ATOA CAE Multiphysics and Multimaterial Design With COMSOL Webinar P

Multiphysics and Multimaterial
Design with COMSOL

Dr Raj C Thiagarajan, PhD
ATOA Scientific Technologies Pvt Ltd
05 APR 2013
Visit
http://www.comsol.co.in/events/953/multiph
ysics-and-multimaterial-design-with-comsol/
ATOA Scientific Technologies
Multiphysics CAE for Innovation TM
Raj@atoastech.com
• Raj C Thiagarajan, MD of ATOAST,
Currently providing Multiphysics
CAE Design Services for Industrial
Innovation.
• Computational mechanics and http://in.linkedin.com/in/ctraj

composite product development
since 1988
• ATOA Scientific Technologies is a

leading Multiphysics CAE Solution
provider
www.atoa.com
• First COMSOL certified Consultant

from India.
ATOA Scientific Technologies Multiphysics CAE for Innovation TM |www.atoastech.com | 05APR13| COMSOL Webinar 2
INTRODUCTION
Engineering is Conversion of Material into Useful Product
Industrial Drivers: Cost, Weight and Performance
CAE product development for first time right
Multimaterial and Multiphysics for Optimal Design
Engineering
Design
Multimaterial Multiphysics
Innovative
Product
Overview
 Multiphysics Product Design
Multiphysics
Product Engineering
 Materials
• Engineering Materials
• Materials in product design
Material Design/
Mechanics
 Multiphysics design of Material
• Composite mechanics
• Examples: CFRP
Composites Multimaterials
 Focus: Product and Material
Design Link
Nature & Multifunctional Composites
• Nature uses simplest material in optimal
form for efficient function.
• Composites are used for single

functionality ~ 80% structural
• The future growth is expected from

multifunctional composites.
• The availability of Multiphysics modeling

capability will accelerate adaptation of
Multifunctional composites.
Engineering Materials
• Conventional Engineering Materials
– Metals
– Ceramics
– Polymer
– Cellular and
– Natural Materials
• Composite Designer Materials
• Emerging Materials
– Smart
– Nano
– Meta
Multimaterial Product Design
• From “ All steel” ,
Low
“All Aluminum ” All Multi
Composites
Material
Composites” To
Multimaterial
WEIGHT
• Leverage the best of Advanced
material for product Materials
performance.
• Challenges
• Fabrication Noble Aluminum Steel
• Multiphysics
High
• Multifunctional
High COST Low
Performance: High
Composites
• Combination of any two are
more materials to perform better
than individual constituents.
• Macroscopically (n scale)
homogeneous and
microscopically (n-1 scale)
heterogeneous.
• Composite principle can be

applied to multimaterial at
macro scale.
Composite Industry Value Chain
Intermediates
Design and Processing
After Service
Constituents
Composite Applications
Fibers: Glass, Carbon, Semi Finish: Design: Constituents, Ply, Aerospace Smart Structural
Kevlar, HDPE, SiC, Boron, Prepregs laminate, product , health
Automobile
process and life monitoring,
Comingled/ Cowoven Transportation
Matrix: Polymer, Metal, Condition
Sheet/bulk molding Consumer monitoring
Ceramic compounds Polymer: PMC:
Industrial maintenance,
Polymer matrix: Reinforced pellets Hand layup, Spray up,
Thermoset, Thermoplastics Resin Transfer Molding, Medical Repair,
Autoclave Molding, Packaging Retrofitting of
Intermediates: Filament, Tape Winding,
Thermoset: Epoxy, Vinyl Oil and Gas composite
Pultrusion,
Ester, Polyester, Polyimides Pultruded rods products
Compression Molding, Energy
Laminates Injection Molding,
Electronics
Sandwich panels Thermoforming.
Thermoplastics: PP, PMI, Infrastructure
PEI, PEEK, PES, PC,ULTEM Composite films/fabrics
Mining
Reinforcement Design
Composite
After
Semi-Finish Intermediate Products
Service
Matrix Processing
• Simulation tools are use at every stage of value chain

• We shall focus on the Material Design of composite products
Type of Composites
Typical Processing cost
Performance Parameter (Strength, Stiffness..)

