Layered Composite Solutions

Transcription

1 Composite Workflow Challenges and Solutions Andreas Hübner, CADFEM (Suisse) AG René Roos, EVEN AG

2 wind energy automobile aerospace aircraft sports & recreation

3 Material Function Shape -2-

4 Concept Preliminary Detailed Analyses Reporting ANSYS FE Analyze Structural Mechanics ANSYS Composite PrepPost Optimization Geometry Design / Drafting ANSYS DesignModeler Identical-Name-Strategy

5 Composite Structure Design Process Concept Geometry FE Analysis Understand behavior of anisotropic material Conceptual and preliminary design without 3D CAD geometry- data Preliminary lay-up design Material database for FE analysis Open to CAD-World (Licensing) Associative CAD- to FE-interface Using identicalname-strategy for plies Layered composite structures Coordinate systems Composite failure criteria Optimization Ply book Draping Flat wrap

6 Composite Structure Design Process Concept Geometry FE Analysis ESAComp ComponeeringInc Helsinki, Finland Tel ANSYS Design Modeler ANSYS Space Claim Direct Modeler ANSYS & ANSYS WB ANSYS Composite PrepPost

7 Material Database, Analysis and Design System Material Database Design Database Analysis Fiber/matrix micromechanics Plies and laminates Structural elements Plates Beams Joints Verification Design User extension Structural concept Material selection Dimensioning Lay-up design Structural details Reverse engineering Interface to ANSYS Composite PrepPost Open Interface

8 ESAComp Preliminary Design Concept Design Concept Material Selection Preliminary Layup design Layered Composite Solutions ESAComp Layout: Laminate / Sandwich Geometry analyses by: Hot spot, Panel (plane, stiffened, curved), Beams, Joint s Material-Databank Multiple failure criteria Polar Plots ESAComp/ANSYS ACP Interface 7

9 ESAComp Data Bank Layered Composite Solutions Material data delivered with ESAComp Types of Materials Fibers Matrix materials Reinforced plies Core materials Adhesives Open Library Material data can also be stored on Company and User levels Advanced features: Statistical data from tests can be stored 8

10 ESAComp Design Database Database levels Data Bank (locked) Company (shared) User (personal) Company Level Library of company verified material data Sharing of project data Design Library Templates Past projects Layered Composite Solutions 9

11 ESAComp Analysis Capabilities Micromechanics analyses for deriving ply properties from fiber and matrix data Laminate level analyses for stiffness, strength, thermal expansion, thermal conductivity, Numerous composite failure criteria Plate, beam, joint and notched laminate analyses Probabilistic analyses for studying the effect of varying material properties, layer orientations or loads Moisture diffusion and other specialized analyses 10

12 ESAComp Design Capabilities Trade-off studies Material selection Structural concept selection Laminate lay-up design For desired laminate properties For desired behavior of a structural element Dimensioning of structures Stiffener spacing, beam crosssection, joint overlap, fastener spacing, Efficient engineering environment Quick modification and duplication of objects Graphical result displays Layered Composite Solutions 11

13 ESAComp ResultSets 3D resultviewer: Contour plots forreserve factor, displacements and loads Failure labels Detailed element through the thickness analysis Failure envelopes, carpet plots and polar plots Available failure criteria: Puck, Max Stress, Max Strain, Tsai-Hill, Tsai-Wu, Hashin, Hoffmann Von Mises, Max Shear stress, Out ofplane shear, Rohacell Sandwich Wrinkling

14 ESAComp Interfaces and User Extension Export of materials and laminate layups to ANSYS and ANSYS Composite PrepPost Import of materials and laminate layups for detailed studies and further refinement in ESAComp XML data exchange with other applications Batch runs User defined micromechanics models and failure criteria 13

15 ESAComp Add-on Modules Layered Composite Solutions Cylindrical Shells (Add-on) For design of tubes, shafts, pressure vessels, Stiffened Cylindrical Shells (AddAdd-on) Further extension of the Cylindrical Shell module Applications, e.g. aerospace 14

