Method, device and equipment for predicting fatigue life of chopped fiber composite structure

Abstract

This application provides a method, apparatus, and device for predicting the fatigue life of chopped fiber composite structures. The method includes: acquiring a geometric model of the chopped fiber composite structure; performing injection molding analysis on the chopped fiber composite structure based on the geometric model to generate injection molding analysis results, wherein the injection molding analysis results include model analysis results and fiber orientation analysis results; acquiring a fatigue analysis model of the chopped fiber composite structure, and generating target fiber orientation analysis results for the chopped fiber composite structure based on the fatigue analysis model, model analysis results, and fiber orientation analysis results; and generating fatigue life prediction results for the chopped fiber composite structure based on the stress analysis results and target fiber orientation analysis results. Therefore, by considering the influence of fiber orientation on material properties, the accuracy and reliability of fatigue life prediction for chopped fiber composite structures are improved.

Description

Technical Field

[0001] This application relates to the field of structural fatigue testing technology, and in particular to a method, apparatus and equipment for predicting the fatigue life of chopped fiber composite structures. Background Technology

[0002] Lightweighting is a crucial direction for automotive development, and replacing steel with plastics in automotive structures, especially load-bearing structures, is a key method for achieving this. Composite materials, due to their lightweight, high strength, and corrosion resistance, have become a primary choice for automotive lightweighting. With the development of new materials technologies and the continuous improvement of manufacturing techniques, the application of chopped fiber composites in the automotive field is becoming increasingly widespread. For example, components such as suspension brackets, interior parts, and structural parts are beginning to be made using chopped fiber composites.

[0003] Statistics show that over 90% of automotive component failures are caused by fatigue. Therefore, accurate prediction of fatigue life is crucial when using chopped fiber composites in automobiles. Chopped fiber composites are materials composed of chopped fibers and a matrix material, and are anisotropic materials, with their anisotropy primarily stemming from the fiber orientation distribution. The orientation of the chopped fibers is influenced by injection molding process parameters, including injection pressure, injection time, holding time, cooling rate, and gate location. These factors collectively determine the final fiber arrangement direction within the part.

[0004] Currently, the traditional fatigue analysis method is commonly used to predict the fatigue life of chopped fiber composite structures, which involves directly calculating stress and assessing fatigue based on the average mechanical properties of the material. However, differences in fiber orientation can lead to significantly different mechanical properties and fatigue behaviors in different directions, resulting in a large deviation between the predicted fatigue life and the actual situation, and failing to accurately reflect the true durability of the structure. Summary of the Invention

[0005] This application aims to at least partially address one of the technical problems in the related art.

[0006] Therefore, the first objective of this application is to propose a fatigue life prediction method for chopped fiber composite structures, which can integrate the real fiber orientation information obtained from injection molding analysis into subsequent structural analysis and fatigue calculation, fully consider the influence of fiber orientation on the anisotropic mechanical properties and fatigue behavior of materials, significantly improve the accuracy and reliability of fatigue life prediction for chopped fiber composite structures, and provide effective technical support for the optimized design of chopped fiber composite structures.

[0007] The second objective of this application is to provide a fatigue life prediction device for chopped fiber composite structures.

[0008] The third objective of this application is to propose an electronic device.

[0009] The fourth objective of this application is to provide a computer-readable storage medium.

[0010] To achieve the above objectives, the first aspect of this application proposes a method for predicting the fatigue life of a chopped fiber composite structure. The method includes: obtaining a geometric model of the chopped fiber composite structure; performing injection molding analysis on the chopped fiber composite structure based on the geometric model to generate injection molding analysis results, wherein the injection molding analysis results include model analysis results and fiber orientation analysis results; obtaining a fatigue analysis model of the chopped fiber composite structure, and generating target fiber orientation analysis results for the chopped fiber composite structure based on the fatigue analysis model, model analysis results, and fiber orientation analysis results; and generating fatigue life prediction results for the chopped fiber composite structure based on the stress analysis results and target fiber orientation analysis results.

[0011] In addition, the fatigue life prediction method for chopped fiber composite structures according to the above embodiments of this application may also have the following additional technical features: According to one embodiment of this application, injection molding analysis of a chopped fiber composite structure based on a geometric model is performed to generate injection molding analysis results. The process includes: meshing the geometric model to obtain a first structural model; determining the analysis type and material type of the first structural model to obtain a second structural model; constructing a gate model and a runner model on the second structural model based on a preset gate method to obtain a third structural model; setting the process parameters of the target structural model to obtain a target structural model; and performing injection molding analysis based on the target structural model to generate injection molding analysis results.

[0012] According to one embodiment of this application, the analysis type includes one or more of cooling, filling, holding pressure, and warping; the process parameters include one or more of cooling parameters, filling and holding pressure parameters, and warping parameters.

