Compositesmodeling

withANSYS

ModelingLayeredComposites
theSimpleWay
MayuranS.Muttulingam
1 2011ANSYS,Inc. October12,2011
 Motivation

Compositesoffer
tremendousweight
savings,increased
performance,anddesign
flexibility

Thecompositesmarketis
arelativelyyoung,fast
growingand
technologicallyevolving
market

2 2011ANSYS,Inc. October12,2011
 Motivation

Compositesoffer
tremendous
weightsavings,
increased
performance,and
designflexibility

3 2011ANSYS,Inc. October12,2011
 Motivation

Thecomposites
marketisarelatively
young,fastgrowing
and
technologically
evolvingmarket

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 LevelsofAnalysis

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 Challenges

Multiplematerials,
complexlayups,large
numberofpliesetc.makes
thejobdifficulttodesign
partswiththesematerials

Comparedtohomogenous
materialslikesteelor
plastic,compositesare
muchmorechallengingto
analyze

6 2011ANSYS,Inc. October12,2011
 ANSYSCompositePrepPost (ACP)

The intuitive implementation of composite design development in ANSYS

Composite PrepPost brought out a revolution in composite simulations. We
are able to realize a continuous design process from simulation results to
manufacturing including design modifications within the development.

HendrikMester,RotorBlade
Development,REpowerSystemsAG
7 2011ANSYS,Inc. October12,2011
 Shellbasedcomposites

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 AnalyzingCompositesinR14.0
Motivation

ANSYSWorkbench
providessuperiorCAD
connectivity,meshingand
aeasyframeworkto
performdesign
optimization

WithR14.0,wegreatly
improvetheworkflowfor
analysisofcomposite
components

9 2011ANSYS,Inc. October12,2011
 EngineeringDataEnhancements
NewinR14

NewatRelease14.0
Orthotropicstress/strain
strengthproperties
TsaiWu,Puck,LaRc03/04
Constants
PropertiesavailabletoACP
andMechanicalandMAPDL

10 2011ANSYS,Inc. October12,2011
 ManuallyDefiningLayersonSimpleGeometries

Userscandefine
simplelayered
sections forashell
bodyaswellasdefine
thicknessesand
anglesasparameters

11 2011ANSYS,Inc. October12,2011
 BasicLayerDefinitioninMechanical
NewinR14

LayeredSectionObject
Allowsausertodefinesimplelayered
sectionforashellbody
InsertedundertheGeometryfolder
fromthetoolbaroritsRMBinsert
menu
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 LayeredSectionObject
Details

Scopetobodiesorfaces

Optionstodefineoffsetandsequencing

Graphicsoptiontodisplayspecificlayerto
helpverifycorrectoffset,sequence,etc.

WorksheetViewtoenterlayerdata

Thickness,anglevaluescan
beparameterized
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 LayeredSectionObjectExample
Graphics:SectionThickness,Location

14 2011ANSYS,Inc. October12,2011
 Postprocessing
LayerControl,Membrane/BendingOutput

NewMembrane
Bendingstress
results.

Abilitytochoose
whichlayerto
viewresults

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 ExplicitCompositeExample
NewinR14
CFRPBaseballbatwithspiralCRFPreinforcement

NormalStressin3rd Ply,45o toBatAxis

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 DefiningLayersonComplexGeometries

Forcomplex
geometries,theANSYS
Courtesy of
TUChemnitz CompositePrepPost
andGHOST
BikesGmbH toolisusedandlayer
definitionsareimported
intheassemblymodel
inANSYSMechanical.

