Lightweight Design (Composites) - Americas ATC 2015 Workshop

Innovation Intelligence®
ATC 2015
Lightweight Composite Design
Workshop
Jeff Wollschlager
Sr. Technical Director
Altair Engineering
(425) 949-9674
jaw@altair.com

Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda
• Introduction of the Problem Statement
• Composite Ply-based Modeling & Visualizations
• Ply Drape Estimator
• Composite Free-Size Optimization Setup
• Composite Free-Size Optimization Post-Processing (OSSmooth)
• Composite Size Detailed Design Optimization
• Composite Size Detailed Design Post-Processing
• Composite Shuffling Optimization
• Comparison of Steel vs Aluminum vs Composite Designs

Composite B-pillar Design Problem Statement
Design a minimum mass composite
B-pillar under the “fictious” loads given with fiber
strains between -8000me and 10,000me. The
resulting laminate should be symmetric and
balanced and have a min drop-off ratio of 1:3.
#1
Axial
(5000N)
#2
Shear
(1250N)
Moment
(10000N/mm)
#3
Axial
Shear
Moment

HyperWorks v13.0 Composites Functionality Overview
HyperMesh
Composites Ply-based Modeling
HyperMesh
Composite Draping Simulation
HyperMesh
Composite Visualizations
OptiStruct
Composites Design Optimization
and Analysis
HyperView
Composites
Post-Processing & Failure Analysis
HyperLaminate Solver
Classical Lamination Theory
Realizations / Absorptions
Ply-based models to
Zone-based models
HyperWorks Partners
Detailed Composite Modeling
Draping Simulation & CAD
Interoperability

Composite Modeling in HyperWorks v12.0
There are two types of composites modeling available
1. Traditional zone-based modeling
2. Modern ply-based modeling
Traditional Zone-based composite modeling
• PCOMP, PCOMPG, or *SHELL SECTION COMPOSITE
• Exists in all preprocessors including HyperWorks v13.0
• Has limitations…
Modern Ply-based composite modeling
• New OptiStruct Cards PLY, STACK, and PCOMPP
• Existed since HyperWorks v11.0 and beyond
• Resolves many of the zone-based modeling limitations…

Traditional Composite Zone-Based Modeling
Requires one property for each laminate zone
Zone-based modeling limitations
• Data duplication
• Difficult to interpret ply shape
• No relationship to the mfg process
• Model updates require multiple steps
P1 45
P2 90
P3 -45
P4 0
Zone #1 Zone #2 Zone #3 Zone #2 Zone #1
P5 -45
P6 90
P7 45Zone #1 Property Table
Ply Mat Thk Theta
P7 M1 0.01 45
P4 M1 0.01 0
P1 M1 0.01 45
Zone #2 Property Table
Ply Mat Thk Theta
P7 M1 0.01 45
P5 M1 0.01 -45
P4 M1 0.01 0
P3 M1 0.01 -45
P1 M1 0.01 45
Zone #3 Property 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
Zone #1
Zone #2
Zone #3

Modern Composite Ply-Based Modeling
A composite part is one laminate made up of several plies which are
placed in a given stacking sequence!
• No data duplication
• Plies defined as “physical objects” w/ shape
• Direct relationship to the mfg process
• Model updates require single step
P1 45
P2 90
P3 -45
P4 0
P6 90
P7 45
P5 -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

Composite Ply-Based Modeling GUI
Create/Edit/Delete Plies and Laminates directly from HyperMesh browsers
Import/Export Ply and Laminate data to/from Excel

Ply-Based Visualizations
Visually verify the engineering data of your math model
3D representation mode is an active representation
3D
Representation
Traditional
Representation
3D Representation
w/ Composite Layers

Composite Ply-based Modeling & Visualizations

Ply Drape Estimator
Flat plies do not lay flat on double curved surfaces without “wrinkling”
G1
G2
Ply Orientation w/ Drape
Ply Orientation w/o Drape
Material Direction
Before Draping
Simple Projection
After Draping
Simulation

