Lecture1 ALL

IFB
A.K. Pickett, 2013-2014

Institut fr Flugzeugbau, University of Stuttgart
Composites modelling:
General introduction to course
Lecture WS 2013/14
8. Semester Luft- und Raumfahrttechnik:
Composites Modelling (Nr. 39 489)
o Vorlesung und bung / 2 SWS, Wahlpflichtfach / Wahlfach
Each Wednesday: Lecture 09.45 11.15; Exercises in CIP-Pool 13.00 14.30
Start:
Wednesday 16th October 2013
o Pfaffenwaldring 31, Hrsaal V31.51
This course covers a wide range of numerical methods for composites analysis including:
Introduction and application of micro-mechanics for composites stiffness and failure.
Laminate analysis for stiffness and failure prediction.
Finite Element simulation of linear, nonlinear and impact/crash loaded composites.
Composites processing including forming and draping of composite fabrics.
Modelling for infusion and heat flow in Liquid Composite Moulding processes.
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IFB
A.K. Pickett, 2013-2014

Lecture 1: General introduction

General overview of course and analysis methods
Composite modelling methods for composites:
Micro-, meso- and macro-mechanics
Laminate analysis
Finite element analysis:
o Basic theory for Implicit, Non-linear and Explicit
o Structural analysis
o Crash and impact
o Preforming (draping and braiding)
o Infusion
Optimisation
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IFB
A.K. Pickett, 2013-2014

Location of lecture material
IFB
A.K. Pickett, 2013-2014

Overview of analysis methods
IFB
A.K. Pickett, 2013-2014

Simulation chain for composites
PROCESS
Injection
PROPERTIES
Draping
(Mapping or FE)
Forming
Infusion
Integration
DESIGN
Courtesy EADS CCR
Crash
simulation
Meso-scale
Stress Analysis
+ Optimisation
IFB
A.K. Pickett, 2013-2014

Simulation chain for composites

and typical analysis methods
Properties
Structural
analysis
Preforming
Infusion
Others
Micro-mechanics
FE - Stiffness
Draping
(mapping)
Filling (FE)
Optimisation
WiseTex (mesomechanics)
FE - Failure
Draping (FE)
FE - Fatigue
Laminate
analysis
FE
Crash/Impact
Braiding
Residual stresses
Laminate
analysis (maco6
mechanics
Process simulation
Etc
IFB
A.K. Pickett, 2013-2014

Lectures to be covered: The order will be vary (sorry)

Wk
Topic
Form
General introduction to Modelling

of composites performance and
manufacturing
Lecture +
Tutorial
Historical developments, Available

numerical methods, basic theory
Micro-mechanics
Lecture +
Tutorial
Basic theory for stiffness and failure

models
CADEC and
WISETEX
Composites design (1):

Simplified and Classical Laminate
Theory (CLT) Methods
Lecture +
Tutorial
Overview of composites design:

Simplified methods
CLT
Introduction to the LAP software
LAP (Laminate
Analysis Program)
software
Composites design (2): Failure

analysis
Lecture +
Tutorial
Failure Criteria and further

application of the LAP software
including failure analysis
LAP software
Implicit Finite Element Method:

Introduction
Lecture +
Tutorial
General introduction:
Basic Principles
Basic theory
1D beam elements
Tutorial examples

Introduction
Lecture +
Tutorial
1D/2D Stress analysis, pre and post

processing. Introduction to the
LUSAS (or SYSPLY) FE packages.
Visual Composites
FE package

Advanced elements
Lecture +
Tutorial
3D elements
Laminate type shell elements
Composite elements
Visual Composites
FE package

Advanced elements
Lecture +
Tutorial
Modelling methods
Material and composites failure
Visual Composites
FE package
IFB
Description
A.K. Pickett, 2013-2014

Wk
Software
Topic
Form

Advanced topics
Lecture
+
Tutorial
Advanced topics:
Buckling, Fatigue
Nonlinear analysis
Description
Software
Visual Composites
FE package