• Particulate Constituents
Composites Form
• Short Fiber
Physics
Reinforced
composites Load:
Static
• Long Fiber Dynamic
Reinforced Time
composites
Results:
• Continuous Singlepoint
Fiber reinforced Multipoint
composites
• Multimaterial Macro Composites
Metal polymer hybrids
Metal hybrid picture from Injection molding,
www.plastictechnology.com, pp11.
Sandwich structures
Material Design/Property Prediction
After US 7838108
• Additive
Normalized Property
• Product Nano
Micro
• Super
– Stiff and tough Macro
– Ultra low weight
Vf
• Meta Material 1 Material 2
– Beyond Nature
Metamaterials
COMPOSITE Material Modeling
• Analytical • Analytical
– Rule of Mixtures tools
• Micromechanics • Micromechanics
– 2D/3D codes
• Lamination Theory • Classical
Lamination Theory
– Ply, Laminates
• General
• Product performance purpose FEA
– Multiphysics software
• Failure mechanics • COMSOL for
– Damage, progressive composite
failure modeling
COMSOL Example
CFRP Composites
• Carbon T300 / Epoxy 914 • Structure
• Multiphysics
– Structural+ Electrical • Part
– Structural + Thermal
– Damage Mechanics
• Laminate
– Structural Health Monitoring
• Micromechanics
– UD composites • Fiber
– Particulates • Matrix
– Laminates
• Constituent c 0.142 nm
• Molecular 0.3345 nm
– Graphene Sheet
0.669 nm
– Carbon fiber • ATOMIC a b
COMSOL Modeling Steps
• Select a suitable physics Structural
(Governing, Constitutive Thermal

equation) x H   E  
E
x E   
H
Electromagnetic t t J  (σ  ε 0 ε"r ω)E  j ε 0 ε 'r E
Acoustic
• Model a representative volume

with periodic boundary condition
• Develop Global/macro and Local/

micro relationship (Virtual Testing)
• Solve and post process for Material

property prediction.
Micromechanics
Homogenization Theory/
Methods
• Continuum Micromechanics based on
homogenization theory • Mean Field Theory
• Aims at finding a volume elements • Variational Bounding

(Representative Volume Element – RVE, periodic methods
Micro field- PMA response to prescribed macro
• RVE (Representative
response) Volume Element) or
PMA ( periodic Micro
• Prediction of macro properties from micro field)
structure and constituents.
• Generalized Method of
Localization relationship Cells
Micro Macro • Embedded Cell

fields fields
• Windowing Approach
Homogenization relationship
Where, • Variational Asymptotic
W volume, G-surface, Method
u(x)– deformation vector
t(x)– surface traction vector
nG – surface normal vector • Multiscale Models
Representative Volume
• Square
Array
• Hexagonal
Array
• Random
Micrograph -> Image map -> Material properties

Numerical Implementation 2D
• Periodic boundary condition
• u xl= u x0 + ex
• v yl= u y0 + ey
• Load
• Body force
• Global (macro) vs local (micro)
stress and strain
• Integration of variables
• Parametric model to predict the

stress strain behavior
2D Results
• Isotropic property
prediction
• Polymer composite
anisotropic property
prediction
• Macro performance
• Micro mechanical
exploration for novel
materials
Matrix
2D Results CFRP Epoxy
914
• T300, Epoxy914, Vf 60% T300

