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MSC Laminate Modeler Version 2008 User's Guide
MSC Laminate Modeler Version 2008 User's Guide
Version 2008
User’s Guide
Main Index
Corporate Europe Asia Pacific
MSC.Software Corporation MSC.Software GmbH MSC.Software Japan Ltd.
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Contents
MSC Laminate Modeler User’s Guide
1 Overview
Purpose 2
2 Tutorial
Introduction 10
Main Index
iv MSC Laminate Modeler User’s Guide
Results Processing 34
Recovering Results by Global Layer 34
Example of a Top Hat Section 34
Benefits of MSC.Laminate Modeler 37
Structural Optimization 38
Introducing Iteration to the Development Process 38
Example of a Torque Tube with a Cutout 38
Benefits of MSC.Laminate Modeler 41
Glossary 42
Element Library 46
Supported Element Topologies 46
Supported Element Types 46
Supported Element Property Words 46
Initialization 48
Creating Materials 49
Create LM_Material Add Form 51
Modify LM_Material Form 52
Show LM_Material Form 53
Delete LM_Material Select Form 54
Creating Plies 55
Create LM_Ply Add Form (Draping) 56
Create LM_Ply Add Form (Projection) 68
Modify LM_Ply Form 69
Show LM_Ply Graphics Form 70
Delete LM_Ply Select Form 71
Main Index
CONTENTS v
4 Example:Laminated Plate
Overview 128
Step-By-Step 132
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vi MSC Laminate Modeler User’s Guide
5 Theory
The Geometry of Surfaces 140
A Bibliography
Main Index
Chapter 1: Overview
MSC Laminate Modeler User’s Guide
1 Overview
J Purpose 2
J MSC.Laminate Modeler Product Information 3
J
What is Included with this Product? 4
J MSC.Laminate Modeler Integration with Patran 5
J What is MSC.Laminate Modeler? 6
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2 MSC Laminate Modeler User’s Guide
Purpose
Purpose
Patran comprises a suite of products written and maintained by MSC.Software Corporation. The core of
the product suite is Patran, a finite element analysis pre and postprocessor. Patran also includes several
optional products such as application modules, advanced postprocessing programs, tightly coupled
solvers, and interfaces to third party solvers. This document describes one of these application modules.
For more information on the Patran suite of products, see the Patran Reference Manual.
MSC.Laminate Modeler is a Patran module for aiding the design, analysis, and manufacture of laminated
composite structures. The user can simulate the application of layers of reinforcing materials to selected
areas of a surface to ensure that a design is realizable. Layers are then used to build up the composite
construction in a manner that reflects the manufacture of the structure. Finite element properties and
laminated materials are automatically generated so that accurate models of the structure can be evaluated
rapidly. Alternative solutions can be compared to optimize the structure at an early stage of the
development process.
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Chapter 1: Overview 3
MSC.Laminate Modeler Product Information
Main Index
4 MSC Laminate Modeler User’s Guide
What is Included with this Product?
Main Index
Chapter 1: Overview 5
MSC.Laminate Modeler Integration with Patran
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6 MSC Laminate Modeler User’s Guide
What is MSC.Laminate Modeler?
Process Simulation
Process simulation methods include draping of fabrics using various material and manufacturing options,
in addition to the more conventional techniques of projecting fibre angles onto a surface. These options
allow the use of MSC.Laminate Modeler for various production methods including manual layup of pre-
preg materials, Resin Transfer Moulding (RTM) and filament winding. Furthermore, MSC.Laminate
Modeler reflects the open systems philosophy of Patran and can cater to customized simulation methods
developed by customers.
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Chapter 1: Overview 7
What is MSC.Laminate Modeler?
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8 MSC Laminate Modeler User’s Guide
What is MSC.Laminate Modeler?
Main Index
Chapter 2: Tutorial
MSC Laminate Modeler User’s Guide
2 Tutorial
J Introduction 10
J Composite Materials and Manufacturing Processes 11
J
Composite Materials and Manufacturing Processes 11
J Composites Design, Analysis and Manufacture 15
J Draping Simulation (Developable Surfaces) 21
J Draping Simulation (Non-Developable Surfaces) 24
J Building Models using Global Layers 30
J
Results Processing 34
J Structural Optimization 38
J Glossary 42
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10 MSC Laminate Modeler User’s Guide
Introduction
Introduction
This manual is intended to introduce the reader to the most common methods of composite manufacture,
and define what is required of an effective tool for simultaneous composites engineering. Thereafter,
some examples of the use of the MSC.Laminate Modeler are presented to illustrate the usefulness of this
module in the composites development process.
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Chapter 2: Tutorial 11
Composite Materials and Manufacturing Processes
Composite Materials
Composite materials are composed of a mixture of two or more constituents, giving them mechanical and
thermal properties which can be significantly better than those of homogeneous metals, polymers and
ceramics. An important class of composite materials are filamentary composites which consist of long
fibres embedded in a tough matrix. Materials of this type include graphite fibre/epoxy resin composites
widely used in the aerospace industry, and glass fibre/polyester mixtures which have wide applicability
in the marine and automotive markets. Because of their predominance in high-quality structures which
need to be analyzed before manufacture, the term composite material will refer to a filamentary
composite having a resin matrix in this document. Furthermore, it will be assumed that the composite is
manufactured in distinct layers, which is appropriate for almost all filamentary composite materials.
By decreasing the characteristic size of the microstructure and providing large interface areas, the
toughness of the composite material is improved significantly compared with that of a homogeneous
solid made of the same material as the fibres. In addition, the manufacturing processes of many
components can be simplified by applying the fibres to the component in a manner which is compatible
with its geometry. These and other considerations mean that composite materials are an effective
engineering material for many types of structure.
However, filamentary composite materials are often characterized by strongly anisotropic behavior and
wide variations in mechanical properties which are a direct result of the manufacturing route for a
component. In addition, the cost of a composite component is highly dependent on the way the fibres are
applied to a surface. This means that designers must be aware of the consequences of manufacturing
considerations from the beginning of the development phase.
Tows
A large proportion of commercially-produced components are built up from layers of fibre tows laid
parallel to each other. Each tow consists of a large number of individual fibres as each fiber is usually too
thin to process effectively. For example, graphite tows typically contain between 1000 to 10000 fibres.
Tows containing many fibres result in cheaper components at some expense of mechanical properties.
Composite structures built up from tows have the greatest volume fraction of fibres which usually lead
to the most favorable theoretical mechanical properties. They are also characterized by extreme
anisotropy. For example, the strength and stiffness of a resulting layer may be ten times greater in the
direction of the fibres compared with an orthogonal direction.
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12 MSC Laminate Modeler User’s Guide
Composite Materials and Manufacturing Processes
Fabrics
Individual tows may also be woven or stitched into fabrics which are used to form the component. This
method effectively allows much of the fibre preparation to be completed under controlled conditions,
while components can be rapidly built up from fabric during the final stage of manufacture.
Composite structures built up from fabrics are generally easier to manufacture and exhibit superior
toughness compared with those built up from tows, with some loss in ultimate mechanical properties.
Mixed
Some processing methods allow the user to mix tows and fabrics to achieve optimum performance. An
example of this is a composite I-beam, where the shear-loaded web consists of a fabric, while the axially-
loaded flanges have a high proportion of fibres oriented along the beam.
Wet Layup
In the wet layup process, fibres are placed on a mould surface in fabric form and manually wetted-out
with resin. Wet layup is widely used to make large structures, like the hulls of small ships.
This process is amenable to high production rates but results in wide variations in quality. In particular,
the inability to control the ratio of fibres to resin means that the mechanical properties of the laminate
will vary from point-to-point and structure-to-structure.
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Chapter 2: Tutorial 13
Composite Materials and Manufacturing Processes
Pre-Preg Layup
In this process, tows or fabrics are impregnated with controlled quantities of resin before being placed on
a mould. Pre-preg layup is typically used to make high-quality components for the aerospace industry.
