MSC Confidential
MSC Virtual Product Development Solution In Aeronautic Industry State of the Art of Composites Modeling / Simulation EMEA Aerospace Center of Competence (May 2009)
MSC Confidential
Composites Structures: Satellites Applications
Intelsat VII
Hubble Space Telescope
Mars Global Surveyor
Mars Global Surveyor 3/11/2009
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MSC Confidential
Composites Structures: Launchers Applications
Ariane 5 Evolution
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MSC Confidential
Composites Structures: Civil Airplanes Applications
Boeing 787
Airbus A350
Bombardier LearJet 85
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MSC Confidential
Composites Structures: Military Airplanes Applications
Airbus A400M
F-111 3/11/2009
Lockheed Martin F-35
Eurofighter Typhoon 5
MSC Confidential
Composites Structures: Air Missiles Applications
Joint Air to Surface Standoff Missile (JASSM) Composite Body
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MSC Confidential
Composites Structures: Helicopters Applications
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MSC Confidential
The progressive use of Composite on Commercial Aircraft
In black the composite parts
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MSC Confidential
Introduction to Composites
• A COMPOSITE MATERIAL is a macroscopic combination of two or more distinct materials, having a recognizable interface between them. • The resulting composite material has a balance of structural properties that is superior to either constituent material alone. • "Composite material" commonly means arrangements of fibres of a resistant material (reinforcing material) which are embedded in a material with a much lower strength (matrix), and stiffness.
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MSC Confidential
Products • SimXpert the fully integrated multidiscipline simulation environment. Integrated with MSC's advanced multidiscipline (MD) solver technologies. • MD Nastran the MSC's multidiscipline solver (MD) to ensure the highest levels of accuracy on composite structures • CATIA V5 to capture a truly complete digital product definition. • FiberSIM goes beyond CAD, enables you to ‘work how you think’ when designing innovative composite structures
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MSC Confidential
SimX Laminate Definition and Verification
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MSC Confidential
SimX Laminate Composite Editor
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MSC Confidential
SimX Verify Tools
Verify the Material Coordinate System to determine the 0 direction
Verify the element normals to determine the location of ply 1
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MSC Confidential
SimX Verify Tools
Plot of ply angles and associated plies
Plot of each ply’s relative thickness
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MSC Confidential
SimEnterprise Composite WorkFlow • Streamline composite product development
Design
• Design • Verification • Connect Design and Analysis Common definition
Analysis
Connect
• Optimization
• Zones • Plies
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MSC Confidential
SimX FiberSim Integration
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MSC Confidential
FiberSim Connect • FiberSIM/SimXpert interoperability – SimXpert does FEM model definitions (mesh, LBC, analysis setup, ..) – FiberSIM does PCOMP property calculation from zones and layup definition
• Composite property verification in SimXpert • Analysis ready full access to MD Nastran composite analysis SimXpert
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MSC Confidential
Composite Interface • FiberSim interface • Interface for users to automatically generate corresponding PCOMP entries based on the zones & layup information previously defined in FiberSIM • All user interactions related to composite definitions will be performed in the standalone CATIA/FiberSIM environment • All FEM model definitions (mesh, LBC, analysis setup, ..) will be done in core SimXpert
• Values • Instant access to zone & layup info currently available in CATIAFiberSIM environment • Composite property definition is calculated with SimXpert generated mesh data • Analysis ready • Completely open to all SimXpert MD solutions
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MSC Confidential
FiberSim: FiberSim: Zone Based Design
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MSC Confidential
FiberSim: Laminate Zone Definition
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MSC Confidential
FiberSim: Laminate Zone Definition
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MSC Confidential
Import zone properties Revision 1
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MSC Confidential
SimXpert: Mesh Geometry and export Element information to FiberSim
Next Material ID Next PCOMP ID
Element 1 1 1 -1.27940e+001 2.69369e+002 -3.32930e+002 3.50059e-002 -5.28049e-001 8.48492e-001 1.74349e-004 8.49016e-001 5.28367e-001 2 -1.26829e+001 2.47728e+002 -3.46025e+002 3.32297e-002 -5.03280e-001 8.63484e-001 2.28378e-004 8.63965e-001 5.03552e-001 3 1.26207e+001 2.69648e+002 -3.32769e+002 -3.04822e-002 -5.28117e-001 8.48624e-001 -1.74349e-004 -8.49016e-001 -5.28367e-001
