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

[email protected]

mailto:[email protected]

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

HyperMeshComposites Ply-based Modeling

HyperMeshComposite Draping Simulation

HyperMeshComposite Visualizations

OptiStructComposites Design Optimization

and Analysis

HyperViewComposites

Post-Processing & Failure Analysis

HyperLaminate SolverClassical Lamination Theory

Realizations / AbsorptionsPly-based models to

Zone-based models

HyperWorks PartnersDetailed 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 ProjectionAfter Draping

Simulation


Modern Composite Optimization Methodology

Initial Design

Final Design

Composite Free-Size OptimizationWhat are the most efficient ply shapes?

Composite Size OptimizationHow many piles are required to meet engineering targets?

Composite ShufflingWhat is a probable stacking sequence to meet

manufacturing requirements?

Ply SlicingDetermines 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

kiktLT

1,

iktPGT ,

LT

PGTPGP

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

Dtq

Dd



Initial Design

Final Design







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



Initial Design

Final Design







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

kiktLT

1,

iktPGT ,

LT

PGTPGP

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…



Initial Design

Final Design







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

SteelSheet Metal

AluminumSheet Metal

SteelMachined

AluminumMachined

CompositeBlack

Aluminum

CompositeComposite

Design

Steel vs Aluminum vs CompositePotential Weight Savings

Mass (grams) % Weight Savings


Thank You! Questions?

HyperMeshComposites Ply-based Modeling

HyperMeshComposite Draping Simulation

HyperMeshComposite Visualizations

OptiStructComposites Design Optimization

and Analysis

HyperViewComposites

Post-Processing & Failure Analysis

HyperLaminate SolverClassical Lamination Theory

Realizations / AbsorptionsPly-based models to

Zone-based models

HyperWorks PartnersDetailed Composite Modeling

Draping Simulation & CAD

Interoperability

lightweight design (composites) - americas atc 2015 workshop

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