MSC Software Composites Solution. MSC Composites Technology Day

Transcription

1 MSC Software Composites Solution MSC Composites Technology Day

2 Agenda for Today Time Agenda: Composites Technology Day with MSC Nastran 9:00-9:15 Welcome 9:15-9:45 Overview of MSC s Composites Solution 9:45-10:30 Introduction to Analysis of Composites Structures Hands-on Training Workshop 1: Stress Analysis of a Composite Wing 10:30-10:45 Break 10:45-12:15 Solid Composite Elements Hands-on Training Workshop 2: Solid Shell Composites Modeling 12:15-12:45 Lunch 12:45-2:15 Progressive Ply Failure and Delamination Modeling Hands-on Training Workshop 3: Open-Hole-Tension Test Coupon 2:15-2:30 Break 2:30-4:00 Optimization of Composite Structures Hands-on Training Workshop 4: Minimizing the Weight of a Composite Wing 4:00-4:30 Curing, Draping, and Direct CAD Interface 4:30-4:45 Feedback/Wrap-up

3 Global Composite Applications What percentage of global composite fiber usage is Carbon Fiber? Copyright 2012 MSC.Software Corporation 2

4 Carbon Fiber Composite Applications Copyright 2012 MSC.Software Corporation 3

5 2010 Distribution of Composite Applications Copyright 2012 MSC.Software Corporation 4

6 Aerospace Composites Usage Boeing's 787 Dreamliner is 50% composite material by weight 80% composite materials by volume What were some of the challenges faced by this composites program? Copyright 2012 MSC.Software Corporation 5

7 Source: Frank Doerner, MSC 2011 User s Conference Keynote Speaker Major growth in cost & time Copyright 2012 MSC.Software Corporation 6

8 Source: Frank Doerner, MSC 2011 User s Conference Keynote Speaker Copyright 2012 MSC.Software Corporation 7

9 Critical Margin of Safety Extensive 1D, 2D, 3D composite element library Static and Dynamics Analyses MSC Software Composites Solution Optimization Draping and CAD Interface Curing and Shrinkage Progressive Ply Failure Analysis and Delamination

10 Extensive 1D, 2D, 3D Composite Element Library Copyright 2012 MSC.Software Corporation 9

11 MSC Software Composites Solution A comprehensive library of composite elements are supported in MSC s pre/post processors and solvers FEA Solvers MSC Nastran Marc Pre/Post Processors Patran/Laminate Modeler SimXpert Mentat For today s hands-on exercises we will use Patran and Nastran. Copyright 2012 MSC.Software Corporation 10

12 Composite Elements Library Beam Element Solid Element Shell Element Copyright 2012 MSC.Software Corporation 11

13 Defining the Composite The general approach is to define a laminate material representation of the layup 1. Define the ply material properties first 2. Then define the laminate ply thickness, orientation, and layup sequence 3. Assign the laminate to elements Copyright 2012 MSC.Software Corporation 12

14 Define the Ply Material Define the ply material 2D or 3D orthotropic Unidirectional tape Woven Material Stitched Material Copyright 2012 MSC.Software Corporation 13

15 User-friendly interface to define the laminate Define the layup Material Thickness Orientation angle Copyright 2012 MSC.Software Corporation 14

16 2D and 3D Composite Elements Shell and solid composite elements Both support progressive ply failure analysis Two types of solid composite elements Solid Layered Composites Solid Shell Composites One integration point per layer Copyright 2012 MSC.Software Corporation 15

17 Critical Margin of Safety Extensive 1D, 2D, 3D composite element library Static and Dynamics Analyses MSC Software Composites Solution Optimization Draping and FiberSIM Interface Curing and Shrinkage Progressive Ply Failure Analysis and Delamination

18 Static and Dynamics Analyses Copyright 2012 MSC.Software Corporation 17

19 Static and Dynamics Strength Evaluation Static Analysis and Dynamics Analysis Stress and Strain computation Failure Theories Failure indices Strength ratios Copyright 2012 MSC.Software Corporation 18

20 Zone vs. Ply Layup Simulate Simulate Simulate Simulate Geometry Zone Layup Ply Layup Ply Details Verification Manufacture feedback loop... OK! Preliminary design Detailed design Copyright 2012 MSC.Software Corporation 19

21 Global Ply 3 Global Ply 2 Global Ply 1 Results Viewable by Layer Number or Global Ply ID View by Layer Number View by Global Ply ID Layer 1 Layer 2 Layer 3 Copyright 2012 MSC.Software Corporation 20

22 Ply Based Modeling in Laminate Modeler Ply based approach Define plies Define Layup Show/Verify Layup Copyright 2012 MSC.Software Corporation 21

23 Critical Margin of Safety Extensive 1D, 2D, 3D composite element library Static and Dynamics Analyses MSC Software Composites Solution Optimization Draping and FiberSIM Interface Curing and Shrinkage Progressive Ply Failure Analysis and Delamination

