simulation-driven design of composite-made cockpit ... · pdf file13.06.2014 ·...
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Unrestricted copy Siemens AG 2014
FEMAP SYMPOSIUM 2014
Discover New Insights Femap Symposium 2014
May 14-16 Atlanta GA USA
Simulation-Driven Design of Composite-Made
Cockpit Aircraft Interior Components
Pier-Olivier Duval eng FEACFD Team Leader Creaform inc
Hugo Bastien eng MScA Senior FEA Engineer Creaform inc
FEMAP SYMPOSIUM 2014
SIMULATION-DRIVEN DESIGN OF COMPOSITE-MADE COCKPIT AIRCRAFT INTERIOR COMPONENTS
AGENDA
Our Organization
Description of our project
Main objectives Project outline
Preliminary Analysis
Detailed Structural Analysis
Modeling Strategies
Abuse load cases
Windmilling Dynamic analysis
Results and Substantiation
Manufacturing
Conclusion
OUR ORGANIZATION
OUR ORGANIZATION
TECHNOLOGY
METROLOGY SOLUTIONS
METROLOGY SERVICES
3D Scanning
Reverse Engineering
Inspection QC
Technology Integration
Application development
NDT SOLUTIONS HEALTH CARE SOLUTIONS
ENGINEERING
ENGINEERING SERVICES
Product development
Tooling design
FEA and CFD
Advanced surfacing
Project management
Consulting Outsourcing
MORE THAN 2000 CUSTOMERS
Aerospace
Consumer Products
Mass Transportation
Energy
FEACFD DEPARTMENT
Structural
Linear and non-linear analysis
bull Implicit and Explicit analysis
bull Modal and buckling analysis
bull Dynamic response (Random amp Sine vibration transient)
bull Contact and assembly
bull Composite analysis
Preparation of test plans and procedures
FEACFD DEPARTMENT
Fluid Dynamics
bull Steady state and transient
bull Optimal turbulence modeling approaches RANS URANS
RSM LES DES
bull Incompressible transonic and compressible flows
bull Rotating equipment and moving bodies
bull Fluid-Structure interaction
bull Heat transfer and thermal modeling
bull Simulation on scan 3D data
OUR PROJECT
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
FEMAP SYMPOSIUM 2014
SIMULATION-DRIVEN DESIGN OF COMPOSITE-MADE COCKPIT AIRCRAFT INTERIOR COMPONENTS
AGENDA
Our Organization
Description of our project
Main objectives Project outline
Preliminary Analysis
Detailed Structural Analysis
Modeling Strategies
Abuse load cases
Windmilling Dynamic analysis
Results and Substantiation
Manufacturing
Conclusion
OUR ORGANIZATION
OUR ORGANIZATION
TECHNOLOGY
METROLOGY SOLUTIONS
METROLOGY SERVICES
3D Scanning
Reverse Engineering
Inspection QC
Technology Integration
Application development
NDT SOLUTIONS HEALTH CARE SOLUTIONS
ENGINEERING
ENGINEERING SERVICES
Product development
Tooling design
FEA and CFD
Advanced surfacing
Project management
Consulting Outsourcing
MORE THAN 2000 CUSTOMERS
Aerospace
Consumer Products
Mass Transportation
Energy
FEACFD DEPARTMENT
Structural
Linear and non-linear analysis
bull Implicit and Explicit analysis
bull Modal and buckling analysis
bull Dynamic response (Random amp Sine vibration transient)
bull Contact and assembly
bull Composite analysis
Preparation of test plans and procedures
FEACFD DEPARTMENT
Fluid Dynamics
bull Steady state and transient
bull Optimal turbulence modeling approaches RANS URANS
RSM LES DES
bull Incompressible transonic and compressible flows
bull Rotating equipment and moving bodies
bull Fluid-Structure interaction
bull Heat transfer and thermal modeling
bull Simulation on scan 3D data
OUR PROJECT
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
AGENDA
Our Organization
Description of our project
Main objectives Project outline
Preliminary Analysis
Detailed Structural Analysis
Modeling Strategies
Abuse load cases
Windmilling Dynamic analysis
Results and Substantiation
Manufacturing
Conclusion
OUR ORGANIZATION
OUR ORGANIZATION
TECHNOLOGY
METROLOGY SOLUTIONS
METROLOGY SERVICES
3D Scanning
Reverse Engineering
Inspection QC
Technology Integration
Application development
NDT SOLUTIONS HEALTH CARE SOLUTIONS
ENGINEERING
ENGINEERING SERVICES
Product development
Tooling design
FEA and CFD
Advanced surfacing
Project management
Consulting Outsourcing
MORE THAN 2000 CUSTOMERS
Aerospace
Consumer Products
Mass Transportation
Energy
FEACFD DEPARTMENT
Structural
Linear and non-linear analysis
bull Implicit and Explicit analysis
bull Modal and buckling analysis