Composites analysis
Lecture
+
Tutorial
Theory and examples in

composites (1)
Visual Composites
FE package

Composites analysis
Lecture
+
Tutorial
Theory and examples in

composites (2)
Visual Composites
FE package
Implicit FE: Flow modelling (1)
Lecture
+
Tutorial
Theory for flow modelling and

introduction to PAM-RTM for resin
infusion simulation
PAM-RTM
Implicit FE: Flow modelling (2)
Lecture
+
Tutorial
Iso-thermal and non-isothermal

analysis and special features
PAM-RTM
Explicit Finite Element:

Impact/crash simulation of composites
Lecture
+
Tutorial
Introduction to the Explicit

method. Simple impact analysis for
metal and multiply composite shell
elements
PAM-CRASH
Explicit Finite Element:

Impact/crash simulation of composites
Lecture
+
Tutorial
Advanced analysis for composite

failure and delamination modelling
PAM-CRASH
Fabric draping simulation
Lecture
+
Tutorial
Theory and examples
QUIK-FORM /PAMFORM
IFB
A.K. Pickett, 2013-2014

First a few composites basics and terms
IFB
A.K. Pickett, 2013-2014

Fabrics: First fibers are brought together as Yarns (~Tows)

Carbon fibre on
a human hair
A creel used in a
weaving or braiding
machine for
fabrics/preforms
12k
48k
6k
6k
k = 1000
The fibres are brought together for yarns: Typically 3k, 6k, 12k, 24k or 48k are made.
6k- ~12k preferred for high
quality (aerospace) applications
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>12k Preferred for cost sensitive (cheaper)

manufacturing/automotive applications
Large tows allow fast layup of layers saves cost.

But are very difficult to infuse with resin >> lower properties and quality.
IFB
A.K. Pickett, 2013-2014

From fibres to Preforms
Fibres
Yarns
Fabrics
Resin can be added
at various stages as a
liquid or semi-solid
Preform
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IFB
A.K. Pickett, 2013-2014

Textile preforms
2D
1D
Some popular composites reinforcement types

UD tapes
We aves
Biaxial
woven
8 harness
satin
woven
NCF
Biaxial
Tri-axial
Braids
Biaxial
braid
Knitting
Weft
knit
Warp
knit
Tubular
braid
Orthogonal
interlock
3D braid
3D
Braids
Triaxial
braid
Throughthickness
angle
interlock
Weaves
Triaxial
woven
Lock
stitch
Stitching
Knitting
Multi-axial
warp knit
Stichbonded laid in
warp
Weft inserted warp

knit laid in warp
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IFB
A.K. Pickett, 2013-2014

Popular textile forms
Popular 2D and 3D textile

forms:
2D Weaving
Braiding
3D Weaving
Non Crimp Fabrics:

Low crimp high stiffness
Efficient manufacture
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IFB
A.K. Pickett, 2013-2014

Example manufacturing with textile composites
Raw fibres
Tow
(Thousands
of fibres)
3D preform
Braiding
Preform lay up
and assembly
Resin
Tool
Liquid infusion
process
The manufacturing steps to produce a textile composite part with LRI
PhD thesis (Cranfield) Michel Fouinneteau 2006
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IFB
A.K. Pickett, 2013-2014

Manufacturing methods and resin types vary greatly

The two main manufacturing methods:
1. Pre-preg technologies: Mix fibres
and resin at the materials stage
Toughened resins
Excellent fibre control
Shaping/
High
Vf ratios
preforming
Low
shapeability/integration
2. Infusion technologies: Mix fibres and

resin at the part manufacturing stage
Low viscosity resins (low

ductility)
Less control over fibres and Vf
Parts integration is possible
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IFB
A.K. Pickett, 2013-2014

Pre-preg composites: Manufacture of pre-preg plies
Pre-pregs are pre-impregnated plies of fibre and

resin systems.
Toughened (viscous) resins can be used.
Polymer may be
thermoplastic or
thermoset
Any fabric or
mat system
pressure
heat
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IFB
A.K. Pickett, 2013-2014

Infusion composites: E.G. Liquid Resin Infusion using the (VARI) process
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IFB
A.K. Pickett, 2013-2014

IFB - Institute for Aircraft Design, Stuttgart
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IFB
A.K. Pickett, 2013-2014