Modern Composite Optimization Methodology
Initial Design
Final Design
Composite Free-Size Optimization
What are the most efficient ply shapes?
Composite Size Optimization
How many piles are required to meet engineering targets?
Composite Shuffling
What is a probable stacking sequence to meet
manufacturing requirements?
Ply Slicing
Determines ply shapes

Composite Free-Size Optimization Setup
What is Previously Known
Part Shape
This Optimization Answers the Question
What are the most efficient ply shapes to carry the load?
Design Variables
Thickness of every ply within every element
4 plies x 11,188 elems = 44,752 desvars
Constraints
Volume Fraction < 0.3
Objective
Minimize Compliance (Maximize Stiffness)
Ply 4 (45o) t4,i
Ply 3 (-45o) t3,i
Ply 2 (90) t2,i
Ply 1 (0o) t1,i
Ply 1 (0o) t1,i
Ply 2 (90o) t2,i
Ply 3 (-45o) t3,i
Ply 4 (45o) t4,i
Iteration 0
Thickness design variables for
each ply of the ith element.
Iteration N
Thickness design variables for
each ply of the ith element.

Manufacturing Constraints
Ply Percentage Constraint 20% < 0o > 75%
Balanced Constraint 45o / -45o
Ply Drop Constraint 1:3 (0.33)
PGT
LT
1, t1,i
2, t2,i
3, t3,i
k, tk,i
n, tn,i
…



n
k
iktLT
1
,
 iktPGT ,
LT
PGT
PGP 
PPMAXPGPPPMIN 
1, t1,i
2, t2,i
3, t3,i
k, tk,i
n, tn,i
…
PGT1
PGT2
 iktPGT ,1
 iktPGT ,2
21 PGTPGT 
Ply k, tk,i Ply k, tk,i+1
Dt
q
Dd

Composite Free-Size Optimization Post-Processing
Ply slicing determines ply shapes
4 ply shapes for each ply by default
Ply 1 t1,1 Ply 1 t1,2 Ply 1 t1,3 Ply 1 t1,iPly 1, Shape 1
Ply 1, Shape 2
Ply 1, Shape j
Ply1, Shape1 Ply1, Shape2 Ply1, Shape3 Ply1, Shape4
Ply1, Thickness Contour

Ply slicing tends to produce “organic” ply shapes
OSSmooth produces ply shapes which are more manufacturable
Manual edit to arrive at final ply shapes
Ply1, Shape1 Ply1, Shape2 Ply1, Shape3 Ply1, Shape4
Free-Size
OSSmooth
Manual Edit

Ply Naming Convention
[ABCDD]
A is the laminate number
B is the ply number
C is the ply shape number for given ply
DD are repeat counts for a given ply shape
[12300]
Laminate 1 Ply 2 Shape 3 Iterate 00

Composite Size Optimization Setup
Part Shape + Ply Shapes
How many plies are required to meet engineering targets?
Design Variables
Thickness of every ply shape
16 ply shapes = 16 desvars
LB < Initial < UB (0mm < 1.5mm < 2.5mm)
Increments of manufactrable ply thicknesses = 0.25mm
Constraints
For all plies
-8000me < Fiber Strain ef < 10,000me
Objective
Minimize Mass

Ply Percentage Constraint 20% < 0o > 75%
Balanced Constraint 45o / -45o
Laminate Drop Constraint (8 plies = 2mm)
PGT
LT
1, t1,i
2, t2,i
3, t3,i
k, tk,i
n, tn,i
…



n
k
iktLT
1
,
 iktPGT ,
LT
PGT
PGP 
PPMAXPGPPPMIN 
1, t1,i
2, t2,i
3, t3,i
k, tk,i
n, tn,i
…
PGT1
PGT2
 iktPGT ,1
 iktPGT ,2
21 PGTPGT 
∑tk,i ∑tk,i+1
Dt

