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MSC Software Composites Solution

MSC Composites Technology Day

Agenda for Today Time Agenda: Composites Technology Day with MSC Nastran

9:00-9:15 Welcome

9:15-9:45 Overview of MSC’s Composites Solution

9:45-10:30

Introduction to Analysis of Composites Structures

Hands-on Training

Workshop 1: Stress Analysis of a Composite Wing

10:30-10:45 Break

10:45-12:15

Solid Composite Elements

Hands-on Training

Workshop 2: Solid Shell Composites Modeling

12:15-12:45 Lunch

12:45-2:15

Progressive Ply Failure and Delamination Modeling

Hands-on Training

Workshop 3: Open-Hole-Tension Test Coupon

2:15-2:30 Break

2:30-4:00

Optimization of Composite Structures

Hands-on Training

Workshop 4: Minimizing the Weight of a Composite Wing

4:00-4:30 Curing, Draping, and Direct CAD Interface

4:30-4:45 Feedback/Wrap-up

Composites Technology Day, January 2012

Copyright 2012 MSC.Software Corporation 2

Global Composite Applications • What percentage of global composite fiber usage is

Carbon Fiber?



Carbon Fiber Composite Applications



2010 Distribution of Composite Applications



Aerospace Composites Usage • Boeing's 787 Dreamliner is

• 50% composite material by weight

• 80% composite materials by volume

• What were some of the challenges faced by this

composites program?



Major growth

in cost & time Source: Frank Doerner, MSC 2011 User’s Conference Keynote Speaker



Source: Frank Doerner, MSC 2011 User’s Conference Keynote Speaker

MSC Software

Composites

Solution

Extensive 1D, 2D, 3D composite

element library

Progressive Ply Failure

Analysis and Delamination

Optimization

Curing and Shrinkage

Draping and

CAD Interface

Static and Dynamics Analyses

Critical Margin

of Safety



Extensive 1D, 2D, 3D Composite

Element Library



MSC Software Composites Solution

• A comprehensive library of composite elements are supported in MSC’s pre/post processors and solvers

• FEA Solvers – MSC Nastran

– Marc

• Pre/Post Processors – Patran/Laminate Modeler

– SimXpert

– Mentat

• For today’s hands-on exercises we will use Patran and Nastran.



Composite Elements Library

Shell Element

Solid Element

Beam Element



Defining the Composite

• The general approach is to define a laminate

material representation of the layup

1. Define the ply material properties first

2. Then define the laminate – ply

thickness, orientation, and layup

sequence

3. Assign the laminate to elements



Define the Ply Material

• Define the ply material

– 2D or 3D orthotropic

Unidirectional tape Woven Material

Stitched Material



User-friendly interface to define the laminate

• Define the layup

– Material

– Thickness

– Orientation angle



2D and 3D Composite Elements

• Shell and solid composite elements

– Both support progressive ply failure analysis

– Two types of solid composite elements

2

1

3

2

Solid Layered Composites

1

3

2

One integration point per layer

Solid Shell Composites

MSC Software

Composites

Solution


element library



Optimization


Draping and

FiberSIM Interface


Critical Margin

of Safety



Static and Dynamics

Analyses



Static and Dynamics Strength Evaluation

• Static Analysis and Dynamics Analysis

– Stress and Strain computation

– Failure Theories

– Failure indices

– Strength ratios



Geometry Zone Layup Ply Layup Ply Details Verification

Simulate Simulate Simulate Simulate

Manufacture

OK!

feedback loop ...

