Composite Workflow Challenges and...
Transcript of Composite Workflow Challenges and...
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Andreas Hübner, CADFEM (Suisse) AGAndreas Hübner, CADFEM (Suisse) AGRené Roos, EVEN AG René Roos, EVEN AG
Composite WorkflowComposite WorkflowChallenges and SolutionsChallenges and Solutions
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Layered Composite Solutions
sports & recreation
aerospace
aircraft
wind energy automobile
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Layered Composite Solutions
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Material
ShapeFunction
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Layered Composite SolutionsConceptConcept
•• PreliminaryPreliminary•• Detailed AnalysesDetailed Analyses•• ReportingReporting
GeometryGeometry
•• Design / DraftingDesign / Drafting•• ANSYS DesignModelerANSYS DesignModeler•• IdenticalIdentical--NameName--StrategyStrategy
ANANSYS SYS FE AnalyzeFE Analyze
•• Structural MechanicsStructural Mechanics•• ANSYS Composite PrepPostANSYS Composite PrepPost•• OptimizationOptimization
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Layered Composite Solutions
Composite Structure Design Process
• Understand behavior of anisotropic material
• Conceptual and preliminary design without 3D CAD geometry- data
• Preliminary lay-up design
• Material database for FE analysis
ConceptConcept GeometryGeometry FE AnalysisFE Analysis
• Open to CAD-World (Licensing)
• Associative CAD- to FE-interface
• Using „identical-name-strategy“ for plies
• Layered composite structures
• Coordinate systems• Composite failure
criteria• Optimization• Ply book• Draping• Flat wrap
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Layered Composite Solutions
Composite Structure Design Process
GeometryGeometry FE AnalysisFE Analysis
• ANSYS & ANSYS WB
• ANSYS Composite PrepPost
• ANSYS Design Modeler
• ANSYS Space Claim Direct Modeler
ConceptConcept
• ESACompComponeering Inc.00180 Helsinki, Finland
[email protected]. + 358 9 4342 1550
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Layered Composite Solutions
Material Database, Analysis and Design System
Design Database
Design
• Structural concept• Material selection• Dimensioning• Lay-up design• Structural details• Reverse engineering
Open Interface
MaterialDatabase
Analysis
• Fiber/matrixmicromechanics
• Plies and laminates• Structural elements
• Plates• Beams• Joints
• Verification
Interface to ANSYS Composite PrepPost
User extension
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Layered Composite Solutions
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ConceptConcept
•Design Concept•Material Selection•Preliminary Layup design
ESACompESAComp
•Layout: Laminate / Sandwich
•Geometry analyses by:• Hot spot, Panel (plane,
stiffened, curved), Beams, Joint‘s
•Material-Databank•Multiple failure criteria•Polar Plots•ESAComp/ANSYS ACP
Interface
ESAComp Preliminary Design
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Layered Composite Solutions
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ESAComp Data Bank
§ Material data delivered with ESAComp
§ Types of Materials
§ Fibers
§ Matrix materials
§ Reinforced plies
§ Core materials
§ Adhesives
§ Open Library
§ Material data can also be stored on Company and User levels
§ Advanced features: Statistical data from tests can be stored
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Layered Composite Solutions
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ESAComp Design Database
§ Database levels
§ Data Bank (locked)
§ Company (shared)
§ User (personal)
§ Company Level
§ Library of company verified material data
§ Sharing of project data
§ Design Library
§ Templates
§ Past projects
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Layered Composite Solutions
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ESAComp Analysis Capabilities
§ Micromechanics analyses for deriving ply properties from fiber and matrix data
§ Laminate level analyses for stiffness, strength, thermal expansion, thermal conductivity, …
§ Numerous composite failure criteria
§ Plate, beam, joint and notched laminate analyses
§ Probabilistic analyses for studying the effect of varying material properties, layer orientations or loads
§ Moisture diffusion and other specialized analyses
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Layered Composite Solutions
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ESAComp Design Capabilities
§ Trade-off studies
§ Material selection
§ Structural concept selection
§ Laminate lay-up design
§ For desired laminate properties
§ For desired behavior of a structural element
§ Dimensioning of structures
§ Stiffener spacing, beam cross-section, joint overlap, fastener spacing, …
§ Efficient engineering environment
§ Quick modification and duplication of objects
§ Graphical result displays
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Layered Composite Solutions
•3D result viewer: • Contour plots for reserve factor, displacements and
loads• Failure labels• Detailed element through the thickness analysis• Failure envelopes, carpet plots and polar plots
•Available failure criteria:• Puck, Max Stress, Max Strain, Tsai-Hill, Tsai-Wu,
Hashin, Hoffmann• Von Mises, Max Shear stress, Out of plane shear,
Rohacell• Sandwich Wrinkling
ESAComp Result Sets
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Layered Composite Solutions
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ESAComp Interfaces and User Extension
§ Export of materials and laminate lay-ups to ANSYS and ANSYS Composite PrepPost
§ Import of materials and laminate lay-ups for detailed studies and further refinement in ESAComp
§ XML data exchange with other applications
§ Batch runs
