accelerate adaptation of
Multifunctional composites.
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 5
Engineering Materials
• Conventional Engineering Materials
– Metals
– Ceramics
– Polymer
– Cellular and
– Natural Materials

• Composite Designer Materials

• Emerging Materials
– Smart
– Nano
– Meta

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 6
Multimaterial Product Design
• From “ All steel” ,

Low
“All Aluminum ” All Multi
Composites
Material
Composites” To
Multimaterial

WEIGHT
• Leverage the best of Advanced
material for product Materials
performance.

• Challenges
• Fabrication Noble Aluminum Steel
• Multiphysics
High

• Multifunctional
High COST Low
Performance: High
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 7
Composites
• Combination of any two are
more materials to perform better
than individual constituents.

• Macroscopically (n scale)
homogeneous and
microscopically (n-1 scale)
heterogeneous.

• Composite principle can be


applied to multimaterial at
macro scale.

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 8
Composite Industry Value Chain

Intermediates

Design and Processing

After Service
Constituents

Composite Applications
Fibers: Glass, Carbon, Semi Finish: Design: Constituents, Ply, Aerospace Smart Structural
Kevlar, HDPE, SiC, Boron, Prepregs laminate, product , health
Automobile
process and life monitoring,
Comingled/ Cowoven Transportation
Matrix: Polymer, Metal, Condition
Sheet/bulk molding Consumer monitoring
Ceramic compounds Polymer: PMC:
Industrial maintenance,
Polymer matrix: Reinforced pellets Hand layup, Spray up,
Thermoset, Thermoplastics Resin Transfer Molding, Medical Repair,
Autoclave Molding, Packaging Retrofitting of
Intermediates: Filament, Tape Winding,
Thermoset: Epoxy, Vinyl Oil and Gas composite
Pultrusion,
Ester, Polyester, Polyimides Pultruded rods products
Compression Molding, Energy
Laminates Injection Molding,
Electronics
Sandwich panels Thermoforming.
Thermoplastics: PP, PMI, Infrastructure
PEI, PEEK, PES, PC,ULTEM Composite films/fabrics
Mining

Reinforcement Design
Composite
After
Semi-Finish Intermediate Products
Service
Matrix Processing

• Simulation tools are use at every stage of value chain


• We shall focus on the Material Design of composite products

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 9
Type of Composites

Typical Processing cost

Performance Parameter (Strength, Stiffness..)


• Particulate Constituents

Composites Form
• Short Fiber
Physics
Reinforced
composites Load:
Static
• Long Fiber Dynamic
Reinforced Time
composites
Results:
• Continuous Singlepoint
Fiber reinforced Multipoint
composites
• Multimaterial Macro Composites
Metal polymer hybrids
Metal hybrid picture from Injection molding,
www.plastictechnology.com, pp11.
Sandwich structures
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 10
Material Design/Property Prediction
After US 7838108
• Additive

Normalized Property
• Product Nano

Micro
• Super
– Stiff and tough Macro
– Ultra low weight

Vf
• Meta Material 1 Material 2

– Beyond Nature
Metamaterials
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 11
COMPOSITE Material Modeling
• Analytical • Analytical
– Rule of Mixtures tools
• Micromechanics • Micromechanics
– 2D/3D codes
• Lamination Theory • Classical
Lamination Theory
– Ply, Laminates
• General
• Product performance purpose FEA
– Multiphysics software
• Failure mechanics • COMSOL for
– Damage, progressive composite
failure modeling

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 12
COMSOL Example
CFRP Composites
• Carbon T300 / Epoxy 914 • Structure
• Multiphysics
– Structural+ Electrical • Part
– Structural + Thermal
– Damage Mechanics
• Laminate
– Structural Health Monitoring
• Micromechanics
– UD composites • Fiber
– Particulates • Matrix
– Laminates
• Constituent c 0.142 nm

• Molecular 0.3345 nm

– Graphene Sheet
0.669 nm

– Carbon fiber • ATOMIC a b

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 13
COMSOL Modeling Steps
• Select a suitable physics Structural

(Governing, Constitutive Thermal


equation) x H   E  
E
x E   
H
Electromagnetic t t J  (σ  ε 0 ε"r ω)E  j ε 0 ε 'r E

Acoustic

• Model a representative volume


with periodic boundary condition

• Develop Global/macro and Local/


micro relationship (Virtual Testing)

• Solve and post process for Material


property prediction.
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 14
Micromechanics
Homogenization Theory/
Methods
• Continuum Micromechanics based on
homogenization theory • Mean Field Theory