[0013] According to one embodiment of this application, the injection molding analysis of the short fiber composite structure based on the geometric model to generate injection molding analysis results further includes: changing the attribute types of the gate model and the runner model on the third structural model, wherein the attribute types include position and / or shape.

[0014] According to one embodiment of this application, injection molding analysis is performed based on a target structural model to generate injection molding analysis results, including: constructing a cooling system based on a preset gate method and a second structural model; and performing injection molding analysis based on the cooling system and the target structural model to generate injection molding analysis results.

[0015] According to one embodiment of this application, a target fiber orientation analysis result for a chopped fiber composite structure is generated based on a fatigue analysis model, model analysis results, and fiber orientation analysis results. This includes: aligning the fatigue analysis model, model analysis results, and fiber orientation analysis results in spatial positions to generate a spatial alignment result; and mapping the fiber orientation information in the fiber orientation analysis results onto the mesh of the fatigue analysis model based on the spatial alignment result to generate the target fiber orientation analysis result.

[0016] According to one embodiment of this application, the fatigue life prediction method for chopped fiber composite structures further includes: analyzing the fatigue life prediction results based on a preset analysis algorithm to obtain the predicted fatigue life of the chopped fiber composite structure.

[0017] To achieve the above objectives, a second aspect of this application proposes a fatigue life prediction device for chopped fiber composite structures, comprising: a modeling module for acquiring a geometric model of the chopped fiber composite structure; a first generation module for performing injection molding analysis on the chopped fiber composite structure based on the geometric model to generate injection molding analysis results, wherein the injection molding analysis results include model analysis results and fiber orientation analysis results; a second generation module for acquiring a fatigue analysis model of the chopped fiber composite structure and generating target fiber orientation analysis results for the chopped fiber composite structure based on the fatigue analysis model, model analysis results, and fiber orientation analysis results; and a third generation module for generating fatigue life prediction results for the chopped fiber composite structure based on the stress analysis results and target fiber orientation analysis results.

[0018] According to the fatigue life prediction device for chopped fiber composite structures of this application, the fatigue life prediction method for chopped fiber composite structures described above is executed. The fatigue life prediction method for chopped fiber composite structures of this application integrates the real fiber orientation information obtained from injection molding analysis into subsequent structural analysis and fatigue calculation, fully considering the influence of fiber orientation on the anisotropic mechanical properties and fatigue behavior of materials, significantly improving the accuracy and reliability of fatigue life prediction for chopped fiber composite structures, and providing effective technical support for the optimized design of chopped fiber composite structures.

[0019] To achieve the above objectives, a third aspect of this application provides an electronic device, including: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the aforementioned fatigue life prediction method for chopped fiber composite structures.

[0020] According to the electronic device of this application, the processor executes a computer program stored in the memory to implement the aforementioned fatigue life prediction method for chopped fiber composite structures. The fatigue life prediction method for chopped fiber composite structures of this application integrates the real fiber orientation information obtained from injection molding analysis into subsequent structural analysis and fatigue calculations, fully considering the influence of fiber orientation on the anisotropic mechanical properties and fatigue behavior of the material. This significantly improves the accuracy and reliability of fatigue life prediction for chopped fiber composite structures, providing effective technical support for the optimized design of chopped fiber composite structures.

[0021] To achieve the above objectives, a fourth aspect of this application provides a computer-readable storage medium having a computer program stored thereon, which is executed by a processor to implement the aforementioned fatigue life prediction method for chopped fiber composite structures.

[0022] According to the computer-readable storage medium of this application, the aforementioned fatigue life prediction method for chopped fiber composite structures is implemented when the computer program stored thereon is executed. The fatigue life prediction method for chopped fiber composite structures of this application integrates the real fiber orientation information obtained from injection molding analysis into subsequent structural analysis and fatigue calculations, fully considering the influence of fiber orientation on the anisotropic mechanical properties and fatigue behavior of the material. This significantly improves the accuracy and reliability of fatigue life prediction for chopped fiber composite structures, providing effective technical support for the optimized design of chopped fiber composite structures. Attached Figure Description

[0023] Figure 1 This is a flowchart of a fatigue life prediction method for chopped fiber composite structures according to some embodiments of this application; Figure 2 This is a structural schematic diagram of the gate model and runner model of a suspension bracket according to a specific embodiment of this application; Figure 3 This is a flowchart of a fatigue life prediction method for a chopped fiber composite structure of a suspension bracket according to a specific embodiment of this application; Figure 4 This is a schematic diagram of an injection molding filling process according to a specific embodiment of this application; Figure 5 This is a schematic diagram of fiber orientation analysis results according to a specific embodiment of this application; Figure 6 This is a schematic diagram of parameter settings considering the influence of fiber orientation according to a specific embodiment of this application; Figure 7 This is a block diagram of a fatigue life prediction device for a chopped fiber composite structure according to some embodiments of this application; Figure 8 This is a block diagram of an electronic device according to some embodiments of this application. Detailed Implementation

[0024] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0025] The fatigue life prediction method, apparatus, and equipment for chopped fiber composite structures according to embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0026] It is understood that the fatigue life prediction method for chopped fiber composite structures in this application can be implemented using various engineering simulation software. These engineering simulation software programs include at least mold flow analysis software, material modeling software, finite element analysis software, and fatigue analysis software.

