A multiscale strategy for the simulation of braided composites with ENVYO

Abstract

Manufacturing processes and parameters have played a crucial role in the design and analysis of composite structures. To exploit potential advantages of composite materials, it is necessary to predict and optimize the manufacturing steps in respect to the optimization of the structure itself. During the past years, the project DigitPro (Digital Prototype) has been developed within the research campus ARENA2036. A multiscale simulation strategy is investigated to cover a full product generation cycle of textile composite components from structure pre-design up to part manufacturing. Start parameters are firstly identified for each step of the cycle. Subsequently, appropriate materials, geometries and manufacturing parameters are found during optimization loops. Finally, the result is sent into real manufacturing process. The mapping tool ENVYO stands as a connector between the various simulations and simulation softwares. Hence, ENVYO allows the transmission of information from one simulation to another. The presentation will focus on two key aspects of the simulation of textile composites. On the mesoscopic scale, detailed finite-element models of the textile laminate are generated, representing closely the complex yarn architecture. The mechanical properties of the laminate are numerically identified by simulating the models under tension, compression and shear loading. The transition to the structure simulation on macroscopic scale is performed via the tool ENVYO following two approaches. The first approach directly uses the material properties generated on the mesoscale for the structure simulation. In the second approach, information from the process simulation is mapped on the structure mesh to take into account the influence of local yarn architecture on the structural behaviour. Both methods will be compared to standard structure simulation and to experimental results. The developed methodology will be illustrated with the example of braided composites and the potential of the process chain will be discussed.