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Simulation of SP6 Central Load...Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge,...

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Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ Phone: 01922 453038 www.hyperon-simulation-and-cad-services.co.uk Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 1 Simulation of SP6_Central_Load Date: 19 January 2016 Designer: Lee Stokes Study name: SP6_CSL_1kN Analysis type: Static Table of Contents Description ............................................ 2 Assumptions .......................................... 3 Model Information ................................... 3 Study Properties ..................................... 6 Units ................................................... 7 Material Properties .................................. 8 Loads and Fixtures................................. 11 Connector Definitions ............................. 12 Contact Information ............................... 13 Mesh information .................................. 14 Sensor Details ...................................... 15 Resultant Forces ................................... 16 Beams ................................................ 16 Study Results ....................................... 17 Conclusion .......................................... 24
Transcript

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ Phone: 01922 453038 www.hyperon-simulation-and-cad-services.co.uk

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 1

Simulation of SP6_Central_Load Date: 19 January 2016 Designer: Lee Stokes Study name: SP6_CSL_1kN Analysis type: Static

Table of Contents Description ............................................ 2

Assumptions .......................................... 3

Model Information ................................... 3

Study Properties ..................................... 6

Units ................................................... 7

Material Properties .................................. 8

Loads and Fixtures................................. 11

Connector Definitions ............................. 12

Contact Information ............................... 13

Mesh information .................................. 14

Sensor Details ...................................... 15

Resultant Forces ................................... 16

Beams ................................................ 16

Study Results ....................................... 17

Conclusion .......................................... 24

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 2

Description This report investigates the response of a composite carbon fibre tube under a central static load. Please refer to the image on page 1 for the general set-up. Further details of the set-up can be found on the next 15 pages of this report. The tube consists of 13 plies, comprised of 2 orthotropic materials, designated B and C respectively, the details of which are given on pages 5, 8, 9 and 10 of this report. The tube is simply supported at either end (in the sense that the tube’s ends can move freely along the tube’s central axis and can rotate freely about each of the three rotational degrees of freedom) and is of length 1,453mm, external diameter 64mm and internal diameter 57.1mm. The loading anvil is 30mm wide with 2.5mm filleted edges. The plies are treated as shells and simulated using the intrinsic composite static load functionality within SolidWorks Simulation. The principal aim of this report is to investigate the response of the tube under the Thai-Wu Failure Criterion (applicable here since we are considering materials with unequal strengths in tension and compression and the cross-fibre stresses are primarily in tension). This manifests itself as a worst-case minimum Factor of Safety across all plies, for a given static load. The static loads are increased up to the point where the Factor of Safety drops to approximately unity. We are particularly interested in which ply or plies these worst-case conditions occur. The results of this are presented graphically on pages 21 of this report. On page 23, we consider two load 2 load cases and present a tabulated list of Minimum Factors of Safety for each of the top and bottom faces of all 13 plies. We present further study results on pages 17-20. Additionally, the deflective response of the tube is represented graphically on page 22. Finally, we draw some conclusions, mainly about which ply or plies might be compromised under load. Note: The first 20 pages of this report cover details of the study performed at 1kN static load. These details are either identical or analogous at higher loadings.

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 3

Assumptions We assume that the tube is axially symmetric and radially homogeneous and isotropic. Additionally, we assume that the V-blocks remain stationary at all times during testing, and that the anvil moves purely vertically in translation with no subsequent rotation about any of its axes of symmetry.

Model Information

Model name: SP6_Central_Load Current Configuration: Default

Solid Bodies

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 4

Document Name and Reference

Treated As Volumetric Properties Document Path/Date

Modified

Fillet1

Solid Body

Mass:1.84209 kg Volume:0.000239233 m^3

Density:7700 kg/m^3 Weight:18.0525 N

C:\Business Paraphernalia\Carbon

Fibre Tubes Ltd\Project 2\SP6\SP6 Centrally

Loaded\30mm_Wide_Anvil.SLDPRT

Jan 14 09:45:48 2016

Composite Bodies

Document Name and Reference

Properties

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 5

Shell-1

Total number of Plies: 13 Symmetric: No

Ply Thickness(mm)