This process results in particularly consistent components and structures. Because of this, pre-preg
techniques are often associated with sophisticated resin systems which require curing in autoclaves under
conditions of high temperature and pressure. However, the application of pre-preg layers to a surface is
highly labor-intensive, and can only be automated for a small class of simple structures.
Compression Moulding
Compression moulding describes the process whereby a stack of pre-impregnated layers are compressed
between a set matched dies using a powerful press, and then cured while under compression. This method
is often used to manufacture small quantities of high-quality components such as crash helmets and
bicycle frames.
Due to the use of matched dies, the dimensional tolerances and mechanical properties of the finished
component are extremely consistent. However, the requirement to trim the component after curing and
the need for a large press means that this method is extremely expensive. Also, it is very difficult to make
components where the plies drop off consistently within the component.
Filament Winding
In this method, tows are wet-out with resin before being wound onto a mandrel which is rotated in space.
This process is used for cylindrical and spherical components such as pipes and pressure vessels.
Winding is inherently automated, so it allows consistent components to be manufactured cheaply.
However, the range of component geometries amenable to this method is somewhat limited.
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14 MSC Laminate Modeler User’s Guide
Composite Materials and Manufacturing Processes
Of course, the equipment required for manufacture is extremely expensive, being of the order of $1
million. In addition, the possibilities for fibre placement are so controllable that no component can
possibly make use of the capabilities of the process at present. However, the development of CAE tools
for optimized design of composite structures will increase its usefulness in the future.
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Chapter 2: Tutorial 15
Composites Design, Analysis and Manufacture
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16 MSC Laminate Modeler User’s Guide
Composites Design, Analysis and Manufacture
Layer-Based Modeling
The fundamental requirement is that the CAE tools treat the composite structure in a manner which
reflects the real-world structure. In particular, many conventional CAE tools store and manipulate data
on the basis of laminate materials as shown in Figure 2-2. This representation means that the model
becomes extremely complicated as soon as the layers making up the structure overlap. In contrast, all
CAE tools should store the data describing the structure in terms of its constituent layers. This ensures
that the construction is always representative of the manufacturing method, making the model easy to
understand. Furthermore, changes are easily effected by adding and removing layers.
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Chapter 2: Tutorial 17
Composites Design, Analysis and Manufacture
Figure 2-2 Comparison of Global Layer and Laminate Material Descriptions for a Simple
Structure
Visualization Tools
Sufficient visualization tools should be provided to ensure that the form of the structure is easily checked
and communicated. Such tools would include the ability to interrogate the extent and orientation of
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18 MSC Laminate Modeler User’s Guide
Composites Design, Analysis and Manufacture
layers, generate core samples at various points, generate cross sections along arbitrary lines, and generate
a layer sequence table.
Manufacturing Guides
Any CAE tool should produce fool-proof manufacturing guides, so that the design and analyses
components are actually manufactured. For structures manufactured from sheet materials, this could take
the form of a “ply-book” which has a page for every layer. This should present the cutout shape, views
of the three-dimensional moulded shape and other essential information.
Drape Analysis
A large proportion of composite structures are manufactured by placing essentially two-dimensional
sheets of fabric onto three-dimensional surfaces. If the surface has curvature, then the shape of the sheet
cannot be inferred directly from a projection of the surface onto a plane. Therefore, the draping
simulation software must produce the cutout shape of the layer before it is applied to the surface.
If the surface is doubly-curved at any point, it is non-developable. In this case, the sheet material must
shear in its plane to allow it to conform to the surface. The software must illustrate the degree of shearing
in the sheet, and update the material property references to account for the changed material state. The
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Chapter 2: Tutorial 19
Composites Design, Analysis and Manufacture
shearing also means that the orientation of the material changes dramatically over a curved surface. The
correct orientations must therefore be passed through transparently to all relevant analysis codes.
Sheet material can be extremely expensive. Therefore, so-called nesting software should be used to
minimize the material required by aligning and placing the cutouts in an optimum way.
Structural Analysis
Any composite part must be thoroughly analyzed to ensure that it will withstand service loads. Many
composite components are relatively thin so that through-thickness stresses are low. This means that shell
elements can be used to model the structure adequately. However, to model through-thickness stresses,
solid elements must be used. For some problems, such as investigating through-thickness stresses at
edges, many high-order elements will be required through the thickness of the laminate to model stresses
at all reasonably.
A major concern with composite materials are their resistance to damage, as the degradation of the
material is very complex and not well understood. It is, therefore, important that the structural analysis
codes provide for modelling the initiation, growth and effects of defects.
Cure Analysis
The curing of a composite component should be analyzed to determine the cycle time of the process.
Also, it is essential to determine the extent of springback in the cured component.
MSC.Mvision
MSC.Mvision allows the user to store and handle complex materials data such as that required for
composites development.
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20 MSC Laminate Modeler User’s Guide
Composites Design, Analysis and Manufacture
MSC.Laminate Modeler
The MSC.Laminate Modeler adds dedicated layer-based modeling and results processing functionality
to Patran. This support greatly improves the ability of the user to define and modify representative
composite structures, and then analyze their behavior using analysis packages supported by preferences.
The module also includes a drape simulation facility which can handle non-developable surfaces. This
allows the user to understand the deformation required of a sheet of fabric to cover a surface, predicts
realistic material orientations over individual elements, and produces cutout shapes for use by CAM
systems.
Patran FEA
This general-purpose finite element analysis solver includes QUAD4/8 and TRI3/6 laminates shell
elements which account for bending and extension deformation of a shell. The linear strain elements also
model the transverse shear flexibility of the laminate.
HEX8/20 and WEDGE6/15 elements are available to model the flexibility of a laminate in all directions.
All composite elements provide the facility for inputting nonlinear material properties.
Patran Composite
This specialized finite element analysis solver is used for detailed analysis of laminates with complex
fibre geometry or unusual material behavior. It utilizes a family of elements with tri-cubic interpolation
functions, with up to HEX64 topology. These allow the calculation of high stress gradients, such as occur
at free edges or in components which suffer severe thermal stress during processing.
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Chapter 2: Tutorial 21
Draping Simulation (Developable Surfaces)
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22 MSC Laminate Modeler User’s Guide
Draping Simulation (Developable Surfaces)
The MSC.Laminate Modeler can be used to quantify the effect of varying fibre orientation both
qualitatively and quantitatively. For example, if a piece of woven fabric is draped from the middle rib so
that the average angle is +/-45 along the webs of the central rib, we see that the angle on the webs near
the edge of the plate are more like 0/90. This latter direction will obviously result in poor shear stiffness
and strength in this direction.
Having understood this limitation, the designer can then make an informed decision whether to specify
a quai-isotropic layup for the whole of the waffle plate, or to make the waffle plate out of several different
plies oriented in different directions. Both alternatives can be modeled and analyzed rapidly using the
MSC.Laminate Modeler, and an informed choice made on the basis of analysis results.
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Chapter 2: Tutorial 23
Draping Simulation (Developable Surfaces)
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24 MSC Laminate Modeler User’s Guide
Draping Simulation (Non-Developable Surfaces)
Gaussian Curvature
The extent of double curvature at any point is reflected in a value called the Gaussian curvature. This is
the product of the curvatures in the principal directions at any point on a surface. The Gaussian curvature
reveals many of the characteristics of a surface. Positive Gaussian curvature means that the surface is
locally dome-shaped, with the curvatures in the same direction with respect to the surface normal. In
contrast, negative Gaussian curvature implies saddle-shaped topology, with curvatures in opposite
directions. Finally, zero Gaussian curvature is characteristic of a developable area.
Note that surfaces often have varying Gaussian curvature over their extent. As an example, a torus
(donut) is saddle-shaped on the inside (negative Gaussian curvature) but dome-shaped on the outside
(positive Gaussian curvature).
Gaussian curvature can be given a physical significance by drawing geodesic lines on a surface.
