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Composite Modeling with FiberSim
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Composite Modeling with FiberSim

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This was a 2012 Americas HTC Composites training presentation given by Shan Nageswaran. This presentation focuses on Zone-based vs. Ply-based HyperWorks composite modeling approach, CATIA - CPD based …

This was a 2012 Americas HTC Composites training presentation given by Shan Nageswaran. This presentation focuses on Zone-based vs. Ply-based HyperWorks composite modeling approach, CATIA - CPD based composite modeling, Fibersim Interface, Conventional shell vs. Continuum shell / solid composite modeling, and optimization and future HyperWorks enhancements. HyperWorks tips for Ply based-PCOMPP and Zone based (PCOMP/PCOMPG) modeling for Multi laminate structures are also covered.

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  • 1. Composite Modeling with FiberSim April 10 2012Innovation Intelligence®
  • 2. Composites Overview within HyperWorks CAD & Mfg Interoperability Geometry HyperMesh Modern Ply Based Composites Pre-Processing Visualizations Realizations Visually Verify the Math Model Export Ply Based Models to Solver Zone Based Models OptiStruct/RADIOSS Composites Design Optimization & AnalysisHyperLaminate Solver HyperViewClassical Lamination Theory Composites Post-Processing & Failure Analysis HyperWorks Partners Detailed Compoiste Material Modeling & Structural Modeling
  • 3. Process of FiberSim- Hypermesh interoperability Import CAD model • Read CAD part ,surface from Catia , UG etc ,geometry etc. • Geometry clean up on imported CAD model Create mesh • Mesh the part ,check element quality etc. Import Equivalent • Extract composite data - Ply, stacking , material info , system definition • Drape data , triangulation data (ply shapes ) etc as table in HM . Fibersim model Geometric ply shape • • Realize geometric shapes to FE ply shapes - Two methods , ‘simple’ , ‘advanced’ Extract elements for each Ply. • Do result Map, result interpolation realization • Correct the drape angles Template properties • Contains additional FE required for design/analysis but not required for manufacturing/documentation Stack & Material • Defines the stacking sequence direction and the reference material orientation orientation Review & Modify • Visually verify math model via 3D visualizations (Ply shapes/orientation/thickness, Stacking sequence) Ply based model • Conversion of ply to zone based modeling • Laminate realization. realization Export & Solve • Export to any supported solver
  • 4. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Step 1: CAD geometry import…• Basic CAD model geometry for the part is imported• HM support all the major CAD systems and Neutral formats • CATIA V5, V4 • UG-Nx • PTC • Parasolid • IGEs • STEP• At this stage, we import the geometry data only • Ply or Composite data is not imported• Use Optistruct Use profile in Hypermesh
  • 5. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Import CAD geometryDo not us this composite datatoggle for Fibersim
  • 6. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.STEP 2: Mesh the CAD Geometry…
  • 7. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.STEP 3: Import FiberSim Composite Data ( HDF5 file *.h5) • Use File/ Import /Geometry • Select FiberSim file filter • Import the HDF5 file *.h5
  • 8. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.FimberSim Model import….• This process will import and populate HM data base with • Laminate data ( ply book– ply stacking data, • Composite Material data • Each ply data – (triangular elements spanning a single ply) • Master Rosette ( coordinate system for the model ) for stacking direction • If the Ply is woven / fabrics HM create additional plies for each direction (P003_1 , P003_2) –two plies
  • 9. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Imported FiberSim Data----Laminate Table….
  • 10. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.SETP3– Correction of Element Normals• Based on the Stacking direction ( Rosette Z direction), element normals are changed to match the Z direction• Use tools/Normal panel in HM to reverse the normal/ or correct the flipped few elements– Red color is in the positive normal direction
  • 11. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.STEP4 – Realize FibersSIm Geometry plies in FEPlies .. (PLY-> Realize)• This step converts the FiberSim Ply entities to Finite element Mesh created in HM. • This process takes each FiberSim Ply date and finds the FE elements which are bounded by the ply boundaries and transfer the ply directions, draping data, ply orientation into FE elements. Geometry plies are converted to FE plies. • HM uses two mapping approaches.. • Simple mapping – Based on proximity checks of the FE elements to ply. • Advance Mapping– Use correct interpolation to fine the FE element for a ply and transfer the data.• Right Mouse click on the Ply entity on the Browser to activate the realize dialog box
  • 12. FiberSIM – HM integration • • Ply realization ( converting geom representation to Fe representation) . • Derive ply boundary from triangulations mesh data. • Project the ply boundary /region on the actual mesh in HM . .
  • 13. What is draping data ?• Corrections to thickness and fiber direction of every element within a Ply.
  • 14. Mapping Fibersim Draping data to HM. Final fiber Direction from Fibersim N4 N3 Ply Fiber Direction Corrected Theta for OS interface as Drape card Material Direction Theta on element Element Material/local axis From N1-N2 N1 Vector provided by N2 Fibersim on every element.
  • 15. Results of realization – Transfer FiberSim composite data toFE based data in HM– STEP4 results• Create FE plies from the mesh model • Elements inside a ply boundary is grouped into individual FE plies• Draping table is created • Each ply FE element will contain the Drape data • The change in ply thickness due to draping ( scale factor) • Change in fiber angle due to draping
  • 16. STEP 4 -- results• Ply sets are created.. Set containing FE elements for each plies
  • 17. STEP 5: Verification of FE plies, thickness and orientation inHM • First step is to create Ply property – PCOMPP • HM support ply based model as default – ( not Zone based model) • Assign this property to all the FE elements
  • 18. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.STEP5 -- Ply Visualization• Set the display to By Property• Set the Visualization mode to• Hide/ show each ply from the Browser
  • 19. STEP 5…… Ply angle Visualization on FE model
  • 20. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.STEP5 --- Ply thickness visualization -3D representation• Turn on 3D representation Mode
  • 21. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.STEP 6: Exporting into Solver Specific Zone models..• Altair solvers –Optistruct / Radioss supports Ply based models• Nastran ( 11.0.130)/ Abaqus (11.0.140 only) and other solvers support Zone Based models• The following step – Laminate Realize shall convert Ply based model to Zone base model • This will create PCOMPG for Nastran • Or *SHELLSECTION_COMPOSITE cards for Abaqus.(11.0.140)