Carbon Fiber
• Quarter segment
• Periodic BC
• Global vs Local
• Transverse
Modulus
• Experiments :
8.96+0.06 GPa
• COMSOL:
9.127 GPa
2D Random Results
2D: Thermo Elastic Performance
100
• Design of a Dynamic
Thermal conductivity
Material
• Thermal Insulator to
conductor
0
• Coupled Thermo 80
elastic Analysis + DoE:
Commercial Materials,
Vf, packaging
• Virtual Design of novel
Thermal material
3D RVE
• Reinforcement shapes
– Fiber
– Whiskers
– Flakes
– Platelets
– Spherical Particles
• Regular or Random
• Create your own 3D RVE using

geometrical modeling tools
3D Results
• CFRP UD: 60% Vf
• T300 /Epoxy 914
• Longitudinal
Modulus
• Experiments :
140+1.2 GPa
• COMSOL:
139.04 GPa
• Transverse
Modulus
• Experiments :
8.96+0.06 GPa
• COMSOL:
9.095 GPa
Nonlinear Performance
Stress
• Elasto Plastic
Strain
Performance polymer
matric composites
• Polycarbonate + Glass
COMPOSITE Damage Mechanisms
• Self sensing of Carbon fiber composites
• Good Thermal and Electrical Conductor
• Fiber
(a)
• Fiber breaks
• Matrix
(b)
• Matrix crack
(c)
• Interface
• Delamination (d)
• cracks
Numerical investigation
• The electrical conduction
mechanism and the
effect of damage in CFRP
composites were
simulated in COMSOL
using AC/DC Electric
Currents Interface.
• Homogeneous composite
model with effective
properties
• Micromechanical model
with constituent
properties
Results : Fiber breaks
• UD composites
• Electrode on edge
• Resistance change vs
fiber breaks
• Parallel resistance
model behavior
• Very sensitive to fiber

breaks.
Results: Matrix Cracks
• Matrix crack
density vs
change in
resistance
• Can detect
matrix cracks
also
Results : Delamination
• Delamination
length vs
resistance
change.
• Delamination
growth
between
fibers
Summary
Negative refraction
• Materials, Multiphysics product design
• Micromechanical modeling with COMSOL
• 2D and 3D modeling method and results
• CFRP Simulation vs Experiments -> good
Electrostatic resonance
• Design for Multiphysics and Multimaterial is the
way forward for First time Right Product Design
• Refer COMSOL CONFERENCE PAPERS for more

Composite cloaks
• Visit for the Presentation @
• http://www.comsol.co.in/events/953/multiphysics
-and-multimaterial-design-with-comsol/
Acoustic super lens
Abstract
• Engineering structures are inherently multimaterial and
multiphysics in nature. However, they are usually
designed for dominant physics. Recent development at
PDE level model and software allows us to design for
Multiphysics and Multimaterial. This webinar will give an
overview of multiphysics and multimaterial mechanics.
The computational design of material and prediction of
structural, thermal, acoustics, and electromagnetic
properties will be detailed. The macro, micro, and nano
scale effects of composites will also be highlighted. The
link between multiphysics engineering application and
the design of material will be detailed.

ATOA CAE Multiphysics and Multimaterial Design With COMSOL Webinar P

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ATOA CAE Multiphysics and Multimaterial Design With COMSOL Webinar P

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Drepturi de autor:

Multiphysics and Multimaterial

Design with COMSOL

• Computational mechanics and http://in.linkedin.com/in/ctraj

• ATOA Scientific Technologies is a

• First COMSOL certified Consultant

• Composites are used for single

• The future growth is expected from

• The availability of Multiphysics modeling

• Composite Designer Materials

• Composite principle can be

Design and Processing

• Simulation tools are use at every stage of value chain

Typical Processing cost

Performance Parameter (Strength, Stiffness..)

– Carbon fiber • ATOMIC a b

(Governing, Constitutive Thermal

• Model a representative volume

• Develop Global/macro and Local/

• Solve and post process for Material

• Aims at finding a volume elements • Variational Bounding

Micro Macro • Embedded Cell

Micrograph -> Image map -> Material properties

• Parametric model to predict the

• T300, Epoxy914, Vf 60% T300

• Create your own 3D RVE using

• Very sensitive to fiber

• Refer COMSOL CONFERENCE PAPERS for more

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