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RADIOSS Composites
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Table of Contents
RADIOSS Composites
Analysis, Concept and Optimization of Composites Structures
Table of Contents.................................................................................................................... II
Chapter 1: Theoretical Introduction........................................................................ 1
1 Composite Material ................................................................................................... 1
1.1 Why Composites .................................................................................................... 1
1.2 - Definitions ............................................................................................................... 2
1.3 - Material Laws (Elastic Linear) ................................................................................. 6
1.3.1 - Adding Thermal Strain........................................................................................ 11
1.4 - Micromechanics of Composite Materials ............................................................... 13
1.5 - Effective Homogenized Stiffness Matrix of a Ply.................................................... 13
2 Macromechanical Behavior of a Laminate (Ply)....................................................... 16
3 Classical Lamination Theory (CLT).......................................................................... 17
3.1 - Laminate Convention ............................................................................................ 17
3.2 Mid-Plane Forces and Moments........................................................................... 18
3.3 The [ABD] Matrix .................................................................................................. 19
3.4 Smear Technology ............................................................................................... 21
3.5 Stacking Sequence Dependence of [ABD] Matrix................................................. 22
3.6 Laminate Examples.............................................................................................. 24
3.7 Composite Failure Theories.................................................................................. 26
Exercise 1.1 - Evaluate the ply and laminate matrices................................................... 27
II
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III
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Chapter 1
Theoretical Introduction
1- Composite Material
The word composite for a structural engineer means that two or more materials are
combined on a macroscopic scale to form a new material. The macroscopic scale is a key
definition, because we intend to look only the global behavior of the component. The advantage
of a composite material is that if the component is well designed, it shows the desired qualities
where it is required, and in almost all cases better than the material alone.
Properties such as strength, fatigue life, wear resistance, thermal insulation, stiffness,
weight, acoustical insulation; etc can be improved by forming a composite material.
The main reason to develop a component built with a composite material is that the
material can have the characteristics needed to optimize the component performance.
There are several different types of composites. The below lists the main ones:
a. Particulate Composites (Particles + Matrix)
b. Laminated Composites (Layers)
c. Fibrous-Matrix Laminated Composites (Layers Long fiber + Matrix)
d. Core Stiffened Laminated Composites
This training will focus on the Fibrous-Matrix Laminated Composites, which are the most
commonly used composites for high performance structural components.
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RADIOSS Composites 1
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1.2 Definitions
a. Microscopic: is a term used to describe physical objects smaller than can easily be
seen by the naked eye and which require a lens or microscope to see
clearly.
b. Micromechanics: is the study of composite material behavior wherein the interaction of
the constituent materials is examined in detail as part of the definition
and behavior of the heterogeneous composite material.
c. Macroscopic: is a term used to describe physical objects that are measurable and
observable by the naked eye and do not require a lens or microscope to
see clearly.
d. Macromechanics: is the study of composite material behavior wherein the material is
assumed homogenous and the effects of the constituent materials are
detected only as averaged apparent properties (i.e. effective
properties) of the composite material.
e. Homogeneous: The material has uniform properties in all points (i.e. the properties are
independent of the position)
f. Heterogeneous: The material has nonuniform properties (i.e. the properties are
dependent of the position)
g. Isotropic: The material properties are the same in all directions (i.e. the properties are
independent of the direction)
h. Orthotropic: The material has properties that are different in three mutually
perpendicular directions and it presents 3 symmetric planes.
i. Anisotropic: The material properties is different for all directions, no symmetric plane can
be defined.
