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Innovation Intelligence®

Innov’Day Composites

Simuler les composites et leur mise en forme

avec HyperWorks

Pierre-Christophe MASSON

23 Octobre 2014

Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

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Composite Simulations

with HyperWorks


Composites Overview within HyperWorks

Hyp

erW

ork

s

HyperMeshModern Ply Based

Composites Pre-Processing

HyperMeshVisualizations

Visually Verify the Math Model

OptiStruct/RADIOSSComposites Design Optimization

& Analysis

HyperViewComposites Post-Processing

& Failure AnalysisHyperWorks Partners

Detailed Composite Material Modeling& Structural Modeling

CAD & Mfg Interoperability

Realizationstranslate Ply Based Models to

Solver Zone Based Models

…


Composite Zone-Based Modeling (PCOMP)

position PCOMP1 PCOMP2 PCOMP3 PCOMP4 PCOMP5

1 Ply 0° Ply 90° Ply 45° Ply 90° Ply 0°

2 Ply 0° Ply 0° Ply 90° Ply 0° Ply 0°

3 Ply 0° Ply 0° Ply 0°

4 Ply 90° Ply 0° Ply 90°

5 Ply 90°

6 Ply 45°


Composite Ply-Based Modeling (PCOMPP)L

am

ina

te1

PLY 1 Ply 45°

PLY 2 Ply 90°

PLY 3 Ply 0°

PLY 4 Ply 0°

PLY 5 Ply 90°

PLY 6 Ply 45°


Composites Technology - Ply Based Modeling

A Composite Part is made up of “n” Plies and One Laminate

No Data Duplication

Direct Relationship to the Manufacturing Process

Ply Based Modeling Process

Define Ply Shapes and Related Ply Data

Define Stacking Sequences

Design Change Requires only 1 Update

P1 45

P2 90

P3 -45

P4 0

P6 90

P7 45

P5 -

45

Stack Table

Ply Mat Thk Theta

P7 M1 0.01 45

P6 M1 0.01 90

P5 M1 0.01 -45

P4 M1 0.01 0

P3 M1 0.01 -45

P2 M1 0.01 90

P1 M1 0.01 45


Ply Based Modeling – 3D Visualizations

3D Representation of Traditional 1D & 2D Representations

Visually Verify Engineering Data Associated with a Math Model

Traditional 1D & 2D Representation

3D Representation3D Representation with

Composite Layers


Composites: Model Review and Realization

Ply to zone based model

realization

• Automatic property creation

• Conversion of ply based into

zone based model

Supported interfaces :

• OptiStruct (direct support)

• Nastran

• Abaqus

• Ansys

• LS-Dyna (13.0)

Ply based model

Creation of equivalent properties

Laminate realization

RADIOSS & OptiStruct have

Embedded Composite Ply

Based Modeling in the Solver,

no need to Realize


Composite Structure Analysis using RADIOSS

Failure Modeling wrt Ballistic impact Bird Strike (Planes, Helicopters)

Race Cars design (DALLARA) Helicopter Cabin design

(EUROCOPTER)

Innovation Intelligence®

Composite Forming

with HyperWorks


Introduction/Context/History

1) To provide a simple solution which gives tendencies

• Simple set up with reduced numbers of input data

• Accurate enough to give main tendencies

• Fast enough to be used in an industrial context

2) Seamless crash model initialization with forming results

Batch mode

Manufacturing

+

Mapping

Composite Forming with HyperWorks

Modeling approaches

B-Pillar model example

Hyperform updates

Mapping

Meso to Macro multiscale approach

Draping

Conclusions


Two modeling approaches

Sandwich approach

One part of shell elements with

• One composite material

• One multi-layers property

To give tendancies

No sliding between layers

No coupling between warp and weft

directions

Independant Layers approach

N parts of shell elements

• One material law per layer

• One property per layer

• Contact between layers

More accurate

Sliding between layers

Coupling between warp and weft

directions

Sandwich approach Independant Layers approach

s11 s11~


Modeling approaches


Hyperform updates

Mapping


Draping

Conclusions


4 layers of UD: 0°, 45°, 90°, -45°

Resin (30%)

r = 3/7*rresin = 1.09*10-09 Mg/mm³

Go = 0.50 MPa Gs= Go – Gl

Gl = 0.35 MPa β = Gs / η

Β = 5000 s η = 30 Pa*s

Soften heated resin parameters

Glass fibers (70%)

