Your Essential Guide to the SIMULIA Regional User Meetings

Your Essential Guide to the SIMULIA Regional User Meetings Park Royal • Cheshire, UK Conference Dates • November 3-4 Advanced Seminar • November 2

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Contents Your Personal Invitation ........................................................................................................ 3 Accommodation .................................................................................................................... 4 Keynote Speakers................................................................................................................. 5 SIMULIA Technical Representatives ..................................................................................... 6 Learn about the latest technology ......................................................................................... 6 Round Table Session ............................................................................................................ 7 User Presentations - The centerpiece of the RUM ................................................................ 8 User Paper Session One: Fracture and Failure ..................................................................... 9

User Paper Session Three: Offshore .................................................................................. 12 User Paper Session Four: Materials.................................................................................... 13 User Paper Session Five: Fundamentals ............................................................................ 17 Advanced Seminar .............................................................................................................. 19 Networking .......................................................................................................................... 20 Partner Sponsors ................................................................................................................ 21 Discover complementary technology................................................................................... 21 Conference Exhibition ......................................................................................................... 22 Preliminary Agenda ............................................................................................................. 23

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User Paper Session Two: Composites ................................................................................ 10

Your Personal Invitation The 2015 SIMULIA UK Regional User Meeting is fast approaching This year is the first time in the UK RUM history that we are making the conference free to attend.

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Register to attend the Strategies and Tools for Material Model Calibration advanced seminar Hear from 2 keynote speakers from NPL and Imperial College London Choose from 6 technical product updates Choose from 6 round table sessions Learn from more than 14 customer papers Visit the interactive exhibition area including academic showcase

As this is a local conference, we are able to tailor the content we deliver towards local trends and industries, making the conference more relevant to UK users. This conference allows attendees to engage with other local customers enabling them to share knowledge and experiences making networking more relevant and valuable. This year the conference will be held at The Park Royal Hotel, Cheshire. More details regarding the venue may be found at http://www.qhotels.co.uk/our-locations/the-park-royal/. We hope this e-Book will help to prepare you for the RUM and we look forward to welcoming you in Cheshire

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Attendees can:

Registration For the first time in the history of the UK Regional User Meeting we are removing the conference fee, making this conference free to attend for both days including the conference banquet. Spaces are limited and, due to the high number of expected attendees, it is essential that you only reserve a place if you will be attending and let us know as soon as possible if you are unable to attend. Accommodation is expected to sell out fast. Please ensure you book directly with the hotel on 01925 730706. We have reserved rooms at the discounted rate of £98 B&B. These rooms are expected to sell fast so please ensure you book as soon possible, quoting Dassault Systemes.

Whilst we encourage attendance from all interested parties, due to the expected attendance for this event, it may be necessary to limit registrations from representatives of Academic institutions and private individuals. If you wish to attend in such a capacity please contact [email protected] for further details. Registrations will be capped and a waiting list will be created for those who register after the maximum registrations have been reached. If you are unable to attend is it essential that you contact [email protected] or call 01925 830900 to cancel your place. Registration link: http://www.3ds.com/events/simulia-regional-user-meetings/uk-regionaluser-meeting/registration/

Accommodation To reserve your accommodation please contact the hotel quoting ‘Dassault Systemes’ in order to receive the discounted rate of £98 for bed and breakfast. It is vital that you make your reservations as soon as possible as the discounted rate is available for a limited time only. The Park Royal Hotel Stretton Road Stretton, WA44NS Cheshire, UK T. 01925 730 706

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Representatives of Academic Institutions and private Individuals

Keynote Speakers Louise Wright, Principal Research Scientist - NPL

Presentation Abstract: Almost all finite element models need material properties. Equally, almost all the methods used to measure material properties use models to extract the required values from the measured data. These models are often derived from sets of simplifying assumptions that can only met by using careful experimental control. At the National Physical Laboratory, we use Abaqus to design experimental apparatus, to test assumptions, and to interpret measured values so that we can ensure that the values extracted from data are a true representation of the material behaviour. This talk will give an overview of some of the measurement procedures we use and the models that support them, and look ahead to how we might measure the parameters that will be used in the materials models of the future. Louise will be presenting on the 3rd November at 10:00am

Silvestre Pinho, Imperial College London Silvestre Taveira Pinho is a Professor in Mechanics of Composites and an EPSRC Research Fellow at the Department of Aeronautics, Imperial College London. In 2010 he was awarded the prize for best young researcher in Composites active in Europe by the European Society for Composite Materials (ESCM). Since June 2012 Silvestre has been a member of the Council and of the Executive Committee of the European Society for Composite Materials (ESCM). In March 2014, Silvestre was awarded an EPSRC fellowship for designing novel forms of more damage tolerant composite structures. Presentation Abstract: This talk will review briefly several developments at Imperial College involving coding subroutines for the FE software Abaqus, before focusing in more detail on two particular recent developments:

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A Multi-Physics Molecular Dynamics Finite Element Method for the design of graphemebased devices;

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A floating node method for the accurate representation of kinking cracks, i.e. cracks that suddenly change orientation, e.g. when reaching an interface between two materials. Silverstre will be presenting on the 4th November at 12:00pm


Louise originally trained as a mathematician and has worked with finite element analysis (FEA) for over 20 years. Her first two jobs involved simulating vehicle impacts and roof tile production processes, before she joined the National Physical Laboratory in 1999. Since joining NPL she has used FEA and related numerical techniques to solve problems across application areas from acoustics to electromagnetics and heat transfer to hydrogen embrittlement. Her current interests include multi-scale modelling to support prediction of bulk-scale behaviour for crystalline materials and composites, by combining measurements of component properties and imaging of microstructure.

SIMULIA Technical Representatives Learn about the latest technology

Dimple Shah, VP WW Sales, SIMULIA Dimple is a simulation enthusiast at heart and is genuinely inspired by our user community solving first of its kind challenges with innovative applications of simulation technology. He has a Master’s degree in Mechanical Engineering from the State University of New York, Stony brook – where he first used Abaqus for his research in thin film fracture mechanics. Dimple has been with SIMULIA for over 20 years and has contributed towards delivering our brand promise in various technical and sales leadership roles. As Vice President of SIMULIA Worldwide Sales, he is committed and excited to build further on our common rich legacy and expand our user community by driving simulation to be at the core of innovation. David Hawla, SIMULIA R&D Technology Director, Durability David has a PhD in Computational Mechanics from University of Cape Town. He was an FEA analyst and manager at CSIR Aeronautics division for 6 years. David started at HKS/Abaqus/Dassault Systemes in 1989 working on development projects in Abaqus/Standard such as cap plasticity, co-simulation with underwater shock and linear perturbations. David has managed the development of physics modelling aspects of Abaqus/CAE for 9 years. David has also been an Abaqus QA Director for 7 years and an R&D Technology Director for SIM/ODB databases for 5 years. More recently David has moved to become the R&D Technology Director for Durability/Fatigue.. Pawel Sobczak, Senior Technical Specialist SIMULIA Growth Pawel is Manager of Technical Applications at SIMULIA and is responsible for product support, customer services and fe-safe training for customers worldwide. He completed his Ph.D. in Mechanical Engineering at Nottingham Trent University, UK, in 2003. Previous roles include post-graduate investigative research in biomechanics of spinal implants and the development and support of commercial software. Pawel has extensive knowledge of fe-safe and its practical application. He is experienced in using Abaqus and other systems for static nonlinear stress and strain simulations, using both interactive GUI and scripting. Karl Kueres, Senior Technical Specialist SIMULIA North-Nordics Karl joined HKS UK in 2002 after graduating from Cambridge University with a Master’s Degree in Engineering. Karl spent 8 years working in the UK technical support team and now works as a Senior Technical Specialist for the SIMULIA EuroNorth and Nordics regions.

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The conference will be attended by representatives from SIMULIA’s Research & Development, Technical Marketing and Worldwide Operations departments; they will provide a unique perspective on product capabilities and potential applications of our technology.

Product & Technology Updates Choose 3 out of these 6 Product and Technology updates which offer detailed information straight from SIMULIA R&D, Centers of Simlatution Excellence and User Experience teams that you can use immediately. Information covered in this session includes new enhancements, under-utilized functionality, new applications, best pratices and tips and tricks pertaining to the topic.

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Abaqus Update: Contact Optimisation (Isight & Tosca update) Fatigue and Durability Update Abaqus Update: Linear Dynamics Abaqus/CAE update Extending realistic simulation beyond medical application using image based models

Round Table Session The objective of each session is to participate in a live discussion with our technical experts and managers to discuss, hear and debate SIMULIA’s strategy, capabilities and new functionalities. Conference delegates will have the opportunity to attend 3 out of the 6 round tables; each round table session will last for 20 minutes and will cover areas such as problem solving, debugging, mentoring, future direction and developments. Round Table Sessions: • • • • • •

SIMULIA Strategy Simulation on the 3DEXPERIENCE platform Automation of simulation processes Analysis techniques and best practices Co-simulation and Multiphysics Fracture and failure

You will be asked to choose your desired product and technology updates and round tables during your registration process.

