composite workflow challenges and...

Andreas Hübner, CADFEM (Suisse) AGAndreas Hübner, CADFEM (Suisse) AGRené Roos, EVEN AG René Roos, EVEN AG

Composite WorkflowComposite WorkflowChallenges and SolutionsChallenges and Solutions

Layered Composite Solutions

sports & recreation

aerospace

aircraft

wind energy automobile


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Material

ShapeFunction

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


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



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

mailto:[email protected]


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


7

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


8

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


9

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


10

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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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


•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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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


14

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



GeometryGeometry FE AnalysisFE Analysis

• ANSYS & ANSYS WB

• ANSYS Composite PrepPost

• ANSYS Design Modeler

• ANSYS Space Claim Direct Modeler

ConceptConcept

• ESAComp


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ANSYSSolver*.rst

Prepare Layup for Composite Modeland Draping Simulartion

Evaluation Composite Model

ANSYS ACP Pre-Processing ANSYS ACP Post-Processing


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


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


§ 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


§ 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



§ 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



§ 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


CADFEM your Partner for:CADFEM your Partner for:••Software SolutionsSoftware Solutions

••ConsultingConsulting••TrainingTraining


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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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§ 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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§ 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


ESAComp (Deutschland / Schweiz / Austria)

CADFEM (Suisse) AG

Andreas Hübner

[email protected]

+41 / 52 / 368 01 20

EVEN AG

René Roos

[email protected]

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composite workflow challenges and...

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