Simulation and analysis chain for

composites: Properties
Properties
Structural
analysis
Preforming
Infusion
Others
Micro-mechanics
FE - Stiffness
Draping
(mapping)
Filling (FE)
Optimisation
FE - Failure
Draping (FE)
FE - Fatigue
FE
Crash/Impact
Braiding
Residual stresses
Laminate
analysis (macomechanics
Etc
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IFB
A.K. Pickett, 2013-2014

Some notation: Scales usually used in composites analysis
ca. 7m
ca. 4-20+ mm
ca. meters
Multiscale modelling
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IFB
A.K. Pickett, 2013-2014

Notation and scales used for composites analysis (Micro- and Macro-)
Idealised
unit cell
Micro-mechanics: Idealisation
(fibre/matrix) at the unit cell level, can
be used to develop:
Micromechanical models for stiffness
Micromechanical models for failure
Macro-mechanics: Idealisation at
the ply level. Macro data (E1, E2, G12,
failure, ) can be determined via
micro-mechanical models or (more
likely) experimental testing of coupons
Note that unit

cells can also
refer to any
repetitive
volume in
2D/3D textiles
Laminate (laminate analysis): At

the laminate level. Summation of
individual plies to give laminate
stiffness and failure (Ex, Ey, Gxy,
failure)
Structural analysis using:
Classical solutions
Finite Element techniques
Twill 2*2 weave
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IFB
A.K. Pickett, 2013-2014

Micro-mechanics: Some theories for stiffness and strength will be covered

Object: The following model/arguments can be used to predict the four independent
variables of an orthotropic continuous fiber-ply:
Notation:
c
: composite
E1 - Modulus in the fiber direction (1)
m
: matrix
E2 - Modulus in the transverse fiber direction (2)
f
: fiber
12 - Poisson's ratio (12)
1
: fibre direction
G12 - Modulus in the direction (12)
2
: transverse direction
2
matrix
fibre
A= total area
Af= fibre area
matrix
Vf = Fibre volume ratio

Am= matrix area
Composite section
Idealisation (Representative Volume Element - RVE)

Plus numerous simplifications
E1 = E f V f + Em (1 V f )
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There are many models for other mechanical stiffness properties and failure
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IFB
A.K. Pickett, 2013-2014

Meso-mechanics: WiseTex code for stiffness prediction of textile composites

Starting point is the WiseTex software to define
architecture of textile composite fabrics
Fabric architecture is fed through to the

TexComp software; where, together
with Matrix mechanical data and Fibre
Volume Ratio the composite stiffness
data Ex, Ey, Gxy, etc., are computed
using:
1. Analytical methods
2. Or the geometry is used to construct
FE models for meso-analysis
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IFB
A.K. Pickett, 2013-2014

WiseTex: Meso-mechanics for stiffness prediction of textile composites

Starting point is the WiseTex software to define
architecture of textile composite fabrics
From matrix and yarn mechanical

data:
analytical
or homogenisation methods
are used to get composite Ex,
Ey, Gxy and other data.
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IFB
A.K. Pickett, 2013-2014

WiseTex: Example results for a braid

Manufacture and braid
modelling
Pattern
3D images
3D image
39 GPa x
Braided cone
Example results for the composite braid
37 GPa
y
16 GPa
Our experience to date:

It works well for bi-axials,
less so for tri-axials.
You must have good data.
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IFB
37 GPa
A.K. Pickett, 2013-2014

FE based Homogenisation methods for mechanical data: Current research

is looking to extend these techniques to damage and failure prediction
Representative Volume Element (RVE) represents material
point on higher level.
RVE volume average of a quantity is coupled to material
point.
= =
1
( x)dV
V
= =
1
( x)dV
V
Meso
model
Prediction of behaviour on high level by averaging small

level models.
= = C = C
Only 6 load cases to be solved to obtain full stiffness
matrix.
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RVE
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The technique is being extended to damage and failure
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IFB
A.K. Pickett, 2013-2014