24 Optimization of Composites Copyright 2012 MSC.Software Corporation 23

25 Types of Optimization in MSC Nastran t init t opt Sizing Change in property (t, I, J, theta, etc.) Shape init Shape opt Shape Change in GRID locations Topology Remove unneeded structure Topo init Topo opt Copyright 2012 MSC.Software Corporation 24

26 Types of Optimization in MSC Nastran Topography Special form of shape optimization Initially flat sheet Optimized with bead Topometry Special form of sizing optimization Each element is separately designed All elements with same initial thickness Varied thickness after optimization Copyright 2012 MSC.Software Corporation 25

27 Composites in Optimization Composites optimization is specifically supported in Sizing optimization Topometry optimization Copyright 2012 MSC.Software Corporation 26

28 Sizing Optimization Objective Minimize weight Minimize compliance Etc. Design Variables Ply orientation Thickness Material properties Constraints Failure indices Strength ratios Weight Stress Strain Etc. Copyright 2012 MSC.Software Corporation 27

29 Sizing Optimization Ply Angles Composite sizing optimization example Optimize ply angles Optimize ply thicknesses Minimize weight 45 o 5 o Total Weight Ply Thickness Initial weight = Final weight = 9.589E Copyright 2012 MSC.Software Corporation 28

30 Topometry Optimization Topometry optimization for composites Material distribution is optimized across all elements Ply-by-ply element thickness optimization Composite element combined thickness distribution 0 degree Ply 90 degree Ply +45 degree Ply -45 degree Ply Copyright 2012 MSC.Software Corporation 29

31 Critical Margin of Safety Extensive 1D, 2D, 3D composite element library Static and Dynamics Analyses MSC Software Composites Solution Optimization Draping and FiberSIM Interface Curing and Shrinkage Progressive Ply Failure Analysis and Delamination

32 Progressive Failure Analysis (PFA) and Delamination Copyright 2012 MSC.Software Corporation 31

33 Going Beyond First-Ply-Failure (FPF) Evaluate the load redistribution in a composite structure as the plies fail progressively Simulate delamination growth from initial flaw Study crack propagation to design for fail-safe structures Copyright 2012 MSC.Software Corporation 32

34 Failure and Delamination Methods Ply Material Failure Delamination VCCT CZM 33 PFA Delamination Breaking Glue Copyright 2012 MSC.Software Corporation 33

35 Progressive Failure Analysis (PFA) The user selects the failure criteria Puck, Hashin, Tsai-Wu, etc. Composite failure on a layer by layer basis Upon failure, scale down E and G Pin bearing on hole Copyright 2012 MSC.Software Corporation 34

36 VCCT Example delamination growing along glued interface Animation shows glued region Animation shows region released from glued Copyright 2012 MSC.Software Corporation 35

37 Cohesive Zone Modeling (CZM) example Copyright 2012 MSC.Software Corporation 36

38 Breaking Glued Contact example Release glued contact when the following stress criterion is met Use contact normal and tangential stresses After break, do regular contact with friction and separation Copyright 2012 MSC.Software Corporation 37

39 Delamination example Split up mesh between materials or within a material when the following stress criterion is met Use stresses normal and tangential to interface Copyright 2012 MSC.Software Corporation 38

40 Critical Margin of Safety Extensive 1D, 2D, 3D composite element library Static and Dynamics Analyses MSC Software Composites Solution Optimization Draping and FiberSIM Interface Curing and Shrinkage Progressive Ply Failure Analysis and Delamination

41 Curing and Shrinkage during Manufacturing Copyright 2012 MSC.Software Corporation 40

42 MSC Composite Curing Capability Cure-induced heating and curing shrinkage Thermal heat generation due to curing Shrinkage strains associated with curing Causes distortion and residual stress in parts Prediction is critical for predicting final shape Coupled thermo-mechanical analysis Critical capability for process development Available for solid and shell elements Marc has this unique capability in the industry Copyright 2012 MSC.Software Corporation 41

43 0 /90, +/- 45 Case Study : Sikorsky S-92 Helicopter Orthotropic Layup Copyright 2012 MSC.Software Corporation 42

44 Case Study Springback.35 actual.345 predicted Copyright 2012 MSC.Software Corporation 43

45 Critical Margin of Safety Extensive 1D, 2D, 3D composite element library Static and Dynamics Analyses MSC Software Composites Solution Optimization Draping and FiberSIM Interface Curing and Shrinkage Progressive Ply Failure Analysis and Delamination

46 Draping and FiberSIM Interface Copyright 2012 MSC.Software Corporation 45

47 Laminate Modeler Process simulation Ply draping Scissor - draping behavior exhibited by fabrics Slide - draping behavior exhibited by tapes Splits and darts Direct interface to CAD FiberSIM Copyright 2012 MSC.Software Corporation 46

48 Ply Draping Simulation in Laminate Modelr Define ply material and layup on doubly curved surfaces Define plies Define Layup Show/Verify Layup Copyright 2012 MSC.Software Corporation 47

49 Interface to FiberSIM Directly access layup data from FiberSIM FiberSIM plies and layup files are imported and mapped onto analysis mesh Copyright 2012 MSC.Software Corporation 48

50 End of Composites Solution Overview Copyright 2012 MSC.Software Corporation 49