Composites Structural Optimization

modeFRONTIER + Ansys Composite Prepost

Guilherme Jenovencio
Rodrigo Ferraz
Data: 2011, August 08th

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 Composites Structures Optimization PAGE 2

• Composites structures are made from two or more materials with different mechanical
and physical properties;

•The great advantage of Composite Materials is to provide light structures with high
mechanical resistance.

sailplane

Epoxy

Carbon
Fiber

carbon fiber - epoxy

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 Composites Structures Optimization PAGE 3

• Designing composite structures, however, involves a large number of variables, such

as fiber material, orientation of layers, number of layers, etc;

• Achieving high mechanical properties depends on the complex relationship between

these variables and the workloads the product will be subjected to;

• Composite design can be interpreted as an Optimization Problem:

Normal Design Parameters

• Material Type of the Fiber;
• Number of layers;
• Layer Orientation;
• Layer Thickness;
• Etc;

Common Objectives on Composites

Structures
• Minimize Weight
• Minimize Risk of Failure

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 ACP PAGE 4

• ACP (Ansys Composite PrePostprocessing) provides an friendly environment to help

designers to model complex composites structures.

• Material properties and laminate structures can be easily specified in ACP environment.

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 Composites Structures Optimization PAGE 5

The optimization software modeFRONTIER® can be used to couple Ansys and ACP in
the same Optimization Study, automating the analyses of different configurations;

ACP
Input Variables:
Output variables:
•Fiber Material
ANSYS •Maximum Strain
•Fiber Orientation
•Weight
•Number of Layers

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Example - Blade Case PAGE 6

Blade Case

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 Example - Blade Case PAGE 7

Introduction:
Find an optimal design in terms of mass and resistance, with a risk of failure<1.
Geometry is fixed. It has been defined from CFD analyses;

Design Parameters: Material List

• Material Type of the Fiber A130
• Number of layers DB120
• Layer Orientation Balsa
LS
Objectives: AL
• Minimize Weight
• Minimize Maximum Strain
(Risk of Failure)

Constraints:
• Risk of Failure < 1
• Weight < Critical Weight

Optimization Process:
• Genetic Algorithm;

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 Didactic Example - Blade Case PAGE 8

Parametric approach
• The proposed solution is to relate each layer as a function of a initial orientation, orientation
increment, local period, global period and material.

Parameterization based on
Design and Optimization of
Laminated Composite by Prof.
Zafer Gurdal

Local Material Initial Orientat Globa

Period Fiber Orientat ion l
ion Incremen Perio
t d

• First Sub laminate

1. First Local Period = 2

2. Material 1 = DB120
3. Initial Orientation = 45
4. Orientation Increment = -90

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 Didactic Example - Blade Case PAGE 9

Parametric approach
• The proposed solution is to relate each layer as a function of a initial orientation, orientation
increment, local period, global period and material.

Local Material Initial Orientat Globa

Period Fiber Orientat ion l
ion Incremen Perio
t d

• Second Sub laminate

1. Second Local Period = 5

2. Material 2 = A130
3. Initial Orientation = 0
4. Orientation Increment =0

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 Didactic Example - Blade Case PAGE 10

Parametric approach
• The proposed solution is to relate each layer as a function of a initial orientation, orientation
increment, local period, global period and material.

Local Material Initial Orientat Globa

Period Fiber Orientat ion l
ion Incremen Perio
t d

• Laminate

1. Global Period = 2
2. Symmetry = enable

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 Didactic Example - Blade Case PAGE 11

Parametric approach
• The proposed solution is to relate each layer as a function of a initial orientation, orientation
increment, local period, global period and material.

• Using this approach the number of design parameters are fixed and a laminate can be
generated automatically.

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 Didactic Example - Blade Case PAGE 12

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 13

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 14

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 15

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

The
ACPdat file generated
Script generated by
by the
Ansys with: project
original
• Type of elements
• Loads and boundary conditions
• Name selections

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 Didactic Example - Blade Case PAGE 16

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 17

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
some support files. ACP
script
• ACP is Automatic run by generatio
modeFrontier provinding n
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 18

Getting the ACP model and

create a string for
starting a sub laminate
ACP line code.

modeFRONTIER Workflow Written the modeFRONTIER input

values in a sub laminate
• Different input parameters string according parametric
for each region in Ansys WB approach.
project.

