Title: New methods for virtual design with a focus on composite materials and structural optimisation

Authors: E. Schnack, A. Albers, J. Minx, Q. Lohmeyer

Addresses: Institute of Solid Mechanics, University of Karlsruhe, P.O. Box 6980, 76128 Karlsruhe, Germany. ' Institute of Product Development, University of Karlsruhe, Kaiserstrasse 10, 76131 Karlsruhe, Germany. ' Institute of Product Development, University of Karlsruhe, Kaiserstrasse 10, 76131 Karlsruhe, Germany. ' Institute of Product Development, University of Karlsruhe, Kaiserstrasse 10, 76131 Karlsruhe, Germany

Abstract: The increasing use of modern composite materials in product development nowadays requires the development of virtual product development methods for these materials. As product development starts with the design of these materials, material production has to be integrated into virtual product development. First a simulation method for the manufacturing process of carbon fibre-reinforced carbon and a hierarchical homogenisation method are presented. Specialised simulation methods of fracture mechanics and material fatigue for composite materials as well as a method for material failure detection based on test data are introduced. Furthermore, an optimisation process for mechanical parts| dynamic behaviour is explained. The demand for these methods is demonstrated on a humanoid robot whose parts are to be made of composite materials. The basis for integration of these methods into product development processes is the new Integrated Product Development Model (IPEM). Its open structure, based on its activities, makes it particularly suitable for the integration of the new method.

Keywords: virtual design; multiscale material modelling; failure phenomena; identification problems; shape optimisation; composite materials; structural optimisation; product development; composites; simulation; carbon fibre reinforced carbon; fracture mechanics; material fatigue; humanoid robots.

DOI: 10.1504/IJPD.2010.032991

International Journal of Product Development, 2010 Vol.11 No.1/2, pp.89 - 114

Published online: 06 May 2010 *

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