Zone vs. Ply Layup

Detailed

design Preliminary

design



Results Viewable by Layer Number or Global Ply ID

View by Layer Number

Layer 1

Layer 2

Laye

r 3

View by Global Ply ID

Glo

bal P

ly 1

G

lobal P

ly 2

G

loba

l P

ly 3



Define plies Define Layup

Ply Based Modeling in Laminate Modeler

Show/Verify Layup

• Ply based approach

MSC Software

Composites

Solution


element library



Optimization


Draping and

FiberSIM Interface


Critical Margin

of Safety



Optimization

of

Composites



Types of Optimization in MSC Nastran

• Sizing – Change in property

(t, I, J, theta, etc.)

tinit topt

Shapeinit Shapeopt

Topoinit Topoopt

• Topology • “Remove” unneeded

structure

• Shape • Change in GRID

locations



Types of Optimization in MSC Nastran

• Topography

– Special form of shape

optimization

• Topometry

– Special form of sizing

optimization

– Each element is

separately designed

All elements with same

initial thickness

Varied thickness after

optimization

Initially “flat” sheet Optimized with “bead”



Composites in Optimization

• Composites optimization is

specifically supported in

– Sizing optimization

– Topometry optimization



Sizing Optimization

• Objective

– Minimize weight

– Minimize compliance

– Etc.

• Design Variables

– Ply orientation

– Thickness

– Material properties

• Constraints

– Failure indices

– Strength ratios

– Weight

– Stress

– Strain

– Etc.



Sizing Optimization Sizing Optimization

• Composite sizing optimization example

– Optimize ply angles

– Optimize ply thicknesses

– Minimize weight 45

o

5o

Ply Angles

0.06

Ply Thickness

Initial weight = 1.598

Final weight = 9.589E-2

Total Weight



Topometry Optimization

• Topometry optimization for

composites

– Material distribution is optimized

across all elements

– Ply-by-ply element thickness

optimization

0 degree Ply 90 degree Ply +45 degree Ply -45 degree Ply

Composite element

combined thickness distribution

MSC Software

Composites

Solution


element library



Optimization


Draping and

FiberSIM Interface


Critical Margin

of Safety



Progressive Failure Analysis (PFA) and

Delamination



Going Beyond First-Ply-Failure (FPF)

• Evaluate the load redistribution in a composite

structure as the plies fail progressively

32

• Simulate delamination growth from initial flaw

• Study crack propagation to design for fail-safe

structures



33

VCCT CZM

Delamination Breaking Glue PFA

Failure and Delamination Methods

Ply Material

Failure Delamination



Progressive Failure Analysis (PFA) • The user selects the failure criteria

– Puck, Hashin, Tsai-Wu, etc.

• Composite failure on a layer by layer basis

• Upon failure, scale down E and G

Pin bearing on hole



Animation shows region

released from glued

Animation shows glued

region

VCCT Example – delamination growing along

glued interface



Cohesive Zone Modeling (CZM) example



Breaking Glued Contact example

• Release glued contact

when the following stress

criterion is met

• Use contact normal and

tangential stresses

• After break, do regular

contact with friction and

separation



• Split up mesh between materials or within a material when the following stress criterion is met

• Use stresses normal and tangential to interface

Delamination example

MSC Software

Composites

Solution


element library



Optimization


Draping and

FiberSIM Interface


Critical Margin

of Safety




during

Manufacturing



MSC Composite Curing Capability

• Cure-induced heating and curing shrinkage

– Thermal heat generation due to curing

– Shrinkage strains associated with curing

– Causes distortion and residual stress in parts

– Prediction is critical for predicting final shape

• Coupled thermo-mechanical analysis

– Critical capability for process development

– Available for solid and shell elements

– Marc has this unique capability in the industry



0°/90°, +/- 45°

Case Study : Sikorsky S-92 Helicopter

Orthotropic Layup



Case Study

.345” predicted

Springback

.35” actual

MSC Software

Composites

Solution


element library



Optimization


Draping and

FiberSIM Interface


Critical Margin

of Safety



Draping and FiberSIM Interface



Laminate Modeler

• Process simulation

– Ply draping

– Scissor - draping

behavior exhibited by

fabrics

– Slide - draping behavior

exhibited by tapes

– Splits and darts

• Direct interface to CAD

– FiberSIM



Define plies Define Layup

Ply Draping Simulation in Laminate Modelr

Show/Verify Layup

• Define ply material and layup on doubly curved surfaces



Interface to FiberSIM

• Directly access layup data from

FiberSIM

– FiberSIM plies and layup files are

imported and mapped onto analysis

mesh


Copyright 2012 MSC.Software Corporation

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