j. Stress Cube:
k. Strain Cube:
RADIOSS Composites 2
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X
Y
Z
x
l1
l2
l3
y
m1
m2
m3
l1 = cos(x, X ) =
X l12
l 2
Y 2
Z l32
=
XY l1l2
YZ l2l3
XZ l1l3
m12
m22
m32
m1m2
m2 m3
m1m3
n12
n22
2l1m1
2l2 m2
2m1n1
2m2 n2
n32
2l3m3
2m3n3
n1n2 l1m2 + m1l2 m1n2 + n1m2
n2 n3 m2l3 + l2 m3 n2 m3 + m2 n3
n1n3 l1m3 + m1l3 m1n3 + n1m3
z
n1
n2
n3
x X
xX
x
y
2l3n3 z
n1l2 + l1n2 xy
l2 n3 + n2l3 yz
n1l3 + l1n3 xz
2l1n1
2l2 n2
or
X l12
l2
Y 2
Z l32
=
XY l1l2
YZ l2 l3
XZ l1l3
m12
m22
n12
n22
2l1m1
2l 2 m2
2m1n1
2 m2 n 2
m32
m1m2
m2 m3
m1m3
n32
n1n2
n 2 n3
n1n3
2l3m3
l1m2 + m1l2
m2 l3 + l2 m3
l1m3 + m1l3
2m3n3
m1n2 + n1m2
n2 m3 + m2 n3
m1n3 + n1m3
HyperWorks 9.0
x
y
2l3 n3 z
n1l2 + l1n2 xy
l2 n3 + n2 l3 yz
n1l3 + l1n3 xz
2l1n1
2l 2 n 2
RADIOSS Composites 3
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{ x } = [TS ]1 { 1 }
x cos 2
2
y = sin
cos sin
xy
sin 2
cos 2
cos sin
2 cos sin 1
2 cos sin 2
cos 2 sin 2 12
{ x } = [TS ]1 { 1 }
[TS ]
[TS ]T
cos 2
= sin 2
cos sin
sin 2
2
cos
cos sin
cos2
=
sin 2
2 cos sin
sin 2
cos2
2 cos sin
2 cos sin
2 cos sin
cos 2 sin 2
cos sin
cos sin
cos2 sin 2
RADIOSS Composites 4
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u = u0 z
w0
x
v = v0 z
w0
y
Kirchhoff Plate
x =
u
x
y =
v
y
xy =
u v
+
y x
u0
2 w0
x =
z
x
x 2
v0
2 w0
y =
z 2
y
y
xy
u0 v0
2 w0
=
+
2z
y x
xy
x x0 k x
0
y = y + z ky
0 k
xy xy xy
{ x } = { x
}+ z{k}
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RADIOSS Composites 5
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i = Cij j
1 C11
C
2 21
3 C31
=
12 C 41
23 C51
13 C61
C12
C22
C32
C42
C52
C62
i , j = 1,...,6
C13 C14
C 23 C 24
C33 C34
C 43 C 44
C53 C54
C63 C64
1 S11
S
2 21
3 S 31
=
12 S 41
23 S 51
13 S 61
C15
C 25
C35
C 45
C55
C65
C16 1
C26 2
C36 3
C46 12
C56 23
C66 13
S16 1
S 26 2
S 36 3
S 46 12
S 56 23
S 66 13
S12
S13
S14
S15
S 22
S 32
S 42
S 52
S 62
S 23
S 33
S 43
S 53
S 63
S 24
S 34
S 44
S 54
S 64
S 25
S 35
S 45
S 55
S 65
RADIOSS Composites 6
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b. Isotropic:
Isotropic materials have an infinite number of planes of material property symmetry and
thus material properties are the same in all directions at a point within a body.
1 C11
C
2 12
3 C12
=
12 0
23 0
13 0
C12
C12
C11
C12
C12
C11
0
0
0
0
0
0
0
0
(C11 C12 )
(C11 C12 )
1
2
3
0 12
0 23
(C11 C12 )
2
13
0
0
0
or
1 S11
S
2 12
3 S12
=
12 0
23 0
13 0
S12
S11
S12
S12
0
0
0
0
S12
0
S11
0
0
2(S11 S12 )
0
0
2(S11 S12 )
1
2
0
3
0
12
23
0
2(S11 S12 ) 13
0
0
S112 S122
S113 3S11 S122 + 2 S123
C12 =
Isotropic linear elastic materials have two independent engineering constants, any two of E, G,
or which are related by equation:
1 E1
2 E
Rewriting the Strain-Stress relationship: 3 = E
12 0
23 0
13 0
G=
E
2(1 + )
1
E
0
0
0
0
1
E
1
G
0
0
0
0
0
0
1
G
0 1
0 2
0 3
0 12
0 23
1
G 13
Plane Stress: 3 = 13 = 23 = 0
1 E1
( ) : 2 = E
0
12
1 Q11
( ) : 2 = Q12
0
12
E
1
E
0
Q12
Q22
0
0 1
0 2
1
G
12
with: 3 =
0 1
0 2
Q44 12
( 1 2 )
E
Q11 =
S22
S11S22 S122
Q22 =
S11
S11 S 22 S122
where:
Q12 =
S12
S11S 22 S122
Q44 =
1
S44
* There are some restrictions to the engineering constants for linear isotropic materials:
E>0
G>0
-1 < <
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RADIOSS Composites 7
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c. Transverse Isotropic:
Transversely isotropic materials have one plane of material property symmetry in which
the material properties are the same within that single plane at a point within a body.
