Abstract

The benefit of fused data from different virtual and experimental resources like CAD, FEM, DIC IR and laser scanners is demonstrated on a recyclable car seat back shell and its mechanical impact testing. Component properties depend on its shape, its material condition and its manufacturing process. Along the whole product lifecycle nowadays a huge amount of data accrues. The aim is the use of this information to improve products and save resources. To understand the mechanics of materials in use and forecast component behavior in simulations, the MaterialDataFusion (MDF) tool was created. MDF correlates information geometrically and in time to one set of fused data. Within the virtual geometry of a component, all available data are registered in a common coordinate system with local accuracy. MDF is able to correlate all data on a common grid. The grid can be created within the tool by using standard shells or solids Finite Element (FE) meshes. The local FE-size can be adjusted dependent on the spatial resolution of the data. Across all scales, data on different levels brought together. To use the accumulated information for the parametrization or validation of material models, the correlation process also can be performed using predefined meshes from usual FE-Preprocessors imported in MDF. That meshes are used within the correlation as an information carrier. The correlated information grid is than exported as a data frame, which contains the local available static or time dependent information on each node. One can include porosity, fiber orientation, heat treatment history, microstructure information, deformation and heat development in mechanical tests and all data measured or simulated on components. As an example, along the product chain of a recyclable car seat shell, consisting of fiber placed and molded basalt fiber laminates and polylactic acid (PLA), different data from multiple institutions where fused in MDF and used to validate a complex hybrid material model. An automatic registration in MDF and the interfaced to process ontologies are part of ongoing works.