[0027] Mold flow analysis software is used to simulate and analyze the injection molding process of chopped fiber composite structures, simulating the flow, filling, holding pressure, and cooling processes of the plastic melt, and calculating the orientation distribution of the chopped fibers during the molding process. For example, Autodesk Moldflow simulation software is an industry-standard tool in the field of plastic injection molding simulation, capable of validating and optimizing plastic parts, injection molds, and injection molding processes.

[0028] Materials modeling software is used to map fiber orientation results obtained from mold flow analysis onto the mesh of a structural fatigue analysis model, thereby achieving the fusion of fiber orientation information and the structural analysis model. For example, Digimat software is an advanced multi-scale materials modeling platform that focuses on the microscopic mechanical modeling of complex multiphase materials such as composites, plastics, and elastomers, bridging the gap between materials, manufacturing processes, and structural component performance.

[0029] Finite element analysis software is used to perform stress analysis on structural models that incorporate fiber orientation information, calculating the stress-strain distribution of the structure under loading conditions. For example, ABAQUS (ABAQUS Finite Element Analysis Software) is a powerful engineering simulation finite element software capable of handling everything from relatively simple linear analyses to many complex nonlinear problems, and is widely considered one of the most powerful finite element software programs available.

[0030] Fatigue analysis software is used to predict the fatigue life of chopped fiber composite structures based on stress analysis results and fiber orientation information, and to assess the service life of the structure under cyclic loading. For example, FEMFAT software (FiniteElement Method Fatigue) is a world-leading application software for fatigue life prediction, which can help users quickly identify fatigue strength-related critical areas in the early stages of development.

[0031] By using the aforementioned software in tandem, the impact of fiber orientation on material properties and structural fatigue life during injection molding can be fully considered, thereby improving the accuracy of fatigue life prediction.

[0032] Figure 1 This is a flowchart illustrating a fatigue life prediction method for chopped fiber composite structures according to some embodiments of this application. (Refer to...) Figure 1 Methods for predicting the fatigue life of chopped fiber composite structures may include: S1, obtain the geometric model of the short-cut fiber composite structure.

[0033] Specifically, a geometric model refers to a three-dimensional digital model of the chopped fiber composite material structure to be analyzed, such as a three-dimensional geometric model of an automotive suspension bracket. The geometric model serves as the fundamental input for subsequent injection molding simulation analysis, used for mesh generation and process simulation in mold flow analysis software.

[0034] For example, the geometric model can be created directly using 3D modeling software or imported from existing structural design files. The geometric model should accurately reflect the shape, size, and features of the structure to be analyzed to ensure the accuracy and reliability of subsequent simulation analysis.

[0035] S2, Based on the geometric model, the short fiber composite structure is subjected to injection molding analysis to generate injection molding analysis results, which include model analysis results and fiber orientation analysis results.

[0036] Among them, chopped fiber composite structures can refer to parts with specific geometric shapes that are composed of chopped fibers and matrix materials, such as suspension brackets, interior parts or structural parts in the automotive industry. Such structures are widely used in the field of automotive lightweighting due to their excellent properties such as light weight and high strength.

[0037] Injection molding analysis refers to the computer simulation of the molding process of chopped fiber composite structures in a mold using mold flow analysis software, in order to simulate the flow behavior of the plastic melt, the orientation distribution of the fibers during the flow process, and the final molding state of the product.

[0038] Injection molding analysis results refer to the data set output after performing injection molding simulation analysis on chopped fiber composite structures using mold flow analysis software. These results characterize the structure's process and material states during the molding process. Specifically, the results include two types of files: Model analysis results, which are data files containing the mesh model information of the injection-molded structure, specifically including geometric feature parameters such as node coordinates, element connection relationships, and thickness distribution. This file records the geometric shape of the structure after injection molding, providing a spatial positioning reference for subsequent material modeling and structural analysis. Model analysis results can be saved in .udm format (a binary result file format specific to Autodesk Moldflow software).

[0039] Fiber orientation analysis results refer to a data file containing the final orientation distribution of chopped fibers during injection molding, specifically including fiber orientation tensor information for each grid cell. This file is stored in Extensible Markup Language (EXPLAIN) format and records the spatial arrangement direction of fibers in various parts of the structure. It is core data characterizing the anisotropy of the material and directly affects the accuracy of subsequent structural analysis and fatigue life prediction. Fiber orientation analysis results can be saved as .xml (eXtensible Markup Language) format files.

