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Innovation Intelligence®
Innov’Day Composites
Simuler les composites et leur mise en forme
avec HyperWorks
Pierre-Christophe MASSON
23 Octobre 2014
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
About Us
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We help businesses
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simulation technology to
accelerate innovation
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We Work with Some of the Best
Automotive Aerospace Heavy Equipment Government
Life/Earth Sciences Energy Architecture
5,000 customers worldwide
Electronics/
Consumer Goods
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All Across the Globe
45+ offices in 22 countries on
5 continents with over 2,200 engineers,
scientists, developers, designers
and creative thinkers
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Through A Unique Blend of Software and Services
ThinkLabs
Human-centered Product Design / Strategy
Analytics Solutions
Visual / Predictive / Prescriptive Analytics
Technical Staffing
Business / Engineering Workforce Talent
HyperWorks Solutions
Tailored Industry / Automation Applications
ProductDesign
Product Engineering / Development
Altair’s focus
on software
and services
is a
differentiating
hallmark of
our business
solidThinking
Concept Design and Development
PBS Works
High Performance Computing
Cloud Solutions
Cloud-based Simulation / Appliances
HyperWorks
Engineering Simulation / Optimization
Partner Alliance
Enabled Partner Software Applications
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Altair has a unique offering
Composite Simulations
with HyperWorks
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Composites Overview within HyperWorks
Hyp
erW
ork
s
HyperMeshModern Ply Based
Composites Pre-Processing
HyperMeshVisualizations
Visually Verify the Math Model
OptiStruct/RADIOSSComposites Design Optimization
& Analysis
HyperViewComposites Post-Processing
& Failure AnalysisHyperWorks Partners
Detailed Composite Material Modeling& Structural Modeling
CAD & Mfg Interoperability
Realizationstranslate Ply Based Models to
Solver Zone Based Models
…
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Composite Zone-Based Modeling (PCOMP)
position PCOMP1 PCOMP2 PCOMP3 PCOMP4 PCOMP5
1 Ply 0° Ply 90° Ply 45° Ply 90° Ply 0°
2 Ply 0° Ply 0° Ply 90° Ply 0° Ply 0°
3 Ply 0° Ply 0° Ply 0°
4 Ply 90° Ply 0° Ply 90°
5 Ply 90°
6 Ply 45°
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Composite Ply-Based Modeling (PCOMPP)L
am
ina
te1
PLY 1 Ply 45°
PLY 2 Ply 90°
PLY 3 Ply 0°
PLY 4 Ply 0°
PLY 5 Ply 90°
PLY 6 Ply 45°
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Composites Technology - Ply Based Modeling
A Composite Part is made up of “n” Plies and One Laminate
No Data Duplication
Direct Relationship to the Manufacturing Process
Ply Based Modeling Process
Define Ply Shapes and Related Ply Data
Define Stacking Sequences
Design Change Requires only 1 Update
P1 45
P2 90
P3 -45
P4 0
P6 90
P7 45
P5 -
45
Stack Table
Ply Mat Thk Theta
P7 M1 0.01 45
P6 M1 0.01 90
P5 M1 0.01 -45
P4 M1 0.01 0
P3 M1 0.01 -45
P2 M1 0.01 90
P1 M1 0.01 45
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Ply Based Modeling – 3D Visualizations
3D Representation of Traditional 1D & 2D Representations
Visually Verify Engineering Data Associated with a Math Model
Traditional 1D & 2D Representation
3D Representation3D Representation with
Composite Layers
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Composites: Model Review and Realization
Ply to zone based model
realization
• Automatic property creation
• Conversion of ply based into
zone based model
Supported interfaces :
• OptiStruct (direct support)
• Nastran
• Abaqus
• Ansys
• LS-Dyna (13.0)
Ply based model
Creation of equivalent properties
Laminate realization
RADIOSS & OptiStruct have
Embedded Composite Ply
Based Modeling in the Solver,
no need to Realize
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Composite Structure Analysis using RADIOSS
Failure Modeling wrt Ballistic impact Bird Strike (Planes, Helicopters)
Race Cars design (DALLARA) Helicopter Cabin design
(EUROCOPTER)
Innovation Intelligence®
Composite Forming
with HyperWorks
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Introduction/Context/History
1) To provide a simple solution which gives tendencies
• Simple set up with reduced numbers of input data
• Accurate enough to give main tendencies
• Fast enough to be used in an industrial context
2) Seamless crash model initialization with forming results
Batch mode
Manufacturing
+
Mapping
Composite Forming with HyperWorks
Modeling approaches
B-Pillar model example
Hyperform updates
Mapping
Meso to Macro multiscale approach
Draping
Conclusions
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Two modeling approaches
Sandwich approach
One part of shell elements with
• One composite material
• One multi-layers property
To give tendancies
No sliding between layers
No coupling between warp and weft
directions
Independant Layers approach
N parts of shell elements
• One material law per layer
• One property per layer
• Contact between layers
More accurate
Sliding between layers
Coupling between warp and weft
directions
Sandwich approach Independant Layers approach
s11 s11~
Composite Forming with HyperWorks
Modeling approaches
B-Pillar model example
Hyperform updates
Mapping
Meso to Macro multiscale approach
Draping
Conclusions
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4 layers of UD: 0°, 45°, 90°, -45°
Resin (30%)
r = 3/7*rresin = 1.09*10-09 Mg/mm³
Go = 0.50 MPa Gs= Go – Gl
Gl = 0.35 MPa β = Gs / η
