rapid optimization of composites - hypersizer express and fea
TRANSCRIPT
5/22/2012Page 1
HyperSizer Express and FEA
PRESENTED BY:
David Cross, Ph.D.Aerospace Stress Engineer
Structural Design and [email protected]
RAPID OPTIMIZATION OF COMPOSITES
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About SDA (Structures.Aero)• SDA was founded in 1997 and provides expert aerospace structural analysis.• We specialize in composites, and developing strong, lightweight structures that are readily
manufacturable. • Some of our previous projects include:
– Aircraft• Aurora Excalibur• AAI Shadow• AAI Aerosonde• Lockheed Constellation restoration for Lufthansa
– Spacecraft• NASA NESC Composite Crew Module (CCM)• NASA Orion Heatshield mass reduction for NESC• NASA Orion Crew Module (with Lockheed)• NASA WFIRST Telescope for Goddard
Aerosonde
Heatshield
Shadow M2
CCM
Orion Crew Module
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Siemens Value Added Reseller Collier Research Corporation Reseller
SDA Partnerships
FEMAP NX Nastran
Fibersim Solid Edge
HyperSizer Pro
HyperSizer Express
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About HyperSizer• Composite Analysis and Structural Sizing Software• Used in a wide variety of aerospace related industries• Just a few of the many companies using HyperSizer
Primary Industries
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HyperSizer Express
The HyperSizer ProcessMinimize mass &
design for strength, stability, and
manufacturability
Final Analysis & Margins
Generate Stress & Margin Reports
Import FEA Model & Results
Update FEM & Re-analyze
Advantages• Optimizes ply boundaries• Determines optimal ply orientations• Sequences plies based on a weighted objective
of mass minimization and manufacturability
Features• Reduce structural weight• Reduce design cycle time and engineering effort• Certify structures faster
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Flat Plate Example• All Four Sides Fixed Boundary Conditions• Uniform Pressure Loading (P)• Resulting internal loads are bending moments. • Membrane forces = 0.0
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• Investigate contour plots of the elemental forces imported from the FEA results.• Displacements and mode shapes can also be imported.
Internal Bending Moments
Mx Elemental Loads My Elemental Loads Mxy Elemental Loads
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Element Optimization – Ply Distributions• Express iterates with FEA to determine optimal ply count and ply orientation for each finite
element.
Number 0’s per Element Number 90’s per Element Number 45’s per Element
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• Element optimization leads to customizable ply boundaries.
• Control the trade-off between weight and producibility by increasing/decreasing the number of property zones.
Optimize Laminate Property Zones to Your Liking
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Flat Plate – Optimized Laminate Results
90’s on IML/OML 0’s on IML/OML
High 45’s in center and corners
Ply Stack Colored by Ply Orientation
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• Pinned Edges with Uniform External Pressure
• Initial model is 0.10” thick Al 7050• Use HS Express to size foam sandwich
core thickness
Fuselage Panel Example
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Final Component Based Margins of Safety Component Based Failure Mode
Optimized Results
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Top Face Thickness Core Placement and Thickness
Optimized Material Results
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• Export “Analysis Detail Report”• Export/Save “Updated FEM and OP2”
Update FEM
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Updated FEM Results• Critical margin is transverse core shear strength
(341 psi): +0.19• HyperSizer critical core shear stress = 286.6 psi• FEA critical core shear stress = 283.6 psi
Analysis/Margin Details
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Questions?
At SDA our engineers are practitioners of our software and are equipped to answer your questions.
If you would rather speak to us one on one, feel free to email the contacts listed below or call the office.
Contact
Structural Design and Analysis46030 Manekin PlazaSterling, VA 20166703-673-1125
• SDA Links– http://structures.aero/ – http://structures.aero/products/hypersizer/ – http://structures.aero/services/
• HyperSizer Resources– http://hypersizer.com/– Forum: http://hypersizer.com/forum/index.php– Help: http://hypersizer.com/help/index.php– News: http://hypersizer.com/media-room/
For Pricing Contact:
Marty SivicSDA, Inc. – Director of [email protected](o): 724-382-5290(c): 724-650-4413
Learn More
David [email protected]