Material Variation for CAE

Methodology for implementation

BACKGROUND Material Variation in CAE

The importance has been recognized to store data about the variation in material quality and
the correlations in the material properties for reuse in a CAE environment.

APPROACH:
How should variation in material properties be captured in simulations, optimizations
and robustness analyses?
How should test data and stochastic effects be stored in order to sample suitable curves
for simulations?

Min Goal
Objective

CAE environment
Material failure variation

Implementation?

Material load

REAR BUMPER CASE VOLVO CARS

Low speed crash represents 70 % of all accidents

Highly integrated components of the rear part of the car
PURPOSE: Minimize replacement costs by letting the rear bumper absorb
all internal energy

CAPTURE A TEST DATA CURVE

Stress vs. Strain

Curve fit model

+ Test data

Arbitrary user defined function

Ex:
Bezier
Spline
Polynomial

Strain hardening

Elastic region

Evaluate the curve fit model

+ Test data
- Curve fit model
Errors

MULTIPLE CURVES
Stress
Fracture stress
Yield stress

How to deal with the variation in material

properties?
Use mean, max, or min?
Youngs Modulus

Strain

Correlations between the material

properties

EXAMPLE: CURVE FIT OF 25 CURVES

Variation in fracture point

25 Tensile strength tests from unique

species of DP600 steel

Curve fit of each Stress vs. Strain curve

Fracture point
Yield stress

Thanks to SSAB for sharing data

CALIBRATION PROCESS

Input of the Stress vs. Strain test data

Constants of
Curve fit model

Evaluation of curve fit model

1 intial guess

One Stress vs. Strain curve for each calibration

100 iterations
to converge

EVALUATE THE CURVE FIT MODEL

Calibration process
Visual inspection of model curve and test
data

+ Test data
- Curve fit model

EVALUATE THE CURVE FIT MODEL

Calibration process
Visual inspection of model curve and test
data

+ Test data
- Curve fit model

EVALUATE THE CURVE FIT MODEL

Calibration process
Visual inspection of model curve and test
data

+ Test data
- Curve fit model

10

EVALUATE THE CURVE FIT MODEL

Calibration process
Visual inspection of model curve and test
data

+ Test data
- Curve fit model

11

CALIBRATION OF THE CURVE SET

Each curve calibrated separately
CURVE ID
Import curve

Calibration project

Constants of each
curve fit calibration

25 designs

12

Individual Curve fit plot

EVALUATE THE CURVE FIT MODEL

Curve ID 23

Evaluate the error variation in

the data set

Curve ID 23
+ Test data
- Curve fit model

13

DISTRIBUTIONS IN THE DATA SET

Distribution fitting to the constants
Constant A of curve fit model

Constant B of curve fit model

Constant C of curve fit model

CORRELATIONS IN THE DATA SET

Correlations value stored for

reproduction of data

RSM OF MATERIAL PROPERTIES IN DATA SET

RSM of each material property

RSM of material properties as a

function of the constants

Fracture strain

Validate the RSM

RSM
VALIDATION DATA

VIRTUAL DATA SET FROM RSM

Monte Carlo Sampling
from distribution

Specified target
correlations

200 designs are sampled to produce a new virtual curve set

PROOF: If the correlation between material properties in the virtual curve set is the
same as in the real data set, the model is validated.

REPRODUCTION OF A CURVE SET

200 Monte Carlo sampling

Test data

REPRODUCTION OF A CURVE SET

200 Monte Carlo sampling

Test data

DATA BASE

Store distribution of constants and RSM of material

properties

Correlations

20

Distributions

RSM

RSM1 (x1,x2,x3)

RSM2 (x1,x2,x3)

RSM3 (x1,x2,x3)

SUMMARY
1. Test data set

2. Choice of curve fit model

3. Calibrate the model and

evaluate errors

4. RSM of material properties

from curve set

5. Virtual curve set from RSM

Validate RSM

Correlations
Distributions
RSM
21

7.

6. DATA BASE
Distribution

Response

RSM1

RSM1 (x1,x2,x3)

RSM2

RSM2 (x1,x2,x3)

RSM3

RSM3 (x1,x2,x3)

CAE implementation