Angle(deg)

Area(m^2)

Volume(m^3)

Density(kg/m^3)

Mass(kg)

Weight(N)

1 0.294 90 0.292143

8.589e-005

1570 0.134847

1.3215

2 0.294 0 0.292143

8.589e-005

1570 0.134847

1.3215

3 0.294 0 0.292143

8.589e-005

1570 0.134847

1.3215

4 0.21 45 0.292143

6.135e-005

1570 0.0963195

0.943932

5 0.21 -45 0.292143

6.135e-005

1570 0.0963195

0.943932

6 0.294 0 0.292143

8.589e-005

1570 0.134847

1.3215

7 0.21 -45 0.292143

6.135e-005

1570 0.0963195

0.943932

8 0.21 45 0.292143

6.135e-005

1570 0.0963195

0.943932

9 0.294 0 0.292143

8.589e-005

1570 0.134847

1.3215

10 0.294 0 0.292143

8.589e-005

1570 0.134847

1.3215

11 0.294 90 0.292143

8.589e-005

1570 0.134847

1.3215

12 0.265 0 0.292143

7.74179e-005

1765 0.136643

1.3391

13 0.265 0 0.292143

7.74179e-005

1765 0.136643

1.3391

Document Name: C:\Business Paraphernalia\Carbon Fibre Tubes Ltd\Project 2\SP6\SP6 Centrally Loaded\64x57.1x1453_Tube.SLDPRT Date Modified: Jan 19 08:43:47 2016

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 6

Study Properties Study name SP6_CSL_1kN

Analysis type Static

Mesh type Mixed Mesh

Thermal Effect: On

Thermal option Include temperature loads

Zero strain temperature 298 Kelvin

Include fluid pressure effects from SOLIDWORKS Flow Simulation

Off

Solver type FFEPlus

Inplane Effect: Off

Soft Spring: Off

Inertial Relief: Off

Incompatible bonding options Automatic

Large displacement Off

Compute free body forces On

Friction Off

Use Adaptive Method: Off

Result folder SOLIDWORKS document (C:\Business Paraphernalia\Carbon Fibre Tubes Ltd\Project 2\SP6\SP6 Centrally Loaded)

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 7

Units Unit system: SI (MKS)

Length/Displacement mm

Temperature Kelvin

Angular velocity Rad/sec

Pressure/Stress N/m^2

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 8

Material Properties

Model Reference Properties Components

Name: Alloy Steel Model type: Linear Elastic Isotropic

Default failure criterion:

Unknown

Yield strength: 6.20422e+008 N/m^2 Tensile strength: 7.23826e+008 N/m^2 Elastic modulus: 2.1e+011 N/m^2

Poisson's ratio: 0.28 Mass density: 7700 kg/m^3

Shear modulus: 7.9e+010 N/m^2 Thermal expansion

coefficient: 1.3e-005 /Kelvin

SolidBody 1(Fillet1)(30mm_Wide_Anvil-1)

Curve Data:N/A

Name: Material C Model type: Linear Elastic

Orthotropic Default failure

criterion: Max von Mises Stress

Yield strength: 1.2e+009 N/m^2 Tensile strength in x: 1.5e+009 N/m^2 Tensile strength in y: 1.5e+009 N/m^2 Compressive strength

in x: 1.2e+009 N/m^2

Compressive strength in y:

1.2e+009 N/m^2

Elastic modulus in x: 1.35e+011 N/m^2 Elastic modulus in y: 1.35e+011 N/m^2 Elastic modulus in z: 1.35e+011 N/m^2 Poisson's ratio in xy: 0.3 Poisson's ratio in yz: 0.3 Poisson's ratio in xz: 0.3

Mass density: 1570 kg/m^3 Shear modulus in xy: 5e+009 N/m^2 Shear modulus in yz: 5e+009 N/m^2 Shear modulus in xz: 5e+009 N/m^2

Shear strength: 5e+009 N/m^2

SolidBody 1(Boss-Extrude1)(64x57.1x1453_Tube-1), Shell-1(SolidBody 1(Boss-Extrude1))(64x57.1x1453_Tube-1)

