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TRANSCRIPT
Converting Metallic Structures to Composites
& Laminate Optimization
Julien Sellier – Managing Director Jonathan Evans - Application Engineer
CompoSIDE | Case Study
Copyright CompoSIDE Ltd 2016
O b j e c t i ve s
Introduction to Case Study ¤ Initial Assessment
¤ Evaluation of composite potential
¤ Optimisation of composite structures
Introduction to CompoSIDE and CMDB
CMDB Questions & Answers
Case Study and Live Demo
Questions & Answers
Slide 2 Copyright CompoSIDE Ltd 2016
G e t s t a r t e d !
Sign up for 30 days free trial!!
Slide 3 Copyright CompoSIDE Ltd 2016
C a s e S t u d y I n t ro d u c t i o n
6m Radius Architectural Sphere Segments: ¤ Aluminium Alloy
¤ Weight = 656.6 kg
¤ Requirement to reduce weight retaining stiffness.
Goal: What is the feasibility of a composite design?
Slide 4 Copyright CompoSIDE Ltd 2016
C a s e S t u d y O b j e c t i ve s
How to assess my composite structural concept?
What are the associated material quantities?
Cost & Time
Strength
(Process)
Weight
(Material)
What technology and materials to select to achieve a lighter solution?
Slide 5 Copyright CompoSIDE Ltd 2016
C a s e S t u d y Wo r k p l a n
Which material should I use?
Where can I get the properties?
How should I orient my fibres / plies?
How do I ensure compliance of my laminate?
Are there opportunities to optimize?
How can I compare total material costs?
Slide 6 Copyright CompoSIDE Ltd 2016
W h a t M a t e r i a l s S h a l l I u s e ?
Manufacturing Process
Fibres
Cores
Resins
Adhesives
Slide 7 Copyright CompoSIDE Ltd 2016
W h a t P ro c e s s S h o u l d I u s e ?
Wet lamination Press Infusion
Pultrusion Prepreg/Resin Film
Infusion Automation
Slide 8 Copyright CompoSIDE Ltd 2016
S h a l l I d o S o m e Te st i n g ?
Slide 9 Copyright CompoSIDE Ltd 2016
Te st i n g C o st
Testing for certification purposes must be conducted by approved test houses. Below is a rough guide to the cost of basic static and fatigue testing for 1 material i.e. 1 fibre, 1 matrix, 1 process…
Aerospace qualifications can cost in excess of > €100k for a single material
Material sourcing and coupon manufacture Fibre volume content Tensile tests Compression tests ILSS Fatigue
€1,500 €6,500 for static tests >€45,000 for fatigue tests up to 5 million cycles
Minimum properties required to start a
design
Slide 10 Copyright CompoSIDE Ltd 2016
Do I real ly need to spend many thousands € before start ing
design with composites?
T h e Te st i n g P y ra m i d
CompoSIDE CMDB Addon
Slide 12 Copyright CompoSIDE Ltd 2016
W h a t d a t a i s i n C M D B A d d o n ?
Testing
Characteristic Values
Project Design Allowables
Statistical Analysis
Industry Partial Safety Factors
CompoSIDE CMDB Addon
Slide 13 Copyright CompoSIDE Ltd 2016
H o w C M D B A d d o n Re d u c e s M a t e r i a l Te st i n g C o st s ?
The CompoSIDE CMDB Addon library is a consolidated set of data that enables a quick and easy start with your projects
This enables you to assess the viability of composites as a solution as an alternative to investing lots of time and money.
