Modeling Layered Composites The Simple Way

Modeling Layered Composites the Simple Way
Mark Swenson Lead Application Engineer ANSYS Mpls
2011 ANSYS, Inc. All rights reserved.
Presented at the 2012 Confidence by Design Workshop Minneapolis, MN May 8, 2012

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Agenda
Composites Overview
ANSYS Solutions for Layered Composites Demonstration Q&A
Composites Overview
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Composites offer tremendous weight savings, increased performance, and design flexibility
The composites market is a relatively young, fast growing and technologically evolving market
Designing parts with these materials can be challenging without appropriate tools
ANSYS develops tools to thoroughly investigate composites designs up to advanced failure analysis, with unparalleled ease of use.
ANSYS Solutions for Layered Composites
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Developing & Delivering Simulation Solutions

Simulation Driven Product Development:
Innovative & higher-quality products Dramatic time-to-market improvement Minimize development, warranty & liability costs
Paper taken from ERA Report 99-0808 Safety on Offshore Installations - Conference Proceedings, 30 November - 1 December 1999, ISBN 0-7008-0700-4, available from ERA Technology Ltd, Cleeve Road, Leatherhead, Surrey, KT21 7SA, UK. Details of the full proceedings are available at shop.era.co.uk
Modeling Layered Composites Efficiently

What makes composites analysis challenging?
Layered composites simulation requires:
Orthotropic material stiffness terms (Es, Gs, nus) Lamina (ply) thickness Fiber Orientation draping Understanding of stacking sequence implications Orthotropic strengths Understanding of numerous potential modes of failure and the various failure theories
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Where does ANSYS stand with composite capabilities?
ANSYS is not new to modeling composites:
Layered shell and solid elements for more than 2 decades Multi-material beams, with support for multiple layers and multiple section integrations Temp-Dep ortho material props with structural temps at each layer Composite PrepPost adds ease of use and results evaluation Integration into Workbench allows for rapid design studies VCCT and CZM, to characterize delamination and debonding for 7 years. Recent addition of progressive damage to characterize post first ply failure
Discrete/Smeared Reinforcement Solid-Shell
Shell
Layered Solid
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Cohesive Zone Model Exponential CZM Law
The bilinear tractionseparation law is used for contact elements
Debonding of a composite beam
Cohesive zone modeling to simulate debonding or crack growth

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Mat. 1
Mat. 2
VCCT is available to compute fracture mechanics parameters

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VCCT-Based Crack Growth Simulation

VCCT Examples
End Notched Flexure (ENF) Specimen
Results from published paper
ANSYS R14
Reference: Progressive crack growth analysis using interface element based on the virtual crack closure technique by De Xiea and Sherrill B. Biggers Jr. Finite Elements in Analysis and Design 42 (2006) 977 984 ANSYS, Inc. Proprietary 14
Start of damage (layer 1)
Progressed damage (layer 1)
Progressed damage (layer 3)
Progressive Damage Analysis available at 14.0

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What do we mean by Modeling Layered Composites Efficiently?
Highlight several focus area for this discussion:
Allow for geometric design changes to model Make changes to layup, ply locations, and orientations Incorporate fluid/thermal loading directly from CFD Incorporate loading from external data or other simulations Solve structural simulations all off the same unified model Static (linear & non-linear) Buckling (linear & non-linear) Transient Dynamic Linear Dynamics Explicit (Bird Strike, Drop Test, Crash and Impact, etc.) Ease of post-processing of composite results
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How can recent advances in ANSYS facilitate composite simulations ?
Lets start with the workflow in ANSYS Workbench for incorporating composites in a typical design:
Composite PrepPost integrated into Workbench workflow Upstream changes in design propagate through to the results In this example we might look at sensitivity of geometry size, shape or layups to deformation, natural frequencies, and failure margin
Model/Cleanup
Materials, Layups & Mesh
B/Cs and Simulations
Composite Post-Processing
Design Studies
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Composites PrepPost is used to define the layup. Here we see the part thickness, cross-sections, and fiber orientations
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Defining the layup with PrepPost
Material Data Fabrics/Stackups
Oriented Element Sets Layup Area
Layup
Layup Direction
Reference Direction
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Make changes to layup, ply locations, orientations Here we change the width of the doubler shown in red
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Make parametric changes to ply dimensions
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Fiber orientation prediction and modification Use internal draping calculations Interface with Vistagys FiberSim Modify the fiber orientation to something that is actually observed on the manufacturing floor. For this we use multiple rosettes (local coordinate systems) specifying the angle to match the measured at known locations, and let PrepPost interpolate in between.
Green parallel to rosette, Blue draped prediction
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Asymmetric laminate definitions Multiple overlapping oriented-element sets used to define asymmetric layups
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Incorporate fluid/thermal loading directly from CFD (1-way and 2-way FSI)
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Incorporate, transform, and validate loading from other simulations
Data Mapping Pressure Temperature Heat Transfer Thickness Displacements

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Solve structural simulations all off the same unified model
Pressure loading, modal, and non-linear buckling example
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Solve structural simulations all off the same unified model
Pressure loading, modal, and tip load non-linear buckling
IRF - Distributed Pressure
2nd Natural Freq = 174 Hz
IRF 4 Tip Displacement
Change spar chord location, wing taper, rib position, add stiffener plies to skin Geometry, mesh, orientations, draping, properties, and results all updated
IRF - Distributed Pressure

2nd Natural Freq = 241 Hz

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IRF 4 Tip Displacement


Here we look at how the tip deflection and 2nd natural frequency change with the 1st rib spanwise location.
Perform what-if studies
Create response surfaces for optimization

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Ease of post-processing of composite results
Results Interrogation
Worst case failure criteria over all layers shows Hm (1) Hashin matrix Layer 1 Pick element and see stress/strain and failure through the thickness
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Explicit dynamic model uses same composite setup
Bird-Strike, Drop Test, Crash and Impact, etc. Simple setup for Eulerian mesh
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Radome Case Study
Connections
Deformations from FSI
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Failure Criteria

Radome Case Study Bird Strike
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Summary
Composites simulations with ANSYS

Setup model one time, make changes to examine what if Look at sensitivities of design changes Investigate damage tolerance to flaws Investigate post first ply failure
Simple Drag-and-Drop Multiphysics

Easily incorporate thermal, fluids, and pressures Additional capability to import 3rd party data
Improve design fidelity by optimization
One single framework ANSYS Workbench
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Modeling Layered Composites The Simple Way

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Modeling Layered Composites the Simple Way

Mark Swenson Lead Application Engineer ANSYS Mpls

2011 ANSYS, Inc. All rights reserved.

Presented at the 2012 Confidence by Design Workshop Minneapolis, MN May 8, 2012

ANSYS, Inc. Proprietary

2011 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary