Innov Day Composites

Transcription

1 Innov Day Composites Simuler les composites et leur mise en forme avec HyperWorks Innovation Intelligence Pierre-Christophe MASSON 23 Octobre 2014

2 About Us We help businesses succeed through the development and application simulation technology to accelerate innovation Concept Design Software Cloud Software Analytics Software Staffing Services Engineering Services CAE Software Patented Licensing Model HPC Software Industrial Design Services

3 We Work with Some of the Best Automotive Aerospace Heavy Equipment Government Electronics/ Life/Earth Sciences Consumer Goods Energy Architecture 5,000 customers worldwide

4 All Across the Globe 45+ offices in 22 countries on 5 continents with over 2,200 engineers, scientists, developers, designers and creative thinkers

5 Through A Unique Blend of Software and Services HyperWorks Engineering Simulation / Optimization ProductDesign Product Engineering / Development solidthinking Concept Design and Development PBS Works High Performance Computing Cloud Solutions Cloud-based Simulation / Appliances Partner Alliance Enabled Partner Software Applications Altair s focus on software and services is a differentiating hallmark of our business ThinkLabs Human-centered Product Design / Strategy Technical Staffing Business / Engineering Workforce Talent HyperWorks Solutions Tailored Industry / Automation Applications Analytics Solutions Visual / Predictive / Prescriptive Analytics

6 Altair has a unique offering

7 Composite Simulations with HyperWorks

8 HyperWorks Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Composites Overview within HyperWorks CAD & Mfg Interoperability HyperMesh Modern Ply Based Composites Pre-Processing HyperMesh Visualizations Visually Verify the Math Model Realizations translate Ply Based Models to Solver Zone Based Models OptiStruct/RADIOSS Composites Design Optimization & Analysis HyperView Composites Post-Processing & Failure Analysis HyperWorks Partners Detailed Composite Material Modeling & Structural Modeling

9 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

10 Laminate 1 Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Composite Ply-Based Modeling (PCOMPP) PLY 1 Ply 45 PLY 2 Ply 90 PLY 3 Ply 0 PLY 4 Ply 0 PLY 5 Ply 90 PLY 6 Ply 45

11 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 P5-45 P6 90 P7 45 Stack Table Ply Mat Thk Theta P7 M P6 M P5 M P4 M P3 M P2 M P1 M

12 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 Representation 3D Representation with Composite Layers

13 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 Laminate realization RADIOSS & OptiStruct have Embedded Composite Ply Based Modeling in the Solver, no need to Realize Creation of equivalent properties

14 Composite Structure Analysis using RADIOSS Failure Modeling wrt Ballistic impact Bird Strike (Planes, Helicopters) Race Cars design (DALLARA) Helicopter Cabin design (EUROCOPTER)

15 Innovation Intelligence Composite Forming with HyperWorks

16 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

17 Composite Forming with HyperWorks Modeling approaches B-Pillar model example Hyperform updates Mapping Meso to Macro multiscale approach Draping Conclusions

18 Two modeling approaches Sandwich approach Sandwich approach One part of shell elements with One composite material One multi-layers property Independant Layers approach Independant Layers approach N parts of shell elements One material law per layer One property per layer To give tendancies No sliding between layers No coupling between warp and weft directions s11 Contact between layers More accurate Sliding between layers Coupling between warp and weft directions ~ s11

19 Composite Forming with HyperWorks Modeling approaches B-Pillar model example Hyperform updates Mapping Meso to Macro multiscale approach Draping Conclusions

20 B-Pillar model: Material description Glass fibers (70%) Resin (30%) UD E11 = 70%E glass = MPa E22 = 0.3 MPa E33 = 50 MPa Woven fabric E22 = E11 E33 = 50 Mpa Initial shear angle 90 r = 3/7*r resin = 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 4 layers of UD: 0, 45, 90, -45

21 B-Pillar model: Kinematic Sandwich approach The Die is going down to the binder The Die is going down to the punch Independant Layers approach

22 Sandwich approach: blank shape during forming

23 Independant Layers approach: blank end shape Sliding effect between layers Due to fiber orientations 0, 45, 90, -45 regarding X axis, the behavior during stamping is different for each layer

24 B-Pillar model: blank end shape Sandwich approach The same compression, tension and shear zones can be observed Wrinkles may also occur Independant Layers approach

25 B-Pillar model: Fiber Orientations Sandwich approach (0 layer) Fiber orientations are consistent with blank shape Independant Layers approach (layers 45 & 90 )

26 Composite Forming with HyperWorks Modeling approaches B-Pillar model example Hyperform updates Mapping Meso to Macro multiscale approach Draping Conclusions

27 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

28 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 Plies definiton Layers are treated as independant blanks

29 Composite Forming with HyperWorks Modeling approaches B-Pillar model example Hyperform updates Mapping Meso to Macro multiscale approach Draping Conclusions

30 Mapping algorithm Forming side Mapping?? Crash side Target integration points Stamping integration points

31 Fiber directions mapping NEW in HC 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

32 Mapping for independant layers approach Target part Composite layers NEW in HC layers of shell elements (MID 58, PID 16) on 1 layer of shell elements (MAT25) associated with a 4 layer sandwitch property (PROP11)

33 Woven fabric forming history influence on crash Reference model Model initialized with fiber directions from forming stage

34 Composite Forming with HyperWorks Modeling approaches B-Pillar model example Hyperform updates Mapping Meso to Macro multiscale approach Draping Conclusions

35 Meso-scopic scale modeling Strip of shells Angle ~90 Angle < 50 E11 >> E22, E33 Contact interface between fibers

36 Coupling from meso to macro thru mapping Model to map and Target mesh Target part after mapping Angle < 55 Re-zoning according to an angle criterion of 55 E = 70%E, G = 70%G etc Second direction after mapping: angle with the first direction

37 Meso-scopic scale approach: improvements in Mapping Volume of fibers Shear angle Rezoned part Rezoning Criteria Rezoning

38 Using a Mesoscale approach within a Macroscale modeling The maximum shear area is modeled at mesoscopic scale Displacements

39 Composite Forming with HyperWorks Modeling approaches B-Pillar model example Hyperform updates Mapping Meso to Macro multiscale approach Draping Conclusions

40 Drape Estimator for Composite Fibers Calculate Draping angles Thickness variation Interfaces OptiStruct Nastran HM Drape Estimator (white) versus competition (red)

41 Drape Estimator for Composite Fibers Final part geometry OneStep OneStep result : flattened shape Fiber directions Final part initialised with Material/fiber directions Material/Fiber directions defined on the flat reference shape

42 Composite Forming with HyperWorks Modeling approaches B-Pillar model example Hyperform updates Mapping Meso to Macro multiscale approach Draping Conclusions

43 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

44 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

45 Merci de votre attention!