16 Composite Structure Design Process Concept Geometry FE Analysis ESAComp ANSYS Design Modeler ANSYS Space Claim Direct Modeler ANSYS & ANSYS WB ANSYS Composite PrepPost

17 ANSYS ACP Pre-Processing ANSYS ACP Post-Processing ANSYS Solver *.rst Prepare Layup for Composite Model and Draping Simulartion Evaluation Composite Model

18 ANSYS Composite PrepPost Preprocessing Pre Processing Material Properties Mat. Reference Direction Ply-Wise Approach Prediction of Manufacturability ANSYS ACP Pre Mapping coordinate systems to one reference path automatic conversion of modeling data to simulation data draping simulation and support for automated manufacturing

19 ANSYS Composite PrepPost Postprocessing Post Processing Composite failure criteria Efficient results interpretation Design optimization Ply-wise post processing Estimation for delamination ANSYS ACP Post one figure per element is plotted, which reveals the safety level at the most critical layer evaluation of different failure criteria over different load cases at same time failure mechanism and layer orientation is plotted for decision making visualization based on physical plies

20 Selection Rules Layered Composite Solutions Key Features for Composites Preprocessing Selection rules provide practical means to reselect group of elements for which the physical plies are applied Cartesian Cylindrical Spherical Tube Cut off rule

21 Key Features for Composites Preprocessing Cutting Rules Tube rule: Rule defined by a circle swept along an edge set. Cut-off rule: Cut the plies when they intersect an imported CAD surface. Example how to suppress plies overlapping

22 Key Features for Composites Preprocessing Concept of oriented element-sets; user can define material application direction and material 0 direction Multiple oriented element-sets can be overlapping and differently oriented allowing for unique possibility of easy asymmetric laminate definition

23 Key Features for Composites Preprocessing Parallel, radial, cylindrical, edge wise and spherical rosette (coordinate systems) as basis for definition of material reference direction Concept of oriented element-sets; user can define material reference direction and ply orientation with respect to that One or several rosettes are assigned to an oriented element-set which avoids need for ply-subdivision

24 CADFEM your Partner for: Software Solutions Consulting Training

25 CADFEM FEM Software & Services 25+ years experience 150+ employees 40 Mio. revenue Central Europe: 12 offices Privately owned Worldwide through partners & TechNet Alliance CADFEM Innovative Certification: ISO 9000 ANSYS Competence Center FEM ANSYS Channel Partner since different seminar topics 100+ ANSYS technical & sales engineers CADFEM Complementary Software Explicit analysis AUTODYN and LS-DYNA Metal forming FTI, eta Robust analysis optislang Materials ESAComp, DIGIMAT, MaterialStudio Acoustics WAON Software Seminars Support Consulting Development -24 / 25-

26 ANSYS in Central Europe CADFEM (Suisse) AG DE CADFEM Berlin CADFEM Hannover CADFEM Dortmund ANSYS Hannover CADFEM Chemnitz ANSYS Darmstadt ANSYS Germany GmbH CADFEM Stuttgart CADFEM Grafing CADFEM Aadorf CH CADFEM Lausanne München ANSYS Otterfing CADFEM Wien AT -25 / 25-

27 CADFEM Partner Companies CAE related CADFEM Russia, Moscow CADFEM India, Hyderabad CCA, Shanghai, China Ozen Engineering, Sunnyvale, USA EnginSoft, Italy (TechNet Alliance) Figes, Turkey (TechNet Alliance) Cybernet, Japan (TechNet Alliance) ESSS, Brazil (TechNet Alliance) TechNet Alliance Your global CAE network 21+ countries 17+ languages 50+ companies Unique CAE expertise Member by invitation only Optimization, mathematics Diffpack, Nuremberg Dynardo, Weimar Virtual cities virtualcitysystems, Dresden -26 / 25-

28 ESAComp (Deutschland / Schweiz / Austria) CADFEM (Suisse) AG Andreas Hübner andreas.huebner@cadfem.ch +41 / 52 / EVEN AG René Roos roos@even-ag.ch -27 -