[0040] In some embodiments of this application, injection molding analysis is performed on the chopped fiber composite structure based on a geometric model to generate injection molding analysis results. This includes: meshing the geometric model to obtain a first structural model; determining the analysis type and material type of the first structural model to obtain a second structural model; constructing a gate model and a runner model on the second structural model based on a preset gate method to obtain a third structural model; setting the process parameters of the target structural model to obtain a target structural model; and performing injection molding analysis based on the target structural model to generate injection molding analysis results.

[0041] Mesh generation refers to the process of discretizing a continuous geometric model into a mesh system composed of a finite number of elements and nodes. This is the foundation for finite element simulation analysis, and the mesh quality directly affects the accuracy and convergence of subsequent simulation calculations.

[0042] The first structural model can refer to the meshed model obtained after mesh generation, which can be used for simulation analysis. This model retains the shape characteristics of the original geometric model, but is presented in the form of a discretized mesh.

[0043] Furthermore, the analysis type and material type of the first structural model are determined to obtain the second structural model.

[0044] The second structural model can refer to the model state after the mesh generation is completed and the simulation analysis type and material properties are further clarified.

[0045] Based on the preset gating method, a gating model and a runner model are constructed on the second structural model to obtain the third structural model.

[0046] The pre-defined gate method refers to the gate location and type predetermined according to the actual injection molding process. The gate is the entry point for molten plastic to enter the mold cavity, and its location directly affects the flow path of the plastic and the final orientation distribution of the fibers. The pre-defined gate method can be set by technicians according to the actual situation.

[0047] A gate model can refer to a model element established in a simulation model to represent the geometric features and properties of an actual gate.

[0048] The runner model refers to the model elements established in the simulation model to characterize the geometric features and properties of plastic conveying channels such as the main runner and branch runners. The third structural model refers to the complete simulation model that further adds gate and runner models based on the second structural model. As a specific embodiment of this example, the third structural model of the suspension bracket can be referred to... Figure 2 The process parameters of the target structure model are set to obtain the target structure model.

[0049] The target structural model can refer to the final model that can be directly used to run injection molding simulation analysis after all the prerequisite settings have been completed.

[0050] In some embodiments of this application, the injection molding analysis of the chopped fiber composite structure based on the geometric model is performed to generate injection molding analysis results. The method further includes changing the attribute types of the gate model and the runner model on the third structural model, wherein the attribute types include position and / or shape.

[0051] Among them, the attribute type can refer to the geometric feature parameters and spatial location parameters of the gate model and the runner model.

[0052] It should be noted that, in some embodiments of this application, the analysis type includes one or more of cooling, filling, holding pressure, and warping; the process parameters include one or more of cooling parameters, filling and holding pressure parameters, and warping parameters.

[0053] Specifically, the analysis types include: cooling analysis, which simulates the cooling and solidification process of the melt in the mold; filling analysis, which simulates the process of the melt filling the cavity; holding pressure analysis, which simulates the process of continuously applying pressure after filling to compensate for material shrinkage; and warpage analysis, which predicts the deformation of the product after demolding. The process parameters are the specific values ​​and conditions required for each of the above analysis types, such as cooling time, cooling temperature, injection pressure, holding pressure, and injection time.

[0054] Furthermore, attribute types include location and / or shape. Location attributes refer to the spatial coordinates of the gate and runner in the model; shape attributes refer to the geometric structure of the gate and runner, such as the gate being a point gate, side gate, or fan gate, and the runner being a circular, trapezoidal, or U-shaped cross-section.

[0055] In some embodiments of this application, injection molding analysis is performed based on a target structural model to generate injection molding analysis results, including: constructing a cooling system based on a preset gate method and a second structural model; and performing injection molding analysis based on the cooling system and the target structural model to generate injection molding analysis results.

[0056] The cooling system refers to the network of cooling water channels arranged in the mold to control the cooling process of the melt. It includes elements such as cooling channels, inlets, and outlets. Its function is to cool the product uniformly, reduce the molding cycle, and control warpage. In simulation analysis, the cooling system is modeled in the mold flow analysis software and together with the gating system and product model, it forms a complete injection molding simulation model.