• Aims at finding a volume elements • Variational Bounding


(Representative Volume Element – RVE, periodic methods
Micro field- PMA response to prescribed macro
• RVE (Representative
response) Volume Element) or
PMA ( periodic Micro
• Prediction of macro properties from micro field)
structure and constituents.
• Generalized Method of
Localization relationship Cells

Micro Macro • Embedded Cell


fields fields
• Windowing Approach
Homogenization relationship
Where, • Variational Asymptotic
W volume, G-surface, Method
u(x)– deformation vector
t(x)– surface traction vector
nG – surface normal vector • Multiscale Models

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 15
Representative Volume
• Square
Array

• Hexagonal
Array

• Random

Micrograph -> Image map -> Material properties


ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 16
Numerical Implementation 2D
• Periodic boundary condition
• u xl= u x0 + ex
• v yl= u y0 + ey
• Load
• Body force
• Global (macro) vs local (micro)
stress and strain
• Integration of variables

• Parametric model to predict the


stress strain behavior

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 17
2D Results
• Isotropic property
prediction

• Polymer composite
anisotropic property
prediction

• Macro performance

• Micro mechanical
exploration for novel
materials
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 18
Matrix
2D Results CFRP Epoxy
914

• T300, Epoxy914, Vf 60% T300


Carbon Fiber
• Quarter segment
• Periodic BC
• Global vs Local

• Transverse
Modulus
• Experiments :
8.96+0.06 GPa
• COMSOL:
9.127 GPa

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 19
2D Random Results

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 20
2D: Thermo Elastic Performance
100
• Design of a Dynamic
Thermal conductivity
Material
• Thermal Insulator to
conductor
0
• Coupled Thermo 80
elastic Analysis + DoE:
Commercial Materials,
Vf, packaging
• Virtual Design of novel
Thermal material

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 21
3D RVE
• Reinforcement shapes
– Fiber
– Whiskers
– Flakes
– Platelets
– Spherical Particles

• Regular or Random

• Create your own 3D RVE using


geometrical modeling tools

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 22
3D Results
• CFRP UD: 60% Vf
• T300 /Epoxy 914
• Longitudinal
Modulus
• Experiments :
140+1.2 GPa
• COMSOL:
139.04 GPa
• Transverse
Modulus
• Experiments :
8.96+0.06 GPa
• COMSOL:
9.095 GPa
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 23
Nonlinear Performance

Stress
• Elasto Plastic
Strain
Performance polymer
matric composites
• Polycarbonate + Glass

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 24
COMPOSITE Damage Mechanisms
• Self sensing of Carbon fiber composites
• Good Thermal and Electrical Conductor

• Fiber
(a)

• Fiber breaks

• Matrix
(b)

• Matrix crack
(c)

• Interface
• Delamination (d)

• cracks
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 25
Numerical investigation
• The electrical conduction
mechanism and the
effect of damage in CFRP
composites were
simulated in COMSOL
using AC/DC Electric
Currents Interface.

• Homogeneous composite
model with effective
properties

• Micromechanical model
with constituent
properties

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 26
Results : Fiber breaks
• UD composites
• Electrode on edge
• Resistance change vs
fiber breaks

• Parallel resistance
model behavior

• Very sensitive to fiber


breaks.

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 27
Results: Matrix Cracks
• Matrix crack
density vs
change in
resistance

• Can detect
matrix cracks
also

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 28
Results : Delamination
• Delamination
length vs
resistance
change.

• Delamination
growth
between
fibers

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 29
Summary
Negative refraction
• Materials, Multiphysics product design
• Micromechanical modeling with COMSOL
• 2D and 3D modeling method and results
• CFRP Simulation vs Experiments -> good
Electrostatic resonance
• Design for Multiphysics and Multimaterial is the
way forward for First time Right Product Design

• Refer COMSOL CONFERENCE PAPERS for more


Composite cloaks
• Visit for the Presentation @
• http://www.comsol.co.in/events/953/multiphysics
-and-multimaterial-design-with-comsol/
Acoustic super lens
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 30
Abstract
• Engineering structures are inherently multimaterial and
multiphysics in nature. However, they are usually
designed for dominant physics. Recent development at
PDE level model and software allows us to design for
Multiphysics and Multimaterial. This webinar will give an
overview of multiphysics and multimaterial mechanics.
The computational design of material and prediction of
structural, thermal, acoustics, and electromagnetic
properties will be detailed. The macro, micro, and nano
scale effects of composites will also be highlighted. The
link between multiphysics engineering application and
the design of material will be detailed.

ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 31

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