OPTIMIZATION OF COMPOSITE: Recent Advances and Application
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Transcript of OPTIMIZATION OF COMPOSITE: Recent Advances and Application
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Martin Kemp, Raphael Fluery and Ming Zhou, Altair Engineering
OPTIMIZATION OF COMPOSITE
Recent Advances and Application
Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
BACKGROUND BOMBARDIER AEROSPACE
• A world-leading
manufacturer of
innovative
commercial aircraft
and business jets
• Products include:
• LearJet
• C-Series
• CRJ-Series
• Q-Series
• Deliver continuous innovations in business jets, regional twinjets and
turboprops, and amphibious aircraft
• Consistently setting new industry benchmarks in airplane performance,
passenger comfort and economics
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
OVERVIEW INTEGRATION OF A NEW COMPOSITE OPTIMIZATION PROCESS
Background
• Accepted, validated
approach in place for
composite design of
Components and Systems
• Integrating Stress, Design
and Manufacturing
New Approach
• Must improve on existing approach
• Must integrate with existing design process and meet
validation/qualification requirements
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
CAD
Interoperability
Mfg Simulation
Interoperability
HyperMesh (Traditional Zone & Modern Ply Based
Composites Pre-Processing)
Visualizations (Visually verify the Math Model)
OptiStruct/RADIOSS (Composites Design Optimization &
Finite Element Analysis)
HyperView (Composites Post-Processing
& Failure Analysis)
HyperLaminate Solver (Classical Lamination Theory)
FEA Solver
Interoperability
Realizations (Export Ply Based Models to
Solver Zone Based Models)
OVERVIEW COMPOSITE DESIGN USING HYPERWORKS
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
COMPOSITE OPTIMIZATION RECENT ADVANCES
• Greater design freedom with composites presents opportunities and
challenges
• Opportunities: Increased design freedom for design optimization; Superior
performance; Unparalleled manufacturing flexibility
• Challenges: Manufacturing efficiency/Cost, complexity of design (Material and
Structural)
• Altair has developed a three stage process building on the well established
two stage metallics optimization process
Laminate Stacking?
Phase 3
Rule based
ply shuffling
45 -45 0 0 0
45 -45 45 90
90 -45 45 -45 0 0
-45 90 45
(a) Ply Level (b) Superply Level
45 -45 0 0 0
45 -45 45 90
90 -45 45 -45 0 0
-45 90 45
(a) Ply Level (b) Superply Level
Automation
Patch Interpretation
Ply Tailoring?
Free Sizing!
Phase 1
Number of Plies?
Ply Bundle Sizing!
Phase 2
Discrete Ply Thickness
Automation Optimized Stacking Sequence!
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
COMPOSITE OPTIMIZATION PROCESS OVERVIEW
• Phase I - Concept: Free-Size or Topology optimization
• Determine composite patch size, shape & location
• Manufacturing constraints
• Phase II - System: Ply-Bundle Sizing with ply-based FEA
modeling
• All behavior constraints
• Manufacturing constraints
• Phase III - Detail: Ply Stacking Sequence Optimization
• All behavior constraints
• Stacking manufacturing constraints
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
COMPOSITE OPTIMIZATION PROCESS EXAMPLE
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Phase III - Detail: Stacking Sequence Optimization
• Meet ply book rules
• All behavior constraints
• Stacking manufacturing constraints
COMPOSITE OPTIMIZATION PROCESS EXAMPLE
45 -45 0 0 0
45 -45 45 90
90 -45 45 -45 0 0
-45 90 45
(a) Ply Level (b) Superply Level
45 -45 0 0 0
45 -45 45 90
90 -45 45 -45 0 0
-45 90 45
(a) Ply Level (b) Superply Level
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
COMPOSITE OPTIMIZATION MANUFACTURING CONSTRAINTS
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
T_45Ply
T_ - 45Ply
Balance_45Ply, T_45Ply = T_ - 45Ply
COMPOSITE OPTIMIZATION MANUFACTURING CONSTRAINTS
Min/Max Total Laminate Thickness
Min/Max Individual Ply Thickness (e.g., Min/Max 0-Deg Thickness…)
Min/Max Individual Ply Angle Percentage (e.g, Ply90 %...)