Β = 5000 s η = 30 Pa*s
Soften heated resin parameters
Glass fibers (70%)
• UD
E11 = 70%Eglass = 50400 MPa
E22 = 0.3 MPa
E33 = 50 MPa
• Woven fabric
E22 = E11
E33 = 50 Mpa
Initial shear angle 90°
B-Pillar model: Material description
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B-Pillar model: Kinematic
The Die is going down
to the binder
The Die is going down
to the punch
Sandwich approach
Independant Layers approach
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Sandwich approach: blank shape during forming
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Sliding effect between layers
Due to fiber orientations 0°, 45°, 90°, -45° regarding X axis, the
behavior during stamping is different for each layer
Independant Layers approach: blank end shape
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B-Pillar model: blank end shape
The same compression,
tension and shear zones
can be observed
Sandwich approach
Independant Layers approach
Wrinkles may also occur
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B-Pillar model: Fiber Orientations
Fiber orientations are consistent
with blank shape
Sandwich approach (0° layer)
Independant Layers approach
(layers 45° & 90°)
Composite Forming with HyperWorks
Modeling approaches
B-Pillar model example
Hyperform updates
Mapping
Meso to Macro multiscale approach
Draping
Conclusions
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HyperForm 13.0 updates for composite forming
Composite available thru User Process tree browser settings
Type of modeling selection popup
Then HF sets up automatically
• Contact interfaces tools and blank(s)
• Contact interface between layers
• Post-treatment cards in engine
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Plies definiton
HyperForm 13.0 updates for composite forming
User Process Tree browser
organisation for the
sandwich approach
User Process Tree browser
organisation for the
independant layers approach
Layers are treated as
independant blanks
Composite Forming with HyperWorks
Modeling approaches
B-Pillar model example
Hyperform updates
Mapping
Meso to Macro multiscale approach
Draping
Conclusions
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Mapping algorithm
Target integration points
Stamping integration points
Forming side Crash side
Mapping
??
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NEW in HC 12.113
Fiber directions mapping
First & Second fiber directions
can be mapped for each layer
Angle between fibers is shown as
iso-values while displaying the
second direction as vector
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Target part
Composite
layers
Mapping for independant layers approach
4 layers of shell elements (MID 58, PID 16) on 1 layer of shell elements
(MAT25) associated with a 4 layer sandwitch property (PROP11)
NEW in HC 12.113
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Woven fabric forming history influence on crash
Reference modelModel initialized with fiber
directions from forming stage
Composite Forming with HyperWorks
Modeling approaches
B-Pillar model example
Hyperform updates
Mapping
Meso to Macro multiscale approach
Draping
Conclusions
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Meso-scopic scale modeling
Strip of shells
E11 >> E22, E33
Contact interface between
fibers
Angle < 50°
Angle ~90°
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Coupling from meso to macro thru mapping
Re-zoning according to an angle
criterion of 55°
E = 70%E, G = 70%G etc …
Angle < 55°
Model to map and Target mesh
Second direction after mapping: angle with the first direction
Target part after mapping
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Meso-scopic scale approach: improvements in 13.110
Volume of fibers
Shear angle
Mapping
Rezoned part
Rezoning Criteria
Rezoning
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Using a Mesoscale approach within a Macroscale modeling
Displacements
The maximum shear area is modeled at mesoscopic scale
Composite Forming with HyperWorks
Modeling approaches
B-Pillar model example
Hyperform updates
Mapping
Meso to Macro multiscale approach
Draping
Conclusions
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Drape Estimator for Composite Fibers
Calculate
• Draping angles
• Thickness variation
Interfaces
• OptiStruct
• Nastran
HM Drape Estimator (white) versus competition (red)
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Drape Estimator for Composite Fibers
OneStep
Final part geometry OneStep result : flattened shape
Material/Fiber directions defined on
the flat reference shape
Final part initialised with
Material/fiber directions
Fiber directions
Composite Forming with HyperWorks
Modeling approaches
B-Pillar model example
Hyperform updates
Mapping
Meso to Macro multiscale approach
Draping
Conclusions
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Conclusions
Several works and studies around composite forming with Radioss
Reduced input data, simple set up, reasonably fast and accurate
Different scales modeling approaches depending on the expected results
Influence of forming results on crash simulation results has been shown
Mapping with re-zoning allows to take into account material degradation
Mapping compatible with sandwitch and multi-layers modeling
Validation is in progress …
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Perspectives
To validate with benchmarks and experimental comparisons
To develop a dual-phase material to model cool and warm resin
To validate and compare draping approach with other methods
To continue to use mesoscopic modeling thru multi-scale coupling or for
macroscopic modeling validation