MSC Software Composites Solution. MSC Composites Technology Day

MSC Software Composites Solution MSC Composites Technology Day

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

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

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

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

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

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 2 3 2 1 3 2 1 Copyright 2012 MSC.Software Corporation 15

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

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

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

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

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

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 = 1.598 Final weight = 9.589E-2 0.06 Copyright 2012 MSC.Software Corporation 28

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

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

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

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

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

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

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