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THE AUTOSIM PROJECT 4.3 Materials Characterisation Materials Characterisation is potentially a large subject if all forms of materials and their modelling methods in different analysis codes are to be considered. Therefore, we have attempted to establish the topics most important to today’s automotive engineers. Some topics have been discussed because of specific gaps identified under the Integration and Confidence themes. Clearly, inferior material characterisation will undermine other efforts to improve automotive CAE. The overall objective is to establish a methodology that can address the key points required to ensure best practice in Materials Characterisation for automotive CAE, and that can also highlight key technological areas where breakthroughs are required. 4.3.1 Initial Topics A number of topics were initially put forward for consideration. These were based in part on the findings of the earlier FENet project (Ref. [9]). The initial topics were as follows: • New materials—such as composites, foams, advanced high strength steels, non-ferrous metals • Choice of constitutive models and the required input data • Modelling connections • Fracture, damage, and failure • Effects of manufacturing and assembly on final material properties It has been clear from the outset that there is much uncertainty as to how best to deal with these issues; moreover, we believe that engineers may not be applying novel material technologies in vehicle design because of uncertainty about how to model them correctly. 4.3.2 Refinement of Topics—Questionnaire and Materials Matrices In order to gauge the industry’s highest priorities, a questionnaire was circulated that set out the initial topics and asked for participants to rank these to indicate Technological Maturity, State of Practice, and Priority Level. However, the results eliminated only a small number of topics, indicating a broad range of interests amongst the participants and a high level of importance attached to most topics relating to Materials Characterisation. SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 AUTOSIM 21 |
CURRENT & FUTURE TECHNOLOGIES IN AUTOMOTIVE ENGINEERING SIMULATION Further refinement of the subject was carried out using a set of matrices indicating the importance of key topics regarding the materials of interest to automotive engineers (mild to ultra high strength steels, non-ferrous metals, plastics, composites, foams, and elastomerics). This was further refined by considering four different load cases typically addressed in automotive design (static, transient short term, transient long term, and cyclic). Analysis of the matrices confirmed that many topics still need more development in order to move automotive CAE forward. The following topics were distilled from the results: • New ultra High Strength Steels require new constitutive models • Strain Rate Sensitivity for all materials (short duration transient loading) • Composites (all load cases) for material properties, modes, failure or damage, connections, and even the effects of forming • Failure/Fracture/Damage involving most materials across all load cases; understanding the differences and how to best model them in CAE • Effects of Forming for all materials for short duration loading and non-metals for other cases; effect of assembly also highlighted, particularly for metals. • Choice of Constitutive Models for non-metals—complexity vs. ease of use • Modelling Connections for all materials and most load cases Several of the presentations to the Technical Workshops have explored one or more of these topics; please see the AUTOSIM web site for details (Ref. [8]). 4.3.3 Best Practice—Is it already in use? To supplement the circulated questionnaire and matrices, an analysis of the automotive development process was carried out. The result was a more detailed view of the material models used in specific areas of virtual car development and the identification of important issues mentioned by CAE engineers in their daily work. These issues were assessed by comparison with other simulation topics, such as model creation, quality of geometrical data, etc. Clearly this analysis is not complete and might vary for each car manufacturer. However, discussions at the Technical Workshops suggest that the findings are valid for most OEMs. 22 | SIXTH FRAMEWORK PROGRAMME PRIORITY [6.2] [SUSTAINABLE SURFACE TRANSPORT] 012497 AUTOSIM
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APPENDIX 1: GLOSSARY OF TERMS • U
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