(Geodesic lines are straight in the plane of the surface at any point; meridians are geodesic, but lines of
latitude are constantly turning in one direction with respect to the surface.) A pair of lines which are
initially parallel will tend to converge on surfaces of positive Gaussian curvature, but will diverge on a
surface of negative Gaussian curvature. In contrast, the lines will remain parallel on the surface until they
reach an edge if the surface is developable.
Another interpretation of Gaussian curvature is the extent of misfit in the surface. Consider a circular disk
made up of several flat segments. This necessarily has zero Gaussian curvature even if it is bent along
the joints between segments. However, if one of the segments is removed and the neighboring segments
joined, the disk will adopt a dome-like shape which is indicative of positive Gaussian curvature. In
contrast, adding a segment will result in the disk forming a saddle-like shape with negative Gaussian
curvature.
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Chapter 2: Tutorial 25
Draping Simulation (Non-Developable Surfaces)
significant effect. A detailed analysis of the draping process for arbitrary geometries is therefore a
considerable analysis task in itself.
This difficulty in analysis reflects a real-world difficulty in manufacturing complex composite
components consistently. Engineering drawings of composite components typically specify fibre angles
within a tolerance of 3 degrees. In practice, if there is significant curvature in a surface, the manufacturing
tolerance could easily reach 15 degrees or more.
These problems can be mitigated to a large extent by limiting the degree of shear developed within
reinforcing layers during the manufacturing process. The degree of shear is primarily dependent on the
Gaussian curvature and the area of a layer. Therefore, a design incorporating two layers of excessive
shear can be replaced by three smaller layers with less shear and greater quality. The MSC.Laminate
Modeler employs a rapid draping module which allows the designer to investigate the likely degree of
shear, and make rational engineering decisions on the basis of manufacturing simulations.
Whatever simulation process is used, two different levels of draping should be considered. Local
Draping reflects the behavior of an infinitesimal material element applied to a point on a surface having
general curvature. This is a material characteristic and is determined from tests on materials. In contrast,
Global Draping considers how the many material elements are placed on a surface, and is dependent on
the manufacturing process used.
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26 MSC Laminate Modeler User’s Guide
Draping Simulation (Non-Developable Surfaces)
MSC.Laminate Modeler currently supports two local draping algorithms: scissor and slide draping. For
scissor draping (Figure 2-5), an element of material which is originally square shears in a trellis-like
mode about its vertices to form a rhombus. In particular, the sides of the material element remain of
constant length. This type of deformation behavior is characteristic of woven fabrics which are widely
used to manufacture highly-curved composite components.
For slide draping (Figure 2-6), two opposite sides of a square material element can slide parallel to each
other while their separation remains constant. This is intended to model the application of parallel strips
of material to a surface. It can also model, very simply, the relative sliding of adjacent tows making up a
strip of unidirectional material.
When draping a given surface using the two different local draping algorithms, the shear in the layer
builds up far more rapidly for the slide draping mechanism than for the scissor draping mechanism. This
observation is compatible with actual manufacturing experience that woven fabrics are more suitable for
draping curved surfaces than unidirectional pre-pregs.
For small deformations, the predictions of the different algorithms are practically identical. Therefore, it
is suggested that the scissor draping algorithm be used in the first instance.
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Chapter 2: Tutorial 27
Draping Simulation (Non-Developable Surfaces)
For the Planar global draping option, the principal axes may be defined by the intersection of warp (and
weft for scissor draping) planes which pass through the viewing direction. This method is appropriate
where the body has some symmetry, or where the layup is defined on a space-centered rather than a
surface-centered basis.
Finally, the Energy global draping option is provided for draping highly-curved surfaces where the
manufacturing tolerances are necessarily greater. Here, the draping proceeds outwards from the start
point, while the direction of draping is controlled by minimizing the shear strain energy along each edge.
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28 MSC Laminate Modeler User’s Guide
Draping Simulation (Non-Developable Surfaces)
Figure 2-7 Fibre Directions for Draping Starting at the Pole of the Vessel
To cover the same area, it is also possible to begin draping on the cylindrical part of the surface
(Figure 2-8). Because this region is developable, there is no shear deformation until the end cap is
reached. This means that the average degree of shear on the surface is much lower, which should lead to
better quality and better mechanical performance.
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Chapter 2: Tutorial 29
Draping Simulation (Non-Developable Surfaces)
Figure 2-8 Fiber Directions for Draping Starting on the Cylindrical Part of the Vessel
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30 MSC Laminate Modeler User’s Guide
Building Models using Global Layers
Figure 2-9 Spreadsheet For Defining the Layup Using Predefined Layers
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Chapter 2: Tutorial 31
Building Models using Global Layers
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32 MSC Laminate Modeler User’s Guide
Building Models using Global Layers
In contrast, the MSC.Laminate Modeler user simply needs to define four layers which cover the areas of
each laminate. Then, multiples of these layers are added to the model, using the layup spreadsheet.
Because the surface is developable, it is permissible to use the Angular Offset option to modify the
orientation of the plies at 45, 90 and -45 to the original layers. All the generation of representative
property regions would be handled completely automatically by the software.
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Chapter 2: Tutorial 33
Building Models using Global Layers
The greatest benefit would, of course, accrue if the model needed to be changed after a preliminary
analysis. For example, the user may wish to define localized reinforcement at the attachment end of the
section. This could be completed in a matter of minutes by defining additional layers and adding them to
the layup.
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34 MSC Laminate Modeler User’s Guide
Results Processing
Results Processing
Figure 2-13
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Chapter 2: Tutorial 35
Results Processing
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36 MSC Laminate Modeler User’s Guide
Results Processing
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Chapter 2: Tutorial 37
Results Processing
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38 MSC Laminate Modeler User’s Guide
Structural Optimization
Structural Optimization
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Chapter 2: Tutorial 39
Structural Optimization
Models were built with a uniform layup, and including layer_2 reinforcement around the cutout.
Analyses were then conducted for both configurations. As shown in the deformation plot in Figure 2-19,
the torsional load generates substantial out-of-plane deflections around the cutout. Therefore, it is to be
expected that reinforcing the cutout edge will have a significant effect on the structural performance of
the tube.
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40 MSC Laminate Modeler User’s Guide
Structural Optimization
The analysis results for both models are summarized in the table below.
This clearly shows that the addition of local reinforcing in highly-loaded areas can have an extremely
significant effect on overall structural performance. By allowing the designer to quantify the effects of
localized reinforcement, the MSC.Laminate Modeler will enable the development of more efficient
structures.
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Chapter 2: Tutorial 41
Structural Optimization
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42 MSC Laminate Modeler User’s Guide
Glossary
Glossary
(ISO 10303 equivalent terms in parentheses)
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Chapter 3: Using MSC.Laminate Modeler
MSC Laminate Modeler User’s Guide
J Procedure 44
J Element Library 46
J
Initialization 48
J Creating Materials 49
J Creating Plies 55
J Creating a Layup and an Analysis Model 72
J Creating Solid Elements and an Analysis Model 87
J
Creating Laminate Materials 89
J Creating Sorted Results 95
J Creating Failure Results 98
J
Creating Design and Manufacturing Data 101
J
Importing Plies and Models 103
J
Importing and Exporting Laminate Materials 106
J
Setting Options 109
J Session File Support 116
J Public PCL Functions 117
J Data Files 125
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44 MSC Laminate Modeler User’s Guide
Procedure
Procedure
The MSC.Laminate Modeler is a specialized tool for the creation and visualization of a ply-based
laminated composite model. An analysis model consisting of appropriate laminate materials and element
properties can be generated automatically for a number of different analysis codes. Following analysis,
specific composite results can be calculated to verify the performance of the model. The general process
for generating a laminate composite model is as follows:
1. Create Homogeneous Materials (Patran)
Materials are typically orthotropic, and the user should specify failure coefficients when defining
materials.
2. Create Mesh (Patran)
The surface on which the composite layup is to be built is defined by the shell elements of the
finite element mesh in the Patran database. The user should generate a mesh of sufficient
resolution for both drape simulation and analysis purposes. It is a requirement that the meshing is
completed before starting a session. Use the tools in the Finite Element application to verify the
element normals and the free edges of the model before creating a new Layup file.
