simulation solution for composite manufacturing - fluid · pdf file1 © 2015 ansys, inc....

1 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential

Simulation solution for Composite ManufacturingBenjamin Lehugeur

Technical Account Manager, Airbus Group


ANSYS Composite Manufacturing Solutions

ANSYS Workbench

Forming

Fabric Deformation

Draping / Explicit

ANSYS LSDyna

ANSYS Mechanical

Impregnation

Resin flow calculation

/ Warping

PlanetsX

Curing

Residual Stresses

/ Distorsion

ANSYS Mechanical

ANSYS Composite Cure (ACCS)

Heat load / Autoclave

ANSYS Fluent

Strength Analysis

Falling

Collision, Shock

ANSYS Mechanical

ANSYS LSDyna

Lightning Strike

ANSYS HFSS

ANSYS Composite

PrePostVariable Material Fields:

Degradation Factor, Temperature,

Void content, …

Multiscale

Simulation



ANSYS Workbench

Forming

Fabric Deformation

Draping / Explicit

ANSYS LSDyna

ANSYS Mechanical

Impregnation


/ Warping

PlanetsX

Curing

Residual Stresses

/ Distorsion

ANSYS Mechanical



ANSYS Fluent

Strength Analysis

Falling

Collision, Shock

ANSYS Mechanical

ANSYS LSDyna

Lightning Strike

ANSYS HFSS

ANSYS Composite



Void content, …

Multiscale

Simulation


ANSYS Composite Pre-post (ACP)

• “Model as you build it” approach

• Parametric modeling of plies– Material properties, ply thickness– Number of layers– Fiber direction– Ply dimension and outline (ACP Rules)– Complex layouts of plies can be automated using

interactive layup definition in EXCEL

• Direct model review– Check the stacking on the fly– Look at area coverage– Produce plybooks for manufacturing

• “Thick-walled” composites structures– ACP offers Shell or Solid Element Modeling– Accurately model out-of-plane stresses


ACP Workflow

Can be used with several solvers:• ANSYS Implicit / Transient• ANSYS Explicit: LS-DYNA, Autodyn• Any others via ACT (for RTM for instance)


ACP / Variable Material Fields

• Each composite structure has its individual challenges!

• Consider degraded material properties in region with low fiber volume content, voids and folding

• Analyse draping shear angle and fiber orientation

• Consider environmental conditions such as temparature and humidity (resin)


ACP / Draping

• Draping simulation or direct measurements allow you to include the shear distortion effect of a fabric in your simulation.

Composite draping: shear and wrinkling(Dr M Sutcliffe, University of Cambridge, UK)

No shear

E1 = E2

E1 ≠ E2

30° shear


ACP / Draping

• Draping allows you to evaluate the shear angle by

- Simulation: Shear angle is estimated using energy algorithm assuming shear modulus distributed uniformly.

- External data: LookUp Table (CSV)


ACP / Draping

• Deformation analysis based on simple geometrical interpretation (without considering blank-sheet’s stiffness).

– Location of folds after forming

– Optimum form of blank sheet before forming


Implicit Simulation / ANSYS Mechanical

• Temperature dependency

• Real forming velocity

• Parametrization of the tooling geometry quickly to optimize the forming process (reduce number of folds)


Explicit Simulation / ANSYS Mechanical – LS Dyna


Multiscale SimulationMultiMech ACT Extension for Mechanical

• MultiMech'sbreakthrough multiscale analysis techniques completely within ANSYS Workbench + ACP

• No longer need to perform destructive testing or use curve-fitting techniques to capture the unique, nonlinear behavior of composite materials.


Multiscale SimulationMultiMech ACT Extension for Mechanical

Main features in the MultiMech App :

• Two-way coupled multiscale Finite Element solver, dynamically linked to ANSYS

• Automatic cracking and composite damage mechanisms

• Automatic composite microstructure generator

• Supports any composite type, orientation, and damage mechanism

• Robust postprocessing features to let users “zoom” into microstructural behavior



ANSYS Workbench

Forming

Fabric Deformation

Draping / Explicit

ANSYS LSDyna

ANSYS Mechanical

Impregnation


/ Warping

PlanetsX

Curing

Residual Stresses

/ Distorsion

ANSYS Mechanical



ANSYS Fluent

Strength Analysis

Falling

Collision, Shock

ANSYS Mechanical

ANSYS LSDyna

Lightning Strike

ANSYS HFSS

ANSYS Composite



Void content, …

Multiscale

Simulation


Infusion / RTM

• PlanetsX intregration insideANSYS Workench

– Coupled to ACP and Mechanicalfor Fabric Deformation and Warpage calculation


Infusion / RTM


Infusion / RTM

• Close-up

– Relation between folds and permability

– Possibility of air trap (void) generation



ANSYS Workbench

Forming

Fabric Deformation

Draping / Explicit

ANSYS LSDyna

ANSYS Mechanical

Impregnation


/ Warping

PlanetsX

Curing

Residual Stresses

/ Distorsion

ANSYS Mechanical



ANSYS Fluent

Strength Analysis

Falling

Collision, Shock

ANSYS Mechanical

ANSYS LSDyna

Lightning Strike

ANSYS HFSS

ANSYS Composite



Void content, …

Multiscale

Simulation


Curing / ANSYS Composite Cure Simulation (ACCS)

