Simulation of woven composite structures considering manufacturing effects

Kurzfassung

In recent years, advanced material models have emerged in finite-element codes for the simulation of composite materials reproducing realistic failure mechanisms. Through the increased reliability in simulation, less conservative designs of composite structures have been made possible. However, most of the current numerical solutions are considering the composite material independently of real manufacturing conditions, which can strongly affect the local material architecture and properties. To extend the potential of composite structures, it is therefore necessary to enhance the simulation models by including additional information from the production processes. To answer this problematic, many works have focused on the detailed simulation of these processes and on the transfer of information between the simulation steps. The present contribution presents the recent advances achieved in the field of numerical process chain for the simulation of woven composite parts within the project Digital Fingerprint in the research campus ARENA2036. In particular, it focuses on the simulation and validation of the draping process using a stacked-shell approach coupled to the material models *MAT_249_REINFORCED_THERMOPLASTIC or *MAT_157_ANISOTROPIC_ELASTIC_PLASTIC. The resulting fibre angles are automatically transferred to a simplified single-layered structural model using the software envyo. An exemplary load case for the structural simulation is investigated and the lately available extension of the draping material card *MAT_249_CRASH is compared with *MAT_262. Finally, a probabilistic simulation framework using the software LS-OPT to account for manufacturing tolerances is presented.