Material testing becomes validation rather than investigation
Slide 14 Copyright CompoSIDE Ltd 2016
M AT E R I A L S
P R O C E S S
E N G I N E E R I N G
D e s i g n i n g w i t h C o m p o s i t e s
C M D B
S E C T I O N S p a c e
L A M I N A S p a c e
F E S p a c e
B O M G e n
Slide 15 Copyright CompoSIDE Ltd 2016
U s i n g C M D B
Manual material
¤ Test data
¤ Reference materials
¤ CMDB Addon Materials
PLYGen materials
¤ Micromechanics
Layered Materials
¤ Classical Laminate Theory
Slide 16 Copyright CompoSIDE Ltd 2016
M a t e r i a l D a t a H a n d l i n g
Material post-processing
¤ Properties for calculation
¤ Materials selection
¤ Data Comparison
¤ Scatter Plots
¤ Materials export (Xls)
Link to FEA Formats
¤ Ansys
¤ Nastran
¤ Radioss OptiStrut
¤ More to come
Slide 17 Copyright CompoSIDE Ltd 2016
M a t e r i a l L i b ra r i e s
CS Material Library: The CMDB Addon which can be used across your projects
My Company Materials: Your own private materials library which can be used across your projects
Active Project Materials: All materials used within your active project
Project materials can be grouped into selections for easier material data management
Slide 18 Copyright CompoSIDE Ltd 2016
C M D B A d d o n
W h a t d o I ge t ?
Slide 19 Copyright CompoSIDE Ltd 2016
Te c h n i c a l O ve r v i e w o f C M D B
Characteristic Values
Materials Data Fit for Design
Industry Proven Values
Across Hundreds of Products
Full Datasets
Fit for FEA
Transferable
Export to FEA
Slide 20 Copyright CompoSIDE Ltd 2016
C M D B A d d o n M a t e r i a l G ro u p s
Adhesives
Plies
Woods & Plywoods
Metals
Resins
Fibres
1277 Materials
Slide 21 Copyright CompoSIDE Ltd 2016
Cores
C o re s
212 Core Materials
Wide Range of Densities Available
Most Commonly Used Materials Available
¤ Honeycomb
• N636
• Nomex
¤ Balsa
¤ PVC Foams
¤ PET Foams
¤ San Foams
¤ PMI Foams
¤ PUR Foams
¤ Linear PVC Foams
¤ Flow Mediums
Slide 22 Copyright CompoSIDE Ltd 2016
P l i e s
No Standards in Composite Industry
One Material One Test Campaign
P l y P r o p e r t i e s
Resin Manufacturing
Process
Fibre Grade
Fibre Sizing Fabric Type
Fibre Type
Slide 23 Copyright CompoSIDE Ltd 2016
P l i e s
9 Fibre Types
7 Fabric Types
¤ UD
¤ Woven
¤ Biaxial
¤ Triaxial
10 Different Matrixes
8 Manufacturing Methods
¤ Quadraxial
¤ Mats
¤ Stack-ups (Combos)
890 Different Plies
Slide 24 Copyright CompoSIDE Ltd 2016
M a t e r i a l s S e l e c t i o n
Slide 25 Copyright CompoSIDE Ltd 2016
… n o t e n o u g h ?
Slide 26 Copyright CompoSIDE Ltd 2016
C re a t e Yo u r O w n P l i e s w i t h P l y G e n
PLYGen Material
Reference Material
Resin Manufacturing
Process
Fibre Type Fabric Type
Slide 27 Copyright CompoSIDE Ltd 2016
N o m e n c l a t u re Fo r C M D B
Fabric Type
¤ U= Unidirectional,
¤ X= Biaxial,
¤ W= Woven
¤ Q= Quadraxial
¤ Y=Triaxial
¤ CSM= Chopped Strand Mat
Fibre Type
¤ C=Carbon
¤ G=Glass
¤ A=Aramid
Fibre Grade
¤ LM= Low Modulus
¤ SM=Standard Modulus
¤ IM=Intermediate Modulus
¤ HM=High Modulus
¤ E=E-glass
¤ S=S-Glass
Matrix Type
¤ UP=Unsaturated Isophthalic Polyester
¤ EP=Epoxy
¤ V=Vinylester
¤ Ph=Phenolic
¤ Bi=Bismaleimide
Manufacturing Process
¤ HL=Hand Layup
¤ VW=Vacuum Wet
¤ SU=Spray-Up
¤ VIN=Vacuum Infusion
¤ FW = Filament Winding
¤ PP=Pre-Preg
¤ PPA=Pre-Preg Autoclaved
¤ CM=Compression Moulding
Fabric Type
Fibre Grade
Matrix Type
Manufacturing Process
Fibre Type
Reinforcement Weight
UC-HM400-EP-VIN
Slide 28 Copyright CompoSIDE Ltd 2016
Questions so Far?
