hyperworks in the analysis and optimization of composite...

Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg

Hyperworks in the Analysis and Optimization of Composite Structures

Ersteller: Markus LongeruE-Mail: [email protected]: 02. November 2009

ALTAIR 3rd European HTC – Ludwigsburg November 2nd- 4th, 2009

Markus Longeru Volker GrundTechnical Leader Stress Engineer

AbstractThe presentation ‚Hyperworks in the Analysis and Optimization of Composite Structures‘ provides an overview of the use of ALTAIR software applications in engineering supplier tasks.The presentation shows the main fields of activities, where ALTAIR products lead to advantages by means of calculation quality and project performance. On the exemplary projects, that have been performed by SOGETI HighTech, such as meshing an AIRBUS wing cover, calculate vibration and shock of a ship antenna, optimizing military antenna structures made of GFRP and secondary aircraft structure made of CFRP the application for various industries with their specific problems and solutions will be shown.For the wing cover, a detailed FE model of shell elements is generated, which needed a high grade of automation due to a large model with a high amount of elements and special demands. The ship antenna is an interesting example for the postprocessing of shock analysis while the military antenna structure, made of GFRP has been optimized regarding its weight using topology- as well as composite optimization tools.Finally, for the secondary structure example, a pilot project from Sogeti HighTech will be discussed where a metallic bracket has been transformed to CFRP. Within the project the bracket has been sized, manufactured and tested. On this example the whole process from structural concept, pre-dimensioning, optimization and test calculation will be shown.

Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 2

Introduction

Agenda

Sogeti High Tech

Technical

Advantages

Summary & Conclusions

IntroductionAgenda

Sogeti High Tech

TechnicalWorkflow and Tools

Pre-processing

Solver

Post-processing

Optimization

AdvantagesTechnical View

Commercial View


Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]


Introduction -Agenda


Introduction -Sogeti HighTech

Introduction

Agenda

Sogeti High Tech

Technical

Advantages



Hyperworks in the Analysis and Optimization of Composite Structures • 83.500 Employees

• 8,7 Billion €• worldwide

• 20.000 Employees

15 countries, with 200+ local offices

Sweden

SwitzerlandSpain

FranceBenlux

The Netherlands

U.S.A.

Ireland

DenmarkUnited Kingdom

India

• 3.500 Employees• 9 Countries

• 350 Employees• focus on fix price projects• 8 locations• EN(AS) 9100; DIN EN ISO 9001:2000


Introduction

Agenda

Sogeti High Tech

Technical

Advantages




Activities

• Numerical Simulation

• DMU and Simulation

• Design and Drafting

• Jigs and tools

• Quality management

• Testing

Introduction -Sogeti HighTech

General Information

• Engineering Services focused on the Aerospace-, Transportation-, Energy- and Machinery Industry

• Team of more than 350 skilled engineers, designers and draftsmen

• Certified EADS E2S-Supplier

• Certified Airbus 1.Level-Supplier (BSF 006)

Optimization

Post-Processing

Solving

Pre-Processing


Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages




Technical -Workflow & Tools

Preparation of Geometry

Meshing

Loads and Boundaries

FE Calculation

Evaluation of Results

Update Mesh

HyperMeshPATRANCARDS (Intern Tool)

NASTRANABAQUSANSYSRADIOSS

Hyper View EXCELPATRAN CARDSFemFatISAMI

CAD-Data

CATIASolid Works




Technical -Pre-Processing

Preparation of Geometry

Brackets – Metallic and Composite

Generation of Midsurfaces- Advanced tools for midsurface manipulation

- Connect Midsurfaces- Convert radii to corners

- Automated property definition- Using the midsurface option

Hypermesh ‘keeps the thickness in mind‘ and can assign it automatically to the elements

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages

Summary & Conclusions Defeaturing

- Close small holes- Eliminate radii -> Edge / Surf Fillets





Meshing and Property definition

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Detailed Model of Test Specimen

Skin

Spar

Ribs

Generate Midsurface

Mesh generation respecting ramps and geometric contours

Automated PCOMP Extraction from CATIA(1 Prop per Elm)

TCL Scripting for generating property sets(delete redundancies)





TCL Scripting Tasks• Generate stringer foot elements

• Double elements

• Duplicate global nodes and renumbering

• Offset stringer blade by RBE2 Elements•Offset equal to average thickness of surrounding skin elements

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


CFRP Wing Cover

Structure

Idealization

Model Size• 33 Ribs• 19 Stringer•115000 Elements





Data Consintency

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Input / Output- Comments and entries that are not known by Hypermesh are kepf in the .bdf