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Product and Technology Updates:

User Presentations - The centerpiece of the RUM The Regional User Meeting has become a time-honoured tradition in the UK. For 26 years industry and academia have met across the country to exchange success stories and challenges, and to debate and predict the future of simulation technologies.

User presentations provide first-hand knowledge of deploying SIMULIA solutions and developing workflows for real world realistic simulation. These presentations usually contain additional detail such as videos and animations not available in the published papers. More importantly, the live presentations enrich the paper by providing unique user-specific viewpoints. Attending the conference also provides you with the opportunity to ask questions at the end of each presentation to clarify specific points and to meet the presenters in the networking sessions for more detailed discussion of ideas.

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The core of the conference is the shared user experiences and this e-Book details the abstracts that will be presented as technical papers during the conference. Some of the other features of the conference are also discussed in order to give as full a picture as possible of the benefits attainable from attending this event.

User Paper Session One: Fracture and Failure

Failure by fatigue crack growth (FCG) is a potential problem for fabricated engineering components that are subjected to in-service cyclic loads. For simple geometries, handbook stress intensity factor (SIF) solutions and the Paris law can be used to estimate the fatigue life of a structure containing a known initial defect. However, accurate SIFs require the use of FEA when the geometry is more complex, such as a crack at a nozzle. Conventional FE modelling requires a mesh that conforms to the crack front to obtain accurate SIFs, making the modelling of crack propagation very time consuming. XFEM combined with the low cycle fatigue (LCF) analysis procedure in Abaqus offers an alternative through the ability to use a mesh that does not conform to the crack front combined with a modelling technique to obtain the stable cyclic plastic response of a structure subjected to periodic loading. In this report, a systematic numerical assessment of the accuracy of the LCF analysis procedure for modelling FCG in Abaqus is performed. The effects of element type, mesh size, and solver controls are assessed against a series of 2D and 3D benchmarks. The accuracy of using XFEM for flaws located in high stress regions such as weld toes is established. The results of the verification studies are used to establish guidelines for using XFEM and the Abaqus LCF procedures for accurate modelling of FCG in engineering criticality assessments. Finally, the proposed guidelines are validated by comparing numerical predictions with experimental test data for a cruciform joint subject to constant amplitude loading.

Simulation of Fully Coupled Thermo-Mechanical Effects in a Disc Brake Rotor - Ganesh Karunakar, Jaguar Land Rover Limited The frictional heat generated during braking of a vehicle can cause numerous negative effects on the brake system, such as brake fade, premature wear, and thermal cracks causing the brake to have inherent noise and vibration issues under braking, called rumble. An opportunity therefore exists to eliminate brake rumble from the vehicle, thus providing a quality improvement opportunity. In this paper, a fully- coupled, temperature- displacement analysis using ABAQUS Standard was carried out to take into the account both thermal and structural effects on the brake rotor. The effect on thermal performance of rotational speed (corresponding to Vmax braking conditions) and rotor temperature, due to the rotating heat source, has been evaluated. Disc thickness variations are shown to arise from the temperature profile across the disc cheek surface. The scenario simulated considers the thermal effect of braking a vehicle which was prone to generating an audible rumble noise. The simulation measured the thermal and geometric changes in the disc, demonstrating the disc thickness variation and thermal banding of the rotor, and the location of these on the disc surface due to the effect of the thermo-mechanical loading. Using this simulation

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An Evaluation of the Low Cycle Fatigue Analysis Procedure in Abaqus for Crack Propagation: Numerical Benchmarks and Experimental Validation - Tyler London, TWI Ltd

technique, design changes to the pads to eliminate the rumble by moving the hottest band of the disc to a more central location, were assessed and verified on a vehicle. Future developments will include further investigation of the sensitivity of the rumble noise to pad friction material compressibility and profile and to the internal vane pattern of the disc.

Modelling the propagation of cracks is a complicated problem; this is compounded when considering graphite because of the heterogeneity of the material. In the UK’s advanced gas cooled reactors (AGR), the material properties of graphite components evolve due to irradiation effects, affecting the fracture behaviour. Furthermore, late in the operational life of the reactor core, the irradiation induced stresses generated by the differential shrinkage in the graphite components are predicted to become large enough for cracking to occur. Understanding how these components fracture is important to structural integrity assessments of the whole core and the safe continued operation of the nuclear power plant. This paper presents a global energy criterion for crack propagation, coupled with the XFEM framework in ABAQUS. Here we manually adjust the direction of propagation for each crack instance during propagation, such that the global energy released is maximised. The stability of propagation can be inferred in post processing by comparing the energy release rate with its measured work of fracture

