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Thermoforming and automated fabric placement processes show promise for reducing the time and cost for the manufacture of textile-reinforced composites. Simulating these processes can give insight into the manufacturability of the composite structure for each option and guide the design of the manufacturing process. Commonly used fishnet algorithms offer a computationally efficient method for modeling the draping of a fabric on a surface but do not consider the mechanical behavior of the material. A finite element solution for draping has the advantage of including the mechanical behavior of the textile, thereby allowing for investigating the relationship among changes in processing conditions and the resulting quality of the part. In the current research, a finite element based methodology for simulating the behavior of textile reinforced composites during the manufacturing process is presented.

Customer Papers

In this paper, Isight and Abaqus are used to simulate and improve the multiple-stage manufacturing process of heavy-duty cylinder head gaskets. An iterative procedure using Abaqus with custom scripting is first used to identify the required power input to achieve steady-state press operation. An Isight process flow is then developed to simulate the manufacturing process of coils of material being fed into continuous process equipment and automatically bonded in a heated platen press simulated by Abaqus. Isight parameter studies are then applied to examine the heater power required to maintain a consistent temperature on the platens to minimize both heat loss and press stabilization time. The combination of Abaqus and Isight is used to improve both the heavy-duty gasket manufacturing process performance and the resulting product quality.

Customer Papers

This paper describes the behavior and subsequent constitutive modelling of a Hytrel thermoplastic elastomer (TPC-ET) for a so-called Jounce bumper, which is a part of the vehicle’s shock absorber system. This component is subjected to large deformations (up to 100% strain) with significant permanent set and loss of stiffness. The objective of the analysis is to predict the component behavior after cyclic loading to obtain the load-displacement response curve of the Jounce bumper in operational conditions. The possibilities and limitations of the hyper-elastic model, including permanent-set and Mullins’ effect are discussed and numerical results compared to the test data from an actual component.

Customer Papers

The SIMULIA Living Heart Human Model provides a unique testing environment where a pacemaker lead can be virtually inserted and mechanically deformed during the cardiac cycle. Once the mechanical deformation results are obtained, the long-term durability of the implant can be assessed. The virtual nature of the test provides a physiologically accurate methodology to test new and existing devices without exposing patients to un-necessary risk.

Tech Notes

The SIMULIA Living Heart Human Model provides a unique testing environment where a stent can be deployed virtually in coronary arteries and deformed mechanically during the cardiac cycle. Once the mechanical deformation results are obtained, the long-term durability of the stent can be assessed. The virtual nature of the test provides a physiologically accurate methodology to test new and existing devices without exposing patients to unnecessary risk.

Tech Notes

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White Papers

Using this model, natural fracture opening and shear slippage are investigated depending on horizontal stress contrast, adjoining fissure conductivity, and hydraulic-natural fracture intersection angle. Modeling results demonstrate the complexities of hydraulic fracture growth through the intersection with natural fracture such as selective branching and throttling at the intersection. Our fracturing simulation results agree with the analytical criteria for fracture crossing or arrest at the intersection.

Customer Papers

Excessive heat generation and retention in ultra-large dump truck tires is among the most common causes of tire failures in the surface mining industry. Accurate prediction of an operating tire temperature profile involves the use of advanced numerical models and solution schemes to mimic the complete elastomeric materials response to operating conditions. The internally generated heat in a tire is a function of its viscoelastic energy dissipation during rolling. Previous research studies have inaccurately predicted off-the-road (OTR) tire heat generation rates and temperatures by the use of linear viscoelasticity to approximate the rather nonlinear viscoelastic rubber material. This paper presents an accurate approach to predicting OTR tire temperature distributions taking into account the true mechanical response of the filled rubber compounds used in tires.

Customer Papers

Subsidence modeling is an important activity in the oil and gas industry, for the environmental and operational implications associated to this phenomenon. Abaqus/Standard has been used for many years in Eni as the main numerical simulator for studying the geomechanical behavior of reservoirs. The results of a large campaign of acquisition of subsidence monitoring data in conjunction with the advanced analysis of laboratory experiments have shown that, in some cases, an improved mechanical characterization can be tailored to better capture the complex behavior of the reservoir rock under the effect of underground fluid withdrawal.

Customer Papers

Material degradation and dynamic loadings are the main reasons for the damage in metals. Material degradation was caused by crack initiation and fatigue or dynamic loadings are the source for crack growth. The precise and realistic modeling of inelastic behavior of metals is crucial for solving several problems in engineering fields. To predict the initiation and growth of damage, there are several failure models & theories available presently. In this paper, progressive damage and failure material model using explicit finite element techniques are applied to predict the failure of aluminum alloy.

Customer Papers

The coupled Eulerian-Lagrangian (CEL) method in Abaqus/Explicit is essential in component design of head protection systems at BMW Group as it allows an accurate modeling of the gas behavior. However, due to the nature of the algorithm, the modeling of the contact between inflator gas and airbag membrane is a challenging task. Using conventional modeling techniques, two airbag membrane sections are not able to separate again, as soon as they come into contact, as the membrane elements are embedded into Eulerian cells entirely filled with inflator gas. The proposed modeling approach overcomes this severe contact issue and allows separation of the membranes after having been in contact. The method has successfully been applied for airbag deployment simulations within the development process at BMW Group.

Customer Papers

In the vehicle design, the interaction between road and vehicle is the main criteria in order to meet the durability, NVH (Noise Vibration and Harshness) & handling performance. Potholes in the road can cause damage to the wheel, suspension and chassis components. Pothole size and vehicle speed were the main factors for the damage. The larger pothole can cause severe damage or alignment issues. Based on the severity of the impact, damage will happen to the wheel rim and there will be a reduction in the air pressure inside the tire. In long-term, it will damage the suspension or steering components and it can also lead to premature tire wear and poor handling of the vehicle.

Customer Papers

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