6 - ALTAIR ID - 23!10!14 - Composites - Diffusion

InnovDay Composites
Simuler les composites et leur mise en forme

avec HyperWorks
Pierre-Christophe MASSON
Innovation Intelligence 23 Octobre 2014
Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
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Altair has a unique offering

Composite Simulations
with HyperWorks
Composites Overview within HyperWorks
CAD & Mfg Interoperability
HyperMesh
Modern Ply Based
Composites Pre-Processing
HyperMesh Realizations
Visualizations translate Ply Based Models to
Visually Verify the Math Model Solver Zone Based Models
OptiStruct/RADIOSS
Composites Design Optimization
& Analysis

HyperWorks
HyperView
Composites Post-Processing
& Failure Analysis
HyperWorks Partners
Detailed Composite Material Modeling
& Structural Modeling
Composite Zone-Based Modeling (PCOMP)
position PCOMP1 PCOMP2 PCOMP3 PCOMP4 PCOMP5
1 Ply 0 Ply 90 Ply 45 Ply 90 Ply 0
2 Ply 0 Ply 0 Ply 90 Ply 0 Ply 0
3 Ply 0 Ply 0 Ply 0
4 Ply 90 Ply 0 Ply 90
5 Ply 90
6 Ply 45
Composite Ply-Based Modeling (PCOMPP)
PLY 1 Ply 45
PLY 2 Ply 90
Laminate 1
PLY 3 Ply 0
PLY 4 Ply 0
PLY 5 Ply 90
PLY 6 Ply 45
Composites Technology - Ply Based Modeling
A Composite Part is made up of n Plies and One Laminate
No Data Duplication
Direct Relationship to the Manufacturing Process
Ply Based Modeling Process

P1 45
Define Ply Shapes and Related Ply Data P2 90
P3 -45
Define Stacking Sequences P4 0
P5 -
45
P6 90
Design Change Requires only 1 Update P7 45
Stack Table
Ply Mat Thk Theta
P7 M1 0.01 45
P6 M1 0.01 90
P5 M1 0.01 -45
P4 M1 0.01 0
P3 M1 0.01 -45
P2 M1 0.01 90
P1 M1 0.01 45
Ply Based Modeling 3D Visualizations
3D Representation of Traditional 1D & 2D Representations
Visually Verify Engineering Data Associated with a Math Model
Traditional 1D & 2D 3D Representation with

3D Representation
Representation Composite Layers
Composites: Model Review and Realization
Ply to zone based model

realization
Automatic property creation
Conversion of ply based into
zone based model
Ply based model
Supported interfaces :
OptiStruct (direct support) Laminate realization
Nastran
Abaqus
Ansys
LS-Dyna (13.0)
RADIOSS & OptiStruct have

Embedded Composite Ply
Based Modeling in the Solver,
no need to Realize Creation of equivalent properties
Composite Structure Analysis using RADIOSS
Failure Modeling wrt Ballistic impact Bird Strike (Planes, Helicopters)
Race Cars design (DALLARA) Helicopter Cabin design

(EUROCOPTER)
Composite Forming
with HyperWorks
Innovation Intelligence
Introduction/Context/History
1) To provide a simple solution which gives tendencies
Simple set up with reduced numbers of input data
Accurate enough to give main tendencies
Fast enough to be used in an industrial context
2) Seamless crash model initialization with forming results
Batch mode
Manufacturing
+
Mapping
Composite Forming with HyperWorks
Modeling approaches
B-Pillar model example
Hyperform updates
Mapping
Meso to Macro multiscale approach
Draping
Conclusions
Two modeling approaches
Sandwich
Sandwichapproach
approach Independant Layersapproach
Independant Layers approach
One part of shell elements with N parts of shell elements

One composite material One material law per layer
One multi-layers property One property per layer
Contact between layers
To give tendancies
No sliding between layers More accurate
No coupling between warp and weft Sliding between layers
directions Coupling between warp and weft
directions
s11 ~
s11
Modeling approaches
Hyperform updates
Mapping
Draping
Conclusions
B-Pillar model: Material description
Glass fibers (70%) Resin (30%)
UD
E11 = 70%Eglass = 50400 MPa r = 3/7*rresin = 1.09*10-09 Mg/mm

E22 = 0.3 MPa
E33 = 50 MPa Go = 0.50 MPa Gs= Go Gl
Gl = 0.35 MPa = Gs /
Woven fabric
= 5000 s = 30 Pa*s
E22 = E11 Soften heated resin parameters
E33 = 50 Mpa
Initial shear angle 90
4 layers of UD: 0, 45, 90, -45

B-Pillar model: Kinematic
Sandwich approach
The Die is going down

to the binder
The Die is going down

to the punch

Sandwich approach: blank shape during forming

Independant Layers approach: blank end shape
Sliding effect between layers
Due to fiber orientations 0, 45, 90, -45 regarding X axis, the

behavior during stamping is different for each layer
B-Pillar model: blank end shape
Sandwich approach
The same compression,
tension and shear zones
can be observed
Wrinkles may also occur

B-Pillar model: Fiber Orientations

Sandwich approach (0 layer)
Fiber orientations are consistent

with blank shape

(layers 45 & 90)
Modeling approaches
Hyperform updates
Mapping
Draping
Conclusions
HyperForm 13.0 updates for composite forming
Composite available thru User Process tree browser settings
Type of modeling selection popup
Then HF sets up automatically

