Transcript Presentation Title Arial 36

Evolving Composites Simulation
Requirements and Solutions
John Klintworth
MSC.Software Ltd.
Industry Trends
• Lower Carbon Fibre Costs
• Sheet Material Replacing Random Fibres
• Heavier Sheet Reinforcement Weights
– Fewer Plies for Required Performance
• New Markets, e.g. Automotive, Energy
BUT:
• Manufacturing Difficulties
– Need more manufacturing simulation
• Less Redundant Material
– Need more structural simulation
2
Development Process
Aero. Shape
Simulate
Simulate
Simulate
Zone Layup
Ply Layup
Ply Details
Simulate
Certification
Manufacture
feedback loop ...
OK!
3
Aerospace
• Wheel cover
• >100 Plies modelled in
CAD
• Transferred to CAE
automatically
• Benefits:
– Correlation between CAD
and CAE
– Verification and failure
tools in CAE
4
Motorsport
• Monocoque
• > 1000 Plies, > 100K
elements
• Quick turnaround
• Benefits:
–
–
–
–
5
Rapid modification
Manufacturing link
Failure analysis
Crash model
Automotive
•
•
•
•
Floorpan
Cheap, heavy fabrics
Manufacturing critical
Benefits:
– Predict producibility
rapidly
– Account for stiffness and
strength of sheared
material
6
Marine
•
•
•
•
America’s Cup Yacht
High performance
Variable loading
Benefits:
–
–
–
–
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Ply based model
Automated generation
Failure analysis
Manufacturing link
Stress Contours under Upwind Loads
By courtesy of
Team NZ & Matrix Applied Computing Ltd.
Energy
•
•
•
•
•
Wind Turbine Blade
Up to 40 m long
Lowest cost
Local buckling, flutter
Benefits:
– Modify materials easily
– Multiple analysis codes
– Manufacturing data
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Leisure
•
•
•
•
•
Helmet
Fabric reinforcement
Sandwich construction
Must reduce cost
Benefits:
– Simulate manufacture
– Account for shear-induced
thickening
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Simulation Drivers
• Each industry has different structural
requirements
• These affect the degree of modelling and
simulation used
Key Structural Requirements in Different Industries
Cost
Performance
Reliability
Speed (of dev.)
10
Aerospace Motorsport Automotive
1
1
2
2
1
2
Energy
1
Marine
1
Leisure
2
2
2
1
Modelling
• Ply modelling used throughout industries
– Rapid modification
– Link to manufacture
• Zone modelling used for preliminary
sizing
Use of Modelling Techniques in Different Industries
Zone
Ply
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Aerospace Motorsport Automotive
y
y
y
y
Energy
y
Marine
y
y
Leisure
y
Manufacturing Simulation
•
•
•
•
Draping is now used universally
Forming only useful for extreme cases
Resin flow simulation in marine market
Curing limited to aerospace
Use of Manufacturing Simulation in Different Industries
Draping
Forming
Resin Flow
Curing
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Aerospace Motorsport Automotive
y
y
y
y
y
Energy
y
Marine
y
y
y
Leisure
y
y
Structural Simulation
• Linear and failure analyses routine
• Crash analyses emerging for motorsport,
automotive
• Durability needed but unresolved
y
M.o.S = (a-b)/b
Use of Structural Simulation in Different Industries
b
Aerospace Motorsport Automotive
Statics/Dynamics
y
y
y
Failure Analysis
y
y
y
Crash
y
y
Durability
y
Energy
y
y
Marine
y
y
Leisure
y
y
a
x
Failure Surface in
Stress Space
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Optimization
• Topology optimisation under research
• Parametric techniques established for
multidisciplinary optimisation
• System optimisation growing
Use of Optimization Techniques in Different Industries
Aerospace Motorsport Automotive
Topology
Parametric
System
14
y
Energy
Marine
y
y
Leisure
Evolving Requirements
•
•
•
•
•
•
•
•
•
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Larger Models
Better Verification
Automated Data Transfer
Mirroring/Rotation
Solid Analysis
Nonlinear Analysis
Crash & Crush Analysis
Quicker Sizing
Account for Material Shear
Larger Models
• Requirements
–
–
–
–
200000 elements
2000 plies
20000 PCOMPS
200 loadcases
• Solutions
– Remove bottlenecks
– 2-1000 x faster
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Better Verification
• Requirements
– Audit model
• Solutions
– Show Layup
• Element
• Cross Section
– Show Laminate
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Automated Data Transfer
• Requirements
– Speed up ply import
– Import and export
laminates
– Export flow model
• Solution
– CAD Ply import 1000x
faster
– LAP interface
– RTM-Worx interface
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LAP interface
• Import materials
and laminates
during zone
definition
• Export materials,
laminates and loads
during certification
Aero. Shape
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Zone Layup
Ply Layup
Ply Details
Certification
Manufacture
RTM-Worx interface
• Export materials,
plies and layup
• Both warp and weft
directions
considered
• Simulate resin flow
for RTM
• Curing analysis
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ESAComp interface
• Import materials
and laminates
during zone
definition
• Export materials,
laminates and loads
during certification
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Mirroring/Rotation
• Requirement
– Reduce
modelling time
for symmetrical
structures
• Solution:
– Transform Layup
Mirror
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Account for Material Shear
• Requirements
– Account for shear
• Solution
– Reference sheared
material properties
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Solid Analysis
• Requirements
– Solid model for
thermal analysis
• Solution
– Extrude solids
– Calculate equivalent
material
– Create coordinate
frames
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Nonlinear Analysis
• Requirements
– Support MSC.Marc
• Solution
– Update preference
25
Crash & Crush Analysis
• Requirements
– Support MSC.Dytran, LS-DYNA, Pamcrash
• Solution
– Update preferences
Element Failure
Time
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Quicker Sizing
• Requirements
– Smeared Laminate
– Discrete variables
Design Variables
1.20E+00
1.00E+00
Thickness
8.00E-01
• Solution
6.00E-01
4.00E-01
– In MSC.Nastran 2001
2.00E-01
0.00E+00
0
5
10
15
20
25
30
35
Design Cycle
LAM option
BLANK
SYM
MEM
BEND
SMEAR
SMCORE
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New 2001 Membrane
[A]
Y
Y
Y
Y
Y
Y
Y
Y
Y (core N)
Bending
[B]
Y
Y
Y
Y
Y
Coupling
[D]
Y
Ply results
Comments
Y
Y
Y
Y
Default.
Wing skins.
Smeared.
Smeared with core.
40
45
50
Conclusions
• Simulation drivers vary widely across
industries
• Ply modeling and kinematic draping are
now universally accepted
• Resin flow and curing simulation show
potential
• Crash and durability analysis developing
rapidly
• Formal optimisation methods promise
improved sizing
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