Laminate analysis: We use the LAP software (but there are many others)
1. The technique requires the loadings on
an element of the structure to be
available. E.g. from:
Analytical calculations or formulae
Finite element analysis
Other methods (e.g. experimental test)
2. Analytical methods (usually in a software product) compute the
stiffness of the proposed laminate to give the [A,B,D] matrix.
3. From which stresses and strains (for
design) may be computed in each ply.
These can be plotted or checked against
failure criteria.
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IFB
N x A11
N
y A12
N xy A16
=
M x B11
M y B12

M xy B16
A12
A22
A26
B12
A16
A26
A66
B16
B11
B12
B16
D11
B12
B22
B26
D12
B22
B26
B26
B66
D12
D16
D22
D26
B16 xo

B26 yo
B66 xyo

D16 x
D26 y

D66 xy
A.K. Pickett, 2013-2014

Laminate analysis (continued)
We shall:
Go through the basic theory
Use software products:
1. The Laminate Analysis Program (LAP)
2. Other codes: CADEC, IFB and Darmstadt
Perform some simple examples:
1. For stress distributions
2. Plate deformations
3. For failure prediction and deformations
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A.K. Pickett, 2013-2014

IFB

composites: Structural analysis
Properties
Structural
analysis
Preforming
Infusion
Others
Micro-mechanics
FE - Stiffness
Draping
(mapping)
Filling (FE)
Optimisation
FE - Failure
Draping (FE)
FE - Fatigue
FE
Crash/Impact
Braiding
Residual stresses
Laminate
Etc
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A.K. Pickett, 2013-2014

IFB
Implicit method
Explicit method
k m f(t),x, x& , &x&
{P} = [K ]{ }
Load
Stiffness
Displacements
m&x& + cx& + kx = f(t)
m&x&n + kxn = fn (t)

Advantages:
Static problems (CPU fast if
in main memory)
Good for mildly non-linear
problems
(1) &x&n = m1(fn kxn )

(2) x& n+1/2 = x& n1/2 + tn&x&n
(3) x n +1 = x n + tn +1/2x& n +1/2
Advantages:
CPU efficient and robust
Very large model sizes possible
Highly non-linear materials
Large deformations
CPU efficient for contact problems
But there are plenty of other specialised methods

Finite difference, Boundary element, Finite strip.....
Meshless methods (SPH, FPM,....)
Eulearian
Specialised methods such as control volume for liquid infusion
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Etc, etc ......
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IFB
A.K. Pickett, 2013-2014

Typical Commercial Codes: Names, importance and applications

Implicit FE
Main codes
1. NASTRAN (large linear

structures)
2. ABAQUS (Non linear)
3. PAM-Implicit
4. MARC (Non linear)
5. ANSYS (general purpose)
6. IDEAS (meshing + FE)....
Literature
Industry
Car companies
Applications
1.
2.
3.
4.
5.
6.
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IFB
Explicit FE
1.
2.
3.
4.
5.
6.
Others
DYNA3D
PAMCRASH
PAMSTAMP
PAMFORM
RADIOSS
ABAQUS explicit
1.
2.
3.
4.
5.
6.
CFD codes
Vehicle dynamics
Welding simulation
Casting simulation
Vibro-acoustics
....
90%
10%
90%
10%
50%
50% (due to importance of crash/safety/etc..)
Stress Analysis
Stiffness
Eigenvalue (vibrations)
Flow problems; eg
Heat, Magnetism.
Fatigue
.
1.
2.
3.
4.
5.
Crash
Safety
Stamping
Biomechanics
..
A.K. Pickett, 2013-2014

FE examples: Typical and advanced applications
Simple (or complex) stress analysis

More advanced topics: e.g. biomechanics
vents
Injection point
Flow problems: eg temperature and (as

shown here) resin injection in RTM
Bird strike simulation with an SPH bird
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IFB
A.K. Pickett, 2013-2014

FE (composites) analysis
The FE method can analyse the full structure (not just a single element)
It is the only general method to analyse complex structures under multiaxial loading.
Special loading conditions could be fatigue, static, dynamic, thermal,
buckling, failure, impact, crash
We shall cover the basic theory and use:
1. PAM-CRASH implicit for (static/non-linear) analysis
2. PAM-CRASH explicit for dynamic (impact) loading
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IFB
A.K. Pickett, 2013-2014

