Design Integration of Lightweight Composite Materials and the Challenges of Multifunctionality

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Dr. Martin Perterer, Head of Research and Simulation, KTM Technologies describes how the ANSYS simulation tool set for composite materials enabled the design team to reduce the weight of the KTM X-Bow sports car monocoque by 20%. You can attend a Live Webcast Thursday, November 14, 2013 • 1 pm EDT. http://bit.ly/1fDnhRy

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Design Integration of Lightweight Composite Materials and the Challenges of Multifunctionality

  1. 1. Advanced Materials System Design Design Integration of Lightweight Composite Materials and the Challenges of Multifunctionality With a Perspective from KTM Technologies Robert Harwood, Ph.D Aerospace and Defense Industry Director ANSYS, Inc Robert.harwood@ansys.com 1 © 2011 ANSYS, Inc. November 19, 2013
  2. 2. Rising Fuel Costs, Environmental Regulation and Competition are Driving Automotive and Aerospace Companies to Invest in Lightweight Composite Materials Rising Fuel Cost Environmental Regulation Competition 2 © 2011 ANSYS, Inc. November 19, 2013 Reduce airframe weight Reduce component weight and tooling costs Lightweight composite materials
  3. 3. Aerospace and Automotive Leaders Are Successfully Incorporating Composites into Their Next Generation Products Boeing 787 Dreamliner: 50% composite by weight Airbus A350 XWB: 53% of composite structures BMW i: The BMW i3 and i8 will mark the first mass produced cars to use structural CFRP 3 © 2011 ANSYS, Inc. November 19, 2013
  4. 4. But the Proliferation of Composite Materials is Challenging Existing Design Processes * Physical prototyping is complex, time consuming and expensive Effective integration of composites into product development requires an understanding of material science, design and manufacturing *S.Riaz, E.S.Greenhalgh, M.S.P.Shaffer, A.Bismarck, "Conference proceeding on Hierarchical carbon fibre reinforced Poly (vinylidine) difluoride composites" ECCM 14, Budapest, Hungary 4 © 2011 ANSYS, Inc. November 19, 2013
  5. 5. Simulation Based Engineering Has an Important Role to Play in the Composite Product Development Process – But It Must Be Efficient When selecting a simulation tool for composite product design, designers should consider whether a tool has: Appropriate failure modes (within layers, delamination, debonding and cracking) Composite layer definition (fabrics, stack ups, sublaminates) Material reference directions for curved structures (draping, fiber angle, correction and flat wrap generation) Critical part identification (failure modes, failed layer and critical load step) Accurate stress failure evaluation (including 3D) Ability to examine through thickness behavior using 3D local sub models where thin shell element approximations are not appropriate Integration with the overall simulation driven product development ecosystem 5 © 2011 ANSYS, Inc. November 19, 2013
  6. 6. Not Only is Efficiency Important, The Increasing Performance Requirements for Composite Materials Mean That Simulations Must Capture “Multifunctional Effects” In this example, an integrated comprehensive multiphysics simulation approach enables the multifunctional performance requirements of an antenna composite radome to be assessed: 6 © 2011 ANSYS, Inc. November 19, 2013
  7. 7. Automotive and Aerospace Innovators are Realizing the Benefit of ANSYS Solutions for Lightweight Composite Material Design Reduce Weight…… The first monocoque designs of the KTM X-Bow were engineered without the use of ANSYS Composite PrepPost. When we did employ the ANSYS software for composites, we were able to reduce the monocoque’s weight – a very important aspect of sports car design – by 20% Click here to read the full story -Dr Martin Perterer CTO KTM Technologies GmbH More Efficient Workflow…… We are using ANSYS software to develop composites that reduce the aircraft weight. Using ANSYS Composite PrepPost within ANSYS Workbench provides accurate results that allow us to reduce modeling time by up to 65% over traditional solid modeling Click here to read the full story 7 © 2011 ANSYS, Inc. November 19, 2013 -Tamas Havar Manager, Lightweight Design EADS Innovation Works
  8. 8. Learn More About How ANSYS is Helping Customers Improve Their Workflow Efficiency and Handle Multifunctionality for Composite Product Development Using Simulation Based Engineering Free webinar…… Dr Martin Perterer CTO KTM Technologies GmbH Watch our free webinar and listen to Dr Martin Peterer of KTM Technologies talk about the challenges of composite monocoque design, including aerodynamic, structural and manufacturing requirements. Register for the On Demand Webinar Free whitepaper…… Download the free white paper by clicking here 8 © 2011 ANSYS, Inc. November 19, 2013
  9. 9. Further information: Connect with me on LinkedIn: Robert Harwood E-mail me directly: Robert.Harwood@ANSYS.com Explore our solutions for composite simulation: www.ansys.com/Products/Simulation+Technology/Structural+Mechanics/ANSYS+Composite+PrepPost Follow us on social media: www.ansys.com/Social@ANSYS Watch out for webinars supporting composite design: www.ansys.com/About+ANSYS/Events 9 © 2011 ANSYS, Inc. November 19, 2013

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