User Paper Session Two: Composites A method to assess impact hazards using a Smoothed Particle Hydrodynamics and Finite Element Approach in Abaqus - Peter Gill, Amec Foster Wheeler In the unlikely event of a pressurised component failing, it is possible that missiles could be generated and potentially strike other components in the plant. This paper presents a multi physics model which enables calculation of missile velocity based on a coupling between Smooth Particle Hydrodynamics (SPH) and Finite Element Method (FEM) in ABAQUS. This is to provide accurate estimations of both the energy of plant generated missiles and the energy required to penetrate steel targets. Investigations were performed using air as the fluid at different pressures; this enabled optimisation of the model so that it could be used to assess high pressure steam as the process fluid. A comparison between a simple hand calculated maximum acceleration, and the peak obtained from the simulation, provided a means of validating the model. In addition to this, the impact of a missile on a target was simulated using FEM with a special material model based on strain rate hardening and shear failure. This methodology provides a means of obtaining missile velocity and penetration energy without being overly conservative. The implications of this work for the treatment of indirect consequences of failure in the UK nuclear industry will also be briefly discussed.

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A Global energy approach to model crack propagation in irradiated graphite components using the XFEM framework in ABAQUS - Owen Booler, Amec Foster Wheeler

Multi-scale Modelling of Composites using Abaqus - Laurence Marks, SSA

Multiscale approaches based on micro-mechanical models provide an improved understanding of these damage and failure mechanisms and predict with greater accuracy the mechanical response of a structure up to final failure. They allow a more refined representation of the failure mechanisms by considering the damage and failure at the constituent scale and distinguish between the various failures events such as matrix cracking, matrix/fibre debonding, fibre kinking and critically their interaction. Manufacturing defects and residual stresses can also be taken into account. AlphaSTAR has implemented a multiscale approach based on Chamis’s theory into their software suite: MCQ and GENOA. MCQ facilitates the evaluation of the composite material properties that can then be used as input for a FE analysis. Various types of composites can be analysed such as UD, woven, braided or chopped fibre composites. GENOA is an add-on tool for FEA packages such as Abaqus that allows modelling the progressive failure response of composite structure. In this paper, an application to notched plates made of woven composite is presented. MCQ has been used to identify the material properties of the carbon/epoxy woven ply. GENOA UMAT has been used with Abaqus for modelling the mechanical response of the notched plates from the first ply failure up to the final failure of the specimens. The multi-scale approach allows identifying the failure modes and their influence on the performance of the components. Comparisons with experimental results are also presented.

Optimisation of Rotary Wing Composite Structures using Isight - Drew Smith, Agusta Westland A need was identified to optimise the the layup of the ply drop-off region of a thick composite structure (designed as an attachment between the rotating mast and blade) in order to minimise through thickness tension and inter-laminar shear. Inter-laminar effects are of particular concern for rotary wing composite structures that are exposed to high levels of centrifugal force and bending. This is particularly true for parts that require significant variations in geometry. A non-linear ABAQUS FEM (2D Section) was evaluated within an ISIGHT DOE loop. The DOE creates a design matrix of various layup combinations for each of the ply-drop property sets. These inputs are initially passed to an Excel spreadsheet which calculates the equivalent material properties required for the FEM. From the Runtime Gateway, the FEA results for the design matrix combinations are used to generate a thorough evaluation of the sensitivity of changes in layup on the through thickness effects from radial force and out-of-

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The increasing use of composite materials is driving the need for a deeper understanding of their ultimate performance, and the damage and failure mechanisms which influence this.

plane bending. This information is used in order to recommend the ideal layup using the Approximation tool.

User Paper Session Three: Offshore

The need for strain based designs due to reeling or lateral buckling, the use of multi-material corrosion resistant pipes (i.e. clad or lined) or the use of welding consumables that undermatch the pipe strength push the design of subsea pipelines beyond the limits of fracture or engineering critical assessments (ECA) using the conventional failure assessment diagram (FAD) approach. As an alternative solution, the pipeline industry is currently using FEA, either based on material damage or flaw mapping approaches. FEA based on the mapping technique, which is the focus of this paper, has the advantage that does not require any material input calibration; however, it has the disadvantage of being expensive in terms of execution time as a relatively large number of sequential FEM are required to determine the ductile tearing through each stage of the flaw development. To overcome this disadvantage, this paper presents a tool that has been developed to automate and significantly reduce the time taken to complete the assessment. The ECA tool uses PYTHON, has a GUI to introduce inputs, fully creates 3D ABAQUS CAE models using scripting, runs and extracts results from the analyses and uses them to simulate the next stage of the flaw development. Sensitivity studies on key parameters are presented to show the robustness of the automation. In the future, this tool will enable the possibility of performing probabilistic ECA with FEA, which is the current trend and research focus in the industry.

