1. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Summary Barcelona – results & setting the scene: Materials Characterisation Trevor Dutton, NAFEMS/Dutton Simulation Summary of topics presented and discussion from 1 st AUTOSIM workshop, Barcelona, January 2006

2. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Initial topics - Materials Characterisation Initial topics from Munich: –Composites, foams, new materials –Fracture mechanics & durability –Manufacturing simulation –Constitutive models and material data –Modelling connections Not yet fixed – initial suggestions for discussion Objective: To refine the list of topics to be addressed during the course of the AUTOSIM project

3. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Composites, Foams, New Materials Crashworthiness of composites –energy absorbed in delamination Structural foams for stiffness Polymers (inc. fibre reinforced) Crushable foams for occupant protection Specialist materials for occupant models New metals e.g., magnesium, HSS

4. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Fracture Mechanics & Durability Fatigue Life Prediction Creep & time-related phenomena Probabilistic methods Modelling Crack Growth –Automatic re-meshing –Damage models –Element-free methods Links to: –Manufacturing simulation effects of forming & assembly (esp. residual stress) –Weld / Bond Modelling –Material properties / material models S-N data etc. (new materials) Crack initiation (initial defects?)

5. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Manufacturing Simulation New Processes = new analysis & data needs –confirm feasible e.g., hot forming of Boron steel Cost analysis & optimisation? Effects of forming (sheet metal) –Work hardening (including hardening model) –Thinning –Residual stress –Shape distortion –Effect on residual ductility (material failure) –Phase change (e.g., TRIP steel) Effects of forming (forging) –Residual stress –Shape distortion on cooling –Effect on residual ductility (material failure) –Phase change

6. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Manufacturing Simulation (cont.) Effects of forming (casting) –Defects (porosity, inclusions) –Shape distortion on cooling Effects of forming (moulding) –Directional properties –Weld line Assembly and Paint Process (& Heat Treatment) Process flow, handling, logistics NB Links to Integration Theme Eagerness for using new materials but manufacturing issues not appreciated

7. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Constitutive Models / Material Data Do we have the models needed to represent the effects believed to be important? –Effects of forming –Multi Physics (one model for all applications?) –Model complexity vs. Ease of Use –Analysis efficiency What data do we need and how is it to be managed? –Full range of parameters Strain rate, Failure, etc –Micro-characterisation –Use of optimisation –Material Suppliers? Links to Confidence Theme 5M element models but wrong input data!

8. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Modelling Connections Different types: –Welds; Spotwelds, MIG, laser, … –Joining; SPR, clinching –Bonding Stiffness Failure, including ductility

9. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Presentations FENET –Topics for consideration Smart use of materials Innovations based on new materials –Method of classification (TRL, SoP, PLI) Modelling elastomerics x2 –Variety of Models –Differing Degrees of Data Required –Complexity vs. acceptability of results Simulation of new metal forming processes –New materials need new processes –Need to be able to simulate with confidence (e.g., TRIP steel) –Balance complexity / accuracy / computation cost Materials Issues / Effects of forming –Importance of manufacturing simulation in predicting product performance –Software Usability vs. User Skill

10. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Requirement Indices - FENET Technological Maturity –Material related issues all at 5 bar one (at 6) i.e., method (no better than) validated on test cases –Hence, these issues are far from “ready for use” in the opinion of FENET members State of Practice –Contrastingly, most issues are 6 or above and many are deemed necessary for sign off (9) Priority Level –Reflecting this, most issues are seen as high priority

11. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Discussion Points Place of Materials in the project –Links to both Integration & Confidence themes, e.g.; Effects of forming in Integration Confidence depends on data and models Number & complexity of material models –Help with selection – recommended values? –Availability of relevant data –Use of optimisation for data fitting –Micro-characterisation – may eventually eliminate test dependency Desire to utilise new materials demands forming simulation plus consideration of effects of forming –Best Practice? –Other new materials / new processes that should be considered? Usability –Relates to Front Loading –Training / Benchmarking –Software design implications Integration Issue?

12. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Way forward Use Materials theme to explore “gaps” determined from Confidence and Integration theme? How to determine topics for further review / detailed presentations? –Questionnaire Based on FENET topics – expanded following discussion Based on FENET classification

13. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Topics for Questionnaire New Materials Metals (including High Strength & Ultra High Strength Steels, Aluminium, Magnesium, Stainless Steel) as well as Polymers, Composites, Foams, Elastomerics Material Data, especially Strain rate sensitivity, Fracture / Failure, Fatigue life, Creep, Formability Material Modelling Constitutive Models, Multi-physics aspects, Micro-characterisation, Multi-scalar Modelling, Algorithms, Buckling / post-buckling, Fracture Mechanics, Damage / deterioration modelling Modelling Connections Spotwelds, Continuous welds, Self-piercing rivets, Clinching, Bonding Manufacturing Simulation Forming simulation, Effects of Forming, Assembly simulation, Paint simulation, Process Flow, Handling, Logistics, Cost analysis

14. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 DEVELOPMENT OF BEST PRACTICES AND IDENTIFICATION OF BREAKTHROUGH TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION - AUTOSIM Questionnaire Results … … tomorrow!