Typical (Static) FE composites analysis (stress analysis with failure criteria)

Traditionally composites failure is treated using simple failure laws at the ply level. PAM-CRASH
has the most popular ones:
= Basic strength

Maximum stress/strain
Modified Puck
Quadratic criteria (TSAI-HILL/WU)
Hoffmann
User defined
Maximum
Stress Theory
Maximum
Strain Theory
Quadratic Failure
Criterion (Tsai-Wu)
eg. Maximum stress failure criterion in the orthotropic

coordinate system (1, 2, 3) = (X, Y, Z) is given by:
1 2 12 23 13
X ,Y , S , T ,U
computed
allowable
34
The

element is eliminated if the criteria is reached in one ply:

No account for laminate damage or strength degradation
No opportunity to separate failure modes
The models are controversial (see for example Hart-Smith and other publications) !
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IFB
A.K. Pickett, 2013-2014


composites: Structural analysis
(crash/impact)
Properties
Structural
analysis
Preforming
Infusion
Others
Micro-mechanics
FE - Stiffness
Draping
(mapping)
Filling (FE)
Optimisation
FE - Failure
Draping (FE)
FE - Fatigue
FE
Crash/Impact
Braiding
Residual stresses
Laminate
Etc
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IFB
A.K. Pickett, 2013-2014

Crash and impact simulation
Crash and impact simulation almost always use explicit Finite Element methods due
to large geometric and material non-linearities (+ contact). The main codes are:
1.
PAM-CRASH (we shall use this one)
2.
Dyna3D, Abaqus (explicit) and Radioss
Detailed analysis should use 3D solid models; but for practical analysis of large scale
structures it is usually necessary to resort to simplified shell models with (or without)
delamination modelling capabilities.
The following gives you some ideas of present capabilities for impact damage and
crash simulation. Typical important applications are aircraft Bird-strike and
composite car crash.
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A.K. Pickett, 2013-2014

IFB
Examples of composites damage

OR
Ply failure coupled with delamination

1. Inter-ply (delamination) damage due to excessive shear
or poissons ratio mismatch between adjacent plies
Fragmentation
2. Delamination is (probably) coupled with ply failure
Delamination sequence
X
Example: Dynamic axial
composite tube crushing
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A.K. Pickett, 2013-2014

IFB
A typical ply damage model

Three damage variables, d1, d2 and d12, characterise ply damage:
1. Axial (Fibre breakage):
E1 = E1o ( 1 - d1 )
2. Transverse (Matrix microcracking):
E2 = E2o ( 1 - d2 )
3. Shear (Fibre matrix debonding):
G12= G12o (1 - d12 )
E1
2
1
G12
Gd = Go (1 - d12 )
Go
12
23
22
E2
13
21
12
11
Ed = Eo (1 - d)
Fibre direction response
12
Diffused matrix
microcracking
due to
transverse
loading
22
12
Shear direction response
Model needed for

damage growth
Model needed for damage

and plasticity growth
11
Fibre/matrix
interface
debonding
due to
shear
loading
1
Fibre failure due

axial loading
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IFB
A.K. Pickett, 2013-2014

Impact and Crash: Delamination modelling

The so-called Arcan test can be used for
initial failure stress in an uncracked material
(no standardised test exists).
The Arcan test

and composite
specimen for
initial failure
stress
The standard DCB, ENF and MMB tests are

used for fracture toughness.
initiation
II
propagation
opening displacement
Cyclic loading
shear (Mode II)
Cyclic loading
compression response
(Mode I)
The DCB test

The ENF test
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A.K. Pickett, 2013-2014

Example: Plate impact with and without pre-loading

Steel frame
40000
UD-unloaded panel
UD-preloaded panel
35000
Composite panel
Loading tab
30000
25000
20000
15000
Damage
10000
5000
0
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
40000
30000
Exp unloaded panel
35000
Sim unloaded panel
30000
25000
Unloaded
20000
15000
Force [N]
35000
Force [N]
Delaminatio
n
40000
10000
Exp preloaded panel