• Residual Stresses during Cure lead to distortion/cracking

• Spring-in, Cure Shrinkage, Consolidation

• Enthalpy, Tool Part interaction

• Design inverted tooling surface

The ACCS chemical solver is embedded within transient thermal module and simulates development of polimerisation, glass transition temperature as well as internal heat generation

related to exothermic cross-linking reactions


Geometry and material

properties input

ANSYS Thermal Cure Simulation

Calculate temperature and cure gradients, degree of

cure, cure rate, viscosity, glass transition

temperature and exotherms

ANSYS Structural Cure SimulationCalculate development of stresses and predict part

distortion

Structural model based on the semi empirical approach

Supported heating methods

Convection

Conduction

Microwave

Electromagnetic induction

The analysis is semi coupled. First we evaluate temperature and degree of cure using thermal solver and then degree of cure and temperature is passed to structural simulation to analyse development of stresses and distortions

Compensated

tooling surface

Curing / ANSYS Composite Cure Simulation (ACCS)


Example problems where ACCS was used

Tooling corrections for landing flap nose caps

Tooling corrections for flaps including ribs, skins and spars

Tooling design corrections for rear spars

Tooling modifications to fan track liners

Tooling design and compensation for the leading edges. Optimisation of the bonding process

Over 100 tooling surfaces were designed with this technology for the A350 -900 and -1000.

Other references: PRIMUS/Triumph Aerospaces (Fairing Angles), GKN Aerospace (trailing spars, landing flaps,

leading edges), CTRM (nose caps, landing flap ribs), Bombardier Aerospace (Spars, skins), Agusta-Westland (door frames), AVIC China (satellite components, radomes), VESTAS (50m long tooling for spars, skins, design and optimisations of heating systems, design of the bonding process).


Curing / Autoclave

• CFD Analysis to get accurate Air flow and Thermal map inside autoclave

– Produce more parts in same time

– Produce less scrap when thermicallyoptimized

– Boundary condition for ACCS !



ANSYS Workbench

Forming

Fabric Deformation

Draping / Explicit

ANSYS LSDyna

ANSYS Mechanical

Impregnation


/ Warping

PlanetsX

Curing

Residual Stresses

/ Distorsion

ANSYS Mechanical



ANSYS Fluent

Strength Analysis

Falling

Collision, Shock

ANSYS Mechanical

ANSYS LSDyna

Lightning Strike

ANSYS HFSS

ANSYS Composite



Void content, …

Multiscale

Simulation


ACP / Postprocessing

• Combined /Extensive failure criteria– Max. Strain & Max. Stress

– Tsai-Wu

– Tsai-Hill

– Hashin

– Puck (delamination)

– LaRC

– Cuntze

– Face Sheet Wrinkling

– Core Failure

– Hoffman

– …

• Advanced failure modes such as crack propagation, progressive damage, interface delamination, …

Crack propagation

Initial crack


Strengh Analysis

• Advanced failure modes such as

– Crack propagation,

– Progressive damage,

– Interface delamination,

– Shock …

CHARPY IMPACT TESTLSDYNA COMPOSITE MAT54


Lightning Strike

• Multifunctional simulations for composites

Strike at wingtip

Exit at tail PeakH at 1HzPenetrates the wings and fuselage

Predator UAV with Carbon Fiber Shell


Lightning Strike

• Predict destruction of samplesof part of plane under lightningstrike test

– Specific design workflow couplingEmag and Mechanical solver

– Including composite + grid

– Plasma thermal condition; Conduccion, radiation and convection of the arc

• Specific failure criteria easilyimplemented as user-definedcriteria (Python)



Simulate the full composite manufacturing process with:

• A single Simulation Platform, open to third party tools (via ACT)

• ANSYS Composite Prepost all along the chain• Best in class specific solvers: accuracy and speed

for structural, resin injection, curing and lightning strike

• Remove Material characterization bottleneck and accurate damage mechanisms with Multiscale approach



ANSYS Workbench

Forming

Fabric Deformation

Draping / Explicit

ANSYS LSDyna

ANSYS Mechanical

Impregnation


/ Warping

PlanetsX

Curing

Residual Stresses

/ Distorsion

ANSYS Mechanical



ANSYS Fluent

Strength Analysis

Falling

Collision, Shock

ANSYS Mechanical

ANSYS LSDyna

Lightning Strike

ANSYS HFSS

ANSYS Composite



Void content, …

Multiscale

Simulation

simulation solution for composite manufacturing - fluid · pdf file1 © 2015 ansys, inc....

Documents