[0057] Specifically, firstly, mold flow analysis software (such as Autodesk Moldflow simulation software) meshes the imported geometric model, discretizing it into a first structural model suitable for numerical calculation. Secondly, the analysis type and material type of the first structural model are determined, resulting in a second structural model. The analysis type includes one or more of cooling, filling, holding pressure, and warpage. Next, based on the preset gate method determined by the actual injection molding process, a gate model and runner model are constructed on the second structural model. The position or shape of the gate and runner are adjusted as needed to obtain a third structural model. Simultaneously, a cooling system is constructed based on the preset gate method and the second structural model. Subsequently, process parameters such as cooling parameters, filling and holding pressure parameters, and warpage parameters are set to form a target structural model that can be directly used for simulation. Finally, injection molding simulation analysis is run based on the target structural model, generating model analysis results containing model mesh information and fiber orientation analysis results containing fiber spatial distribution data.

[0058] S3: Obtain the fatigue analysis model of the chopped fiber composite structure, and generate the target fiber orientation analysis results of the chopped fiber composite structure based on the fatigue analysis model, model analysis results, and fiber orientation analysis results.

[0059] The fatigue analysis model refers to the finite element model used for subsequent structural mechanical performance and fatigue life analysis. This model represents the geometry and topological relationships of the structure under analysis in the form of a mesh and serves as the basic framework for stress analysis and fatigue calculation. In some embodiments of this application, the fatigue analysis model can be saved as a file with the .inp extension.

[0060] It should be noted that, in some embodiments of this application, generating the target fiber orientation analysis result of the chopped fiber composite structure based on the fatigue analysis model, the model analysis result, and the fiber orientation analysis result includes: aligning the fatigue analysis model, the model analysis result, and the fiber orientation analysis result in spatial position to generate a spatial alignment result; and mapping the fiber orientation information in the fiber orientation analysis result onto the mesh of the fatigue analysis model based on the spatial alignment result to generate the target fiber orientation analysis result.

[0061] Spatial alignment and fiber orientation information mapping can be performed using material modeling software, such as Digimat.

[0062] Spatial alignment refers to the coordinate registration of the mesh system of the fatigue analysis model with the mesh system of the modulus flow analysis based on the geometric reference information provided in the model analysis results, ensuring that the two correspond precisely in space. Specifically, since the fatigue analysis model and the modulus flow analysis model usually use different meshing methods and densities, directly using fiber orientation data will lead to positional misalignment. Therefore, spatial alignment is needed to establish the correspondence between the two sets of meshes.

[0063] Fiber orientation information mapping refers to transferring aligned fiber orientation data from the modulus flow analysis mesh to each mesh element of the fatigue analysis model. This mapping process, based on the spatial alignment results, uses interpolation or volume averaging algorithms to calculate the equivalent fiber orientation values ​​for each element of the fatigue analysis model based on the fiber orientation tensor of each element in the modulus flow analysis mesh, thus generating the target fiber orientation analysis result. The target fiber orientation analysis result imbues each element of the fatigue analysis model with true fiber orientation information, which can be saved as a file with the .dof extension (a binary format specific to Digimat software) for subsequent stress analysis and fatigue life prediction.

[0064] Specifically, material modeling software (such as Digimat) first spatially aligns the fatigue analysis model, model analysis results, and fiber orientation analysis results, ensuring precise spatial correspondence between mesh systems from different sources. Then, it maps the aligned fiber orientation information from the modulus flow analysis mesh to each mesh element of the fatigue analysis model, generating a target fiber orientation analysis result with accompanying real fiber orientation data. This result can be saved as a .dof file for subsequent stress analysis and fatigue life prediction.

[0065] S4. Based on the stress analysis results and target fiber orientation analysis results of the chopped fiber composite structure, the fatigue life prediction results of the chopped fiber composite structure are generated.

[0066] The stress analysis results refer to the data set obtained by performing mechanical calculations on a structural model incorporating fiber orientation information using finite element analysis software. Specifically, this includes the distribution of physical quantities such as nodal displacements, element stresses, and element strains under loading conditions. These results can be saved in binary form as a file with the .odb extension (OutputDatabase File, a binary format specific to Abaqus finite element analysis software). They reflect the mechanical response state of the structure under actual working conditions and serve as the basic input data for fatigue life analysis.

[0067] Fatigue life prediction results refer to the conclusive data obtained after evaluating the durability performance of a structure under cyclic loading using fatigue analysis software. Specifically, this includes key indicators such as the fatigue life distribution of various parts of the structure, potential failure locations, and safety factors. The results are presented in the form of visual cloud maps and data tables to determine whether the structure meets design life requirements and to guide structural optimization and improvement.

[0068] Specifically, fatigue analysis software (such as FEMFAT) first imports the stress analysis result file (.odb) and the target fiber orientation analysis result file (.dof) into the fatigue analysis software; then, in the software's analysis parameter settings, the option to consider the influence of fiber orientation is checked to ensure that the influence of fiber orientation on the anisotropic fatigue performance of the material is fully considered during the fatigue calculation; finally, fatigue life analysis is run. Based on stress distribution data and fiber orientation information, combined with the material's fatigue performance curve and fatigue damage accumulation theory, the software calculates the fatigue life of the structure under cyclic loading and generates fatigue life prediction results that include fatigue life distribution cloud maps and analysis data.