3. Create Ply Materials (MSC.Laminate Modeler)
These materials are analogous to raw ply materials and include a reference to a homogeneous
material for specifying mechanical properties, as well as manufacturing related information like
thickness.
4. Create Plies (MSC.Laminate Modeler)
Create plies in a manner which reflects the manufacturing process.
5. Create a LM_Layup and an Analysis Model (MSC.Laminate Modeler)
A layup, or sequence of plies, is defined, allowing the creation of corresponding laminate
materials and element properties required to define an analysis mode..
6. Analyze (Patran and analysis code)
The analysis is submitted in the usual way. The user may have to explicitly request layered
composites results from the analysis code.
7. Create Results (MSC.Laminate Modeler)
The user may sort results on the basis of physical plies or define new ones based on a failure
analysis.
These operations are summarized schematically overleaf.
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Chapter 3: Using MSC.Laminate Modeler 45
Procedure
Overview
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46 MSC Laminate Modeler User’s Guide
Element Library
Element Library
Standard shell elements define the surfaces used in the MSC.Laminate Modeler module. The standard
Patran geometry and mesh generation commands can be used to create a valid model.
The elements in the Patran database are used to define the draping surface in addition to acting as analysis
elements
After the laminate descriptions have been generated they are applied to the Finite Element model in a
controlled manner. The user is allowed to select the type of element for the currently selected analysis
preference.
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Chapter 3: Using MSC.Laminate Modeler 47
Element Library
If the applicable data type for the prop_ids described is not available, then the MSC.Laminate Modeler
cannot generate the required property cards.
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48 MSC Laminate Modeler User’s Guide
Initialization
Initialization
The initialization form controls the opening of the current MSC.Laminate Modeler database (Layup) file
and the resultant display of the main Action Object Method control forms. To display the initialization
form, select MSC.Laminate Modeler from the Tools menu.
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Chapter 3: Using MSC.Laminate Modeler 49
Creating Materials
Creating Materials
When using MSC.Laminate Modeler there are three levels of material generation.
1. Patran homogeneous materials should be generated using standard Patran functionality. These
contain mechanical, thermal or physical data which can be manually input or imported Using
Patran Materials (p. 10) in the Patran Materials Enterprise.
1. MSC.Laminate Modeler ply materials. These ply materials have thickness and manufacturing
data in addition to a reference to an appropriate material in the Patran database. These ply
materials are used to create plies in the MSC.Laminate Modeler module.
1. Patran laminate materials which are built up from Patran homogeneous materials by the
MSC.Laminate Modeler software on the basis of the user-specified layup sequence, offsets and
tolerances.
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Creating Materials
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Creating Materials
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Creating Materials
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Creating Materials
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Creating Materials
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Creating Plies
Creating Plies
What is a Ply?
A ply is an area of LM_Material which is stored and manipulated as a single entity. A ply represents a
piece of reinforcing fabric which is cut from sheet stock and placed on a mould during the manufacturing
process. A ply is fully characterized by the LM_Material it is made of, the area it covers, and the way in
which it is applied to the surface. The latter is particularly important for non-developable surfaces where
there are many different ways of placing the fabric on a surface.
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Creating Plies
Note: When a ply is created, a group of the same name and containing the Area Definition entities
is created.
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Creating Plies
Start Point
This defines the starting point of the drape simulation process. It is analogous to the point at which a ply
is first attached to a mould surface during manufacture. As the distortion usually increases away from the
starting point, it is best to begin draping near the center of a region to minimize shear distortion. If the
start point coordinates do not lie on the selected surface, the coordinates are projected onto the surface
along the application direction vector. The start point must lie on the selected area.
Application Direction
The application direction defines the side of the surface area on which a ply is subsequently added when
the final layup is defined. The “Top” of the surface covered by the ply is defined as the side on which the
ply is originally applied when created. When defining a layup, the ply can be added to the “Top” or
“Bottom” side of the mesh. It follows that the “Top” side is the same side as the application direction
used to define the ply, whereas the “Bottom” side is the side opposite the application direction.
The concept of side is very important as composite structures are often built using molds or forms,
limiting the side of application to a single direction. The plies of reinforcing fabric can be added to either
the outside of a male mould or the inside of a female mould. When defining plies and a layup, it is useful
to consider the manufacturing process.
The application direction is also used to project the start point and reference direction onto the surface.
Reference Direction
The reference direction is used to specify the initial direction of the fabric. The input vector is projected
onto the surface along the application direction to define the principal warp axis of the material at the
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Creating Plies
start point. Note that the direction of the material will usually change away from the starting point if the
surface is curved.
Reference Angle
The principal warp axis of the material on the surface can be rotated from the reference direction by
inputting a non-zero reference angle. This rotation is counterclockwise when viewed along the
application direction.
Note that the application direction is used to project the start point and reference direction vector onto the
selected surface. This means that the same start point and reference direction vector results in different
values when projected onto the surface along different application directions, as shown in Figure 3-4. It
follows that the start point and reference direction should be defined as close to the surface as practical,
while the application direction should be defined as perpendicular to the surface as possible.
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Creating Plies
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Creating Plies
This example shows the view as it would appear in the viewport in addition to the input that would appear
on the Create LM_Ply Add form.
Axis Type
The principal warp and weft axes are the paths the warp and weft fibers follow along the surface away
from the start point. By defining the paths of the principal axes, it is possible to constrain the ply uniquely
in the region bounded by the principal axes.
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Creating Plies
• Planar
The principal axes are defined by the intersection of planes defined by the start point, application
direction and reference direction rotated about the application direction through the reference
angle.
Extension Type
The extension type controls the draping process if no axis type is defined, or the draping extends beyond
the region uniquely defined by the principal axes. In this case, the material cells on each edge are
kinematically unconstrained, and so some extension type must be specified to control the extension of
the fabric.
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Creating Plies
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Creating Plies
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Creating Plies
Note: Avoid starting to drape near split definitions to prevent ambiguous draping results.
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Creating Plies
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Creating Plies
Note: This capability is particularly useful when draping over a series of conical sections. First
drape the most critical section, ensuring minimal shear. Thereafter, drape peripheral areas.
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Creating Plies
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Creating Plies
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Creating Plies
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Creating Plies
Note: When an LM_Ply is deleted, the group of the same name created at LM_Ply creation time
will also be deleted.
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Creating a Layup and an Analysis Model
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Creating a Layup and an Analysis Model
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Creating a Layup and an Analysis Model
The spreadsheet is used to specify which of the previously defined LM_Plies are used in the generation
of the model LM_Layup. The form allows the selection and ordering of the required LM_Plies.
Manipulation of the LM_Plies within the spreadsheet is used to create different stacking sequences
and layups.
Select the specific LM_Ply from the definitions in the Existing LM_Plies frame The method of
application of that LM_Ply to the existing layup is controlled by the LM_Layup Controls. Continue by
Adding, Inserting, and Deleting LM_Plies until the LM_Layup is finished.
LM_Plies can be added to the layup at any time to reinforce the model between analyses. The ability to
redefine laminates rapidly is one of the key features of the MSC.Laminate Modeler.
The spreadsheet works in two distinct but connected modes. They are called “Expanded” and
“Compressed.” In expanded mode, the multiplier column on the spreadsheet is always set equal to 1. This
enables you to work at the level of single LM_Plies and the Delete and Replace commands will only act
on the single LM_Ply selected. In compressed mode, the Delete and Replace commands can be used to
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Creating a Layup and an Analysis Model
do multiple “single actions” at the same time. For example, if a row is specified as having a multiplier of
10, then a replace instruction will replace all 10 rows with the new LM_Ply. The same is true for delete.
You can switch between the two methods at any time and take advantage of the quicker set up time of
the stack building, while still being able to modify the LM_Ply sequence at the single LM_Ply level if
required.