Composite Size Optimization Post-Processing
DESIGNED PROPERTY ITEMS TABLE
--------------------------------------------------------------
DVPREL1/2 USER-ID PROP-TYPE PROP-ID ITEM-CODE PROP-VALUE
--------------------------------------------------------------
DVPREL1 11100 PLY 11100 T 5.000E-01 2 plies, ply1 shape1
DVPREL1 11200 PLY 11200 T 2.500E-01 1 ply, ply1 shape2
DVPREL1 11300 PLY 11300 T 0.000E+00
DVPREL1 11400 PLY 11400 T 5.000E-01 2 plies, ply1 shape4
DVPREL1 12200 PLY 12200 T 0.000E+00
DVPREL1 12300 PLY 12300 T 0.000E+00
DVPREL1 13200 PLY 13200 T 0.000E+00
DVPREL1 13300 PLY 13300 T 0.000E+00
DVPREL1 13400 PLY 13400 T 1.250E+00 5 plies, ply3 shape4
DVPREL1 14200 PLY 14200 T 0.000E+00
DVPREL1 14300 PLY 14300 T 0.000E+00
DVPREL1 14400 PLY 14400 T 1.250E+00 5 plies, ply4 shape4
------------------------------------------------------------------------------------------
19 plies sym, 38 total

Number of ply iterates for every ply shape are known,
but not exactly how to stack them…

Composite Shuffling Optimization Setup
Part Shape + Ply Shapes + Number of Ply Iterates
Exactly how do I stack the plies to meet engineering targets?
Design Variables
Ply Stacking Sequence
Maximum Successive Plies = 6
Cover Stacking Sequence -45 / 0 / 45 / 90
Objective
Find a stacking sequence which meets all constraints

Composite Shuffling Optimization Setup

Composite Shuffling Optimization Post-Processing
Import Stacking Sequence in .prop file with fe-overwrite

Composite Optimization Final Design
Final Mass = 395 grams
Fiber Strain Compression Fiber Strain Tension

Composite Shuffling & Final Design Post-Processing

Unique Composite Design Methodology
Design Synthesis (Concept Design) Technologies
• Isotropic Solid Topology
• Isotropic Shell Topology
• Isotropic Free-Size
• Composite Free-Size
Design Tuning Technologies
• Isotropic Size/Shape Optimization
• Composite Size/Shape Optimization
• Composite Shuffling Optimization
Unique Composite Design Synthesis Methodology
1. Topology – What is the Shape of the Part?
2. Composite Free-Size – What are the most efficient ply shapes?
3. Composite Size/Shape – How many Plies required to meet Engineering Targets?
4. Composite Shuffling – What is a Probable Stacking Sequence for Manufacturing?

Lightweight Composite Design
***Results are relative due to the “fictitious” loads and include quasi-static considerations only,
however are representative of the general trends of various designs with these materials***
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0
500
1000
1500
2000
2500
3000
3500
4000
Steel
Sheet Metal
Aluminum
Sheet Metal
Steel
Machined
Aluminum
Machined
Composite
Black
Aluminum
Composite
Composite
Design
Steel vs Aluminum vs Composite
Potential Weight Savings
Mass (grams) % Weight Savings

Thank You! Questions?
HyperMesh
Composites Ply-based Modeling
HyperMesh
Composite Draping Simulation
HyperMesh
Composite Visualizations
OptiStruct
Composites Design Optimization
and Analysis
HyperView
Composites
Post-Processing & Failure Analysis
HyperLaminate Solver
Classical Lamination Theory
Realizations / Absorptions
Ply-based models to
Zone-based models
HyperWorks Partners
Detailed Composite Modeling
Draping Simulation & CAD
Interoperability

Lightweight Design (Composites) - Americas ATC 2015 Workshop

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