§ User defined micromechanics models and failure criteria
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Layered Composite Solutions
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ESAComp Add-on Modules
§ Cylindrical Shells (Add-on)
§ For design of tubes, shafts, pressure vessels, …
§ Stiffened Cylindrical Shells (AddAdd-on)
§ Further extension of the Cylindrical Shell module
§ Applications, e.g. aerospace
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Layered Composite Solutions
Composite Structure Design Process
GeometryGeometry FE AnalysisFE Analysis
• ANSYS & ANSYS WB
• ANSYS Composite PrepPost
• ANSYS Design Modeler
• ANSYS Space Claim Direct Modeler
ConceptConcept
• ESAComp
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Layered Composite Solutions
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ANSYSSolver*.rst
Prepare Layup for Composite Modeland Draping Simulartion
Evaluation Composite Model
ANSYS ACP Pre-Processing ANSYS ACP Post-Processing
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Layered Composite Solutions
ANSYS Composite PrepPost – Preprocessing
Pre ProcessingPre Processing
•Material Properties•Mat. Reference Direction •Ply-Wise Approach•Prediction of Manufacturability
ANSYS ACP Pre ANSYS ACP Pre
•Mapping coordinate systems to one reference path
•automatic conversion of modeling data to simulation data
•draping simulation and support for automated manufacturing
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Layered Composite Solutions
ANSYS Composite PrepPost – Postprocessing
Post ProcessingPost Processing
•Composite failure criteria •Efficient results interpretation •Design optimization•Ply-wise post processing•Estimation for delamination
ANSYS ACP PostANSYS ACP Post
•one figure per element is plotted, which reveals the safety level at the most critical layer
•evaluation of different failure criteria over different load cases at same time
•failure mechanism and layer orientation is plotted for decision making
•visualization based on physical plies
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Layered Composite Solutions
§ Selection Rules
§ Selection rules provide practical means to reselect group of elements for which the physical plies are applied
§ Cartesian
§ Cylindrical
§ Spherical
§ Tube
§ Cut off rule
Key Features for Composites Preprocessing
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Layered Composite Solutions
§ Cutting Rules
§ Tube rule: Rule defined by a circle swept along an edge set.
§ Cut-off rule: Cut the plies when they intersect an imported CAD surface. Example how to suppress plies overlapping
Key Features for Composites Preprocessing
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Layered Composite Solutions
§ Concept of oriented element-sets; user can define material application direction and material 0° direction
§ Multiple oriented element-sets can be overlapping and differently oriented allowing for unique possibility of easy asymmetric laminate definition
Key Features for Composites Preprocessing
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Layered Composite Solutions
§ Parallel, radial, cylindrical, edge wise and spherical rosette (coordinate systems) as basis for definition of material reference direction
§ Concept of oriented element-sets; user can define material reference direction and ply orientation with respect to that
§ One or several rosettes are assigned to an oriented element-set which avoids need for ply-subdivision
Key Features for Composites Preprocessing
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CADFEM your Partner for:CADFEM your Partner for:••Software SolutionsSoftware Solutions
••ConsultingConsulting••TrainingTraining
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Layered Composite Solutions
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Software – Seminars – Support – Consulting – Development
Complementary SoftwareCADFEM
§ Explicit analysisAUTODYN and LS-DYNA
§ Metal formingFTI, eta
§ Robust analysisoptiSLang
§ MaterialsESAComp, DIGIMAT, MaterialStudio
§ AcousticsWAON
FEM Software & ServicesCADFEM
§ 25+ years experience § 150+ employees
§ € 40 Mio. revenue§ Central Europe: 12 offices§ Privately owned
§ Worldwide through partners & TechNet Alliance
§ CADFEM Innovative
§ Certification: ISO 9000
§ ANSYS Channel Partner since 1982
§ 50+ different seminar topics
§ 100+ ANSYS technical & sales engineers
Competence Center FEMANSYS
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Layered Composite Solutions
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§ CADFEM (Suisse) AG
§ ANSYS Germany GmbH
ANSYS in Central Europe
DE
ATCH
München
ANSYS Otterfing
ANSYS Hannover
ANSYS Darmstadt
CADFEM Grafing
CADFEM Stuttgart
CADFEM Hannover
CADFEM Chemnitz
CADFEM Lausanne
CADFEM WienCADFEM Aadorf
CADFEM Berlin
CADFEM Dortmund
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Layered Composite Solutions
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§ CAE related§ CADFEM Russia, Moscow§ CADFEM India, Hyderabad§ CCA, Shanghai, China§ Ozen Engineering, Sunnyvale,
USA§ EnginSoft, Italy (TechNet
Alliance)§ Figes, Turkey (TechNet Alliance)§ Cybernet, Japan (TechNet
Alliance)§ ESSS, Brazil (TechNet Alliance)
§ Optimization, mathematics§ Diffpack, Nuremberg§ Dynardo, Weimar
§ Virtual cities§ virtualcitysystems, Dresden
CADFEM Partner Companies
§ Your global CAE network
§ 21+ countries§ 17+ languages§ 50+ companies
§ Unique CAE expertise
§ Member by invitation only
TechNet Alliance
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Layered Composite Solutions
ESAComp (Deutschland / Schweiz / Austria)
CADFEM (Suisse) AG
Andreas Hübner
+41 / 52 / 368 01 20
EVEN AG
René Roos
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