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Creating a Layup and an Analysis Model
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Creating a Layup and an Analysis Model
Important: Ignore Offsets is required for analysis preferences like ABAQUS and Patran
Advanced FEA which do not allow any offset definition for composite shells. This is
not the same as having an offset = 0.0. An offset with a specified value will cause an
error as it is interpreted as a set value.
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Creating a Layup and an Analysis Model
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Creating a Layup and an Analysis Model
As only a single layup is allowed in a single Layup file, the form for layup modification is identical to
that for layup creation.
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Creating a Layup and an Analysis Model
This capability allows the user to verify the definition and application direction of the plies defined in
a layup.
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Creating a Layup and an Analysis Model
This capability allows the user to define cross-section plots of the plies defined in a layup.
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Creating a Layup and an Analysis Model
This capability allows the user to verify the resulting layup on individual elements. Visualization
capabilities are similar to those provided by the Show Laminate function.
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Creating a Layup and an Analysis Model
This capability allows the user to model a repeated unit of a symmetrical model, and mirror as appropriate
to generate the full model. For example, only one half of a composite chassis may be modeled prior to
mirroring the mesh and layup about the center plane.
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This form allows the user to delete the single layup defined in the current Layup file.
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Creating Solid Elements and an Analysis Model
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Creating Solid Elements and an Analysis Model
This capability allows the user to generate solid elements and the associated materials and element
properties needed for detailed analysis of thick laminates.
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Creating Laminate Materials
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Creating Laminate Materials
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Creating Laminate Materials
Preview Form
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Creating Laminate Materials
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Creating Laminate Materials
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Creating Laminate Materials
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Creating Sorted Results
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Creating Sorted Results
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Creating Sorted Results
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Creating Failure Results
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Creating Failure Results
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Creating Failure Results
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Creating Design and Manufacturing Data
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Creating Design and Manufacturing Data
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Importing Plies and Models
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Importing Plies and Models
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Importing Plies and Models
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Importing and Exporting Laminate Materials
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Importing and Exporting Laminate Materials
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Importing and Exporting Laminate Materials
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Setting Options
Setting Options
Options for the display of graphical information in a viewport, and the export of manufacturing data,
must be set before creating plies and layups.
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Setting Options
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Setting Options
The 2D flat pattern shape can be generated in different formats. The DXF format is typically used to drive
nesting and cutting machines.
Note that the flat pattern shape does not indicate the edges of the fabric where the maximum strain value
has been exceeded.
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Setting Options
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Setting Options
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Setting Options
The flat pattern shape is displayed on the screen perpendicular to the application direction arrow. The
variation that occurred between the draped fabric on the model and the undeformed fabric shape can
be seen.
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Setting Options
Figure 3-10 Flat Pattern Displayed for Surface with Split Definition
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Session File Support
It is also advisable to change the full path names for the files to just the file names. For example:
“/usr/people/demo/test/testrun. Layup” becomes “testrun.Layup”.
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Public PCL Functions
p3cm.new ( <filename> )
Input:
STRING <filename> Name of the new Layup file.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine is
successful.
Begins a MSC.Laminate Modeler session using a new Layup file with the name <filename>.
p3cm.open ( <filename> )
Input:
STRING <filename> Name of the existing Layup file.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine is
successful.
Begins a MSC.Laminate Modeler session by opening an existing Layup file with the name <filename>.
p3cm.save_as ( <filename> )
Input:
STRING <filename> Name of the target Layup file.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine
is successful.
Saves a copy of the current Layup file with the name <filename>.
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Public PCL Functions
Input:
STRING <type-name> Application type.
STRING <material_name> Material name.
STRING <analysis_material_name> Analysis material name.
REAL <thickness> Initial thickness of the ply material.
REAL <max_strain> Maximum permissible strain of the ply material.
REAL <warp_weft_angle> Initial angle between warp and weft fibres.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the
routine is successful.
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Public PCL Functions
Input:
STRING <type_name> Application type.
STRING <material_name> Ply material name.
STRING <ply_name> Ply name.
REAL ARRAY <start_pt> Coordinates of starting point.
REAL ARRAY <appliqueing> Vector defining application direction.
REAL ARRAY <ref_dirn> Vector defining the reference direction.
REAL <ref_ang> Reference angle.
REAL <warp_weft_angle> Initial angle between warp and weft fibres.
REAL <max_strain> Maximum permissible strain of the ply material.
REAL <step_length> Step length.
INTEGER <axis_type> Axis type.
INTEGER <max_sweeps> Maximum number of sweeps.
REAL ARRAY <bounds> Maximum fabric bounds.
STRING <area_str> Selected area.
STRING <split_str> Split definition.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the
routine is successful.
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Public PCL Functions
Input:
INTEGER <num_plies> Number of plies.
STRING ARRAY <ply-names> Ply names.
STRING ARRAY <type_names> Application types.
INTEGER ARRAY <instances> Instances.
STRING ARRAY <sides> Side of application.
REAL ARRAY <offsets> Angular offset values.
INTEGER <num_offs> Number of offset regions defined.
REAL ARRAY <off_values> Value of offset.
STRING ARRAY <off_flags> Side of offset.
REAL ARRAY <off_starts> Coordinates of starting points for offset definition.
REAL ARRAY <off_views> Vectors defining view direction for offsets.
STRING ARRAY <off_areas> Selected areas for offset definition.
INTEGER <num_tols> Number of tolerance regions defined.
REAL ARRAY <ang_tols> Angular tolerance values (degrees).
REAL ARRAY <thick_tols> Thickness tolerance values(degrees).
STRING ARRAY <tol_areas> Selected areas for tolerance definition.
LOGICAL <model_flag> Generate analysis model.
STRING <element_type> Selected element type.
LOGICAL <solid_flag> Generate solid element file.
LOGICAL <bacon_flag> Generate BACON command file.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the
routine is successful.
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Public PCL Functions
Input:
STRING <type_name> Application type.
STRING <material_name> Material name.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine
is successful.
Input:
STRING <type_name> Application type.
STRING <ply_name> Ply name.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the
routine is successful.
p3cm.create_results_sort (<res_names> )
Input:
STRING ARRAY <res_names> A string array containing the loadcase name, subcase
name, primary label, secondary label and dummy
layer name of result to be sorted.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine
is successful.
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Public PCL Functions
p3cm.create_results_failure (<res_names>,<area>,<criterion>,<basis>,
<num_mats>,<mat_names>,<mat_allows>,
<name>,<ply_sort>,<ply_results>,<failure_index>,
<reserve_factor>,<margin_safety>,<critical_compo
nent>,<critical_ply> )
Input:
STRING ARRAY <res_names> A string array containing the loadcase name, subcase
name, primary label, secondary label and dummy layer
name of result to be sorted.
STRING <area> A list of elements for which results are to be calculated.
STRING <criterion> The name of the criterion to be used.
STRING <basis> The basis to be used: "STRESS" or "STRAIN".
INTEGER <num_mats> The number of material allowables.
STRING ARRAY <mat_names> A <num_mats> array of material names.
REAL ARRAY <mat_allows> A <num_mats>x<8> array of material allowables.
STRING <name> Result name.
LOGICAL <ply_sort> Flag to sort ply results by LM_Ply. (Not yet
implemented.)
LOGICAL <ply_results> Flag to generate failure index, reserve factor, margin of
safety and critical component results for every ply in the
Patran database. (Not yet implemented.)
LOGICAL <failure_index> Flag to generate failure index results in the Patran
database. (Not yet implemented.)
LOGICAL <reserve_factor> Flag to generate failure index results in the Patran
database. (Not yet implemented.)
LOGICAL <margin_safety> Flag to generate margin of safety results in the Patran
database.
LOGICAL <critical_component> Flag to generate margin of safety results in the Patran
database.
LOGICAL <critical_ply> Flag to generate critical ply results in the Patran database.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine is
successful.
Creates composite failure index results. These are stored in a text file and optional results in the Patran
database.
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Public PCL Functions
Input:
LOGICAL <msg> Display the message file.