[0069] The fatigue life prediction method for chopped fiber composite structures provided in this application firstly obtains a geometric model of the structure to be analyzed; then, based on the geometric model, injection molding simulation analysis is performed using mold flow analysis software to generate injection molding analysis results that include model analysis results and fiber orientation analysis results; next, a fatigue analysis model of the structure is obtained, and the fatigue analysis model, model analysis results, and fiber orientation analysis results are spatially aligned and mapped using material modeling software to generate target fiber orientation analysis results with real fiber orientation information; finally, the stress analysis results are combined with the target fiber orientation analysis results using fatigue analysis software to generate fatigue life prediction results that consider the influence of fiber orientation.

[0070] The fatigue life prediction method for chopped fiber composite structures provided in this application incorporates the real fiber orientation information obtained from injection molding analysis into subsequent structural analysis and fatigue calculations. This fully considers the influence of fiber orientation on the anisotropic mechanical properties and fatigue behavior of the material, avoiding prediction biases caused by neglecting fiber orientation in traditional methods, and significantly improving the accuracy and reliability of fatigue life prediction results. Furthermore, this method employs full-process digital simulation technology, enabling fatigue performance evaluation through computer simulation during the product design stage. This eliminates the need for repeated physical prototype manufacturing and bench testing, significantly shortening the R&D cycle and reducing testing costs, thus providing effective technical support for the optimized design of chopped fiber composite structures.

[0071] In some embodiments of this application, the fatigue life prediction method for chopped fiber composite structures further includes: analyzing the fatigue life prediction results based on a preset analysis algorithm to obtain the predicted fatigue life of the chopped fiber composite structure.

[0072] The preset analysis algorithm refers to the mathematical method or data processing rule used to extract and calculate specific life values ​​from fatigue life prediction results. The algorithm can be implemented in a manner appropriate to the specific application scenario.

[0073] For example, an extreme value extraction algorithm based on fatigue life distribution cloud map is used to identify the most dangerous part of the structure and its corresponding minimum fatigue life value; a life calculation algorithm based on cumulative damage theory is used to calculate the degree of cumulative damage and inversely estimate the fatigue life based on stress cycle and material SN curve (Stress-Number of Cycles curve); a life assessment algorithm based on statistical analysis is used to perform statistical analysis on multiple working conditions or multiple simulation results to obtain a predicted life range with a confidence level; or a life verification algorithm based on the safety factor method is used to compare the calculated life with the design target life to evaluate the safety margin of the structure.

[0074] By further processing the fatigue life prediction results using the aforementioned preset analysis algorithm, more intuitive and engineering-guiding predicted fatigue life values ​​can be obtained, facilitating structural optimization and life verification by designers.

[0075] As a specific embodiment of this application, taking a suspension bracket as an example, the fatigue life prediction method for the chopped fiber composite material structure of this application may include: S301, Obtain the geometric model of the suspension bracket.

[0076] A three-dimensional digital model of the suspension bracket is created using 3D modeling software. This model accurately reflects the shape, size, and characteristics of the bracket, serving as the basic input for subsequent injection molding simulation analysis.

[0077] S302, perform injection molding simulation analysis on the geometric model of the suspension bracket to generate injection molding analysis results.

[0078] The geometric model is meshed and repaired; the analysis type and material type are determined; the gate model, runner model, and cooling system are constructed according to the actual injection molding process; process parameters are set; the injection molding simulation analysis is run, generating injection molding analysis results including model analysis results (.udm file) and fiber orientation analysis results (.xml file). The injection molding filling process is referenced. Figure 4 .

[0079] S303 maps the fiber orientation analysis results to the fatigue analysis model to generate the target fiber orientation analysis results.

[0080] Obtain the fatigue analysis model (.inp file) of the suspension bracket, and import this model along with the model analysis results (.udm file) and fiber orientation analysis results (.xml file) from the injection molding analysis results into the material modeling software. Through spatial alignment and fiber orientation information mapping, transfer the fiber orientation data to each mesh element of the fatigue analysis model, generating a target fiber orientation analysis result (.dof file) with actual fiber orientation information. The fiber orientation analysis result mapping is referenced... Figure 5 .

[0081] S304, Perform stress analysis on the suspension bracket to generate stress analysis results.

[0082] The target fiber orientation analysis results (.dof file) and fatigue analysis model are imported into the finite element analysis software and co-simulated with the material modeling software to perform stress analysis on the suspension bracket under load conditions, calculate the displacement, stress and strain distribution of the structure, and generate stress analysis results (.odb file).

[0083] S305. Based on the stress analysis results and the target fiber orientation analysis results, fatigue analysis is performed on the suspension bracket to generate fatigue life prediction results.

