JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 38

FEATURE predictive simulation

Fig. 2: Example of
a FiRMA processed
model

the part will be costly and overweight.
All these considerations point to the
conclusion that the traditional approach
is not appropriate for materials of high
variability. A different design and analysis
approach is needed - one that takes into
account the size of the chips (a chip being
a fibre tow with a distinct orientation within the matrix) and informs the engineer of
what the population of parts will achieve
and not what they might achieve having
made some pessimistic assumptions about
the material properties.
Geometry and scale considerations
When considering applications, the effect
of chip size is important. Chip size affects
material cost with a smaller chipped composite costing more than a larger chipped
version. It also affects the strength and
stiffness distribution across a population
of parts. This cost/performance balance
can be investigated using the FiRMA
simulation method.

Fig. 3: Comparison of simulation versus test using the FiRMA method (test data shown as black points)

The problem
Variation in performance
When determining composite material
properties through testing, all coupons
exhibit variation in performance.
Typically, five coupons are tested and
various statistical quantities are calculated,
including standard deviation and COV
(coefficient of variation), to indicate the
level of variability among the samples. To
ensure a high probability of satisfactory
part performance, a pessimistic approach
is taken: In simplistic terms, for primary
structural parts, calculate the mean minus
three standard deviations to determine
the material allowable to design with. This
traditional approach works if the COV
for the structural properties is small. This

38

results in a population of parts with a tight
distribution of performance.
This is not the case for C-SMC. The calculated COV can be large. If the designed
part is much larger than the test coupons
used, COV for the parts performance
distribution maybe low. But it is more
likely that the part (wanting to make use of
its high, albeit variable, specific stiffness)
is thin walled and therefore also prone to
high part performance variability.
Figure 1 shows results for a single coupon
geometry and 50 test repeats. Taking any
five values to create an allowable is undesirable. If a high material allowable happens
to be created (Point A, Figure 1), many of
the resulting parts will be unsatisfactory in
performance. If a low material allowable
happens to be created (Point B, Figure 1),

jec composites magazine / N°134 May - June 2020

The new approach
FiRMA takes a different approach. It makes
use of RLVEs (representative laminate
volume elements) in the FE (finite element)
model. The FE model is first shell meshed.
The elements are then grouped into subsets.
Each subset is an RLVE - a stack of plies, each
with a random fibre orientation assigned to
each ply (Figure 2). The size of the RLVEs is
related to the chip size of the material, and the
number of plies in any one RLVE stack is dictated by the desired wall and chip thickness.
CLPT (classical laminate plate theory) is used
as standard.
The model is assigned a damage evolution
method, allowing not only stiffness to be
recovered but also the ultimate strength of the
part. The random orientation distribution is
structured to mimic the material, which consists of multiple chip angles. In a population
of parts, each ply orientation will be unique
to each part. The key question is whether any
orientation could lead to an unacceptable
performance. The FiRMA approach automatically redefines all plies on all elements
with an alternative random lay-up. The model
is repeatedly re-run, allowing a population of
results to be constructed, each run with its
own unique stiffness and failure response.
This process is handled by Altair's Hypermesh



JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020

Cover
Edito
“Our products will be mainly designed for the industrial sector”
Contents
NEWS
In brief
Investment
Agenda
BUSINESS
Thermoplastic - The Netherlands: the country of thermoplastic composites
Startup - The beauty of wood with the performance of composites
Strategy - Selling your business, Part 2:finding the right buyer, closing the deal
MANUFACTURING
3d printing - Large-scale additive manufacturingof composite thermoplastics – where are we?
Resin - Epoxy silica resin for highly-stressed composite springs, high-pressure vessels and cryogenic rockets
Surface treatment - The violet light at the end of the tunnel
FEATURE SIMULATION - Is it still possible to skip this step?
- Data managment : Agile design and engineering of advanced materials
- Modelling - Unified modelling and simulation of composite materials and structures
- Sheet moulding compound - Making SMC decisions at an early design phase
- Predictive simulation - Making SMC decisions at an early design phase
- Engineering simulation - Gliding farther and faster
- Building & construction - The future of building and construction lies in project simulation
SOLUTIONS
Sustainability - Sustainable food packaging materials using bionanocomposite films
Composites among us - Composites on the field
Healthcare - Wearable exoskeleton robots to reach a global market of US$ 5.2 billion by 2025
TECHNOLOGY
Matrix - Advanced polyurethane resin for wind turbine blades: enhanced performance at lower blade cost
Inside the lab - Hamburg University of Technology’s Institute of Polymer and Composites
Biocomposites - Advanced polyurethane resin for wind turbine blades: enhanced performance at lower blade cost
Index
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JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - “Our products will be mainly designed for the industrial sector”
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 10
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 11
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Investment
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Thermoplastic - The Netherlands: the country of thermoplastic composites
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 16
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Startup - The beauty of wood with the performance of composites
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 18
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Strategy - Selling your business, Part 2:finding the right buyer, closing the deal
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 20
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 3d printing - Large-scale additive manufacturingof composite thermoplastics – where are we?
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 22
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Resin - Epoxy silica resin for highly-stressed composite springs, high-pressure vessels and cryogenic rockets
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 25
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 26
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 27
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Surface treatment - The violet light at the end of the tunnel
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 29
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - - Data managment : Agile design and engineering of advanced materials
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 31
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - - Modelling - Unified modelling and simulation of composite materials and structures
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 33
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 34
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - - Sheet moulding compound - Making SMC decisions at an early design phase
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 36
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - - Predictive simulation - Making SMC decisions at an early design phase
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 38
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 39
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - - Engineering simulation - Gliding farther and faster
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 41
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 42
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - - Building & construction - The future of building and construction lies in project simulation
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 44
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 45
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 46
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Sustainability - Sustainable food packaging materials using bionanocomposite films
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 48
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 50
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Composites among us - Composites on the field
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 52
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Healthcare - Wearable exoskeleton robots to reach a global market of US$ 5.2 billion by 2025
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 54
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 56
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Matrix - Advanced polyurethane resin for wind turbine blades: enhanced performance at lower blade cost
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 59
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Inside the lab - Hamburg University of Technology’s Institute of Polymer and Composites
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Biocomposites - Advanced polyurethane resin for wind turbine blades: enhanced performance at lower blade cost
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #134 - May/June 2020 - 68
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