Let ’s design!
M AT E R I A L S
P R O C E S S
E N G I N E E R I N G
Approach with CompoSIDE
C M D B
S E C T I O N S p a c e
L A M I N A S p a c e
F E S p a c e
B O M G e n
Slide 31 Copyright CompoSIDE Ltd 2016
C a s e S t u d y
6m Radius Architectural Sphere Segments: ¤ Aluminium Alloy
¤ Aluminium Weight = 656.6 kg
¤ Requirement to reduce weight retaining stiffness.
Requirements ¤ Structure to withstand gravity and wind
loading
¤ Maximum deflection = 10mm MAX.
¤ Ensure sufficient strength
Slide 32 Copyright CompoSIDE Ltd 2016
C o m p o S I D E Wo r k f l o w
Outputs
Select Materials
Create 2D Sections
Create 3D Model using sections and analyse
Baseline Design
Analysis
Slide 33 Copyright CompoSIDE Ltd 2016
C o m p o S I D E Wo r k f l o w
Outputs
Select Materials
Create 2D Sections
Create 3D Model using sections and analyse
Baseline Design
Analysis
Replace Material in 2D section with composite
Replace Section and analyse
with composite
Composite Analysis
Select Materials
Slide 34 Copyright CompoSIDE Ltd 2016
B u s i n e s s C a s e C o m p a r i s o n S u m m a r y F i rs t A n a l y s i s
Weight Comparison
¤ Weight Saving of 40%!
Lets look at optimising the laminate.
Material Material Weight
Aluminium 656.6 kg
Carbon Fibre – Single Skin 396.5 kg
Slide 35 Copyright CompoSIDE Ltd 2016
C o m p o S I D E Wo r k f l o w
Outputs
Select Materials
Create 2D Sections
Create 3D Model using sections and analyse
Baseline Design
Analysis
Replace Material in 2D section with composite
Replace Section and analyse
with composite
Composite Analysis
Select Materials
Replace Material in 2D section with composite
Replace Section and analyse
with composite
Composite Optimisation
Select Materials
Optimise Laminates
Slide 36 Copyright CompoSIDE Ltd 2016
B u s i n e s s C a s e C o m p a r i s o n S u m m a r y F i n a l A n a l y s i s
Weight Comparison
¤ Total Weight Saving of 52%!
The structure can still be further optimised from here using the same process
Material Weight
Aluminium 656.6 kg
Carbon Fibre – Single Skin 396.5 kg
Carbon Fibre – Sandwich 314.6 kg
Slide 37 Copyright CompoSIDE Ltd 2016
Summary
C o m p o S I D E
Slide 39 Copyright CompoSIDE Ltd 2016
C a s e S t u d y S u m m a r y W h a t p ro b l e m s d i d w e s o l ve ?
Which material should I use? ¤ CMDB can help in the selection of the materials
Where can I get the properties? ¤ CMDB Addon provides 1,200+ Materials Data
How should I orient my fibres / plies? ¤ Quick optimization loops within CompoSIDE
How can I compare total material quantities? ¤ BoMGen automatically provides costs and weights
Slide 40 Copyright CompoSIDE Ltd 2016
G e t s t a r t e d !
Sign up for 30 days free trial!!
Slide 41 Copyright CompoSIDE Ltd 2016
S u p p o r t & Tra i n i n g
Video Tutorials
Live Chat
Support
FAQs
Webinars
Knowledge Base
Online Training
Site Training
Engineering Services
www.composide.com/support-and-training
Slide 42 Copyright CompoSIDE Ltd 2016
Questions & Answers
43 Copyright CompoSIDE Ltd 2016
Thank you
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Copyright CompoSIDE Ltd 2016