Curve Data:N/A

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 9

Name: Material C Model type: Linear Elastic

Orthotropic Default failure

criterion: Max von Mises Stress

Yield strength: 1.2e+009 N/m^2 Tensile strength in x: 1.5e+009 N/m^2 Tensile strength in y: 1.5e+009 N/m^2 Compressive strength

in x: 1.2e+009 N/m^2

Compressive strength in y:

1.2e+009 N/m^2

Elastic modulus in x: 1.35e+011 N/m^2 Elastic modulus in y: 1.35e+011 N/m^2 Elastic modulus in z: 1.35e+011 N/m^2 Poisson's ratio in xy: 0.3 Poisson's ratio in yz: 0.3 Poisson's ratio in xz: 0.3

Mass density: 1570 kg/m^3 Shear modulus in xy: 5e+009 N/m^2 Shear modulus in yz: 5e+009 N/m^2 Shear modulus in xz: 5e+009 N/m^2

Shear strength: 5e+009 N/m^2

<Material_ComponentList1/>

Curve Data:N/A

Name: Material B Model type: Linear Elastic

Orthotropic Default failure

criterion: Max von Mises Stress

Yield strength: 4.25e+009 N/m^2 Tensile strength in x: 4.4e+008 N/m^2 Tensile strength in y: 4.4e+008 N/m^2 Compressive strength

in x: 4.25e+008 N/m^2

Compressive strength in y:

4.25e+008 N/m^2

Elastic modulus in x: 2.5e+010 N/m^2 Elastic modulus in y: 2.5e+010 N/m^2 Elastic modulus in z: 2.5e+010 N/m^2 Poisson's ratio in xy: 0.2 Poisson's ratio in yz: 0.2 Poisson's ratio in xz: 0.2

Mass density: 1765 kg/m^3

<Material_ComponentList1/>

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 10

Shear modulus in xy: 4e+009 N/m^2 Shear modulus in yz: 4e+009 N/m^2 Shear modulus in xz: 4e+009 N/m^2

Shear strength: 4e+009 N/m^2

Curve Data:N/A

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 11

Loads and Fixtures

Fixture name Fixture Image Fixture Details

On Flat Faces-1

Entities: 1 face(s) Type: On Flat Faces

Translation: 0, ---, 0 Rotation: 0, ---, ---

Units: mm, rad

Resultant Forces Components X Y Z Resultant

Reaction force(N) -0.782886 0 -0.114702 0.791244

Reaction Moment(N.m) 0 0 0 1e-033

Load name Load Image Load Details

Force-1

Entities: 1 face(s) Type: Apply normal force

Value: 1000 N

Remote Displacement

(Rigid connection)-1

Entities: 1 edge(s) Type: Displacement (Rigid

connection) Coordinate System: Coordinate System1 Translation Values: ---, 0, 0 mm

Rotation Values: ---, ---, --- deg Reference coordinates: 0 0 0 mm

Components transferred: Translation

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 12

Remote Displacement

(Rigid connection)-2

Entities: 1 edge(s) Type: Displacement (Rigid

connection) Coordinate System: Coordinate System2 Translation Values: ---, 0, 0 mm

Rotation Values: ---, ---, --- deg Reference coordinates: 0 0 0 mm

Components transferred: Translation

Connector Definitions No Data

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 13

Contact Information

Contact Contact Image Contact Properties

Contact Set-1

Type: No Penetration contact pair

Entites: 6 face(s) Advanced: Node to

surface

Contact/Friction force

Components X Y Z Resultant

Contact Force(N) 8.8922E-015 2.3626E-013 0 2.3642E-013

Global Contact

Type: Bonded Components: 1 component(s)

Options: Compatible mesh

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 14

Mesh information Mesh type Mixed Mesh

Mesher Used: Curvature based mesh

Jacobian points 4 Points

Jacobian check for shell On

Maximum element size 0 mm

Minimum element size 0 mm

Mesh Quality High

Remesh failed parts with incompatible mesh Off

Mesh information - Details

Total Nodes 6033

Total Elements 3046

Time to complete mesh(hh;mm;ss): 00:00:02

Computer name: LEESTOKES-PW

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 15

Sensor Details No Data

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 16

Resultant Forces

Reaction forces

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model N -0.782886 -5.73698 -0.114702 5.79128

