Composite Modeling with FiberSim

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Composite Modeling with FiberSim

April 10 2012

Composites Overview within HyperWorks

HyperMesh Modern Ply Based

Composites Pre-Processing

Visualizations Visually Verify the Math Model

OptiStruct/RADIOSS Composites

Design Optimization & Analysis

HyperView Composites

Post-Processing & Failure Analysis

HyperLaminate Solver Classical Lamination Theory

Realizations Export Ply Based Models to

Solver Zone Based Models

HyperWorks Partners Detailed Compoiste Material

Modeling & Structural Modeling

CAD & Mfg Interoperability

Geometry

Process of FiberSim- Hypermesh interoperability

• Read CAD part ,surface from Catia , UG etc ,geometry etc. Import CAD model

• Geometry clean up on imported CAD model

• Mesh the part ,check element quality etc. Create mesh

• Extract composite data - Ply, stacking , material info , system definition

• Drape data , triangulation data (ply shapes ) etc as table in HM .

Import Equivalent Fibersim model

• Realize geometric shapes to FE ply shapes - Two methods , ‘simple’ , ‘advanced’

• Extract elements for each Ply.

• Do result Map, result interpolation

• Correct the drape angles

Geometric ply shape realization

• Contains additional FE required for design/analysis but not required for manufacturing/documentation Template properties

• Defines the stacking sequence direction and the reference material orientation Stack & Material

orientation

• Visually verify math model via 3D visualizations (Ply shapes/orientation/thickness, Stacking sequence) Review & Modify

• Conversion of ply to zone based modeling

• Laminate realization.

Ply based model realization

• Export to any supported solver Export & Solve

Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Step 1: CAD geometry import…

• Basic CAD model geometry for the part is imported

• HM support all the major CAD systems and Neutral formats

• CATIA V5, V4

• UG-Nx

• PTC

• Parasolid

• IGEs

• STEP

• At this stage, we import the geometry data only

• Ply or Composite data is not imported

• Use Optistruct Use profile in Hypermesh


Import CAD geometry

Do not us this composite data

toggle for Fibersim


STEP 2: Mesh the CAD Geometry…


STEP 3: Import FiberSim Composite Data ( HDF5 file *.h5)

• Use File/ Import /Geometry

• Select FiberSim file filter

• Import the HDF5 file *.h5


FimberSim Model import….

• This process will import and

populate HM data base with

• Laminate data ( ply book– ply

stacking data,

• Composite Material data

• Each ply data – (triangular elements

spanning a single ply)

• Master Rosette ( coordinate system

for the model ) for stacking direction

• If the Ply is woven / fabrics HM

create additional plies for each

direction (P003_1 , P003_2) –two

plies


Imported FiberSim Data----Laminate Table….


SETP3– Correction of Element Normals

• Based on the Stacking direction ( Rosette Z direction), element

normal's are changed to match the Z direction

• Use tools/Normal panel in HM to reverse the normal/ or correct the

flipped few elements– Red color is in the positive normal direction


STEP4 – Realize FibersSIm Geometry plies in FE

Plies .. (PLY-> Realize)

• This step converts the FiberSim Ply entities to Finite element Mesh

created in HM.

• This process takes each FiberSim Ply date and finds the FE elements which are

bounded by the ply boundaries and transfer the ply directions, draping data, ply

orientation into FE elements. Geometry plies are converted to FE plies.

• HM uses two mapping approaches..

• Simple mapping – Based on proximity checks of the FE elements to ply.

• Advance Mapping– Use correct interpolation to fine the FE element for a ply and transfer

the data.

• Right Mouse click on the Ply entity on the Browser to activate the realize

dialog box

FiberSIM – HM integration

•

• Ply realization ( converting geom representation to Fe representation) .

• Derive ply boundary from triangulations mesh data.

• Project the ply boundary /region on the actual mesh in HM .

.

What is draping data ?

• Corrections to thickness and fiber direction of every element within a

Ply.

Mapping Fibersim Draping data to HM.

N1 N2

N3 N4

Material Direction

Theta on element

Ply Fiber Direction

Final fiber Direction from Fibersim

Vector provided by

Fibersim on every

element.

Corrected Theta for OS

interface as Drape card

Element Material/local axis

From N1-N2

Results of realization – Transfer FiberSim composite data to

FE based data in HM– STEP4 results

• Create FE plies from the mesh model

• Elements inside a ply boundary is grouped into individual FE plies

• Draping table is created

• Each ply FE element will contain the Drape data

• The change in ply thickness due to draping ( scale factor)

• Change in fiber angle due to draping

STEP 4 -- results

• Ply sets are created.. Set containing FE elements for each plies

STEP 5: Verification of FE plies, thickness and orientation in

HM

• First step is to create Ply property – PCOMPP

• HM support ply based model as default – ( not Zone based model)

• Assign this property to all the FE elements


STEP5 -- Ply Visualization

• Set the display to By Property

• Set the Visualization mode to

• Hide/ show each ply from the

Browser

STEP 5…… Ply angle Visualization on FE model


STEP5 --- Ply thickness visualization -3D representation

• Turn on 3D representation Mode


STEP 6: Exporting into Solver Specific Zone models..

• Altair solvers –Optistruct / Radioss supports Ply based models

• Nastran ( 11.0.130)/ Abaqus (11.0.140 only) and other solvers support

Zone Based models

• The following step – Laminate Realize shall convert Ply based model to

Zone base model

• This will create PCOMPG for Nastran

• Or *SHELLSECTION_COMPOSITE cards for Abaqus.(11.0.140)

Composite Modeling with FiberSim

Technology

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