Constant Individual Ply Thickness
Designable and non-designable regions
Can be applied to Composite Free-Size and Composite Size Optimization
Ply Draping Accommodation
Ply Linking through ‘sub-stacks’
T = Ply4 (nom) 45
PCOMP
T = Ply3 (nom) 90
T = Ply2 (nom) -45
T = Ply1 (nom) 0
T_Laminate Min/Max T_0Ply Min/Max = Sum(T_0Ply)
T = Ply1 (nom) 0
T = Ply2 (nom) -45
T = Ply3 (nom) 90
T = Ply4 (nom) 45
T_Laminate
T_90Ply (1)
Ply90% = Sum(T_90Ply)/T_Laminate
T_90Ply (2)
T_0Ply Constant
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
COMPOSITE OPTIMIZATION TYPICAL MANUFACTURING CONSTRAINTS
• Substacks (SUB) define partial stacking sequences
• Interfaces (INT) indicate how the substacks are assembled
• During ply stacking optimization, substacks are shuffled independently as
to avoid undesirable ‘penetration’ effects
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Efficient tools required at System and Component Level to:
• Increase refinement
• Update Designs
• Map Loads
• Respect composite boundaries/zones
• Increased refinement models can be efficiently solved; a model of > 250K elements
would be a manageable concept model
COMPOSITE OPTIMIZATION MODELLING AUTOMATION
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
PROCESS IMPLEMENTATION BOMBARDIER AEROSPACE DESIGN TEAM
Bombardier Shorts Global
FEM
Altair Composite Optimization
Process
Bombardier Shorts Design
(FibreSim)
Concept
•Global Fem Foundation
•Freeform Design with Scientific Basis
•Fast/flexible
Fine Tuning
•Ply Continuity locked in
•Manufacturing rules
•Combined performance targets
Delivery
•Conversion to Bombardier Design Input
•Tailored for FibreSim Acceptance
Customisable
Constraints
Module
(Margin Calcs)
OSZone
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
PROCESS IMPLEMENTATION BOMBARDIER AEROSPACE DESIGN TEAM
Zones Defined by Element Sets•Load Extraction Elements Auto-Detected
•Component Dimensions Auto-Defined
Zone Laminates Extracted from Ply Based OS Format•Mapping from Plys to Zones (ie if cloth boundary bisects zone)•Selection of Zone Highlights in viewport and identifies load extraction elements
Results Section Loads OS Results•Generates and Contours Zone Margins of Safety
•Tabulates Zones (when selected, detail view populates)
3D View Showing Secant Margin Contours
Multiple Export Formats:•FibreSim•Spreadsheet
•Iges Zone Boundary Curves
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
COMPOSITE OPTIMIZATION TYPICAL EXAMPLE
CAD Export (FibreSim)
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
COMPOSITE OPTIMIZATION TYPICAL EXAMPLE
• Zone-based pattern grouping
• Custom Constraints Facilitated through OS plug-in or HyperMath
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
CONCLUSION INTEGRATION OF A NEW COMPOSITE OPTIMIZATION PROCESS
• Successful integration/application of Composite optimization process in live
aerospace design environment
• Efficient exploration of designs / weight saving potential for range of
components and systems
• New process advantages:
• free-form stage: Rapid ‘what-if’ studies facilitating early design focus
• Manufacturing constraints built into process from the start
• Significant mass savings and design drivers systematically identified
• Efficient interfaces between stress and design facilitate rapid iterations
• Repeatable process, which accommodates the composite design
qualification requirements suitable at component and system level
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Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Martin Kemp, Altair Product Design
THANK YOU (QUESTIONS)
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