Sim preloaded panel
Delamination
25000
20000
Preloaded
15000
10000
5000
5000
0
0
0,005
0,01
0,015
Time [s]
0,02
0,025
0,005
0,01
0,015
0,02
0,025
Time [s]
40
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IFB
A.K. Pickett, 2013-2014

State-of-the-Art simulation of birdstrike

Oblique high velocity impact
Composite plies with full delamination
modelling
Bonded joints at rib to skin connections
Metal leading edge
SPH model for bird impactor
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A.K. Pickett, 2013-2014

Example: Bird strike and debris impact

Brite-Euram HICAS project: Leading edge
(test and simulation)
Test DLR
Delamination and ply damage
PAM-CRASH simulation:
6 plies QI fabric with
delamination model and SPH
impactor
Simulation ESI
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A.K. Pickett, 2013-2014

Example models for the CAI test: Shell with delamination versus Solid only
Multi-layered shell model with 10 sublaminates representing 40 plies. Delamination
interfaces are set between the sub-laminates.
A full 3D solid model of the composite

impact (quarter symmetry).
Test setup for the

CAI test
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A.K. Pickett, 2013-2014

Example Results: For shell and solid model
SHELL MODEL: CPU

ca. 30 mins
CONTOUR PLOT
(SHEAR STRESSES 31 )
SOLID MODEL: CPU

ca. 6 hours
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A.K. Pickett, 2013-2014


composites: Preforming (draping)
Properties
Structural
analysis
Preforming
Infusion
Others
Micro-mechanics
FE - Stiffness
Draping
(mapping)
Filling (FE)
Optimisation
FE - Failure
Draping (FE)
FE - Fatigue
FE
Crash/Impact
Braiding
Residual stresses
Laminate
Etc
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IFB
A.K. Pickett, 2013-2014

Typical composites manufacturing (draping and infusion)
Resin Transfer
Moulding RTM
Pre-forming
Liquid Resin
Infusion LRI
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A.K. Pickett, 2013-2014

IFB
Fabric draping analysis: Comparison of methods

Kinematic mapping methods
Finite Element
methods
Kinematic
methods
FE methods
(macro-level)
FE methods
(meso-level)
LOW (OLD
1950+)
HIGH (NEW
2000+)
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A.K. Pickett, 2013-2014

IFB
Effort/complexity
Input requirements
Modelling effort
CPU costs
Accuracy
Fabic forming (Draping)
Purpose: To predict if a dry (or impregnated) fabric fits to a given shape.

And to predict possible imperfections (wrinkling, over compactions)
Two main computational methods are available:

1. Mapping methods (very approximate).
2. Detailed Finite Element methods (usually based on explicit FE codes and
adopted from more popular metal stamping codes).
The main codes are:

1. Mapping methods: PAM-QUIKFORM (we shall use this), FibreSim and several
others.
2. FE methods: PAM-FORM (we shall use this), but also DYNA3D and Abaqus
could (probably) be used.
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A.K. Pickett, 2013-2014

Mapping methods: Fabric deformations computed using the pin

joint model
Main assumptions:
L1
Fibres are inextensible.

A
L2
i-1, j
a
b
i, j-1
i, j
Trellis deformations only via shear (the

fibre crossovers act as pin joints).
Initial starting point (eg A) and initial
fibre direction (warp L1, weft L2) must
be assumed to get the process started.
surface F(x ij , y ij , z ij )
A
Uses simple mathematics:

First the two geodesic lines L1 and L2 are
developed then new points xij are found from
old points xi-1, j and xi , j-1.
(x ij x i 1, j ) 2 + (y ij y i 1, j ) 2 + (z ij z i 1, j ) 2 = a 2
(x ij x i , j1 ) 2 + (y ij y i , j1 ) 2 + (z ij z i, j1 ) 2 = b 2
L2
L1
EG ESI Product QUIK-FORM
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Example industrial application using the kinematic mapping method
Draping Strategy 1
Seed point
Draping Strategy 2
Seed line
Catia V5 example study (using PAM-QUIKFORM):

Two variations of seed lines and their influence on the fabric shear distributions
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From Crash to Metal and Fabric Forming