[0084] Import the stress analysis results (.odb file) and the target fiber orientation analysis results (.dof file) into the fatigue analysis software. In the analysis parameter settings, select the option to consider the influence of fiber orientation. Refer to... Figure 6 The fatigue life analysis is performed, and the fatigue life of the suspension bracket is calculated based on stress distribution data and fiber orientation information. The fatigue life prediction results, which include fatigue life distribution cloud maps and analysis data, are generated.

[0085] S306, analyze the fatigue life prediction results to obtain the predicted fatigue life of the suspension bracket.

[0086] The fatigue life prediction results are further processed based on the preset analysis algorithm to extract the minimum fatigue life value of the suspension bracket or the life distribution of key parts, so as to obtain the final predicted fatigue life, which is used to evaluate whether the bracket meets the design life requirements and guide structural optimization.

[0087] This application also provides a fatigue life prediction device for chopped fiber composite structures, referring to... Figure 7 The device 700 includes: a modeling module 710, a first generation module 720, a second generation module 730, and a third generation module 740.

[0088] The modeling module 710 is used to obtain the geometric model of the chopped fiber composite structure; the first generation module 720 is used to perform injection molding analysis on the chopped fiber composite structure based on the geometric model to generate injection molding analysis results, wherein the injection molding analysis results include model analysis results and fiber orientation analysis results; the second generation module 730 is used to obtain the fatigue analysis model of the chopped fiber composite structure, and generate the target fiber orientation analysis results of the chopped fiber composite structure based on the fatigue analysis model, model analysis results and fiber orientation analysis results; the third generation module 740 is used to generate the fatigue life prediction results of the chopped fiber composite structure based on the stress analysis results and target fiber orientation analysis results of the chopped fiber composite structure.

[0089] In some embodiments of this application, the first generation module 720 performs injection molding analysis on the chopped fiber composite material structure based on a geometric model to generate injection molding analysis results. Specifically, it is used to: mesh the geometric model to obtain a first structural model; determine the analysis type and material type of the first structural model to obtain a second structural model; construct a gate model and a runner model on the second structural model based on a preset gate method to obtain a third structural model; set the process parameters of the target structural model to obtain the target structural model; and perform injection molding analysis based on the target structural model to generate injection molding analysis results.

[0090] In some embodiments of this application, the first generation module 720 determines that the analysis type includes one or more of cooling, filling, holding pressure and warping; and the process parameters include one or more of cooling parameters, filling and holding pressure parameters and warping parameters.

[0091] In some embodiments of this application, the first generation module 720 performs injection molding analysis on the chopped fiber composite material structure based on the geometric model to generate injection molding analysis results. It is also used to: change the attribute types of the gate model and runner model on the third structural model, wherein the attribute types include position and / or shape.

[0092] In some embodiments of this application, the first generation module 720 performs injection molding analysis based on the target structure model to generate injection molding analysis results. Specifically, it is used to: construct a cooling system based on a preset gate method and a second structure model; and perform injection molding analysis based on the cooling system and the target structure model to generate injection molding analysis results.

[0093] In some embodiments of this application, the second generation module 730 generates the target fiber orientation analysis result of the chopped fiber composite structure based on the fatigue analysis model, the model analysis result, and the fiber orientation analysis result. Specifically, it is used to: spatially align the fatigue analysis model, the model analysis result, and the fiber orientation analysis result to generate a spatial alignment result; and map the fiber orientation information in the fiber orientation analysis result onto the mesh of the fatigue analysis model based on the spatial alignment result to generate the target fiber orientation analysis result.

[0094] In some embodiments of this application, the third generation module 740 is further configured to: analyze the fatigue life prediction results based on a preset analysis algorithm to obtain the predicted fatigue life of the chopped fiber composite material structure.

[0095] It should be noted that for details not disclosed in the fatigue life prediction device for chopped fiber composite structures in the embodiments of this application, please refer to the details disclosed in the fatigue life prediction method for chopped fiber composite structures in the embodiments of this application, which will not be repeated here.

[0096] Corresponding to the above embodiments, this application also provides an electronic device, specifically referring to... Figure 8 The electronic device 800 includes: a memory 810, a processor 820, and a computer program stored in the memory 810 and executable on the processor 820. The processor 820 executes the program to implement the aforementioned fatigue life prediction method for chopped fiber composite structures.

[0097] This application also provides a computer-readable storage medium having a computer program stored thereon, which is executed by a processor to implement the aforementioned fatigue life prediction method for chopped fiber composite structures.