Having a Blast! - David Winfield, Freudenberg Oil & Gas Technologies Freudenberg Oil & Gas Technologies (FO>) supplies complex, metal to metal sealing solutions to the oil & gas and energy industries. As part of its core business, supporting the development and expansion of further qualification procedures for its clients, FO> have specified a blast chamber for its new factory. Utilizing traditional hand calculations and finite element methods undertaken with Abaqus/CAE, work has been undertaken aiming to developing a realistic ballistic-type model to be used for the correlation of testing data obtained through the FE models, focusing on chamber displacement. Constructed of high strength steel columns, with horizontal wooden sleepers reinforced by steel panels, the blast chamber has an internal volume of 450m3 to cope with large pressure vessels and equipment; being designed to withstand up to 0.25 MJ of impact energy. Dampers placed in the walls and floor allow large amounts of chamber flexure, maintaining the desired containment characteristics for internal projectile(s).

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Automation of ECA Assessments in Subsea Pipelines using Abaqus Ismael Ripoll, INTECSEA

A range of experimental elasto-plastic, visco-elastic and hyper-elastic material models combined with ductile damage and eroding surface contact, are used within the explicit finite element model, assessing the large displacements expected from high speed impacts, ensuring containment. To aid the flexure characteristics of the blast chamber both on a global and local level, FO> have utilized in-house expertise with a derived ‘Freudenberg rubber model’ for the dampers, together with factory test data depicting deflection performance for the wooden sleepers used in its walls.

Incorporating Finite Element Analysis Techniques into the Design Process for Subsea Annular Blowout Preventers - Richard James Windslow, Queen Mary University of London Annular Blowout Preventers, ABOPs, are the primary safety device on a BOP stack. If pressure control over the petroleum reservoir is lost they can successfully seal off the wellbore whilst undergoing large hydrostatic pressures. Due to the rigorous testing regime required within the industry, ABOPs are tested daily in service leading to significant and cumulative abrasion. In some cases the ABOP seals against 138MPa of fluid pressure at 80°C. This extreme testing schedule combined with the severe environment restricts the component’s service life. Once in situ it is very expensive to remove the ABOPs to replace the elastomeric packer, therefore it is imperative that the wear mechanisms be studied. Currently the development of ABOPs is based upon on the performance of prototypes during product testing. This iterative design methodology cannot easily identify poor design aspects however computational based design approaches have yet to be adopted. As the industry targets more extreme conditions under increased economic strains the outdated iterative prototyping process handicaps future developments. Whilst the extreme strains and complex contact scenarios present difficulties for simulation, it is imperative this approach be pursued as it allows the sealing process to be visualised fully for the first time. In this talk a modelling strategy for simulating the sealing procedure of an ABOP will be presented. This will demonstrate how computational approaches can be used to highlight aspects of the design and ultimately optimise the component. From this the model will be used to show how simulation can influence material selection.

User Paper Session Four: Materials Rubber creep modelling based on modified hyperelastic models using Abaqus - Robert Luo, Trelleborg

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Initial FEA results have shown good correlation with traditional calculation methods under current loadings conditions.

A Proposed Methodology for studying microscale behaviour of MnS Inclusions in FCS steel - Didier Farrugia, Tata Steel Part of a long standing strategy within Tata Steel UK to develop understanding of mechanisms across the physical length scale affecting ductile damage and edge cracking in a range of Free Cutting steels [1-3], a new automated procedure using python scripting within ABAQUS/CAE to enable the study of the steel matrix and MnS inclusion material response within a 2D representative volume (RVE) has been developed. MnS inclusions are “controllable” objects with respect to position, size, orientation (rotation, x,y position) and mechanical properties within an RVE volume of FCS steel grade. Generation of inclusions based on a library of MnS shape/morphology can be done randomly based on a volume fraction and likelihood that a given inclusion will be added to the micro-model. Inclusions can also be imposed to extract knowledge about influencing zone, strain and stress localisation based on an initial periodic or specific location or based on an initial spacing to diameter ratio. The RVE FEM model (200 microns x 200 microns) is contained within a “brace” where boundary conditions (periodic) are imposed. The procedure involves running ABAQUS/CAE from a python script with input from an ASCII text file which can be easily parameterised within the modelling workbench Isight-FD®, thus enabling Design of Experiment (DoE) analysis to be run and executed remotely onto a Linux cluster using the mono remote execution services. Parameters which can be changed include, temperature generally varied between [850-1200oC], relative strength between inclusion and matrix, shape/ morphology, spacing to diameter, area fraction, etc. Both ABAQUS/Explicit Dynamics and Standard (version 6.10 upwards) can be selected with ABAQUS/Standard for this type of analysis representing a significant speed-up whilst solving a pure static case. Following execution of the RVE environment, DoE FEM micro RVE runs usually create hundred of thousands of discrete results for specific state or field variables, making it difficult to assess the statistics as well as the general effect of changing inclusion variables. Therefore a Python script has been developed to output each discretised FEM plot into TIFF greyscale format image files. Each TIFF file is then input into a Matlab image based analysis GUI program. The image analysis loops through all DoE TIFF generated