Transversely isotropic materials have 5 independent engineering constants, E1, E2, 12, 23, and
G12. In the case of unidirectional fiber-matrix composites the 23 plane is the single plane of
material property symmetry as shown in
1 C11
C
2 12
3 C12
=
12 0
23 0
13 0
C12
C22
C12
C23
0
0
0
0
C23
0
C22
0
0
C44
0
0
(C22 C23 )
1 S11
S
2 12
3 S12
=
12 0
23 0
13 0
S12
S 22
S12
S 23
0
0
0
0
S 23
0
S 22
0
0
S 44
0
0
0
0
0
0
0
0
( S22 S23 )
0 1
0 2
0 3
0 12
0 23
C44 13
0 1
0 2
0 3
0 12
0 23
S 44 13
Combining these equations we can isolate the stiffness matrix terms as function of the
compliance terms:
C11 =
where:
2
2
S 22
S 23
S
C12 =
S12 S 23 S12 S 22
S
C 22 =
S11 S 22 S122
S
C 23 =
S122 S 23 S11
S
2
2
2
S = S11 S 22
S11 S 23
2 S 22 S122 + 2 S12 S 23
23
12
1
0
0
0 2
E2
2 E1 E2
E1
E2
3 E112 E223 E12
0
0
0 3 where: G =
G23 =
12
2(1 + 12 )
2(1 + 23 )
0
0 G112 0
0 12
12 0
23 0
0
0
0 G123 0 23
0
0
0
0 G112 13
13 0
RADIOSS Composites 8
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3 = 13 = 23 = 0
Plane Stress:
1 E11
12
2 = E1
0
12
12
E1
1
E2
0 1 S11
0 2 = S12
1
0
G12 12
S12
S 22
0
0 1
0 2
S 44 12
with: 3 = 12 1 + 23 2
E2
E1
1 Q11 Q12 0 1
2 = Q12 Q22 0 2
0
0 Q44 12
12
where: Q11 =
S 22
S11 S 22 S122
Q12 =
S12
S11 S 22 S122
Q22 =
S11
S11 S 22 S122
Q44 =
1
S44
* There are some restrictions to the engineering constants for linear transversely isotropic
materials:
12 <
E1 , E1 , G12 > 0
1 2122
E1
E2
23 < 1
E2
E
2
23
2122 23 2 > 0
E1
E1
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RADIOSS Composites 9
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d. Orthotropic:
Orthotropic materials have three orthogonal planes of material property symmetry in
which the material properties are the same within these three mutually orthogonal planes at a
point within a body. Orthotropic materials have 9 independent engineering constants, E1, E2, E3,
12, 23, 13, G12, G23, and G13.
1 C11
C
2 12
3 C12
=
12 0
23 0
13 0
1
2
3
=
12
23
13
S11
S
12
S12
0
0
C12
C22
C23
0
0
0
C12
C23
C22
0
0
0
0
0
0
C44
0
0
0
0
0
0
C55
0
0 1
0 2
0 3
0 12
0 23
C66 13
S12
S12
S 22
S 23
S 23
0
S 22
0
0
S 44
0
0
S 55
0 1
0 2
0 3
0 12
0 23
S 66 13
31
E3
32
E3
1
E3
1
G12
0
0
0
0
0
0
0
0
21
E2
1
E2
23
E2
1
G 23
0 1
0 2
0 3
0 12
0 23
1
G13
13
RADIOSS Composites 10
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3 = 13 = 23 = 0
Plane Stress:
S is symmetric:
1 E11
12
2 = E1
0
12
12
E1
1
E2
ij
Ej
ji
i, j = 1,2,3.
Ej
0 1 S11
0 2 = S12
1
0
G12 12
S12
S 22
0
i j
0 1
0 2
S 44 12
with: 3 = 12 1 + 23 2
E2
E1
1 Q11 Q12 0 1
2 = Q12 Q22 0 2
0
0 Q44 12
12
where: Q11 =
S 22
S11 S 22 S122
Q12 =
S12
S11 S 22 S122
Q22 =
S11
S11 S 22 S122
Q44 =
1
S44
* There are some restrictions to the engineering constants for linear orthotropic materials:
12 <
E1
E2
23 <
1 122
E2
E3
13 <
E1
E3
E
E
E2
2 E2
23
132 3 212 2313 3 > 0
E1
E3
E1
E1
Total strains are the summation of both the free thermal and mechanical strains.