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 DataIntegratedACPwithWB
NewinR14

ACPintroducedasacomponentsysteminsideWB
LikeatypicalWBsystem,filemanagementand
standardactionslikeUpdate,Duplicate
ConsumematerialsfromEngineeringData

18 2011ANSYS,Inc. October12,2011
 ACPMechanicalLinkage
NewinR14

ACPPresystemcontainsEDA,
Geometry,ModelandSetup
(sameasMechanicalsystem)
SetupcelllaunchesACPEditor
Mesh(shell)istransferred
fromMechanicalintoACP
ACPthenpasses,discrete
sectiondatatoMechanicalas
ImportedLayeredSection
object
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 ACPMechanical:ExampleSchematic
NewinR14
Explicit Implicit
(Autodyn) (MAPDL)

ParameterSupport
IncludeaspartofDesign
Exploration

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 MaterialDefinition

Youcandefineadditionalcomposite
layersusingtheconceptoffabrics,
stackups andsublaminates
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 Manualdefinition

ComplexCurvedStructures
Asystemofrosette
combinationcanbeusedto
Definematerialreference
directions

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 Draping

Forstructureswithhigh
curvaturesetc.
Manufacturabilityisabig
factorindesign
ACPcanpredictdraping,
fiberanglecorrectionetc.

23 2011ANSYS,Inc. October12,2011
 Validation

Verifymodelsetupby
viewingthestacking
sequencesorby
generatingaPlybook

Crosssectionviews

PlyBookgeneration
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 AsymmetricLaminates

ACPallowsmulti
orientationsofthe
sameregionto
supportasymmetric
laminatedefinition
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 PostProcessing

Stateoftheartpostprocessing
Identifycriticalpartsby
highlightingfailuremode,failed
layerandcriticalloadcasein
oneplot

tw(31)(0)

tw(31)(0)

tw(31)(0)

tw(31)(0)

26 2011ANSYS,Inc. October12,2011
 MiscellaneousEnhancements
NewinR14

VCCT
InR14,ACPyoucandefineamodelingplyasa
VCCTlayer.Whenthesolidmodelisgenerateda
VCCTlayerisintroducedbetweenthecorresponding
plies.
Performance
InR14,ACPnowgroupselementswithsimilaror
identicalsectiondefinition(basedonlimitangleand
thickness).Formostmodelsthisresultsinadrastic
reductionofsectiondata whichhelpsimprovesolver
performance

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 Solidcompositesmodels

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 SolidExtrusion

UseCADdatato
createcutoffrules

CADdatacanbeused
toextrudepliesfrom
surfacetoSOLID
meshtomodel
complex3Dshapes

29 2011ANSYS,Inc. October12,2011
 SolidExtrusion

Varyingcore
thickness
appliedby
tablesor3D
CADmodel

30 2011ANSYS,Inc. October12,2011
 AutoDetectButtJoinedPlyBoundaries
NewinR14

InR13ACPcreatesdrop
offelementsonallply
boundaries

Threeadjacentplieswith
intermediatedropoff WithR14ACPwillnow
elements(R13)
automaticallycollectnon
overlappingpliesand
extrudetheminonegroup
inordertocreatesmooth
Threeadjacentplies transitionzonesin
withsmoothtransition
zone(R14)
betweenofthem.
31 2011ANSYS,Inc. October12,2011
 MultiComponentMeshextrusion
NewinR14

InR14ACPwilldetectfreesharededgesand
automaticallyeliminateinternalfreeedgeends
toenableafullyautomaticsolidextrusionofa
moregeneralclassofshellmeshes.

Twocomponenttubeassembly Threevirtualcomponents SolidextrusioninACP14

withtwofreesharededges (R14) (illustrationwithoutbuttjoinedplies)

32 2011ANSYS,Inc. October12,2011
 PartnerESAComp

Concept

DesignConcept
MaterialSelection
PreliminaryLayupDesign

ESAComp
Laminateanalyses:Solid
laminate/Sandwich
Analysesinvolving
geometry:Panel(flat,
stiffened,curved),
Beams,Joints,Notches
MaterialDataBank
Multiplefailurecriteria
Polarplots,Layercharts
ESAComp/ANSYSACP
Interface
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 PartnerESAComp

Concept Geometry FEAnalysis

ESAComp ANSYS ANSYS&

DesignModeler ANSYSWB
ANSYSSpaceClaim ANSYSComposite
DirectModeler PrepPost

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 Interactwith
Vistagys
FiberSIM for
manufacturing
details

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 CompositesModelingwithANSYSSolutions

36 2011ANSYS,Inc. October12,2011