Agency: Department of Defense | Branch: Air Force | Program: STTR | Phase: Phase I | Award Amount: 150.00K | Year: 2014
ABSTRACT: Global Engineering and Materials, Inc. (GEM) along with its team member Columbia University propose to develop a simulation tool for modeling mixing process of multi-particle composite systems and generating the ultimate microstructure. A combined theoretical, numerical, and experimental approach will be developed to create a high fidelity software product with a reduced order modeling capability for an optimal exploration of the mixing process. Our innovative approach consists of Discrete Element Method (DEM) and Dissipative Particle Dynamic (DPD) coupled algorithms, reliable experimental and numerical measurement methods for validation of the proposed algorithms, a multiscale modeling/characterization approach to an objective homogeneity metrics, and a viable scale-up technique for quantifying the mixing results in the industry-scale from the laboratory-scale system. Quantitative understanding of mixing process will be achieved by using novel numerical algorithms and experimental studies for on-line control and optimization of mixing performance. The outcomes of the proposed research and development include numerical models for two or more types of particles mixing in a viscous fluid, experimental validation of the proof of concept models, standardized homogeneity metrics for quantification of mixing processes, and a reliable and efficient software package providing instant modeling/simulation for insights into the physical mixing process. BENEFIT: The results from this research will have significant benefits and broad commercial application in the Air Force, DoD labs, food, pharmaceutical, catalysis, mineral and other related industries. The results from Phase I will provide the framework to develop an enhanced and fully validated software package for a more heterogeneous system with up to six particle types under realistic mixing scenarios. Once the proposed DEM/DPD coupled algorithm and the software package are developed, it will provide customers with the key functionality and performance to realize maximum productivity benefits from engineering simulation to product design. With integration of the proposed computational algorithms and the high fidelity software product into the design workflow, industries can significantly reduce testing costs and increase the productivity and reliability of the equipment and processes. The finalized software will have an easy-to-use GUI that speeds simulation set-up time with tools to quickly create a particle-scale parameterized model of a bulk granular solids system. By integrating its reduced order model with an optimizer, we can look for a cost effective solution without performing an exhaustive testing.
Agency: Department of Defense | Branch: Navy | Program: STTR | Phase: Phase I | Award Amount: 79.99K | Year: 2015
A multi-scale/multi-physics integrated tool will be developed to virtually and qualitatively predict the manufacturing defects in structural thermoset polymer composites through a first-principles based approach. The chemo- and thermo- mechanical properties of the thermoset resin during the autoclave process will be characterized with a reactive force field full atomistic and coarse-grained molecular dynamics. A physics-based mapping between these atomistic properties and the actual autoclave processing parameters will be established through the response surface-based reduced order modeling techniques. Then this physics-based mapping will be adopted in the micro- and macro-continuum level analysis to predict fabrication-induced defects. Through this combined multi-scale/multi-physics approach, a macroscopic defect-distribution map will be created with the indication of defects occurrence of various types in composite product level; note that this information will serve as an initial manufacturing-induced material damage for further damage growth/interaction analysis via the XFEM approach. During the process, extensive verification and validation will be conducted to ensure the accuracy of the multi-scale/multi-physics integrated tool on predicting actual damage distributions. GEM has already secured commitments for technical, verification and validation supports from University of Colorado, Lockheed Martin, NRL, and NIAR for the success of the proposed work.
Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase II | Award Amount: 746.51K | Year: 2012
A fully coupled fire-structure interaction module will be developed and implemented within GEM"s Abaqus Fire Interface Simulator Toolkit (AFIST) for fire response prediction in aluminum ship structures. This enhanced AFIST will be able to characterize a 3D complex geometry where its topology is not in conformation with a rectilinear CFD grid. An immersed boundary method developed by NIST will be generalized and integrated with the customized Fire Dynamics Simulator. A sharp interface characterization of the solid boundary will be created and the mapping of the boundary conditions from the interface to its immersed boundary nodes will be constructed through local interpolation. A kinematic description of the moving boundary will be accomplished via its coupling with Abaqus. GEM has secured commitments for the joint tool development and validation support from NIST and Virginia Tech, and application guidance from SGH and Navy Lab. The Phase II studies consist of the implementation of the immersed boundary method in AFIST, enhancement of material characterization of marine aluminums in AFIS, verification of the accuracy of the improved coupling method, exploration of the effects of structural deformation on the local flow field, and performance of structural level validation using NICOP and VT"s pool fire test data.
Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase II | Award Amount: 747.04K | Year: 2014
Global Engineering and Materials, Inc. (GEM) along with its team members (National Institute for Aviation Research (NIAR) at Wichita State University, Carnegie Mellon University, and Air Force Research Lab (AFRL)) will develop an add-on toolkit for Abaqus with high fidelity prediction of residual strength and life of bonded composite structures. A coupled continuum and discrete damage analysis will be developed for Abaqus to capture the entire failure sequence under monotonic and fatigue loading. To accurately capture the effect of fabrication induced initial defect and the mechanism driven bondline failure, a novel macro-micro bridging model will be developed to determine the cohesive model parameters. A unified cohesive interaction for crack initiation and propagation will be developed for the macro-level fatigue damage prediction with a local strain based delamination initiation criterion. The validated static and fatigue analysis toolkit will then be enhanced during the 2nd year program through its integration with a thermal and moisture diffusion model to study the environmental aging on the residual strength and life of a bonded composite structure. An integrated CAD and FEM demonstration and a validation study of the developed toolkit will be performed using the test data from NAVAIR, NIAR and AFRL.
Agency: Department of Defense | Branch: Air Force | Program: SBIR | Phase: Phase II | Award Amount: 749.92K | Year: 2012
ABSTRACT: A Hybrid Structure Evaluation and Fatigue Damage Assessment (HYSEFDA) toolkit for Abaqus will be developed for advanced hybrid structures under multi-axial and variable amplitude cyclic loading. The tool will be able to characterize arbitrary geometric configurations of fiber metal laminates with the coexistence of multiple metal ply and delamination cracks. High computational efficiency and modeling fidelity will be achieved via the development of a mesh independent discrete crack network model for co-simulation of a curvilinear fatigue crack growth in a metal ply and propagation of a delamination with its arbitrary front. A Moment Schema Finite Element coupled with XFEM will be developed to efficiently simulate the crack growth in a thin laminated structure. A mesh independent adaptive fracture process zone model will also be developed in HYSEFDA for accurate extraction of fracture parameters along the delamination crack front that is not in conformation to the existing FEM mesh. An advanced fatigue damage accumulation model coupled with a cycle-by-cycle numerical integration will be developed to capture the load sequence effects. GEM has secured commitments for technical support and commercialization assistance from Alcoa for module development, toolkit verification and validation at component and structural level. BENEFIT: The Phase II research will develop a versatile, user-friendly, and computationally efficient toolkit for Abaqus (HYSEFDA) that is capable of prediction of fracture pattern and fatigue life of non-traditional hybrid materials/structures under variable amplitude loading. The end product from this research will have significant benefits and commercial application in the Air Force, DoD Labs, and other commercial industries for optimal hybrid system design and performance of virtual testing of the selected hybrid material/structure system. The tool can be used by government agencies and private industries as follows: 1) to accelerate fatigue damage and residual strength assessment, assist in decision making for effective maintenance and repairs, and design reliable AHSs to ensure airworthiness; 2) to specify fatigue performance limits and safety standards for structural certification and design agencies; and 3) to provide optimal designs through the effective use of new analysis tools, risk evaluation methods, and health management procedures for aircraft manufacturers.
Agency: National Aeronautics and Space Administration | Branch: | Program: SBIR | Phase: Phase II | Award Amount: 749.66K | Year: 2012
A Probabilistic Fatigue Damage Assessment Network (PFDAN) toolkit for Abaqus will be developed for probabilistic life management of a laminated composite structure with both microcracking induced stiffness degradation and cyclic loading induced delamination crack growth without remeshing. It is based on a high fidelity Fatigue Damage Assessment Network (FDAN) which includes 1) a coupled continuum damage and discrete crack model for ply damage characterization; 2) a moment schema finite element coupled with XFEM for efficient crack growth simulation in a thin ply; 3) a mixed mode fatigue delamination module to account for the mode mixity and failure mode interaction; and 4) an adaptive fracture process zone model for mesh independent delamination growth. A reduced-order model of FDAN will be generated using a combined response surface and a Gaussian process surrogate model builder to perform the subsequent probabilistic analysis efficiently. For the module verification and validation, experimental studies at the sub-component level will be performed along with the use of a damage monitoring and characterization system. The developed toolkit will be used to perform damage prognosis and risk informed life management using SHM data. GEM has secured commitments for technical support and commercialization assistance from Clarkson University, Sikorsky Aircraft, and Boeing.
Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase II | Award Amount: 247.37K | Year: 2016
Global Engineering and Materials, Inc. (GEM) along with its team member National Institute for Aviation Research (NIAR) at Wichita State University will extend, enhance, and validate CB2ATA (Composite Bolted and Bonded Analysis Toolkit for Abaqus). The capability of using a hybrid discrete damage and continuum modeling methodology will be demonstrated via its prediction of fatigue damage evolution, remaining life, and residual strength in laminated composite bolted joints. The completion of Phase II Base program will result in a single bolted composite joint analysis tool for a flat composite component while the completion of Phase II Option will provide an enhanced CB2ATA for a curved composite structure with multiple bolts subjected to a large displacement boundary condition. In addition, a probabilistic version of CB2ATA will be developed under Phase II Option by the integration of its reduced order model with a probabilistic analysis framework. The enhanced graphic user interface will make the CB2ATA toolkit easy to use for life- and strength- predictions for depot engineers. The matured and validated CB2ATA toolkit will be applied in assisting design and certification of bolted components of the Triton system along with their sustainment.
Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase I | Award Amount: 80.00K | Year: 2016
A multi-scale/multi-physics integrated tool will be developed to predict fatigue crack initiation and propagation in a metallic structure by bridging the length scale from its polycrystals microstructure to a smeared continuum of its complex geometry. In order to simulate the microstructure and localized plasticity driven crack initiation, its micro-growth within a grain or across several grains, and its macro-growth that leads to the final rupture of an aircraft structural component, a fast Fourier transform (FFT) based computational approach integrating phase-field method (PFM) and crystal plasticity (-pro) developed by Prof. Chens research group at the Pennsylvania State University (PSU) will be enhanced and integrated with our 3D extended finite element toolkit for Abaqus (XFA3D). The effects of plasticity will be included for characterization of crack nucleation, its transition to a short crack, and its transition from a short crack to a long crack that will be governed by a linear fracture mechanics theory. A well balanced modeling accuracy and computational efficiency along with our newly implemented isogeometric solution capability in the integrated toolkit will offer its broad use for life prediction of large scale complex structures. GEM has already secured commitments from PSU for the success of the proposed work.
Agency: Department of Defense | Branch: Air Force | Program: SBIR | Phase: Phase II | Award Amount: 323.43K | Year: 2016
ABSTRACT: Global Engineering and Materials, Inc. (GEM) along with Columbia University propose to develop a simulation tool for modeling mixing process of multi-particle composite systems and generating the ultimate microstructure. A combined theoretical, numerical, and experimental approach will be developed to create a high fidelity software product with a reduced order modeling capability for an optimal exploration of a full scale mixing process. Our innovative approach consists of a novel combined local and global homogeneity identification metrics, an advanced multi-scale model for large scale mixing simulations, a high fidelity DEM/SPH coupling module for high shear mixing of suspensions, a two-scale simulation framework to bridging the continuum and discrete description of an interactive solid particle and fluid system, a parallelized code base that enables both GPU and CPU computing, and customized case study wizard within a GUI to streamline the model generation and solution process for both experienced and inexperienced users. The resulting Particle Dynamics Parallel Simulator (PDPS) toolkit will be validated using test data of multi-particle systems with different solid loads and fluid contents. The validated toolkit will be used to establish a design table for users to describe the trade space as a function of system properties and mixing parameters.; BENEFIT: The results from this research will have significant benefits and broad commercial applications in the Air Force, DoD labs, food, pharmaceutical, catalysis, mineral and other related industries. The results from Phase II will result in an enhanced and fully validated software package for a more heterogeneous system with up to six particle types under realistic mixing scenarios. The proposed DEM/SPH, two-scale solution algorithm and the parallelized software package will provide customers with the key functionality and performance to realize maximum productivity benefits, from engineering simulation to product design. By incorporating the proposed computational algorithms and the high fidelity software product into the design workflow, industries may reduce testing costs significantly while increase the productivity and reliability of the equipment and processes. The finalized software will have an easy-to-use GUI and case wizard that simplify model setup and speeds up simulation set-up time.
Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase I | Award Amount: 80.00K | Year: 2015
Global Engineering and Materials, Inc. (GEM) along with its team member Carnegie Mellon University (CMU) propose to develop an isogeometric finite element model creation and analysis toolkit for Abaqus. The isogeometric analysis toolkit for Abaqus (IGAFA) will be developed by integrating existing computer aided design (CAD) software with a customized Abaqus toolkit for automatic model generation and response and failure prediction using a T-spline based geometry description. Polycube-based parametric mapping methods are used to build volumetric T-splines from B-Reps for CAD models of complex free-form surfaces. An unstructured all-hexahedral mesh is converted to T-spline volumes for their applications in isogeometric analysis. The IGAFA toolkit will feature 1) FEM model generation that retains exactly the original geometric description of the solid structure; 2) re-construction of Abaqus user-defined elements using the control points without remeshing; 3) reliable 3D stress/strain prediction using a user-defined high order function; 4) progressive failure evaluation in composite structures using accurate stress/strain predictors; and 5) visualization of stress concentration zones and performance of design alternations without user intervention. Verification and validation of both 3D stress analysis and failure prediction of a composite structure will be performed based on existing test data collected from team members.