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


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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http://www.bombardier.com/en


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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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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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


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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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


• Stacking manufacturing constraints

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COMPOSITE OPTIMIZATION PROCESS EXAMPLE

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Phase III - Detail: Stacking Sequence Optimization

• Meet ply book rules


• 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


45 -45 0 0 0

45 -45 45 90

90 -45 45 -45 0 0

-45 90 45


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COMPOSITE OPTIMIZATION MANUFACTURING CONSTRAINTS

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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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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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• 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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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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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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COMPOSITE OPTIMIZATION TYPICAL EXAMPLE

CAD Export (FibreSim)

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COMPOSITE OPTIMIZATION TYPICAL EXAMPLE

• Zone-based pattern grouping

• Custom Constraints Facilitated through OS plug-in or HyperMath

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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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Martin Kemp, Altair Product Design

[email protected]

THANK YOU (QUESTIONS)

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optimization of composite: recent advances and application

Technology

composite

composite

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martin kemp

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