= T +M
Free thermal strains are the strains caused by free thermal expansion or contraction.
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RADIOSS Composites 11
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Typically the mechanical strains are the strains of interest in engineering calculations.
Note, however, that most commercial FEA codes output the total strains by default and
therefore the user must set an option to output the needed mechanical strains if thermal
boundary conditions are present.
Then the Stress-strain relation becomes:
i = Cij ( j j T )
i, j = 1 6
where:
j is the total strain, the sum of free thermal and mechanical strains;
j T is the free thermal strain
M = T is the mechanical strain which causes stress
RADIOSS Composites 12
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Cij = Cij (E f , f , V f , E m , m , Vm )
The rule of mixtures is the simplest of the strength of materials approaches and makes
the following broad assumptions:
o
Hypothesis Representation
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RADIOSS Composites 13
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Determination of Ply E1
P = 1 A = f A f + m Am
1 = E1 1
f = Ef f
m = E m m
1 = f = m
as:
E1 = E f V f + EmVm
Unidirectional Stress (1)
Determination of Ply E2
W = 2W = f V f W + mVmW
2 =
2
E2
f =
m =
Ef
m
Em
1 = f = m
as:
E2 =
E f Em
E f V f + EmVm
Determination of Ply 12
12 =
W = 2W = 121W
W = f 1V f W + m1VmW
12 = f V f + mVm
Unidirectional Stress (1)
RADIOSS Composites 14
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= 12W = f V f W + mVmW
12 =
12
G12
f =
f
Gf
m =
m
Gm
12 = f = m
G12 =
G f Gm
G f V f + GmVm
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1 Q11
2 = Q12
0
12
Q12
Q22
0
1 1
+ T
2 2
Q44 12 3
0
0
However, in order to determine the global behavior of a ply we need to write this
relationship in the global x-, y-, z- coordinate system. This is accomplished by using the 2D
plane stress transformations, with the addition of free thermal strain considerations, as shown
below:
{ x } = [TS ]1 [Q ][TS ]T ({ x } { x }T )
{ x } = [Q ]({ x } { x }T )
On global coordinate the stiffness matrix is:
[Q ] = [TS ]
[Q ][TS ]T
RADIOSS Composites 16
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Note that the xy plane defined by the global coordinate system goes through the middle surface
of the plate with z-axis defined using right hand rule, which in this case is down.
Taking a plane section through the plate, Plane A, the details of the laminate stacking sequence
and ply z-coordinate conventions can be investigated.
z-coordinate value for the kth ply is always defined as the most positive zcoordinate interface for that ply.
Laminates are typically specified in the engineering community using the notation shown below:
[ply1/ply2/(ply3/ply4)n /.../plyn]s/as/n
s: Symmetric Laminate
For symmetric and anti-symmetric laminates only the most positive half, of the plies are
specified.
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RADIOSS Composites 17
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N x t / 2 x
N y = y dz
N t / 2
xy
xy
For a laminated plate made up of n constant thickness plies the mid-plane forces can
be written in terms of the sum of the stress variation through the thickness of each ply as:
Nx
x
n zk
N y = y dz
N k =1 z k 1
xy
xy
The positive sign convention for homogeneous or laminated plate mid-plane moments is
given in Figure below. For a homogenous single ply plate of constant thickness the midplane
moments can be written in terms of stress variation through the thickness of the plate as:
M x t / 2 x
M y = z y dz
M t / 2
xy
xy
Positive Mid-Plane Moments
Mx
x
zk
n
M y = z y dz
M k =1 z k 1
xy
xy
RADIOSS Composites 18
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{ x } = [Q ]({ x } { x }T )
We can by adding the subscript k designate the equation on the laminated coordinates for
each ply:
{ x }k
[ ] ({ } { } T )
= Q
x k
x k
zk
{N x } = ([Q ]k ({ x
} + z {k } { } T ))dz
}+ [B]{k } {N }
k =1 z k 1
x k
{N x } = [A]{ x
T
x
Where:
n
k =1
{N }= 12 ([Q ] { } (z
T
x
x k
zk 1 )
k =1
zk
{M x } = ([Q ]k ({ x
k =1
} + z {k } { } T ))zdz
k
x k
z k 1
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RADIOSS Composites 19
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{M x } = [B]{ x
}+ [D]{k } {M }
x
T
x
Where:
n
{M }= 12 ([Q ] { } (z
T
x
x k
2
k
zk21 )
k =1
With it we finally can define the relationship between the mid-plane generalized forces and
strain:
N A B 0 N T
=
k T
M
B
D
M
[A]
o
A14 and A24 these terms represent extensional shear coupling between the
mid-plane forces and midplane shear strain.