Reaction Moments

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model N.m 0 0 0 1e-033

Beams No Data

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 17

Study Results

Name Type Min Max

Stress1 VON: von Mises Stress 5234.86 N/m^2 Node: 409

6.10468e+007 N/m^2 Node: 1978

SP6_Central_Load-SP6_CSL_1kN-Stress-Stress1

Name Type Min Max

Displacement1 URES: Resultant Displacement 0.0050947 mm Node: 1871

2.24991 mm Node: 119

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 18

SP6_Central_Load-SP6_CSL_1kN-Displacement-Displacement1

Name Type Min Max

Strain1 ESTRN: Equivalent Strain 7.32038e-008 Element: 644

0.000517765 Element: 1894

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 19

SP6_Central_Load-SP6_CSL_1kN-Strain-Strain1

Name Type Min Max

Factor of Safety1 Max von Mises Stress 15.407 Node: 968

118517 Node: 409

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 20

SP6_Central_Load-SP6_CSL_1kN-Factor of Safety-Factor of Safety1

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 21

Graphical Detail

PLOT 1

Plot 1, shown above, utilizes the Tsai-Wu Failure Criterion. The ordinate axis represents the worst-case

minimum Factor of Safety across all plies. We present Plot 2, a plot of Load versus Maximum Deflection

below.

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 22

PLOT 2

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 23

Minimum Factor of Safety Tabulated Detail

TABLE 1

Table 1, shown above, presents the Minimum Factor of Safety under the Tsai-Wu Failure Criterion for each

ply at loads of 9kN and 17kN. Each ply contains an entry for both the top and bottom faces of the respective

ply, together with an average of the two. Note that Plies 1 and 13 represent the innermost and outermost

plies respectively, with the top and bottom faces of each ply corresponding to the external and internal

diameters respectively.

Min. FOS at 9kN Min. FOS at 17kN

Ply Top Bottom Average Top Bottom Average

1 1.93 1.74 1.835 1.04 0.94 0.99

2 2.16 1.93 2.045 1.16 1.04 1.10

3 2.43 2.16 2.295 1.31 1.16 1.235

4 3.35 2.91 3.13 1.80 1.56 1.68

5 3.97 3.35 3.66 2.12 1.80 1.96

6 3.17 2.90 3.035 1.68 1.55 1.615

7 5.93 5.17 5.55 3.16 2.76 2.96

8 6.01 5.93 5.97 3.21 3.16 3.185

9 3.06 3.13 3.095 1.63 1.66 1.645

10 2.97 3.06 3.015 1.58 1.63 1.605

11 2.86 2.97 2.915 1.52 1.58 1.55

12 4.46 4.69 4.575 2.38 2.50 2.44

13 4.14 4.46 4.3 2.22 2.38 2.3

Hyperon Simulation & CAD Services Ltd 9 Hatherton Place, Aldridge, Walsall, West Midlands, WS9 8AZ

Lee Stokes 19/01/2016

Analyzed with SOLIDWORKS Simulation Simulation of SP6_Central_Load 24

Plot 1 shows quite a dramatic drop in Minimum Factor of Safety between 1-5kN, with a much less dramatic

decrease thereafter. We see that, based upon the Tsai-Wu Failure Criterion, the Minimum Factor of Safety

becomes unity at a Static Load of approximately 17kN. From Table 1 we see that, in both cases, the lowest

Minimum Factor of Safety occurs on the bottom face of Ply 1, with the highest occurring on the top face of

Ply 8. From the Average columns, Ply 1 appears to be the least robust and Ply 8 the most. In addition to Ply

1, plies 2 and 3 have relatively low values and so could also be a matter for attention. Plot 2 yields a

strongly linear relationship between Static Load and Maximum Deflection and compare well with the results

of traditional hand calculations.

Conclusion


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