OPTIMIZATION OF COMPOSITE: Recent Advances and Application

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  • 1. Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. OPTIMIZATION OF COMPOSITE Recent Advances and Application Martin Kemp, Raphael Fluery and Ming Zhou, Altair Engineering
  • 2. 1 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. BACKGROUND BOMBARDIER AEROSPACE • A world-leading manufacturer of innovative commercial aircraft and business jets • Products include: • LearJet • C-Series • CRJ-Series • Q-Series • Deliver continuous innovations in business jets, regional twinjets and turboprops, and amphibious aircraft • Consistently setting new industry benchmarks in airplane performance, passenger comfort and economics
  • 3. 2 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. OVERVIEW INTEGRATION OF A NEW COMPOSITE OPTIMIZATION PROCESS Background • Accepted, validated approach in place for composite design of Components and Systems • Integrating Stress, Design and Manufacturing New Approach • Must improve on existing approach • Must integrate with existing design process and meet validation/qualification requirements
  • 4. 3 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. OVERVIEW COMPOSITE DESIGN USING HYPERWORKS CAD Mfg Simulation Interoperability Interoperability HyperMesh (Traditional Zone & Modern Ply Based Composites Pre-Processing) Realizations Visualizations (Export Ply Based Models to (Visually verify the Math Model) Solver Zone Based Models) OptiStruct/RADIOSS (Composites Design Optimization & Finite Element Analysis) HyperLaminate Solver HyperView FEA Solver (Composites Post-Processing Interoperability (Classical Lamination Theory) & Failure Analysis)
  • 5. 4 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION RECENT ADVANCES • Greater design freedom with composites presents opportunities and challenges • Opportunities: Increased design freedom for design optimization; Superior performance; Unparalleled manufacturing flexibility • Challenges: Manufacturing efficiency/Cost, complexity of design (Material and Structural) • Altair has developed a three stage process building on the well established two stage metallics optimization process Phase 1 Phase 2 Ply Tailoring? Number of Plies? Free Sizing! Phase 3 Laminate Stacking? 45 45 -45 0 -45 0 0 0 0 45 Rule based 0 45 -45 45 -45 45 Automation Ply Bundle Sizing! 90 90  90 90  -45 -45 45 -45 45 -45 0 0 ply shuffling 0 0 -45 90 -45 90 45 Patch Interpretation 45 (a) Ply Level (a) Ply Level Optimized Stacking (b) Superply Level (b) Superply Level Automation Sequence! Discrete Ply Thickness
  • 6. 5 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION PROCESS OVERVIEW • Phase I - Concept: Free-Size or Topology optimization • Determine composite patch size, shape & location • Manufacturing constraints • Phase II - System: Ply-Bundle Sizing with ply-based FEA modeling • All behavior constraints • Manufacturing constraints • Phase III - Detail: Ply Stacking Sequence Optimization • All behavior constraints • Stacking manufacturing constraints
  • 7. 6 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION PROCESS EXAMPLE
  • 8. 7 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION PROCESS EXAMPLE Phase III - Detail: Stacking Sequence Optimization • Meet ply book rules • All behavior constraints • Stacking manufacturing constraints 45 45 -45 0 -45 0 0 0 0 0 45 45 -45 45 -45 45  90  90 90 90 -45 -45 45 -45 45 -45 0 0 0 0 -45 90 -45 90 45 45 (a) Ply Level (b) Superply Level) Ply Level (b) Superply Level
  • 9. 8 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION MANUFACTURING CONSTRAINTS
  • 10. 9 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION MANUFACTURING CONSTRAINTS  Min/Max Total Laminate Thickness  Min/Max Individual Ply Thickness (e.g., Min/Max 0-Deg Thickness…)  Min/Max Individual Ply Angle Percentage (e.g, Ply90 %...)  Constant Individual Ply Thickness  Designable and non-designable regions  Can be applied to Composite Free-Size and Composite Size Optimization  Ply Draping Accommodation 45 T = Ply4 (nom) T_45Ply  Ply Linking through ‘sub-stacks’ 90 T = Ply3 (nom) T_90Ply (1) -45 T = Ply2 (nom) T_ - 45Ply 0 T = Ply1 (nom) PCOMP Ply90%T_0Ply Balance_45Ply, T_45Ply = T_ - 45Ply T_0PlySum(T_90Ply)/T_Laminate = Constant Min/Max = Sum(T_0Ply) T_Laminate T_Laminate Min/Max 0 T = Ply1 (nom) -45 T = Ply2 (nom) 90 T = Ply3 (nom) T_90Ply (2) 45 T = Ply4 (nom)
  • 11. 10 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION TYPICAL MANUFACTURING CONSTRAINTS • Substacks (SUB) define partial stacking sequences • Interfaces (INT) indicate how the substacks are assembled • During ply stacking optimization, substacks are shuffled independently as to avoid undesirable ‘penetration’ effects
  • 12. 11 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION MODELLING AUTOMATION • Efficient tools required at System and Component Level to: • Increase refinement • Update Designs • Map Loads • Respect composite boundaries/zones • Increased refinement models can be efficiently solved; a model of > 250K elements would be a manageable concept model
  • 13. 12 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. PROCESS IMPLEMENTATION BOMBARDIER AEROSPACE DESIGN TEAM Bombardier Shorts Global FEM • Global Fem Foundation • Freeform Design with Scientific Basis Concept • Fast/flexible Customisable Altair Composite • Ply Continuity locked in • Manufacturing rules Constraints Optimization Fine Tuning • Combined performance targets Module Process (Margin Calcs) • Conversion to Bombardier Design Input Delivery • Tailored for FibreSim Acceptance Bombardier OSZone Shorts Design (FibreSim)
  • 14. 13 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. PROCESS IMPLEMENTATION BOMBARDIER AEROSPACE DESIGN TEAM Multiple Export Formats: Results Section Loads OS Results •FibreSim •Generates and Contours Zone Margins •Spreadsheet of Safety •Iges Zone Boundary Curves •Tabulates Zones (when selected, detail view populates) 3D View Showing Secant Margin Contours Zone Laminates Extracted from Ply Based OS Format •Mapping from Plys to Zones (ie if cloth boundary Zones Defined by Element Sets bisects zone) •Load Extraction Elements Auto- •Selection of Zone Highlights in viewport and Detected identifies load extraction elements •Component Dimensions Auto-Defined
  • 15. 14 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION TYPICAL EXAMPLE CAD Export (FibreSim)
  • 16. 15 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. COMPOSITE OPTIMIZATION TYPICAL EXAMPLE • Zone-based pattern grouping • Custom Constraints Facilitated through OS plug-in or HyperMath
  • 17. 16 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. CONCLUSION INTEGRATION OF A NEW COMPOSITE OPTIMIZATION PROCESS • Successful integration/application of Composite optimization process in live aerospace design environment • Efficient exploration of designs / weight saving potential for range of components and systems • New process advantages: • free-form stage: Rapid ‘what-if’ studies facilitating early design focus • Manufacturing constraints built into process from the start • Significant mass savings and design drivers systematically identified • Efficient interfaces between stress and design facilitate rapid iterations • Repeatable process, which accommodates the composite design qualification requirements suitable at component and system level
  • 18. 17 Copyright © 2009 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. THANK YOU (QUESTIONS) Martin Kemp, Altair Product Design martin.kemp@uk.altair.com