Brite-Euram Project,
"Investigation for an Innovative
Methodology for Sheet Metal
Stamping", 1989 - 1992.
First (?) simple

metal stamping
simulation ca. 1988
PAM-STAMP: Metal stamping

and sheet forming
Typical industrial
metal stamping
Brite-Euram Project:
"Industrial Press Forming of
Continuous Fibre Reinforced
Thermoplastic Sheets and the
Development of Numerical
Simulation Methods", 19921996.
PAM-FORM: Fabric
and composite draping
Fabric (Carpet)
stamping ca. 2000
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Numerical simulation of preforming
52
Courtesy Eurocopter (ESI

Technical Forum 2010)
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Example NCF Finite Element drape simulation of an automotive floor

pan (courtesy ESI and Sotira)
Some features of the FE
model:
Blankholder
NCF fabric
Shell elements for plies

with interface stitching for
NCF
Lower die
Punch
Rigid body tooling (note

the meshing for accurate
geometry)
Pressure blank-holders
correctly modelled
Contacts defined between
fabrics and tooling / blankholders
Tooling is velocity driven
with final pressure loads
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composites: Preforming (braiding)
Properties
Structural
analysis
Preforming
Infusion
Others
Micro-mechanics
FE - Stiffness
Draping
(mapping)
Filling (FE)
Optimisation
FE - Failure
Draping (FE)
FE - Fatigue
FE
Crash/Impact
Braiding
Residual stresses
Laminate
54
Etc
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Braiding: The machine and FE modelling

Braiding
ring
Braiding
mandrel
Braiding takeup direction
Standing yarns
Yarn paths
Braiding yarns
Bobbin elements
Models typically 50,000+

elements.
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CPU: hrs to days on high end

PCs.
A.K. Pickett, 2013-2014

2D braiding: Examples for single layer and overbraiding
Example: Tri-axial 176 axis and off-axis yarns

Example: Overbraiding for thick preforms
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Braiding: The machine and FE modelling

Overbraidin
g 3-layers
Extracted
yarn model
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Structural meso-modelling: Analysis results

Torsion Moment@10
Test
300 kNmm
Simulation
283 KNmm
Linear FE
analysis
Test
Principle stresses matrix
(GPa)
Yarn forces
(kN)
Ongoing work:
Failure/max load prediction

and (maybe) crash
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composites: Infusion
Properties
Structural
analysis
Preforming
Infusion
Others
Micro-mechanics
FE - Stiffness
Draping
(mapping)
Filling (FE)
Optimisation
FE - Failure
Draping (FE)
FE - Fatigue
FE
Crash/Impact
Braiding
Residual stresses
Laminate
Etc
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Typical composites manufacturing (draping and infusion)
Resin Transfer
Moulding RTM
Pre-forming
Liquid Resin
Infusion LRI
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Vacuum bagging process and filling (infusion)

Styrofoam
Flow media
Peel ply
Styrofoam
Vacuum
bagging film
Fabric
To vacuum pump
Peel ply
Flow media
Mould with release agent
Sealant
tape
Different layers
Final 61
part
Infusion
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Bagging film
A.K. Pickett, 2013-2014

Basic flow model: Darcys Law
resin
inlet
m/s
section A
resin
outlet
m3/s
m2
Pa
m2
Pas
K : permeability (m2)
: resin viscosity (Pa.s)
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vent
Example RTM injection: Process and simulation
Example for end injection

racers
START
injection
INTERMEDIATE
Potential
dry spots
Experimental setup
FINAL
Example for central injection
vents
Final part
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injection
PAM-RTM Simulation
A.K. Pickett, 2013-2014

Composites infusion (flow simulation)
Finite Element methods for flow problems:Typically these are heat and fluid
flow through a medium.
We shall concentrate of liquid fluid flow (infusion) through composite fabrics

with the code PAM-RTM.
Other infusion codes are:

