EXTENDED ABSTRACT: Material design, production, forming into a machine component and performing service are important stages of material life. The most desirable product design is an of optimization considering all aspects of material life, i.e., material performance requirements when in service, the material forming and its impact on product performance, material choice or material design and its impact on forming and performance. The presentation reports the results of the project ‘development of ICME tools of carbon fiber for vehicle applications’. The research team included Ford, Northwestern University, Dow Chemical, University of Maryland, and software developers LSTC, Autodesk, HBM and ESTECO.The mechanical properties of a composite depend not only on resin and fiber properties, but also layout of the fibers and the
bonding between matrix and fibers. The numerical tools developed and integrated into ICME framework included those for preforming and compression molding simulation, multiscale models for continuous and chopped fiber composites which link material micro and meso structures to macro mechanical properties, crash analysis and fatigue analysis. The ICME tools have been integrated and used for a simultaneous optimization of component design and manufacturing of a multi-material subframe that achieves a ≥25% weight reduction at an additional variable cost of ≤$4.27/lb of weight saved when compared to baseline stamped steel technology.
Keywords: Integrated Computational Material Engineering, carbon fiber reinforced polymer composites, multiscale models,
optimized product and material design
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hysteresis and transport, multi-scale simulation, machine learning
Dr. Xumig Su is the director of Integrated Material Forming Technology and Intelligent Equipment Zhejiang Provincial Engineering Technology Center at Hangzhou City University. He earned his Ph D degrees at Shanghai University and Purdue University. Before joining Hangzhou City University, he was a technical leader at Ford Moor Company. Dr Su’s research areas include material characterization, material modeling, constitutive relation, fatigue and fracture, thermal stress and residual stress. He has been active in the research and development of integrated computational material engineering tools, and is an early practitioner and original contributor in the area.