LOGICAL <ply_gr> Display the ply graphics control form.
LOGICAL <layup_gr> Display the layup graphics control form.
LOGICAL <view> Display the view direction arrow of a ply.
LOGICAL <init> Display the reference direction arrow of a ply.
LOGICAL <maxstrn> Display the maximum strain value of a ply.
LOGICAL <area> Display the border of the selected area of a ply.
LOGICAL <cutout> Display the 2D flat pattern of a ply.
LOGICAL <pattern> Display the 3D draped pattern of a ply.
LOGICAL <offset> Display the angles of the surface plies of a layup.
LOGICAL <angles> Display the angles of a ply.
REAL <offval> Offset value of the 2D flat pattern of a ply.
REAL <scale> Scale value of the angles of the surface plies of a layup.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine is
successful.
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Public PCL Functions
Input:
LOGICAL <pat> Export the 3D draped pattern.
LOGICAL <cut> Export the 2D flat pattern.
LOGICAL <mould> Export mould surface.
LOGICAL <iges> Export files in IGES format.
LOGICAL <dxf> Export files in DXF format.
LOGICAL <post> Export files in postscript format.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine is
successful.
p3cm.delete_properties_all ()
Input:
None.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine is
successful.
p3cm.delete_laminates_all ()
Input:
None.
Output:
INTEGER <Return Value> Status return value. The value will be 0 if the routine is
successful.
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Data Files
Data Files
MSC.Laminate Modeler uses a variety of files to store and communicate the extensive data required for
composites analysis. The file name prefix <filename> is set when entering the MSC.Laminate Modeler.
The default prefix is the name of the database. For data files, additional suffices <.bak>, <.igs>, <.dxf>
and <.ps> denote backup, IGES, DXF or postscript files respectively.
1. <filename>.Layup
This is the external MSC.Laminate Modeler database.
2. <filename>.lm_msg
This message file is produced by the “layup” executable and provides a record of the ply
application and manipulation processes. Any errors will always be reported in this file. This file
can be displayed automatically after every user command by setting a toggle on the Set Display
Options form.
3. <filename>.lm_mould
This file contains mould surface data.
4. <filename>.lm_solid
This file contains data describing solid elements created by extruding the shell elements through
the thickness of the plies.
5. <filename>.lm_bacon
This file contains BACON (SAMCEF preprocessor) commands to build the analysis model.
6. <filename>.lm_report
This file contains a text summary of the layup.
7. <filename>.lm_results
This file contains the results of a laminate failure analysis.
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Data Files
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Chapter 4: Example:Laminated Plate
MSC Laminate Modeler User’s Guide
4 Example:Laminated Plate
J Overview 128
J Model Description 129
J
Modeling Procedure 130
J Step-By-Step 132
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Overview
Overview
This example will show the use of MSC.Laminate Modeler by building and modifying a simple layup on
a flat plate. The Functionality shown is extendable to general shapes.
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Model Description
Model Description
• L=Length = 10 units
• H=Height = 6 Units
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Modeling Procedure
Modeling Procedure
Step 1: Open a new database and set parameters
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Modeling Procedure
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Step-By-Step
Step-By-Step
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Step-By-Step
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Step-By-Step
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Step-By-Step
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Step-By-Step
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Step-By-Step
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Step-By-Step
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Chapter 5: Theory
MSC Laminate Modeler User’s Guide
5 Theory
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The Geometry of Surfaces
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The Geometry of Surfaces
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The Fabric Draping Process
Local Draping
Local draping is concerned with fitting a small section of material to a generally curved surface. If the
surface has nonzero Gaussian curvature, the material element must shear in its plane to conform to the
surface. This deformation is highly dependent on the microstructure of the material. As a result, local
shearing behavior can be regarded as a ply material property.
MSC.Laminate Modeler currently supports two local draping algorithms: scissor and slide draping. For
scissor draping, an element of material which is originally square shears in a trellis-like mode about its
vertices to form a rhombus. In particular, the sides of the material element remain of constant length. This
type of deformation behavior is characteristic of woven fabrics which are widely used to manufacture
highly-curved composite components.
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The Fabric Draping Process
For slide draping, two opposite sides of a square material element can slide parallel to each other while
their separation remains constant. This is intended to model the application of parallel strips of material
to a surface. It can also model, very simply, the relative sliding of adjacent tows making up a strip of
unidirectional material.
When draping a given surface using the two different local draping algorithms, the shear in the plies
builds up far more rapidly for the slide draping mechanism than for the scissor draping mechanism. This
observation is compatible with actual manufacturing experience that woven fabrics are more suitable for
draping curved surfaces than unidirectional pre-pregs.
For small deformations, the predictions of the different algorithms are practically identical. Therefore, it
is suggested that the scissor draping algorithm be used in the first instance.
Global Draping
Global draping is concerned with placing a real sheet of material onto a surface of general curvature. This
is not a trivial task as there are infinite ways of doing this if the surface has nonzero Gaussian curvature
at any point. Therefore, it is important to define procedures for the global draping simulation which are
reproducible and reflect what can be manufactured in a production situation. As a result, global draping
behavior can be regarded as a manufacturing, rather than material, property.
MSC.Laminate Modeler currently supports three different global draping algorithms: Geodesic, Planar
and Energy. For the Geodesic global draping option, principal axes are drawn away from the starting
point along geodesic paths on the surface (i.e., the lines are always straight with respect to the surface).
Once these principal axes are defined, there is then a unique solution for draping the remainder of the
surface. This may be considered the most “natural” method and appropriate for conventional laminating
methods. However, for highly-curved surfaces, the paths of geodesic lines are highly dependent on initial
conditions and so the drape simulation must be handled with care.
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The Fabric Draping Process
For the Planar global draping option, the principal axes may be defined by the intersection of warp (and
weft for scissor draping) planes which pass through the viewing direction. This method is appropriate
where the body has some symmetry, or where the layup is defined on a space-centered rather than a
surface-centered basis.
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The Fabric Draping Process
Finally, the Energy global draping option is provided for draping highly-curved surfaces where the
manufacturing tolerances are necessarily greater. Here, the draping proceeds outwards from the start
point, while the direction of draping is controlled by minimizing the shear strain energy along each edge.
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The Fabric Draping Process
Note that all draping simulations are discrete and use a specific step length. A default value is calculated
on the basis of the area of the selected region. This may be modified or overridden, using the step length
databox on the Additional Controls/Geometry form.
The sections above relate only to how the fabric algorithm works internally. When the graphics are drawn
to the screen, they are drawn in the same manner for all of the selected types, if applicable. The fabric
drawing to the screen has no relevance to the method that the fabric generation routine executed. In
particular, do not expect to see the fabric being drawn in a manner similar to the calculation method for
the Energy Option.
Projected Angles
MSC.Laminate Modeler supports two different methods of projecting fiber angles onto a surface. In the
first Planar method, the angles are defined by the intersection of parallel planes with the surface. Using
the Axis method, axes are projected onto the elements and rotated as specified. The appropriate method
will depend on the manufacturing process followed.
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The Fabric Draping Process
Using the “Plane X-axis” option, a plane passing through the Z-axis and rotated through an angle α from
the X-axis. The elemental material angle is the angle between the intersection of this plane, or one parallel
to it, with the element and the first edge of the element.
“Plane Y-axis” uses plane through X-axis measured from Y-axis.
“Plane Z-axis” uses plane through Y-axis measured from Z-axis.
Using the “Project X-axis” option, the global X-axis is projected normally onto the element at the first
node. This axis is then rotated through the reference angle α in the counter (anti-) clockwise direction
from the viewing point. It is important to note that the element material angle θ is generally not equal the
angle α.
“Project Y-axis” uses the Y-axis
“Project Z-axis” uses the Z-axis
MSC.Laminate Modeler also allows the user to define angles with respect to the element datum (i.e., the
first edge of the element). This feature can also be used to visualize the relative orientation of elements
where this is not immediately obvious, such as if the pave mesher is utilized.
