Simulation based Engineering of Composite Materials

Summary

Joran Fernland, president of Convergence Manufacturing Technologies, discusses the role of composite materials like carbon fiber reinforced plastics in modern engineering, especially in aerospace. He highlights the evolution of materials from wood to aluminum, and now to advanced composites, which offer greater strength, stiffness, and lightness. Through computer simulations, engineers can optimize manufacturing processes, reducing time and costs. Fernland emphasizes the importance of simulation in improving design efficiency, reducing emissions, and addressing global challenges like climate change through innovations in materials engineering.

Takeaways

• 😀 Composite materials, like carbon fiber reinforced plastics (CFRP), offer significant benefits such as being lighter, stronger, and stiffer than traditional materials like aluminum.
• 😀 The development of composite materials is a natural evolution in engineering, starting from wood to aluminum, and now to high-performance composites like CFRP.
• 😀 Simulation technology plays a crucial role in modern materials engineering by allowing engineers to optimize manufacturing processes without the need for costly trial-and-error experiments.
• 😀 By simulating the curing and molding processes, engineers can predict how materials will behave, saving time and money in product development, particularly for large, complex structures like aircraft fuselages.
• 😀 The Boeing 787's manufacturing process benefits from computer simulations, which allow engineers to test hundreds of design variations quickly, reducing the testing time from years to just weeks.
• 😀 Composites are particularly valuable in industries where weight is critical, such as aerospace and electric vehicles, as they reduce fuel consumption and improve performance.
• 😀 The process of composite manufacturing is highly automated, with robots laying down raw materials, which are then cured under specific heat and pressure conditions to form the final product.
• 😀 Materials engineering plays a key role in decarbonization efforts, as the production of lighter, more efficient materials contributes to reducing CO2 emissions, especially in electric vehicles and clean energy technologies.
• 😀 Simulation technology provides engineers with 'x-ray vision' into the internal structure of materials, enabling them to measure and predict material behavior in ways that are impossible in physical testing.
• 😀 The ability to simulate manufacturing and material processes enables engineers to explore vast design spaces quickly, making it possible to test many different variations and refine designs faster than ever before.
• 😀 Fernland's passion for materials engineering is driven by the opportunity to make a global impact, using cutting-edge research to solve real-world challenges like climate change and sustainability.

Q & A

What role do composite materials like carbon fiber reinforced plastics play in modern engineering?

Composite materials, particularly carbon fiber reinforced plastics (CFRPs), are crucial in modern engineering for creating lightweight, strong, and durable products. These materials are especially important in industries like aerospace and electric vehicles, where reducing weight improves performance, fuel efficiency, and emissions.

How do composites differ from traditional materials like wood and aluminum?

Composites, such as carbon fiber reinforced plastics, are stronger, stiffer, and lighter than traditional materials like wood and aluminum. While wood and aluminum were used in the past for manufacturing products like aircraft, composites offer higher performance and are now commonly used in advanced aerospace applications.

What is the basic structure of a composite material?

A composite material consists of two or more materials combined on a macroscopic level. Typically, it includes a fiber (like carbon fiber) combined with a matrix (a plastic or resin). This combination provides strength, stiffness, and low weight, making composites ideal for high-performance applications.

Why are composites important for industries such as aerospace and electric vehicles?

Composites are vital for aerospace and electric vehicles because they reduce weight, which is crucial for improving performance and energy efficiency. In aerospace, lighter materials lead to better fuel efficiency, while in electric vehicles, reducing weight lowers power requirements, improving battery life and range.

How does the process of manufacturing composite materials work in the aerospace industry?

In the aerospace industry, composite materials are typically automated in the manufacturing process. Robots lay down raw materials in molds, and the structures are then placed in an oven to cure. The key is applying the correct temperature and pressure to achieve the desired microstructure, ensuring the final product meets safety and performance standards.

What is the significance of simulation in the design and manufacturing of composite materials?

Simulation plays a critical role in designing and manufacturing composite materials. It allows engineers to simulate the entire manufacturing process digitally, testing different scenarios and refining designs without the cost and time involved in physical trials. This process accelerates development, helping to optimize materials and designs more efficiently.

How does simulation help reduce testing time and costs in the manufacturing process?

Simulation reduces testing time and costs by allowing engineers to conduct numerous virtual tests before any physical testing is done. For example, Boeing used simulations to optimize the curing process for their Dreamliner, reducing what would have been several years of trial-and-error testing to just a few weeks of computer-based simulations.

What challenges do engineers face when validating simulation models in materials engineering?

One of the main challenges in validating simulation models is that some critical measurements, like the microstructure of the material, are difficult or impossible to capture in real-world testing. Engineers often validate simulations on a smaller scale, where testing is more affordable, before scaling up to full-size components.

How does the concept of 'virtual manufacturing' work in materials engineering?

Virtual manufacturing involves using computer simulations to model the manufacturing process. This allows engineers to predict how materials will behave under various conditions, such as temperature and pressure, before physical production begins. It helps in fine-tuning the process, ensuring that the final product meets performance standards.

What role does materials engineering play in addressing global challenges like climate change?

Materials engineering is essential in addressing climate change by developing sustainable materials and technologies. For example, the use of lightweight composite materials in electric vehicles and aircraft can reduce emissions. Additionally, the decarbonization of materials manufacturing processes is a significant opportunity for reducing CO2 emissions across various industries.