[0098] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0099] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0100] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0101] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

[0102] Any process or method described in the flowchart or otherwise herein is to be understood as representing a module, segment, or portion of code comprising one or more executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0103] It should be noted that the logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be specifically implemented in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device. More specific examples (a non-exhaustive list) of computer-readable media include: an electrical connection having one or more wires (electronic device), a portable computer disk drive (magnetic device), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Alternatively, the computer-readable medium may be paper or other suitable media on which the program can be printed, since the program can be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in a computer memory.

[0104] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0105] Those skilled in the art will understand that all or part of the steps of the methods in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

[0106] Furthermore, the functional units in the various embodiments of this application can be integrated into a processing module, or each unit can exist physically separately, or two or more units can be integrated into a module. The integrated module can be implemented in hardware or as a software functional module. If the integrated module is implemented as a software functional module and sold or used as an independent product, it can also be stored in a computer-readable storage medium.

[0107] The storage medium mentioned above can be a read-only memory, a disk, or an optical disk, etc. Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of this application.

[0108] It should be understood that the various forms of processes shown above can be used to rearrange, add, or delete steps. For example, the steps described in this application can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this application can be achieved, and this is not limited herein.

[0109] The specific embodiments described above do not constitute a limitation on the scope of protection of this application. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method of predicting the fatigue life of a chopped fiber composite structure, characterized by, include: Obtain the geometric model of the chopped fiber composite structure; Based on the geometric model, the short-cut fiber composite material structure is subjected to injection molding analysis to generate injection molding analysis results, wherein the injection molding analysis results include model analysis results and fiber orientation analysis results; Obtain the fatigue analysis model of the chopped fiber composite structure, and generate the target fiber orientation analysis result of the chopped fiber composite structure based on the fatigue analysis model, the model analysis result, and the fiber orientation analysis result. Based on the stress analysis results and the target fiber orientation analysis results of the chopped fiber composite structure, fatigue life prediction results of the chopped fiber composite structure are generated.

2. The method of claim 1, wherein, The step of performing injection molding analysis on the chopped fiber composite structure based on the geometric model to generate injection molding analysis results includes: The geometric model is meshed to obtain the first structural model; Determine the analysis type and material type of the first structural model to obtain the second structural model; Based on the preset gating method, a gating model and a flow channel model are constructed on the second structural model to obtain the third structural model; The process parameters of the target structure model are set to obtain the target structure model; Injection molding analysis is performed based on the target structural model to generate the injection molding analysis results.

3. The method of claim 2, wherein, The analysis type includes one or more of cooling, filling, holding pressure, and warpage; the process parameters include one or more of cooling parameters, filling and holding pressure parameters, and warpage parameters.

4. The method of claim 2, wherein, The step of performing injection molding analysis on the chopped fiber composite structure based on the geometric model to generate injection molding analysis results also includes: The attribute types of the gate model and runner model on the third structural model are changed, wherein the attribute types include position and / or shape.

5. The method of claim 2, wherein, The injection molding analysis based on the target structural model to generate the injection molding analysis results includes: Based on the preset gate method and the second structural model, a cooling system is constructed; Injection molding analysis is performed based on the cooling system and the target structural model to generate the injection molding analysis results.

6. The method of claim 1, wherein, The step of generating the target fiber orientation analysis results for the chopped fiber composite structure based on the fatigue analysis model, the model analysis results, and the fiber orientation analysis results includes: The fatigue analysis model, the model analysis results, and the fiber orientation analysis results are spatially aligned to generate a spatial alignment result. Based on the spatial alignment result, the fiber orientation information in the fiber orientation analysis result is mapped onto the mesh of the fatigue analysis model to generate the target fiber orientation analysis result.

7. The method of claim 1, wherein, Also includes: The fatigue life prediction results are analyzed based on a preset analysis algorithm to obtain the predicted fatigue life of the chopped fiber composite material structure.

8. An apparatus for predicting fatigue life of a chopped fiber composite structure, characterized by, include: The modeling module is used to obtain the geometric model of the chopped fiber composite structure. The first generation module is used to perform injection molding analysis on the chopped fiber composite material structure based on the geometric model to generate injection molding analysis results, wherein the injection molding analysis results include model analysis results and fiber orientation analysis results; The second generation module is used to obtain the fatigue analysis model of the chopped fiber composite material structure, and generate the target fiber orientation analysis result of the chopped fiber composite material structure based on the fatigue analysis model, the model analysis result and the fiber orientation analysis result. The third generation module is used to generate fatigue life prediction results for the chopped fiber composite structure based on the stress analysis results and the target fiber orientation analysis results of the chopped fiber composite structure.

9. An electronic device, characterized in that, include: The memory, the processor, and the computer program stored in the memory and executable on the processor, the processor executing the program to implement the fatigue life prediction method for chopped fiber composite structures as described in any one of claims 1-7.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, The program is executed by the processor to implement the fatigue life prediction method for chopped fiber composite structures as described in any one of claims 1-7.

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