• UD

E11 = 70%Eglass = 50400 MPa

E22 = 0.3 MPa

E33 = 50 MPa

• Woven fabric

E22 = E11

E33 = 50 Mpa

Initial shear angle 90°

B-Pillar model: Material description


B-Pillar model: Kinematic

The Die is going down

to the binder

The Die is going down

to the punch

Sandwich approach



Sandwich approach: blank shape during forming


Sliding effect between layers

Due to fiber orientations 0°, 45°, 90°, -45° regarding X axis, the

behavior during stamping is different for each layer

Independant Layers approach: blank end shape


B-Pillar model: blank end shape

The same compression,

tension and shear zones

can be observed

Sandwich approach


Wrinkles may also occur


B-Pillar model: Fiber Orientations

Fiber orientations are consistent

with blank shape

Sandwich approach (0° layer)


(layers 45° & 90°)


Modeling approaches


Hyperform updates

Mapping


Draping

Conclusions


HyperForm 13.0 updates for composite forming

Composite available thru User Process tree browser settings

Type of modeling selection popup

Then HF sets up automatically

• Contact interfaces tools and blank(s)

• Contact interface between layers

• Post-treatment cards in engine


Plies definiton

HyperForm 13.0 updates for composite forming

User Process Tree browser

organisation for the

sandwich approach

User Process Tree browser

organisation for the

independant layers approach

Layers are treated as

independant blanks


Modeling approaches


Hyperform updates

Mapping


Draping

Conclusions


Mapping algorithm

Target integration points

Stamping integration points

Forming side Crash side

Mapping

??


NEW in HC 12.113

Fiber directions mapping

First & Second fiber directions

can be mapped for each layer

Angle between fibers is shown as

iso-values while displaying the

second direction as vector


Target part

Composite

layers

Mapping for independant layers approach

4 layers of shell elements (MID 58, PID 16) on 1 layer of shell elements

(MAT25) associated with a 4 layer sandwitch property (PROP11)

NEW in HC 12.113


Woven fabric forming history influence on crash

Reference modelModel initialized with fiber

directions from forming stage


Modeling approaches


Hyperform updates

Mapping


Draping

Conclusions


Meso-scopic scale modeling

Strip of shells

E11 >> E22, E33

Contact interface between

fibers

Angle < 50°

Angle ~90°


Coupling from meso to macro thru mapping

Re-zoning according to an angle

criterion of 55°

E = 70%E, G = 70%G etc …

Angle < 55°

Model to map and Target mesh

Second direction after mapping: angle with the first direction

Target part after mapping


Meso-scopic scale approach: improvements in 13.110

Volume of fibers

Shear angle

Mapping

Rezoned part

Rezoning Criteria

Rezoning


Using a Mesoscale approach within a Macroscale modeling

Displacements

The maximum shear area is modeled at mesoscopic scale


Modeling approaches


Hyperform updates

Mapping


Draping

Conclusions


Drape Estimator for Composite Fibers

Calculate

• Draping angles

• Thickness variation

Interfaces

• OptiStruct

• Nastran

HM Drape Estimator (white) versus competition (red)


Drape Estimator for Composite Fibers

OneStep

Final part geometry OneStep result : flattened shape

Material/Fiber directions defined on

the flat reference shape

Final part initialised with

Material/fiber directions

Fiber directions


Modeling approaches


Hyperform updates

Mapping


Draping

Conclusions


Conclusions

Several works and studies around composite forming with Radioss

Reduced input data, simple set up, reasonably fast and accurate

Different scales modeling approaches depending on the expected results

Influence of forming results on crash simulation results has been shown

Mapping with re-zoning allows to take into account material degradation

Mapping compatible with sandwitch and multi-layers modeling

Validation is in progress …


Perspectives

To validate with benchmarks and experimental comparisons

To develop a dual-phase material to model cool and warm resin

To validate and compare draping approach with other methods

To continue to use mesoscopic modeling thru multi-scale coupling or for

macroscopic modeling validation

Merci de votre attention !

[email protected]

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