Element ID
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Centroid
Normal
Node 1-2 Direction
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MSC Confidential
FiberSim: PCOMP Evaluation • FiberSIM PCOMP Evaluation – Property (Material and PCOMP) file and Assignment file – The Property file is a Nastran BDF containing MAT and PCOMP data
Element ID
Material Angle (Radians) PCOMP ID
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MSC Confidential
SimXpert: Automatically PCOMP created by FiberSim
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MSC Confidential
CAE-CAD iterations Modify the layup in SimX Revision 2
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MSC Confidential
Modify the layup in SimX for Zone/PCOMP 6
Add 2 plies +45 and +45 to the zones 6 and export to FiberSIM (revision2) 3/11/2009
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MSC Confidential
FiberSIM Import Modified LayUp in SimX
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MSC Confidential
Validation
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MSC Confidential
FiberSIM Draping Simulation
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MSC Confidential
SimXpert FiberSim Connect Advantages • Eliminate errors and inefficiencies of translating composite data between design and analysis • Define or update properties in Design or Analysis • Use common definitions & methods for composite properties • Native CAD update (SimX & FiberSIM share common native Catia V5rxx models )
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MSC Confidential
Access to MD Nastran Advanced Composite Solution
Extensive MD content now – Structures workspace Linear Contact Non Linear Contact Progressive Failure Analysis Adv. Progressive Failure Analysis Fracture Mechanics and Delamination: VCCT (Virtual Crack Closure Tecnique) • Delamination: Cohesive Zone Modeling • Delamination: Breaking glued contact • 3D Composites • • • • •
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MSC Confidential
Progressive Failure Analysis
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MSC Confidential
Progressive failure Analysis
• The progressive failure analysis is a method developed for predicting the nonlinear response and failure of laminated composite structures from initial loading to final failure. • Failure is indicated by the failure criteria used. • When failure occurs, the FEM element stiffness is degraded. • The material will not heal; the damaged elements keep the degraded properties after unloading. • Investigations of effect of overloads on composite structures
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MSC Confidential
Progressive failure Analysis •
Once the strains and stresses are known throughout the composite laminate, a failure theory is used to detect failures for each lamina at a given load level, when failure index is larger than one, degrade material stiffnesses
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Available for existing criteria (maximum stress etc): Hill Tsai-Wu Hoffman
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Available for NEW criteria: These failure theory are able to predict the failure load and also the mode of failure such as fiber failure and/or matrix failure. Puck Hashin Hashin-tape Hashin-fabric
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MSC Confidential
Progressive failure • How does failure affect the different material moduli ? • Assume – 1-direction is fiber direction – 2-direction is matrix direction in the plane of the ply – 3-direction is through the ply thickness
• Fiber failure – Reduce E1 and E3
• Matrix failure – Reduce E2, G12, G23 and G31
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MSC Confidential
Progressive failure
Progressive Failure Analysis of a Plate with Hole 3/11/2009
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MSC Confidential
Adv. Progressive Failure Analysis
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MSC Confidential
Genoa Integration: Micromechanical Composite Material Definition •
GENOA is an integrated structural analysis software suite to predict strength, reliability and durability of structural composite components
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The use of material library from Genoa is available in MD Nastran.
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Based on constituent properties, Fiber and Matrix, evaluates the structural and material response including degradation of material properties due to initiation and growth of damage.
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Over 20 Micro Mechanical Failure Criteria Failure Criteria available with MD Nastran Adv. PFA analysis
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MSC Confidential
Adv. Progressive Failure Analysis
• Analysis is set up and post processed in SimXpert environment. • It is a fully integrated solution, Genoa material stiffness evaluation is in the increment loop, MD Nastran calls Genoa for each element, damage reflected as modified stiffness. • At each individual load step, the stresses and strains, obtained through the composite microstress analysis, are checked according to distinct failure criteria.