bull Dynamic response (Random amp Sine vibration transient)
bull Contact and assembly
bull Composite analysis
Preparation of test plans and procedures
FEACFD DEPARTMENT
Fluid Dynamics
bull Steady state and transient
bull Optimal turbulence modeling approaches RANS URANS
RSM LES DES
bull Incompressible transonic and compressible flows
bull Rotating equipment and moving bodies
bull Fluid-Structure interaction
bull Heat transfer and thermal modeling
bull Simulation on scan 3D data
OUR PROJECT
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
OUR ORGANIZATION
OUR ORGANIZATION
TECHNOLOGY
METROLOGY SOLUTIONS
METROLOGY SERVICES
3D Scanning
Reverse Engineering
Inspection QC
Technology Integration
Application development
NDT SOLUTIONS HEALTH CARE SOLUTIONS
ENGINEERING
ENGINEERING SERVICES
Product development
Tooling design
FEA and CFD
Advanced surfacing
Project management
Consulting Outsourcing
MORE THAN 2000 CUSTOMERS
Aerospace
Consumer Products
Mass Transportation
Energy
FEACFD DEPARTMENT
Structural
Linear and non-linear analysis
bull Implicit and Explicit analysis
bull Modal and buckling analysis
bull Dynamic response (Random amp Sine vibration transient)
bull Contact and assembly
bull Composite analysis
Preparation of test plans and procedures
FEACFD DEPARTMENT
Fluid Dynamics
bull Steady state and transient
bull Optimal turbulence modeling approaches RANS URANS
RSM LES DES
bull Incompressible transonic and compressible flows
bull Rotating equipment and moving bodies
bull Fluid-Structure interaction
bull Heat transfer and thermal modeling
bull Simulation on scan 3D data
OUR PROJECT
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
OUR ORGANIZATION
TECHNOLOGY
METROLOGY SOLUTIONS
METROLOGY SERVICES
3D Scanning
Reverse Engineering
Inspection QC
Technology Integration
Application development
NDT SOLUTIONS HEALTH CARE SOLUTIONS
ENGINEERING
ENGINEERING SERVICES
Product development
Tooling design
FEA and CFD
Advanced surfacing
Project management
Consulting Outsourcing
MORE THAN 2000 CUSTOMERS
Aerospace
Consumer Products
Mass Transportation
Energy
FEACFD DEPARTMENT
Structural
Linear and non-linear analysis
bull Implicit and Explicit analysis
bull Modal and buckling analysis
bull Dynamic response (Random amp Sine vibration transient)
bull Contact and assembly
bull Composite analysis
Preparation of test plans and procedures
FEACFD DEPARTMENT
Fluid Dynamics
bull Steady state and transient
bull Optimal turbulence modeling approaches RANS URANS
RSM LES DES
bull Incompressible transonic and compressible flows
bull Rotating equipment and moving bodies
bull Fluid-Structure interaction
bull Heat transfer and thermal modeling
bull Simulation on scan 3D data
OUR PROJECT
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MORE THAN 2000 CUSTOMERS
Aerospace
Consumer Products
Mass Transportation
Energy
FEACFD DEPARTMENT
Structural
Linear and non-linear analysis
bull Implicit and Explicit analysis
bull Modal and buckling analysis
bull Dynamic response (Random amp Sine vibration transient)
bull Contact and assembly
bull Composite analysis
Preparation of test plans and procedures
FEACFD DEPARTMENT
Fluid Dynamics
bull Steady state and transient
bull Optimal turbulence modeling approaches RANS URANS
RSM LES DES
bull Incompressible transonic and compressible flows
bull Rotating equipment and moving bodies
bull Fluid-Structure interaction
bull Heat transfer and thermal modeling
bull Simulation on scan 3D data
OUR PROJECT
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
FEACFD DEPARTMENT
Structural
Linear and non-linear analysis
bull Implicit and Explicit analysis
bull Modal and buckling analysis
bull Dynamic response (Random amp Sine vibration transient)
bull Contact and assembly
bull Composite analysis
Preparation of test plans and procedures
FEACFD DEPARTMENT
Fluid Dynamics
bull Steady state and transient
bull Optimal turbulence modeling approaches RANS URANS
RSM LES DES
bull Incompressible transonic and compressible flows
bull Rotating equipment and moving bodies
bull Fluid-Structure interaction
bull Heat transfer and thermal modeling
bull Simulation on scan 3D data
OUR PROJECT
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
FEACFD DEPARTMENT
Fluid Dynamics
bull Steady state and transient