- are moved to the end of the file

- .bdf files become very large due to Hypermesh comments

- can be swiched off in V10

Components from geometry file- Components are automatically generated

- By Hypermesh comment - By Property- By One component

Sustain file structures- Include structure can be conserved

Property IDs- Division Hypermesh ID / Solver ID

- may be different- may lead to user errors





Pre-Processing Evaluation

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Quality Performance

Precise Geometry Data

Good Mesh Quality

Less errors due to routines

Fast GUI -> Needs Training

High Level of Adaptivity

Relatively fast Geometry update

Low effort for midsurface modification before meshing

Fast thickness definition for isotropic properties or PSHELL idealization

Scripting for repetitive tasks

Fast adaption of geometry updates with morphing function




Technical -Solver

Compatibility to various solvers

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Conversion of NASTRAN Models to ABAQUS

Solver –Independant software package-> Good fit to all types of solvers

Problems Hypermesh V9:

NASTRAN RBE3 toABAQUS DCOUP3D




Technical -Post-Processing

Static Analysis

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Static analysis of CFRP structures are mostly performed using own Java Tool package due to

- Automation- Number of LC- Individual content of result tables- Easy implementation of arbitrary failure criteria- etc.

Results for composite Justification:

Element Forces (Fluxes)- In Material Axes

Element Strains- In Material Axes

Free-Body Forces





Dynamics

Military Ship Antenna

Weight Optimization at best structural Performance at

• Wind Loads

• Movement of the Ship

• Shock

• Vibration

• Top Load of 50kg

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages






Dynamics

Military Ship Antenna

10 times deformation scale15 time steps [0s, 0.9s]

0 times deformation scale15 time steps [0s, 0.9s]von Mises stresses

Displacements per Timestep Stresses per Timestep

Shock 120g for 15msIntroduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages






Post-Processing Evaluation

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Quality Performance

Good result quality for isotropiy materials(v.Mises, etc)

Impossible to relate results to material coord system(Composite Materials)

TCL differs from HyperMesh

Large result files can be handeled

Interface to partner Products (FEMFAT)

Limited Adaptivity for own justification criteria

FEMFAT Plot




Technical -Optimization

Optimizing Composites

Weight Optimization of Aircraft Primary Structure

Primary Structure made of Foam Sandwich

Model:

Foam and Booster idealized with CHEXA8,

CPENTA, CTETRA Elements

CFRP Covers idealized with CQUAD4 Elements

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages







Weight Optimization of Aircraft Primary Structure

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Booster

Skin

Core

CTETRA

CPENTA

CHEXA

CQUADModel Created by own Routines

Manual Work (Cleaning) done in Hypermesh





Optimizing Composites – Free-Size

CFRP Foam Sandwich Structures

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Load:Combined Torsion / Bending

Start plies:3 plies (+ 45; 0; -45)

Constraints:Displacement in Tip

Objective:Minimize Mass

0° Plies

45° Plies

-45° Plies





Optimizing Composites – Ply Optimization

CFRP Foam Sandwich Structures

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Initial Sets (Global Ply Ids)

Resultant Thickness per Set

First shot Results for 45° Plys

Constraint: Design Space:3500 με Skin only

Objective:Minimize Mass





Optimization Evaluation

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Quality Performance

Hints for required fibre directions

Essencial hints for patch design

Number of layers needed for applied loads

Calculation time for the given example:Approx. 4-5 hours

Comfortable GUI




Advantages -Commercial View

Costs

Lower Costs due to

• Time Saving

• Quick Geometry Updates

• Direct way to good mesh quality

• Partner Program

• Licence System

Price Performance Ratio

Constant use of Units required to use Hyperworks effectively

Partner Products

Presently in use at Sogeti High Tech:

FEMFAT

Support

Good and Quick Support

Quick & Effective Answers

Licence System

Stacking

Introduction

Technical

Advantages

Technical View

Commercial View




Thank You For Your Attention

Questions?

Suggestions?

Please contact:

Markus Longeru Volker Grund

Technical Leader Stress Engineer

Tel.: +49 (0)40 743 60185 Tel.: +49 (0)40 743 60275

[email protected] [email protected]

Introduction

Technical

Gain in Experience

Advantages





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Boundaries & Loads

Introduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


Stationary Antenna

Definition of Ice and Wind Load

Ice Masses as CONMElements

Wind loads on beam elements as force vectors

Wind loads on surfaces as pressure distributionEquation on spherical coordinates






Optimization of Stiffener PositionGFRP Radar Dome

Variation of Size and Location of Stiffeners to maximum stiffness

Aim of Optimization:

All Eigenfrequencies >20Hz

Dimensions:

4,5m in Height

3,5m in diameterIntroduction

Technical

Workflow & Tools

Pre-Processing

Solver

Post-Processing

Optimization

Advantages


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