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This paper presents an engineering approach to simulating the creep response of the rubber structures based on modified hyperelastic models. The work is a further study extended from Luo et al. since 2013. A function, in a form of damage, is introduced to link the rubber creep to its structure change, leading to a degradation of the material over the elapsed time. Hence, a hyperelastic model is not only related to the loading condition, but also to a function of the elapsed time so that a creep evaluation can be performed at a design stage using the existing models widely available in industry. The simulation was performed using well-know non-linear software Abaqus and validated by a well defined experiment. A creep test was carried out in a control room where the temperature was kept at 27± 1º. A typical industrial product was selected for verification. It has been shown that the predictions offered by the new model are consistent with the creep histories yielded by the experiment. It is shown that this method can be easily incorporated with FE software, e.g. Abaqus. The proposed approach provides the reliable prediction and can be used for engineering design and industrial applications.The proposed approach may need to be further verified using more engineering cases.

This methodology is original and allows a full exploration and extraction of knowledge based on FEM modelling, python scripting and the Isight-FD® Workbench. From the initial elastoplastic material properties imposed, other possibilities to study viscoplastic behaviour, decohesion and damage have been explored (see [2]). Recently some of the outputs of this approach have been validated at the microscale using microgrid and DIC in-situ experimental measurement techniques.

(c) Imposed array with spacing to diameter ratio (a) Imposed distribution

(d) Isight-FD® DoE

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(b) Random distribution


outputs to perform calculations based on greyscale contrast (default) to evaluate for each DoE run, the strain/stress or any state variable distribution for the matrix and inclusions. For the inclusion only, additional calculations are performed to output properties such as spacing/diameter ratio, inclusion average diameter, etc. which are useful when several plots at different elongation are extracted from a single FEM analysis to compute changes in inclusion spacing and relate it to the strain partitioning. Outputs are under the form of histogram plots showing mean and variance of the variable of interest. Additionally, the user can select to perform further detailed analysis using Black and White contrast to study inclusion cluster and orientation of these clusters to the deformation axis (shear bands). All outputs are saved automatically to an Excel file.

(f) Matlab FEM image based analysis software

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(e) ABAQUS microFEM results with soft inclusion (plasticity index 0.9) and hard inclusion (plasticity index 0.5)

(g) Histogram extraction of various outputs (spacing to diameter ratio, equivalent strain in inclusion and steel matrix)

Shaped metal deposition (SMD) is a manufacturing process in which a metal is deposited in the molten condition and allowed to solidify to form a specific geometric shape. SMD can be employed either to manufacture a complete component by building it up from multi-layers or to repair an existing component by adding material to it. The process involves intense heating to melt the metal and fairly rapid cooling when the metal is allowed to solidify to form the new structure. The intense thermal cycles cause significant local plasticity, resulting in large thermal stresses that lead to large residual stresses. Manufacturing by SMD often involves constraining the component as it is being deposited and built, followed by releasing it once SMD has been completed. Depending on the component geometry and the residual stress field, it is common to experience substantial distortion as the constraints are removed and consequently residual stresses partially relax. An effective and efficient means to determine residual stresses and distortion is to apply the finite element (FE) method. In this paper, the FE modelling of the process of SMD is reported. The modelled component is a vertical wall made of a sequence of six layers produced by plasma transferred arc (PTA) deposition onto a substrate. The material of the built wall as well as the substrate is Ti-64. The FE modelling comprises a thermal analysis and a sequentially-coupled structural analysis. The simulation consists of two and three-dimensional (2 & 3D) analyses, with the 2D model assuming either plane strain or generalized plane strain conditions, leading to a comparison between the two assumptions. The FE study is validated thermally and mechanically by firstly mapping and comparing the FE isotherms against microstructural regions detected in a cut and etched cross-section of the deposited component and secondly comparing the final FE-determined distortion of the substrate with actual distortion measurements. Finally, the findings of the study are discussed and conclusions are presented.