bull Optimal turbulence modeling approaches RANS URANS
RSM LES DES
bull Incompressible transonic and compressible flows
bull Rotating equipment and moving bodies
bull Fluid-Structure interaction
bull Heat transfer and thermal modeling
bull Simulation on scan 3D data
OUR PROJECT
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
OUR PROJECT
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
ABOUT OUR PROJECT
Customer Delastek inc
Location Grand-Megravere Queacutebec Canada
Business Area Aerospace and mass transportation
components integrator
Specialities Electrical integration and composite parts
production
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
ABOUT OUR PROJECT
bull Project Design validate and produce all cockpit interior
components for a new aircraft
bull Schedule About 3 years from initial design (beginning of 2010)
to first production parts delivery
bull Responsibilities of Creaform Structural integrity validation
material qualification and selection
bull Budget About 2700-3000 hours for Creaform FEA experts
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
ABOUT OUR PROJECT
Center Pedestal
bull Carbon fiber outer shell
bull Metal bulkhead
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
ABOUT OUR PROJECT
Glareshield
bull Carbon fiber outer shell and main structural
support
bull Machined aluminum components
bull Components riveted and bonded together
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
ABOUT OUR PROJECT
Side Console
bull Complex carbon fiber shells with
phenolic honeycomb cores
bull Machined aluminum components
bull Components riveted and bonded
together
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
ABOUT OUR PROJECT
Main Instrument Panel
bull Full machined aluminum components
bull Hydro formed sheet metal
bull Components riveted and fastened together
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MAIN OBJECTIVES
PROJECT OUTLINE
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MAIN OBJECTIVES PROJECT OUTLINE
Mass optimisation
Trade-off Aluminium vs
Composite
Targeted Stiffness and
strength based on end
customer requirements
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
CHALLENGES AND REQUIREMENTS
2 Structural Analysis Challenges a) Avoiding useless conservatism
b) Providing safe design guidelines
3 FEA Analyses Lab test interdependence
Mettre images 1 Design Challenges
a Lightweight
b Up to 9G inertial load amp 300 lbs
push loads
c Windmilling requirement (engine
imbalance FAA-AC 25-24)
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
DESIGN INPUTS
Structural support (flight instruments
accessories)
Reduction of effect of glare
Relaxation mean for pilots
Help for pilots movements and seat
LOADS ON COMPONENTS
References (FAA FAR Part 25)
Nature
Loading conditions
Environmental conditions
Purpose and General Function of the Cockpit Interior Components
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
DESIGN INPUTS
Emergency landing inertial load cases
Pilot amp Abuse load cases
Initial loading conditions
Selection of covering load cases
Contact and non-linear analysis
needed in some cases
Emergency amp Abuse Load Cases
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
DESIGN INPUTS
Rotor fan blade loss during
operation
Out-of-balance forces and
vibrations
Specific frequency range
excited
Minimum stiffness requirement
Transmissibility and frequency
response analysis
Windmilling requirement
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
PRELIMINARY ANALYSIS
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
PRELIMINARY ANALYSIS
From previously determined
loads on componentshellip
Load paths
Reaction loads
Line and body diagrams
Modes of failures
Challenges
Accurate representation
Extraction of pertinent
information
LOAD PATHS AND REACTION LOADS
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
PRELIMINARY ANALYSIS
Establishment of
Stiffness guidelines
Attachments guidelines
Challenges
Accurate stiffness
representation
Extraction of pertinent
information
Expected Natural frequencies
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
DESIGN FROM PRELIMINARY ANALYSIS
Initial layup and plies orientation
Aluminium Composite trade-off