• modeFRONTIER needs
some support files. ACP
script
• ACP is Automatic run by generatio
modeFrontier provinding n
several possible design. Written the ACP line codes
for global laminate to each
• The possible solution are sub region defined on geometry
moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 19

• Python routine generates a

sub laminates line codes.

modeFRONTIER Workflow Sub laminate line codes

• Different input parameters
for each region in Ansys WB
project.
• The will
line be
codes are injected
injected here in the ACP base script , which
is a support file.
Sub laminate line codes

• modeFRONTIER needs
some support files. ACP
script
• ACP is Automatic run by generatio
modeFrontier provinding n
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 20

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
some support files. ACP
script
• ACP is Automatic run by generatio
modeFrontier provinding n
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 21

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
Run ACP Pos processing
some support files.
results
• ACP is Automatic run by
modeFrontier provinding
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 22

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

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 Didactic Example - Blade Case PAGE 23

• 50 Initial Designs
• Each design takes +/-
1m:10s

•Max Strain <

4E-4
modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB • Weight < 2.7E8
project.

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.

• The possible solution are

moved to a trade-off of
optimal solutions

Constraints for
the whole body
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 Didactic Example - Blade Case PAGE 24

•Minimize Maximum
Strain

modeFRONTIER Workflow

• Different input parameters

for each region in Ansys WB
project.

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.
•Minimize Weight
• The possible solution are
moved to a trade-off of
optimal solutions

Objectives for
the whole body

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 Didactic Example - Blade Case PAGE 25

•Minimize Maximum
Strain

A Genetic Algorithm
movies the designs
modeFRONTIER Workflow to the Pareto
Frontier
• Different input parameters
for each region in Ansys WB
project.

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.
•Minimize Weight
• The possible solution are
moved to a trade-off of
optimal solutions

Objectives for
the whole body

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 Didactic Example - Blade Case PAGE 26

•Minimize Maximum
Strain

Total Designs = 708

Unfeasible Designs
modeFRONTIER Workflow = 52
Feasible Designs =
• Different input parameters 656
for each region in Ansys WB Total Time = 13.8
project. hours

• modeFRONTIER needs
some support files.

• ACP is Automatic run by

modeFrontier provinding
several possible design.
•Minimize Weight
Optimal Trade-off
• The possible solution are
moved to a trade-off of
optimal solutions

Objectives for
the whole body

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 Didactic Example - Blade Case PAGE 27

Optimazation Results

• Design generated by modeFRONTIER

Optimal Trade-off find by

modeFRONTIER
• 58 Pareto Designs

Original Project is not a

•optimal
Dominated design.
design.

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 Didactic Example - Blade Case PAGE 28

Optimazation Results Maximum Strain = 7E-5

Original Project
Weight = 1.14E8
Pros
• Comparison among some Cases
• Possible solution
• Respect the constraints
• Low Risk of Failure

Cons
• It is not a optimal
solution
• The weigh can be reduced
• The strain can be
reduced

Original Project

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 Didactic Example - Blade Case PAGE 29

Optimazation Results
Maximum Strain = 1.5E-4
• Comparison among some
Case Cases
1 Weight = 4.67E7

Pros
Case 1 • It is a optimal design
• Respect the constraints
• Smallest weight

Cons
• Risk of failure bigger
than original project

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 Didactic Example - Blade Case PAGE 30

Optimazation Results

• Comparison among some Cases

Case 2
Maximum Strain = 6.9E-5
Weight = 8.07E7

Pros
• It is a optimal design
• Respect the constraints
• Low weight

Cons
• Risk of failure similar
to original project

Case 2

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 Didactic Example - Blade Case PAGE 31

Optimazation Results

• Comparison among some Cases

Case 3 Maximum Strain = 5.2E-5
Weight = 9.05E7
Pros
• It is a optimal
design
• Respect the
constraints
• Low weight
• Low risk of failure

Cons
• Risk of failure
bigger than case 4
• Weight bigger than
case 1 and 2

Case 3

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 Didactic Example - Blade Case PAGE 32

Optimazation Results
Maximum Strain = 1.9E-5
• Comparison among someCase
Cases
4 Weight = 2.59E8

Pros
• It is a optimal design
• Respect the constraints
• Smallest risk of failure

Cons
• Weight bigger than case
1, 2, 3 and original
project

Case 4

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 Didactic Example - Blade Case PAGE 33

Optimazation Results

• Comparison among some Cases

Case 1
Table of results

Original Project
Case 2

Case 3

Case 4

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 Final Considerations PAGE 34

• Composites structures can be optimized easily using ACP

and modeFRONTIER just defining some free parameters
as materials, number of layers, fiber orientation, etc.

• It is possible reduces weight and minimize the risk of

failure, since modeFRONTIER deals with muitiobjetive
optimization.

• A multidisciplinary optimization can be performed using a

parametric geometry and CFD simulations couple with
Structural Analysis.

• Different parameterization approach can be easily

implemented to generate particular laminated configuration.

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