A virtual testing methodology for the identification of optimal parametric concept models in multi-bolted composite applications.

Abstract

Virtual Testing (VT) aims to develop finite element (FE) models that represent accurately the structural behaviour of a real product, such that less time is lost in time-consuming and costly physical experiments. However, detailed modelling and advanced simulations for certain applications (e.g. joints or composite materials) involve a number of challenges such as high computational cost and poor convergence due to the large nonlinearities involved in the process. To overcome these issues, we propose a VT methodology with a strong focus on joining technologies, which aims to deliver parametric concept models able to represent faithfully the highly nonlinear behaviour of detailed FE models at different scales. The methodology has been validated in a use case consisting of a composite panel connected to two aluminum profiles through 8 high-strength steel bolts. Applying the VT methodology on the 8 bolts resulted in a reduction of computational time of approximately a factor of 50, while keeping the error consistently below 10%.