Nonlinear FEA Test for PP Panel

Project Title: Nonlinear FEA of an Injection-Molded PP Ground Panel Under Plate Load (Stage 1 – Test)

About the project

We manufacture modular injection-molded plastic ground panels, used to build temporary roads for trucks, cranes and heavy equipment. We’re planning a full FEA study for our technical documentation. This first stage is a paid test on a single panel with one loading setup. If the quality is right, more stages will follow: other load cases, multi-panel assemblies with interlocking joints, and calibration against physical tests.

What we provide

3D model of the panel (STEP), one piece, solid geometry with ribs
Material datasheet: Borouge BD265MO, heterophasic PP block copolymer for injection molding
Tensile modulus: 1200 MPa (ISO 527-2)
Flexural modulus: 1250 MPa (ISO 178)
Tensile stress at yield: 22 MPa at 6% strain
Density: 900–910 kg/m³
Notched Charpy/Izod at 23 °C: No Break

Scope: Stage 1

One panel, fully supported on the ground, loaded by a rigid square plate of 152.4 × 152.4 mm, in two load positions:

Case A: plate centered over a rib
Case B: plate centered between ribs

Load is increased incrementally up to 200 kN, or until displacement reaches 10% of the panel thickness or excessive plastic strain occurs, whichever comes first.

Modeling requirements

Material: nonlinear elastic-plastic model (at least bilinear) built from the datasheet: yield at 22 MPa / 6% strain, with a reasonable post-yield tangent modulus. Poisson’s ratio 0.40 unless you justify another value.
Support: panel resting on a rigid flat floor (like concrete), modeled with contact, not fixed supports. Panel–floor friction μ ≈ 0.3, or justify your choice.
Loading plate: rigid steel body in contact with the panel (frictionless or μ ≈ 0.2).
Analysis: static, nonlinear (material + contact + large deformation where relevant), quasi-static loading at 23 °C, no creep.
Mesh: good quality solid mesh, refined under the plate and at the rib tops and fillets. Include a mesh convergence check, at least two mesh densities compared on peak displacement and stress.
Use symmetry if applicable, and state it clearly.
Every assumption must be documented.

Deliverables (for each case, A and B)

High-resolution color maps (PNG, at least 1920 px wide):
Von Mises stress
Equivalent plastic strain
Total deformation
At least one section cut through the loaded rib zone
Load vs. displacement curve (plate displacement), as a chart plus raw data in CSV/Excel
Load at first yield, and load at the stop criterion (10% thickness or plastic-strain limit)
Screenshot of the mesh in the software (global view and close-up under the plate), with element type, size and count
Critical points of the geometry marked on the images
Short technical report (PDF, in Portuguese preferred, English acceptable): assumptions, material curve, mesh, boundary conditions, results, and a brief interpretation
Editable simulation files (ANSYS Workbench preferred, .wbpz archive, or Abaqus .cae/.inp), with the software version stated

Requirements

Proven experience with nonlinear FEA of plastic parts (ANSYS, Abaqus or similar)
Solid understanding of contact modeling and convergence in nonlinear analysis
A commercial or academic research license with no node limit that would affect results (student versions with node limits are not acceptable)
Ability to explain results in plain language for a technical catalog
NDA required: the geometry is confidential and must not be shared or reused

Timeline: 2–3 days after receiving files

Revisions: 1 round included (minor adjustments to setup or outputs)

To apply, please include:

Software and version you’ll use
One or two examples of nonlinear plastic or contact FEA you’ve done. Images with sensitive details hidden are fine.
Your proposed post-yield material approach, in one or two lines
Price and delivery time

Proposals without answers to these questions won’t be considered.