RTM-WORX (commercial for mostly 2D, 2.5D analysis)
LIMS (US academic code)
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composites: Optimisation
Properties
Structural
analysis
Preforming
Infusion
Others
Micro-mechanics
FE - Stiffness
Draping
(mapping)
Filling (FE)
Optimisation
FE - Failure
Draping (FE)
FE - Fatigue
FE
Crash/Impact
Braiding
Residual stresses
Laminate
Etc
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Optimisation: Used for optimisation of lay-ups, stitching and tow

placement
1.Gradient based methods used for

stitch placement.
2.Genetic based methods used for
fibre angles and tow placement.
Local
minimums
Object Function
Global
minimum
Design variables
Example applications
1. Placement of tufting
2. Fibre directions
3. Tow fibre placement
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Optimisation methods and the Genetic algorithm

Essentially two optimisation methods are most commonly used:
1. Search and gradient methods try to bound the optimum
(minimum) and then chase down its value:
Local minimum
Global minimum
Can be fast with minimum number of calls (solutions)

But can easily get trapped at local minimum (and not
the global minimum)
2. Evolutionary (Genetic) methods use evolutionary

concepts to create initial and subsequent (improved)
populations:
A random first population
Require a large number of calls (solutions) for each

population.
But selection of the fittest solutions for
subsequent populations can overcome difficulties
of local minimums.
A subsequent
improved population
Partnering best solutions, crossover and mutation

operations lead to improved populations.
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Tailored Fibre Placement
Modelling tow reinforced composites

Conventional multilayered shell element :
Elastic
Possible damage and failure
Link elements:
Elastic with possible failure
Stickkopf
Beam or bar elements:

Elastic with possible failure
Roving
Neadle
Head movement
Zig-zag stitch
Base material
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Optimisation methodology and example results

Generic optimisation methods used to
determine best tow layout for
minimum stresses in base composite
fibre max
0.280 kN/mm2
fibre max
0.153 kN/mm2
3,4,1
3,4,3
5
3,5,4,2
3,3,3,4
+45% strength increase
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Optimisation Tutorial
Various optimisation techniques
Various objective functions
Various design parameters
Why its not that easy!
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IFB

A.K. Pickett, 2013-2014

A.K. Pickett, 2013-2014

Lecture 1: General introduction

A.K. Pickett, 2013-2014

Location of lecture material

A.K. Pickett, 2013-2014

Overview of analysis methods

A.K. Pickett, 2013-2014

Simulation chain for composites

A.K. Pickett, 2013-2014

Simulation chain for composites

A.K. Pickett, 2013-2014

Lectures to be covered: The order will be vary (sorry)

General introduction to Modelling

Historical developments, Available

Basic theory for stiffness and failure

Composites design (1):

Overview of composites design:

Composites design (2): Failure

Failure Criteria and further

Implicit Finite Element Method:

Implicit Finite Element Method:

1D/2D Stress analysis, pre and post

Implicit Finite Element Method:

Implicit Finite Element Method:

A.K. Pickett, 2013-2014

Implicit Finite Element Method:

Implicit Finite Element Method:

Theory and examples in

Implicit Finite Element Method:

Theory and examples in

Implicit FE: Flow modelling (1)

Theory for flow modelling and

Implicit FE: Flow modelling (2)

Iso-thermal and non-isothermal

Explicit Finite Element:

Introduction to the Explicit

Explicit Finite Element:

Advanced analysis for composite

Fabric draping simulation

Theory and examples

A.K. Pickett, 2013-2014

First a few composites basics and terms

A.K. Pickett, 2013-2014

Fabrics: First fibers are brought together as Yarns (~Tows)

>12k Preferred for cost sensitive (cheaper)

Large tows allow fast layup of layers saves cost.

A.K. Pickett, 2013-2014

From fibres to Preforms

A.K. Pickett, 2013-2014

Some popular composites reinforcement types

Weft inserted warp

A.K. Pickett, 2013-2014

Popular textile forms

Popular 2D and 3D textile

Non Crimp Fabrics:

A.K. Pickett, 2013-2014

Example manufacturing with textile composites

The manufacturing steps to produce a textile composite part with LRI

PhD thesis (Cranfield) Michel Fouinneteau 2006

A.K. Pickett, 2013-2014

Manufacturing methods and resin types vary greatly

2. Infusion technologies: Mix fibres and