Contact interfaces tools and blank(s)
Contact interface between layers
Post-treatment cards in engine
HyperForm 13.0 updates for composite forming
User Process Tree browser User Process Tree browser

organisation for the organisation for the
sandwich approach independant layers approach
Plies definiton
Layers are treated as
independant blanks
Modeling approaches
Hyperform updates
Mapping
Draping
Conclusions
Mapping algorithm
Forming side Crash side
??
Mapping
Target integration points

Stamping integration points
Fiber directions mapping
NEW in HC 12.113
First & Second fiber directions

can be mapped for each layer
Angle between fibers is shown as
iso-values while displaying the
second direction as vector
Mapping for independant layers approach
Target part
Composite
NEW in HC 12.113
layers
4 layers of shell elements (MID 58, PID 16) on 1 layer of shell elements
(MAT25) associated with a 4 layer sandwitch property (PROP11)
Woven fabric forming history influence on crash
Model initialized with fiber

Reference model
directions from forming stage
Modeling approaches
Hyperform updates
Mapping
Draping
Conclusions
Meso-scopic scale modeling
Angle ~90
Strip of shells Angle < 50
E11 >> E22, E33
Contact interface between

fibers
Coupling from meso to macro thru mapping

Model to map and Target mesh
Target part after mapping
Angle < 55
Re-zoning according to an angle
criterion of 55
E = 70%E, G = 70%G etc
Second direction after mapping: angle with the first direction

Meso-scopic scale approach: improvements in 13.110
Volume of fibers
Mapping
Shear angle
Rezoned part
Rezoning Criteria
Rezoning
Using a Mesoscale approach within a Macroscale modeling

The maximum shear area is modeled at mesoscopic scale
Displacements
Modeling approaches
Hyperform updates
Mapping
Draping
Conclusions
Drape Estimator for Composite Fibers
Calculate
Draping angles
Thickness variation
Interfaces
OptiStruct
Nastran
HM Drape Estimator (white) versus competition (red)

Drape Estimator for Composite Fibers
Final part geometry OneStep result : flattened shape
OneStep
Fiber directions
Final part initialised with Material/Fiber directions defined on

Material/fiber directions the flat reference shape
Modeling approaches
Hyperform updates
Mapping
Draping
Conclusions
Conclusions
Several works and studies around composite forming with Radioss
Reduced input data, simple set up, reasonably fast and accurate
Different scales modeling approaches depending on the expected results
Influence of forming results on crash simulation results has been shown
Mapping with re-zoning allows to take into account material degradation
Mapping compatible with sandwitch and multi-layers modeling
Validation is in progress
Perspectives
To validate with benchmarks and experimental comparisons
To develop a dual-phase material to model cool and warm resin
To validate and compare draping approach with other methods
To continue to use mesoscopic modeling thru multi-scale coupling or for
macroscopic modeling validation

Merci de votre attention !
pcmasson@altair.com

6 - ALTAIR ID - 23!10!14 - Composites - Diffusion

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InnovDay Composites

Simuler les composites et leur mise en forme

We Work with Some of the Best

Automotive Aerospace Heavy Equipment Government

5,000 customers worldwide

All Across the Globe

45+ offices in 22 countries on

Through A Unique Blend of Software and Services

Altair has a unique offering

Composites Overview within HyperWorks

CAD & Mfg Interoperability

Composite Zone-Based Modeling (PCOMP)

position PCOMP1 PCOMP2 PCOMP3 PCOMP4 PCOMP5

1 Ply 0 Ply 90 Ply 45 Ply 90 Ply 0

2 Ply 0 Ply 0 Ply 90 Ply 0 Ply 0

3 Ply 0 Ply 0 Ply 0

4 Ply 90 Ply 0 Ply 90

Composite Ply-Based Modeling (PCOMPP)

Composites Technology - Ply Based Modeling

A Composite Part is made up of n Plies and One Laminate

Direct Relationship to the Manufacturing Process

Ply Based Modeling Process

Ply Based Modeling 3D Visualizations

3D Representation of Traditional 1D & 2D Representations

Visually Verify Engineering Data Associated with a Math Model

Traditional 1D & 2D 3D Representation with

Composites: Model Review and Realization

Ply to zone based model

Ply based model

RADIOSS & OptiStruct have

Composite Structure Analysis using RADIOSS

Failure Modeling wrt Ballistic impact Bird Strike (Planes, Helicopters)

Race Cars design (DALLARA) Helicopter Cabin design

1) To provide a simple solution which gives tendencies

Simple set up with reduced numbers of input data

Accurate enough to give main tendencies

Fast enough to be used in an industrial context

2) Seamless crash model initialization with forming results

B-Pillar model example

Meso to Macro multiscale approach

Two modeling approaches

One part of shell elements with N parts of shell elements

Meso to Macro multiscale approach

B-Pillar model: Material description

Glass fibers (70%) Resin (30%)

E11 = 70%Eglass = 50400 MPa r = 3/7*rresin = 1.09*10-09 Mg/mm

4 layers of UD: 0, 45, 90, -45

B-Pillar model: Kinematic

The Die is going down

The Die is going down

Independant Layers approach

Sandwich approach: blank shape during forming

Independant Layers approach: blank end shape

Sliding effect between layers

Due to fiber orientations 0, 45, 90, -45 regarding X axis, the

B-Pillar model: blank end shape

Wrinkles may also occur

Independant Layers approach

B-Pillar model: Fiber Orientations

Fiber orientations are consistent

Independant Layers approach

Meso to Macro multiscale approach

HyperForm 13.0 updates for composite forming

E11 = 70%Eglass = 50400 MPa r = 3/7rresin = 1.0910-09 Mg/mm