Recent Enhancements for Composite Design Optimization

1,832 views

Published on

Published in: Technology, Business
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
1,832
On SlideShare
0
From Embeds
0
Number of Embeds
362
Actions
Shares
0
Downloads
48
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

Recent Enhancements for Composite Design Optimization

  1. 1. Recent Enhancements forComposite Design OptimizationMing Zhou, Raphael FleuryAltair Engineering, Irvine, California
  2. 2. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Agenda1.Brief Overview of Composite Optimization Process2.Ply Drop-off Constraints and Other Enhancements3.Application Examples3. Conclusion
  3. 3. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Composite Optimization ProcessAutomationPatch InterpretationTailoring?Free Sizing!Phase 1Number of Plies?Ply Bundle Sizing!Phase 2Laminate Stacking?Optimized StackingSequence!Phase 3Rule basedply shuffling45-45 00045-45 459090 -4545 -4500-45 9045(a) Ply Level (b) Superply Level45-450045-459090 -454500-4545(a) Ply LevelDiscrete Ply ThicknessAutomation
  4. 4. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Composite Box Beam
  5. 5. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Composite Optimization ProcessPhase III - Detail: Stacking Sequence Optimization• Meet ply book rules• All behavior constraints• Stacking manufacturing constraints45-45 00045-45 459090 -4545 -4500-45 9045) Ply Level (b) Superply Level45-45 00045-45 459090 -4545 -4500-45 9045(a) Ply Level (b) Superply Level
  6. 6. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.T_45PlyT_ - 45PlyBalance_45Ply, T_45Ply = T_ - 45PlyComposite 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 %...) Balanced Ply Angles (i.e. Balance +/- 45’s) Constant Individual Ply Thickness Ply Draping Accommodation Zone based Pattern Grouping Ply Drop-Off Constraints Can be applied to Composite Free-Size and Composite Size OptimizationT = Ply4 (nom)45PCOMPT = Ply3 (nom)90T = Ply2 (nom)-45T = Ply1 (nom)0T_Laminate Min/MaxT_0Ply Min/Max = Sum(T_0Ply)T = Ply1 (nom)0T = Ply2 (nom)-45T = Ply3 (nom)90T = Ply4 (nom)45T_LaminateT_90Ply (1)Ply90% =Sum(T_90Ply)/T_LaminateT_90Ply (2)T_0Ply Constant
  7. 7. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Composite – Concept DesignManufacturing Constraints:
  8. 8. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Composite – Concept DesignManufacturing Constraints:),(||:ratedropPly kjdistikij  xx
  9. 9. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Free Size Optimization – Manufacturing Constraints• Ply Drop-Off Constraints• Reduce stress concentrations leading to failure through delamination• Thickness drop-off for free-sizing• Actual drop-off for sizing• Directional drop-off control• Constraints can be defined based on the slope or thickness• Available in composite free sizing optimization (element based)• Available in composite sizing optimization (property/ply based)
  10. 10. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Drop – Off Constraints: Plate Example
  11. 11. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Free Size Optimization – Manufacturing Constraints• Visualization of Manufacturing Constraints in H3DNo Drop-OffConstraintPly ThicknessPly Thickness1% Drop-OffConstraintPly Drop-OffContourMax =1%Ply Drop-OffContourMax =20%CantileverPlate
  12. 12. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Free Size Optimization – Usability Enhancements• Automatic Offset Updating (ZOFFS and Z0)• Improved process for working with and optimizing models where the mesh is atTOP or BOTTOM surface of physical thickness• Works with shells and composites• Works for free sizing and sizing optimization• Automatic Generation of Ply Bundle Sizing Model (OUTPUT,FSTOSZ)• Rewritten using a pure ply based approach• Advanced algorithm to capture thickness variation is now available for 2, 4 and 8ply bundles• Multiple ply bundle generation methods (ADVFREE, ADVMAN, SIMFREE,SIMMAN)• IGNORE option for plies with very low thicknesses
  13. 13. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Free Size Optimization – Usability Enhancements• Designable Core Layer• Core can also be free-sized• Used with SMCORE (smeared core) laminate definition• Optionally, can be set as non-design• Support for Mixed Ply Structures• Different ply layups for different properties
  14. 14. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Free Size Optimization – Manufacturing Constraints• Constraints can be defined BYPLY and BYSET (set of plies) in additionto BYANG (by orientation)• Comprehensive solution allowing various options to apply manufacturingconstraints• Constraints by material can be applied using BYSET option• Constraints can be defined locally• Account for regions requiring reinforcements such as bolt or mounting locations• Different manufacturing requirements for different sections of the design• EXCLUDE option to exclude CORE or CONST (plies defined in theCONSTant constraint) from certain manufacturing constraints
  15. 15. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Free Size Optimization – Manufacturing Constraints• Consistent syntax on the DSIZE (free sizing) and DCOMP (ply bundlesizing) cards• Manufacturing constraints are automatically carried over from free sizing to sizing• Preserves continuity of manufacturing constraints across the optimization process
  16. 16. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Bombardier Composites OptimizationOptimization of Composites – Zone-Based Pattern Grouping and DRESP3Successful integration/application ofcomposite optimization process in liveaerospace design environment
  17. 17. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Composite WingComposite skins with 0, +45/-45, 90 pliesManufacturing Constraints:max. ply thickness ≤ 10 mm+45/-45 plies linked8 mm ≤ total thickness ≤ 32 mmmin. ply percentage ≥ 10%Minimize MassSubject to:Tip displacement constraints(Bounds different for 10 load cases)Phase I - Concept: Free-Size
  18. 18. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.PLY DROP-OFF – WING EXAMPLENO DROP-OFFCONSTRAINTPLY THICKNESSPLY THICKNESSWITH 1% DROP-OFFCONSTRAINT
  19. 19. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Ply sequence optimisation• Utilities created to generate solid visualisation of plies• Thickness scale factor applied (x5)• Element & ply Z offsets included• Top cover:
  20. 20. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.OSSmooth Enhancements – Ply Shape Interpretation• Benefits• FE based plies need to be manually interpreted• OSSmooth interprets ply shapes• Ply boundary smoothing• Treatment for small ply patch regions – keep or discard• Disconnected patches can be created as separate ply entities• OptiStruct ply bundle sizing deck is generated with updated data• Streamlined overall composite optimization process
  21. 21. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.elimination of small regionssmoothing on ply shapesExample – ply shape interpretation
  22. 22. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.SmallRegion = 0.001 (by area ratio)SmallRegion = 0.003 (by area ratio)original ply shapeExample – ply shape interpretation
  23. 23. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Conclusions• Comprehensive Composite Optimization Process• Three-Phase optimization process – from concept to Ply-Book details• Manufacturing constraints through out the process• Ply-Drop constraints• Ply shape smoothing tool• Quick adoption by aero, race car, yacht industries• Ongoing R&D• Stress/strain/failure index constraints for Free-Size phase

×