User Paper Session Five: Fundamentals Pressure test and Abaqus analysis of an aluminum pressure vessel Bob Johnson, REAL The aim of the work is to determine the burst-pressure and failure mode of a screw-top coke bottle. Real-life test will be used to pressurise the coke bottle to the point of failure. The test will be carried out on bottles that have already been opened (no connection between cap and retention ring). A number of bottles will be tested in order to see consistency in the

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Numerical Modelling of Shaped Metal Deposition and Experimental Measurement of Distortion- Anas Yaghi, MTC

magnitude of the failure pressure and that all vessels fail in the same manner. Where failure is due to thread failure then further tests will be conducted with the pressure tapping moved (say) to the domed underside of the main vessel.

What is a straight line? Does this matter in mechanical analysis? Alison McMillian, Glyndŵr University It is an assumption that engineers make every day: we draw a straight line to define our product geometry, and then we analyse the product performance – but do we ever challenge the reality of the geometry and how that would influence the performance? Small and smooth variations to a product geometry are generally anticipated in the design drawing tolerance definitions, and for a simple product or component these can be taken into account in analysis by assuming the maximum or minimum dimensions. For a more complex component, containing multiple load paths, it is not necessarily the case that choosing to analyse the maximum or minimum dimension cases would identify the strongest or weakest component within the tolerance range. This becomes further complicated when considering non-smooth geometry. How is lack of smoothness defined and recognised and what kinds of influence does it have on the performance of the component? For example, component inspection might identify a small geometrical defect triggering a concession analysis of the stress raiser feature. On a more systematic level, should we not have a more systematic approach? Non-smooth geometry can be represented in mathematics by fractals and wavelets. In this paper I will explore non-smooth edge and surface effects on a range of analysis types, including natural vibration, wave propagation and contact mechanics, by modifying smooth surfaces with fractals at different orders.

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Several coke bottles will be cut up to accurately determine the dimensions of the bottles. This exercise will determine all diameters and wall thicknesses along with thread details and sealing flanges etc. The same process will be used for the screw-top lid. Material properties (axial and hoop) will be determined from actual bottles. The Abaqus system will be employed to predict the burst pressure of the coke bottle. The analysis will start with 2D work followed by full 3D. The 2D work will consider the threads as axi-symmetric grooves while the full 3D work will model the thread helix angle in full. The FEA models will not include the redundant retaining ring which is only making a contribution when brand new. The FEA work will take account of contact and friction, plasticity, non-linear geometry effects and pre-load. All results will be compared to the real life testing.

Advanced Seminar: Maximize the value of your investment in SIMULIA technology and enhance knowledge 2nd November Strategies and Tools for Material Model Calibration

The key to success with FEA simulation is correlation to the real-world behavior of physical products. Lack of physical connection is often directly related to the lack of accuracy in the material model. This class will give you extra tools to assess the material models that you are currently using and showcase new material models in Abaqus that might better capture the physics important to your component and its loading environment. We will cover advanced material modelling for metals, elastomers, polymers and engineering plastics. Attendees will come away with a thorough understanding of the best practices that they can immediately apply in their projects to improve accuracy and performance. For additional details visit: http://www.3ds.com/events/simulia-regional-user-meetings/ukregional-user-meeting/seminar/

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Stuart Nixon, Senior Technical Specialist

Networking - Connect to your local community We expect more than 100 attendees at the 2015 RUM. The attendees will come from all over the UK and represent a variety of unique organizations. The agenda for the 2015 conference has been planned to maximise the opportunities for networking allowing delegates to learn from the experiences of others.

In addition to the usual three breaks per day, the 2015 RUM will offer the following networking opportunities: TUESDAY 3RD NOVEMBER 18:00 DRINKS RECEPTION – GARDEN SUITE 19:00 CONFERENCE BANQUET – GARDEN SUITE

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With delegates representing a wide range of industries and academic institutions you are sure to meet somebody working in a similar field to yourself. However, often the breakthroughs in simulation methods come from looking at work on quite different applications, so be sure to speak to a range of delegates.

Partner Sponsors Discover complementary technology Partner Sponsors are a significant asset to our conference, offering innovative complementary solutions that will help you streamline your overall engineering process. Learn more about select product offerings during the Complementary Solutions sessions taking place each day after lunch.

Gold Sponsors

Silver Sponsors

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SIMULIA is pleased to recognise those partners participating in the 2014 UK SIMULIA Regional User Meeting.

Conference Exhibition SIMULIA 3DEXPERIENCE Come and try the 3DEXPERIENCE Platform by tackling day to day modelling tasks in the new environment

Get hands on with all that SIMULIA has to offer by, tackling a small workshop on Abaqus, Tosca, Isight and fe-safe!