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The Fabric Draping Process
sharp edges). However, the simulation is likely to fail where it is physically impossible to drape a real
sheet of material.
Geometrical features leading to poor draping include:
1. Excessive Gaussian Curvature. For example, the apex of a cone has extreme Gaussian
curvature, and is therefore impossible to drape realistically. The user should use the Split
Definition facility to cut the cone between its base and apex before simulating the drape.
2. Holes in Surfaces. It is recommended that holes be temporarily filled with dummy elements
while a layup is being defined. If these elements are put in a separate Patran group, they can be
excluded from the analysis by only analyzing the current group.
3. Incomplete Boundary Definition. Many surfaces, such as cylinders, do not have a complete
boundary; draping will continue around the body until an internal program storage limit is
reached. Define artificial boundaries using the split definition facility on the Create LM_Ply,
Additional Controls, Definition form.
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Chapter 5: Theory 149
The Fabric Draping Process
4. “T” Sections. These can be draped along three separate paths. The user must make sure that the
correct elements are selected, and that a consistent definition of top and bottom surfaces is
maintained. This prevent plies crossing over unexpectedly.
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The Fabric Draping Process
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Chapter 5: Theory 151
Results for Global Plies
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Results for Global Plies
Example
Spectrum was updated for each picture so contours were assigned per plot.
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Chapter 5: Theory 153
Results for Global Plies
As can be seen, the analysis references to plies can be in error. This rearrangement of results does not
give “better” or “more accurate results” but provides a more realistic grouping of results. The
functionality can be used to rearrange any results stored and referenced by plies in the database. For
example, you could create failure criteria results using P/LAM or an in-house program, read the results
into Patran, and then sort these results on the basis of global plies. The initial release of this functionality
extracts and creates results at element centroids.
Some more simple examples can be used to help visualize the difference.
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Results for Global Plies
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Chapter 5: Theory 155
Composite Failure Criteria
Nomenclature
Failure criteria compare the loading state at a point (stress or strain) with a set of values reflecting the
strength of the material at that point (often referred to as the material allowables). Both loading and
strength values should be reflected in the same material coordinate system. For unidirectional materials,
this is typically in the direction of the fibres. However, for woven and knitted fabrics , this direction is
not obvious, and might change as the material is formed to shape.
In general, the load is represented by a full stress or strain tensor having six independent components. By
convention, for lamina materials the material X axis lies in the direction of the warp fibres while the Z
axis lies in the through-thickness direction of the sheet. Note than in Patran, shear strains are stored in
tensor rather than engineering notation, and any experimental failure strengths should reflect this.
STRESS σx,σy,σz,τxy,τyz,τxz
STRAIN εx,εy,εz,γxy,γyz,γxz
The strength of a composite can be expressed by an arbitrarily large number of values, depending on the
complexity of the failure criterion. However, lamina materials, used in composites, are often assumed to
be orthotropic; the through-thickness stresses or strains are ignored and it is assumed that there is
negligible interaction between the different failure modes. The strength of the material can therefore be
represented by seven independent variables:
In the Tsai-Wu criterion, these values have been supplemented by an interaction term which reflects the
interdependence of failure modes due to loading along both the X and Y material directions.
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Composite Failure Criteria
Note that the above values can be applied to either stress or strain.
The form of the failure criterion is typically described as a mathematical function of the above variables
which reaches the value of unity at failure as follows.
Failure Index = FI (load, strength) = 1
The strength of a structure can be given as a Strength Ratio (SR), which is the ratio by which the load
must be factored to just fail. (Note that the Strength Ratio is not necessarily the reciprocal of the Failure
Index.) Alternatively, the Margin of Safety (MoS), where MoS = SR - 1, is used.
Maximum Criterion
This criterion is calculated by comparing the allowable load with the actual strength for each component.
Mathematically, it is defined by:
FI = max (σx/TX, -σx/CX, σy/TY, -σy/CY,
In this case,
SR = 1/FI
Hill Criterion
The Hill criterion was one of the first attempts to develop a single formula to account for the widely
different strengths in the various principal directions:
where
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Chapter 5: Theory 157
Composite Failure Criteria
In the Laminate Modeler, the Tsai-Wu criterion for in-plane loads (representing fiber failure) has been
supplemented by a maximum load theory for out-of-plane shear loads (representing matrix failure):
FI = max( abs(γyz)/SYZ, abs(γxz)/SXZ)
In this case,
SR = 1/FI
For every ply, the lower of the Margins of Safety for fibre and matrix failure is calculated and displayed.
Tsai-Wu Criterion
The Tsai-Wu failure criterion is an unashamed, empirical criterion based on the sum of the linear and
quadratic invariants as follows:
where Fi and Fij are dependent on the material strengths. For the restrictions of lamina materials, this
equation reduces to:
where:
FX = 1/TX - 1/CX
FY = 1/TY - 1/CY
FXX = 1/(TX CX)
FYY = 1/(TY CY)
FXY = IXY sqrt(FXX FYY) = IXY / sqrt(TX CX TY CY)
FSS = 1 / (SXY SXY)
Because this failure theory is quadratic, the Strength Ratio (SR) = 1/FI. However, multiplying the failure
criterion by SR and rearranging gives
a SR2 + b SR - 1 = 0
where
b = FX σx + FY σy
Therefore
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Composite Failure Criteria
In the Laminate Modeler, the Tsai-Wu criterion for in-plane loads (representing fiber failure) has been
supplemented by a maximum load theory for out-of-plane shear loads (representing matrix failure):
FI = max( abs(γyz)/SYZ, abs(γxz)/SXZ )
In this case,
SR = 1/FI
For every ply, the lower of the Margins of Safety for fibre and matrix failure is calculated and displayed.
Hoffman
FXY = - 1 / (2 TX CX)
Hankinson
FXY = 0.5 / (1/(TX CX) + 1/(TY CY) - 1/SXY2)
Cowin
FXY = 1 / sqrt(TX CX TY CY) - 0.5 /SXY2
User-Defined Criterion
The user can write a custom PCL function to generate failure indices and margins of safety according to
specialized failure criteria. For example, sophisticated failure criteria are being developed which
incorporate a mixture of equations depending on the expected mode of failure. These could be expected
to outperform simple criteria where there is a complex loading state, particularly within thick laminates.
To use this facility, the user should modify the function user() within the class
p3CM_create_res_fail_user. A sample function based on the criteria of maximum loading is illustrated
below. The function has input values of loading state and material strength data. The output values are
the margin of safety, the critical component, and a failure index. The required function should be edited
into a file “p3CM_create_res_fail_user.user.pcl.” This function must then be substituted for the default
dummy function in the Laminate Modeler PCL library. To do this, save a backup copy of the existing
laminate_modeler.plb, and issue the following commands in the command line:
!! LIBRARY ADD laminate_modeler.plb
!! COMPILE p3CM_create_res_fail_user.user INTO laminate_modeler.plb
The PCL source code required to implement the maximum failure criteria
follows as an example:
CLASS p3CM_create_res_fail_user
FUNCTION user(res_array,mat_array,out_res_array)
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Chapter 5: Theory 159
Composite Failure Criteria
REAL res_array()
REAL mat_array()
REAL out_res_array()
REAL sxx,syy,szz,sxy,syz,sxz
REAL fxt,fxc,fyt,fyc,fs12,fs23,fs31
REAL margin,component,fi
REAL fi11t,fi11c,fi22t,fi22c,fi12,fi23,fi31
/*
* Set input values.
*/
sxx = res_array(1)
syy = res_array(2)
szz = res_array(3)
sxy = res_array(4)
syz = res_array(5)
sxz = res_array(6)
fxt = mat_array(1)
fxc = mat_array(2)
fyt = mat_array(3)
fyc = mat_array(4)
fs12 = mat_array(5)
fs23 = mat_array(6)
fs31 = mat_array(7)
/*
* Check that failure values are reasonable.