3D Fiber
2D Woven Vehicle
Component FEM
Laminate
Traditional FEM stops here GENOA goes down to micro-scale
Micro-Scale FEM results carried down to micro scale Sliced unit cell Reduced properties propagated up to vehicle scale
Lamina
Unit cell at node
Takes full advantage of MD Nastran capabilities and Genoa material library 3/11/2009
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MSC Confidential
Adv. Progressive Failure Analysis Modeling composite materials at constituent level
• Typically failure is assessed at laminate/lamina scales • But failure has its source at micro scale fiber/matrix • Failure is indicated by the Micro Mechanical failure criteria selected • When failure occurs degrade Fiber and Matrix stiffnesses
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MSC Confidential
Adv. Progressive Failure Analysis Modeling composite materials at Ply Level
• Failure is indicated by the Micro Mechanical failure criteria selected • With lamina or ply properties as input: the ply stress is compared to the strength limit of the ply directly without going through the constituents and fiber of matrix volume ratios. • When failure occurs degrade plies properties
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MSC Confidential
Modeling composite materials: Composite architectures
• UD tape • Woven fiber • 3-D braided
• Using fiber angles and volume fractions in both in-plane and out-of-plane directions 3/11/2009
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MSC Confidential
Modeling composite materials: HoneyComb • Predicts damage resistance, durability and damage tolerance of honeycomb composite structures • Uses an advanced theory to predict the various failure mechanisms in honeycomb composite structures • Cell geometry definition
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MSC Confidential
Failure theories for Adv. Progressive Failure Analysis
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Longitudinal tension
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Fiber micro-buckling
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Longitudinal compression
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Tsai-Wu theory
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Transverse tension
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Hill theory
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Transverse compression
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Hoffman theory
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Normal tension
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Maximum stresses theory
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Normal compression
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Maximum strain theory
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In-plane shear
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First strain invariant failure
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Transverse normal shear
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Longitudinal normal shear
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Inter-ply relative rotation
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Modified distortion energy
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Fiber crashing
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Inter-ply relative rotation
theory
Honeycomb failure modes recognized
Wrinkling 3/11/2009
Crimping
Dimpling 45
MSC Confidential
Genoa Integration: Modeling composite materials at constituent Level Fusolage Stiffened Panel Adv. Progressive Failure Analysis with Micromecanical material definition (Fiber / Matrix)
Stress Strain
Micromechanical Damage Index
Glued Contact between frames and panel 3/11/2009
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MSC Confidential
3D Composites
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MSC Confidential
3D Composites • Needed for detailed out-of plane stress recovery
NAFEMS: Three-point bending test 3/11/2009
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MSC Confidential
3D Composites Detailed out-of plane stress recovery
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MSC Confidential
Fracture Mechanics and Delamination
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MSC Confidential
Delamination Introduction • Delamination is one of the main failure mechanisms in laminated composites • Possible reasons for delamination are: Manufacturing defects and stress Gradients near geometric discontinuities (like stiffener terminations and bolted joints)
• Delamination may result in local failure or even a significant loss of the structural integrity • Three different approach available: VCCT CZM Breaking glued contact
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MSC Confidential
Fracture Mechanichs with VCCT (Virtual Crack Closure Tecnique) • The VCCT is the fracture mechanics approach for studying delamination and crack initiation and growth. • It is used for calculating the energy release rate of single or multiple cracks. The results will be obtained for each crack separately. Each crack consists of a crack tip grid for shells and a crack front for solids.
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MSC Confidential
Delamination of NASA Test Specimen (Virtual Crack Closure Tecnique)
VCCT
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Delamination of NASA Test Specimen (Virtual Crack Closure Tecnique)
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Delamination: Cohesive Zone Modeling (CZM) • The interface elements can be modeled between 2D and 3D structural finite elements: • The cohesive material models are defined in terms of relative displacements (between the top and bottom edges/faces) versus tractions
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MSC Confidential
Delamination of NASA Test Specimen Cohesive Zone Modeling (CZM)
Cohesive Zone Modeling
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MSC Confidential
Delamination of NASA Test Specimen Cohesive Zone Modeling (CZM)
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MSC Confidential
Delamination: Breaking glued contact • Release glued contact when stress criteria is satisfied:
• Use contact normal and tangential stress • After break, do regular contact with friction and separation
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MSC Confidential
Delamination: Breaking glued contact
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Computational Performance • Fast Shell Integration PCOMPF Card • Composite shell elements with a large number of layers may need a large amount of CPU time and memory because of: – the integration in thickness direction to determine the generalized stress-strain law and the generalized stresses – storage of stresses and strains on a layer basis
• Results should be the same as with standard integration
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MSC Confidential
Virtual Product Development http://www.mscsoftware.com/
Armando Mete Technical Consultant EMEA Center of Competence Aerospace +39 06 42272249 +39 335 7851319
[email protected]
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