Interface (rivets fasteners) using general
design guidelines
Set the baseline for optimization
Composite Parts Definition
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
DETAILED STRUCTURAL ANALYSIS
MODELING STRATEGIES
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MODELING STRATEGIES
From simple to detailed FEM
Few elements preliminary FEMs
Preliminary concepts
Design sensitivity
Detailed final FEMs
Precise stress computation
Adequate representation of stress
concentration regions
Challenges
FEM efficiency
184035 elements
6786 elements
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MODELING STRATEGIES
Styled surfaces and small details
in CAD need to be simplified to
ensure good quality of the mesh
Holes are normally
suppressed
Only Structural parts are
taken into account non-
structural are represented
using mass points
Time used to prepare good
geometry in CAD is time
saved to get good mesh in
CAE
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MODELING STRATEGIES FASTENED JOINT MODELING
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MODELING STRATEGIES FEM
Metallic parts
plate and solid elements
Fasteners
beam elements
Boundary conditions
attachments stiffness
Mesh density and element
quality
Supported Instruments
Contacts
Bonded joints RBE2
RBE3
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MODELING STRATEGIES COMPOSITES
Laminate elements
Oriented bidirectional properties
Fiber and matrix strength
Evolution of layup stiffness and
strength through time non-
linear progressive ply failure
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
Stiffness driven modeling
MODELING STRATEGIES BOUNDARY CONDITIONS
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MODELING STRATEGIES OUTPUT
Stress
Translation
Interface amp fasteners
loads
Safety factor over linear
instability (buckling)
Linear vs non-linear
analysis
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
DETAILED STRUCTURAL ANALYSIS
ABUSE LOAD CASES
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
ABUSE LOAD CASES
Contact and non-linear analysis are not used extensively in aeronautics for this kind of structurehellip
In this case contact algorithm allow very good representation of the structure and avoid the need of full scale test in early design stage
Linear analysis
No Contact
Non-Linear load application and contact
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
ABUSE LOAD CASES
The analysis using contact non-linear application of load and
progressive ply failure analysis allowed to identify high risk of failure
Non-Linear analysis
Contact
PPFA
Bottom view
Non-Linear load application and contact
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
ABUSE LOAD CASES
Evolution of layup stiffness
and strength through time
Simulates progressive rupture
of material
Non-Linear Progressive Ply Failure
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
DETAILED STRUCTURAL ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
WINDMILLING DYNAMIC ANALYSIS
Natural frequencies
Mode Shapes
Modal effective masses
Strain energies
Modal Analysis
Effective Mass Summary
Mode Freq (Hz) Effective mass ()
X Y Z Rx Ry Rz 1 345 07 20 00 19 07 06 2 357 568 01 00 01 552 587 3 360 00 02 61 15 00 00 4 364 21 00 00 00 18 24 5 402 21 01 03 00 21 17 6 494 01 28 665 192 01 01 7 539 175 01 02 02 189 170 8 599 23 17 04 20 22 26 9 679 17 01 01 01 17 16
10 739 01 28 01 20 01 01 hellip hellip hellip hellip hellip hellip hellip hellip 21 1108 02 01 00 01 03 02
TOTAL up to
120 Hz 878 515 917 612 877 894
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
AC
C (
G)
FREQ (Hz)
Diversion mission
Long
Lat
Vert
WINDMILLING DYNAMIC ANALYSIS
Environment built with the
different flight phases
Acceleration levels amp
excitation frequencies are
used directly within Sine
Analysis
Time duration of each flight
phase is used for cumulated
damage calculation
Windmilling Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
WINDMILLING DYNAMIC ANALYSIS
Instruments peak
accelerations amp frequencies
Transmissibility Analysis
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
RESULTS AND SUBSTANTIATION
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
Too low first frequency