*/
IF ( (fxt<=0.) || @
(fxc<=0.) || @
(fyt<=0.) || @
(fyc<=0.) || @
(fs12<=0.) || @
(fs23<=0.) || @
(fs31<=0.) ) THEN
END IF
/*
* Initialise variables.
*/
margin = 0.0
component = 1.0
fi = 1.0
sys_allocate_array(out_res_array,1,3)
out_res_array(1) = 0.0
out_res_array(2) = 1.0
out_res_array(3) = 1.0
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Composite Failure Criteria
/*
* Calculate strength ratios for each component.
*/
/*
* Set output values.
*/
out_res_array(1) = margin
out_res_array(2) = component
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Chapter 5: Theory 161
Composite Failure Criteria
out_res_array(3) = fi
END FUNCTION
END CLASS
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162 MSC Laminate Modeler User’s Guide
Composite Failure Criteria
Main Index
Appendix A: Bibliography
A Bibliography
Main Index
164 MSC Laminate Modeler User’s Guide
Bibliography
1. Bergsma, O.K. and Huisman, J. “Deep Drawing of Fabric Reinforced Thermoplastics,” in
Brebbia, C., et al., CAD in Composite Material Technology (Southampton, Computational
Mechanics, 1988).
2. Bergsma, O.K. Deep Drawing of Fabric Reinforced Thermoplastics: Simulation and Experiment
(Delft University of Technology, Department of Aerospace Engineering).
3. Calladine, C. Theory of Shell Structures, Chapter 5.
4. Heisey, F.L., et al. “Three-Dimensional Pattern Drafting,” Textile Research Journal, November
1990, pp. 690-696.
5. Collier, J.R., Collier, B.J., O’Toole, G. and Sargand, S.M. “Drape Prediction by Means of Finite-
Element Analysis,” J. Text. Inst., 1991, Vol. 82, No. 1, pp. 96-107.
6. Heisey, F.L., and Haller, K.D. “Fitting Woven Fabric To Surfaces in Three Dimensions,” J. Text.
Inst., 1988, No. 2, pp. 250-263.
7. Hinds, B.K., McCartney, J., and Woods ,G. “Pattern Development for Three Dimensional
Surfaces” (Queens University Belfast, Department of Mechanical and Manufacturing
Engineering).
8. Kawabata, S. The Standardization and Analysis of Hand Evaluation, 2nd ed., (Osaka, Japan, The
Textile Machinery Society of Japan, 1980).
9. Mack, C., and Taylor, H.M. “The Fitting of Woven Cloth to Surfaces,” J.Text. Inst., 1956, No.
47, pp. T477-88.
10. Mallon, P.J., O’Bradaigh, C.M., and Pipes, R.B. “Polymeric Diaphragm Forming of Complex-
Curvature Thermoplastic Composite Parts,” Composites, Vol. 20, No. 1, Jan. 1989, pp.48-56.
11. Monaghan, M.R., Mallon, P.J., O’Bradaigh, C.M., and Pipes, R.B. “The Effect of Diaphragm
Stiffness on the Quality of Diaphragm Formed Thermoplastic Composite Components,” The
Journal of Thermoplastic Composite Materials, Vol. 3, July 1990, pp.202-215.
12. Okine, R.K. “Analysis of Forming Parts from Advanced Thermoplastic Composite Sheet
Materials,” The Journal of Thermoplastic Composite Materials, Vol. 2, Jan. 1989, pp.50-77.
13. Potter, K.D. “The Influence of Accurate Stretch Data for Reinforcements on the Production of
Complex Structural Mouldings -- Part 1. Deformation of Aligned Sheets & Fabrics,” Composites,
July 1979, pp.161-167.
14. Potter, K.D. “The Influence of Accurate Stretch Data for Reinforcement on the Production of
Complex Structural Mouldings -- Part 2. Deformation of Random Mats,” Composites, July 1979,
pp. 168-173.
15. Potter, K.D. Deformation Mechanisms of Fibre Reinforcements and Their Influence on the
Fabrication of Complex Structural Parts (London, Controller HMSO, 1980).
16. Robertson, R.E., et al. “Fiber Rearrangements During the Moulding of Continuous Fiber
Composites. 1: Flat Cloth to a Hemisphere,” Polymer Composites, July 1981, Vol. 2, No. 3, pp.
126-131.
17. Skelton, J. Shear Of Woven Fabrics (Dedham MA, USA, FRL, 1979).
Main Index
Appendix A: Bibliography 165
18. Smiley, A.J., and Pipes, R.B. “Analysis of the Diaphragm Forming of Continuous Fiber
Reinforced Thermoplastics,” The Journal of Thermoplastic Composite Materials, Vol. 1, Oct.
1988, pp. 298-321.
19. Stubbs, N., and Fluss, H. “A Space-truss Model for Plain-Weave Coated Fabrics,” Appl. Math.
Modeling, Vol. 4, Part 1, Feb. 1980, pp. 51-58.
20. Tam, A.S., and Gutowski, T. “Ply-Slip During the Forming of Thermoplastic Composite Parts,”
Journal of the ASCE Engineering Mechanics Division, Vol. 104, Part 5, Oct, 1978.
21. Testa, R.B., Stubbs, N., and Spillers, W.R. “Bilinear Model For Coated Square Fabrics,” The
Journal of the ASCE Engineering Mechanics Division, Vol. 104, Part 5, Oct. 1978, pp. 1027-
1042.
22. Van Der Weeen, F. “Algorithms For Draping Fabrics on Doubly-Curved Surfaces,” International
Journal for Numerical Methods in Engineering, Vol. 31, 1991, pp. 1415-1426.
23. Van West, B.P., et al. The Draping and Consolidation of Commingled Fabrics (Delaware USA,
Center for Composite Materials and Dept. of Mechanical Engineering, University of Delaware,
1990).
24. Wormersley, J.R. “The Application of Differential Geometry to the Study of the Deformation of
Cloth Under Stress,” J. Text. Inst., 1937, pp.T97-112.
Main Index
166 MSC Laminate Modeler User’s Guide
Main Index
MSC.Fatigue Quick Start Guide
Index
MSC Laminate Modeler User’s Guide
A F
anisotropic behavior, 11 fiber angles, 146
Index anisotropy, 11 axis method, 146
automated tow placement, 13 planar method, 146
Ind filament winding, 6, 13
ex filamentary composites, 11
B
bottom, 57 fabrics, 11, 12
glass fibre/polyester mixture, 11
graphic fibre/epoxy resin, 11
C tows, 11
CAD systems, 19, 21 finite element analysis, 20
CADDS 5, 19 flat plates, 140
CATIA, 19
composites data, 6
compression moulding, 13 G
conceptual design, 15 Gaussian curvature, 24, 25, 140
core samples, 18 negative, 24, 140
cross sections, 18 positive, 24, 140
curved shells, 140 zero, 140
geodesic global draping, 26, 143
geodesic lines, 140
D global draping, 25, 26, 143
degree of shear, 25 energy, 27, 145
detailed development, 15 geodesic, 26, 143
developable surfaces, 21 planar, 27, 144
dome-shaped surfaces, 24
doubly-curved, 18
doubly-curved surfaces, 24 H
drape simulation, 20 holes in surfaces, 148
draping
global, 143 I
local, 142 incomplete boundary definition, 148
scissor, 142 initial direction, 57
slide, 143 initial direction vector, 58
E L
energy global draping, 27, 145 lamination theory, 12, 13
Euclid 3, 19 layer, 42, 55
excessive Gaussian curvature, 148
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168 MSC Laminate Modeler User’s Guide
V
O view direction, 58
outline design, 15
W
P waffle plate, 21
planar global draping, 27, 144 warp, 144
ply, 42 warp/weft angle, 50
ply laminate, 42 weft, 144
ply-book, 18 wet layup, 12
pressure vessels, 27
Pro/ENGINEER, 19
production methods Z
filament winding, 6 zero Gaussian curvature, 21
manual layup, 6
resin transfer method (RTM), 6
R
resin flow, 19
resin transfer moulding, 6, 13
Main Index