Multi-scale probabilistic simulation chain for the continuous modelling of the manufacturing process and the structural behavior of disordered fiber-reinforced injection molded components (MeproSi)

用于对无序纤维增强注塑部件 (MeproSi) 的制造过程和结构行为进行连续建模的多尺度概率仿真链

• 批准号: 464119659
• 负责人: Dr. Carla Beckmann
• 金额: --
• 依托单位: Fraunhofer-Institut für Werkstoffmechanik (IWM)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/464119659?language=en
• 关键词: Multi; scale; probabilistic; simulation; chain

Due to the increasing demand for lightweight components not only in aerospace applications but also areas dominated by industrial scale mass production such as the automotive sector, discontinuously fiber reinforced materials gain an increasing importance. Modern long fiber composites manufactured in thermoset injection molding might exhibit similar mechanical properties as aluminum. Nevertheless, distinctively lower amounts of energy are consumed during the manufacturing process, further improving the CO2-footprint. A major shortcoming is their random, disordered and process dependent microstructure, causing an inherent inevitable uncertainty in their macroscopic material response. This uncertainty is caused by the uncertainties in the local fiber content, length and orientation distributions as well as by uncertainties in the material response of the constituents themselves and the fiber matrix interfaces. Superimposed are local variations in the microstructural properties imposed by the manufacturing process. In structural application, the inevitable uncertainty in the material response results in over-conservative designs, unnecessarily large safety margins and thus a suboptimum exploitation of the materials lightweight potential.The objective of the proposed project is a prediction of the process-related aleatoric uncertainties in the material response and the resulting structural behavior of injection molded parts under in-service conditions. For this purpose, an integrated probabilistic multiscale simulation along the process chain on all relevant scales will be established. Starting point is the uncertain process, resulting in an uncertain microstructure and thus an uncertain structural response. Based on a probabilistic process simulation, the local microstructure and the probability distributions of its governing parameters will be derived. Using a probabilistic homogenization procedure, a stochastic description of the material behavior is obtained, providing the input for a random field representation of the material response. Appropriate strategies for determination of individual representations of the random fields based on spatially varying stochastic properties obtained in the process simulation have to be defined and implemented. By this means, the effect of uncertainties on the structural response of short fiber reinforced components can be predicted in an integrated manner, starting from the process conditions. By this means, the inherent uncertainties in the material and structural response become accessible and controllable by computational methods. The initial focus is on aleatoric uncertainties. In a second phase, an extension to include epistemic uncertainty, e.g. from measurement or modelling inaccuracies, is intended.

由于对轻量化部件的需求不断增加，不仅在航空航天应用中，而且在工业规模大规模生产主导的领域，如汽车行业，不连续纤维增强材料变得越来越重要。用热固性注射成型制造的现代长纤维复合材料可能表现出与铝相似的机械性能。然而，在制造过程中消耗的能源明显减少，进一步改善了二氧化碳足迹。其主要缺点是其随机、无序和工艺依赖的微观结构，导致其宏观材料响应固有的不可避免的不确定性。这种不确定性是由局部纤维含量、长度和取向分布的不确定性以及组分本身和纤维基体界面的材料响应的不确定性引起的。叠加是由制造过程造成的微观结构特性的局部变化。在结构应用中，材料响应中不可避免的不确定性导致过度保守的设计，不必要的大安全裕度，从而导致材料轻量化潜力的次优开发。拟建项目的目的是预测在使用条件下与材料响应和注塑成型零件的结构行为有关的过程的任意不确定性。为此，将在所有相关尺度上建立沿工艺链的集成概率多尺度模拟。起点是不确定的过程，导致微观结构的不确定，从而导致结构响应的不确定。在概率过程模拟的基础上，导出了局部微观结构及其控制参数的概率分布。使用概率均匀化过程，获得了材料行为的随机描述，为材料响应的随机场表示提供了输入。必须定义和实现基于过程模拟中获得的空间变化的随机特性来确定随机场的个别表示的适当策略。通过这种方法，可以从工艺条件出发，综合预测不确定性因素对短纤维增强构件结构响应的影响。通过这种方法，材料和结构响应的固有不确定性可以通过计算方法获得和控制。最初的重点是任意的不确定性。在第二阶段，打算扩展到包括认知不确定性，例如来自测量或建模的不准确性。