caused by an additional
display used only on first
flight vehicle
Stiffness Issues
RESULTS AND SUBSTANTIATION
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
RESULTS AND SUBSTANTIATION
Design philosophy
Targeted Von-Mises
Stress
Linear stability
Metallic Components
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
Composite Parts Fiber amp Matrix failure
Failure in fastened joints area
Custom Composite Failure Criterion amp routine based on detailed test campaign and multi-components stress state
Fatigue amp damage considerations
RESULTS AND SUBSTANTIATION
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
Von-Mises stresses within metallic components
Von-Mises stresses within Composite parts
Complexity of composite parts validation in dynamic analysis
Displacement amp acceleration
Ply stress available in dynamic analysis within Nei Nastran
Sine Analysis
WINDMILLING DYNAMIC ANALYSIS
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
WINDMILLING DYNAMIC ANALYSIS
Dynamic Stress
Cumulated Damage
Sine Analysis
Stress extraction
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
WINDMILLING DYNAMIC ANALYSIS
Composite ply stresses
Composite Failure Indices
Sine Analysis
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
RESULTS AND SUBSTANTIATION
Theoretical computation of safety
factors on metallic components
interfacing
Computation of safety factors based
on test data for composite parts
interfacing Property 30 Rivets Lower Shell - Bracket
Ultimate loading
Element ID Fitting Factor Tension [lbs] Shear [lbs] MStension MSshear MSglobal
1000 115 017 335 143213 11267 gt3
1001 115 022 713 107507 5245 gt3
1003 115 009 140 262775 27106 gt3
1004 115 005 163 497263 23318 gt3
1005 115 002 426 1091486 8847 gt3
1008 115 017 297 137322 12726 gt3
1009 115 022 704 110108 5309 gt3
1011 115 005 032 471713 119535 gt3
1012 115 005 141 469975 26953 gt3
1013 115 002 242 1266684 15658 gt3
Fasteners
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
All joint allowable are obtained through
physical testing
RESULTS AND SUBSTANTIATION
Fasteners
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
Modeling of Bonded amp riveted
joints
Bonded Joints
RESULTS AND SUBSTANTIATION
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
As for joint allowable bonding
allowable are obtained through
physical testing
Correlation between test data and
detailed modelling of test sample
RESULTS AND SUBSTANTIATION
Bonded Joints
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
Full 3D modeling showing peeling
stresses occuring in single lap shear test
Edge of bonded joint are critical
In FE model bonding edges are subjected to singularities and stresses are highly dependant to mesh size
Detailed and simplified FE models are created to replicate the physical testing and determine an allowable for the first row of elements
RESULTS AND SUBSTANTIATION
Bonded Joints
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MANUFACTURING
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MANUFACTURING
Parts and tooling are developed at the
same time by the same team
All tools are linked (ply definition flat
pattern nesting cutting table etc)
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MANUFACTURING
Pre-impregnated composite layer boundaries are projected into the mold using laser projection
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
MANUFACTURING
Parts are cured in autoclave and machined using 5-axis machining for trimming and cut-outs
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
CONCLUSION
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
CONCLUSION
Initial design guidelines
Reduction of full scale tests
Better understanding of failure mechanisms
Optimisation
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
QUESTION
pier-olivierduvalcreaform3dcom
hugobastiencreaform3dcom
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom
2014-05-15
Unrestricted copy Siemens AG 2014
Page 61 Siemens PLM Software
Contact
Pier-Olivier Duval
FEACFD Team Leader
Creaform Engineering Services
5825 St-Georges
Leacutevis Queacutebec G6V 4L2
Canada
Phone (418) 833-4446
Fax (123) 833-9588
pier-olivierduvalcreaform3dcom
Web
wwwcreaform3dcom