Academic Poster Session We have invited our academic users to showcase their work to industry in an academic poster section of our exhibition. Each poster will visually demonstrate the student’s research, methodology and results.

Z-Space experiences Imagine a realistic 3D model of a beating human heart floating in the air right in front of you. Attendees of the RUM will not have to imagine. “The Living Heart Project Exhibit’ will be featured in this year’s conference exhibition area. Alternatively, interactively explore inside an automotive crash model through the duration of the event or peel away the layers of a Geomechanics simulation using the unique Z-space tablets to investigate Abaqus output.

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Visit the Power of the Portfolio

Preliminary Agenda Title

10:00

Models, materials and measurement: Abaqus usage at the National Physical Laboratory Coffee and Exhibition Break User Paper Session 1 - Fracture and Failure • An Evaluation of the Low Cycle Fatigue Analysis Procedure in Abaqus for Crack Propagation: Numerical Benchmarks and Experimental Validation - Tyler London, TWI • Simulation of Fully Coupled Thermo-Mechanical Effects in a Disc Brake Rotor, Ganesh Karunakar, Jaguar and Land Rover • A Global energy approach to model crack propagation in irradiated graphite components using the XFEM framework in ABAQUS, Owen Booler, AMEC-FW

10:30 11:00

12:00 12:45 13:45 14:15

15:15 16:00 16:30

17:30 18:00 19:00

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Welcoming Remarks SIMULIA Executive Summary

Technology, Functionality and Usage Updates in the Power of the Portfolio Lunch Sponsor Presentation User Paper Session 2 – Composites • A method to assess impact hazards using a Smoothed Particle Hydrodynamics and Finite Element Approach in Abaqus, Peter Gill, AMEC-FW • Multi-scale Modelling of Composites using Abaqus, Laurence Marks, SSA • Optimisation of Rotary Wing Composite Structures using Isight, Drew Smith, Agusta Westland Coffee and Exhibition Break Using SIMULIA to Maximise the Value of Additive Layer Manufacturing User Paper Session 3 – Offshore • Automation of ECA Assessments in Subsea Pipelines using Abaqus, Ismael Ripoll, INTECSEA • Having a Blast!, David Winfield, Freudenberg Oil & Gas Technologies • Incorporating Finite Element Analysis Techniques into the Design Process for Subsea Annular Blowout Preventers, Richard James Windslow, Queen Mary, University of London Day One Ends Drinks Reception Conference Banquet

Presenter

Dimple Shah, VP WW Sales, SIMULIA Louise Wright, Principal Research Scientist - NPL

David Hawla, SIMULIA R&D Technology Director Lenovo

David Hawla, SIMULIA R&D Technology Director


Day One 9:00 9:15

9:45 10:15 10:45 11:15

Title Welcoming Remarks User Paper Session 4 - Materials • Rubber creep modelling based on modified hyperelastic models using Abaqus, Robert Luo, Trelleborg • A Proposed Methodology for studying microscale behaviour of MnS Inclusions in FCS steel, Didier Farrugia, Tata Steel • Numerical Modelling of Shaped Metal Deposition and Experimental Measurement of Distortion, Anas Yaghi, MTC Multibody Simulation - Introduction to SIMPACK ANSA & μETA as State-of-the-art of Pre- & PostProcessing Solutions for the SIMULIA Product Line Coffee and Exhibition Break Simulation on the 3DEXPERIENCE Platform

12:00

Recent numerical developments implemented in Abaqus: Multi-physics nano-scale simulations and floating degrees of freedom

12:30

User Paper Session 5 - Fundamentals • Pressure test and Abaqus analysis of an aluminum pressure vessel, Bob Johnson, REAL • What is a straight line? Does this matter in mechanical analysis? Alison McMillan, Glyndŵr University Lunch Technology and Product Updates, choose 3 of 6: Abaqus Update: Contact Optimisation (Isight & Tosca update) Fatigue and Durability Update Abaqus Update: Linear Dynamics Abaqus/CAE update Extending realistic simulation beyond medical application using image based models

13:00 14:00

15:00

Round Table Session , choose 3 of 6: SIMULIA Strategy Simulation on the 3DEXPERIENCE platform Automation of simulation processes Analysis techniques and best practices Co-simulation and Multiphysics Fracture and failure

16:00

Closing Remarks

Presenter

Ioannis Nerantzis, Beta CAE Karl Kueres, Senior Technical Specialist SIMULIA North-Nordics Silvestre Taveira Pinho, Professor of Mechanics of Composites, Imperial College London

Register now: http://www.3ds.com/events/simulia-regional-user-meetings/uk-regional-usermeeting/registration/

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4th November 8:30 8:45