Mid-plane forces coupling between plate curvature strain (bending and twist)
D14 and D24 These terms represent bending - twist coupling between the midplane moments and plate curvatures.
[B]
[D]
RADIOSS Composites 20
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[A]
([Q ] (z
k
HOMOGENEOUS
[Q ]t
zk 1 )
k =1
[B]
[D]
1 n
Q k (zk2 zk21 )
2 k =1
1 n
Q k (zk3 zk31 )
3 k =1
([ ]
([ ]
1
1
Q t 3 = [A]t 2
12
12
[]
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RADIOSS Composites 21
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Looking at the plot the following statements can be made about the various components
of the [Q] matrix for the kth ply:
1. Q 11 and Q 22 are ninety degrees out of phase (i.e. a 90-deg ply is a 0-deg ply in the yaxis) and are always positive for any positive or negative theta angle.
2. The Q 12 and Q 44 terms are in phase with each other and are always positive for any
positive or negative theta angle.
3. The Q 14 and Q 24 components are thirty degrees out of phase and change sign with
theta angle. Both are positive for positive angles and negative for negative angles. In
addition, Q 14 and Q 24 components are zero for theta angle values of zero and ninety.
RADIOSS Composites 22
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We will assume that each ply is made of the same material; however each ply can have
its own unique theta angle. As shows bellow the values for the (zkn-zk-1n) terms for each ply.
-3
Ply a, t=1
-2
Ply b, t=1
-1
Ply c, t=1
0
Ply d, t=1
1
Ply e, t=1
2
Ply f, t=1
3
Z coordinate
Ply a
Ply b
Ply c
Ply d
Ply e
Ply f
[A]
zk
z k z k 1
-3
-2
-1
0
1
2
3
(-2)-(-3)=1
(-1)-(-2)=1
(0)-(-1)=1
(1)-(0)=1
(2)-(1)=1
(3)-(2)=1
[B]
2
k
z z
[D]
2
k 1
3
k
z z k31
(-2)2-(-3)2=-5
(-1)2-(-2)2=-3
(0)2-(-1)2=-1
(1)2-(0)2=1
(2)2-(1)2=3
(3)2-(2)2=5
(-2)3-(-3)3=19
(-1)3-(-2)3=7
(0)3-(-1)3=1
(1)3-(0)3=1
(2)3-(1)3=7
(3)3-(2)3=19
[A] Characteristics
o
o
o
independent.
[A] is equal for any stack sequence with the same number of plies.
A14 and A24 are zero for any balanced Laminated. Because Q 14 and Q 24 are on
domain (odd function).
[B] Characteristics
o
[B] is zero for any symmetric laminate. (Odd function on thickness domain)
[D] Characteristics
o
o
o
o
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D14 and D24 terms become insignificant for laminates with grater than 16 plies.
i - [0 / 45 / 90 / 45 / 0] [0 / 45 / 90]s
ii - [0 / 45 / 90 / 90 / 45 / 0] [0 / 45 / 90]s
b. Anti-Symmetric Laminates
An anti-symmetric laminate is defined as a laminate for which every + and - ply on one
half of the middle surface there exist a - and + ply respectively of the same thickness and
material property at the same location on the other half of the middle surface. In addition, 0 plies
and 90 plies must be symmetric about the middle surface.
iii - [0 / 45 / 90 / 45 / 0] [0 / 45 / 90]as
iv - [0 / 45 / 90 / 90 / 45 / 0] [0 / 45 / 90]as
v - [0 / 90 / 45 / 45 / 90 / 0] [0 / 90 / 45]as
Anti-Symmetric laminates must have an even number of layers if adjacent laminas also have
alternating signs of the principal material property direction with respect to the laminate axes (iv
and v). If the adjacent laminas do not have alternating signs, then the number of layers not need
be even (iii).
c. Balanced laminates
A balanced laminate is defined as a laminate for which every + ply there exists a - ply
of the same thickness and material property.
o
A balanced laminate does not define where in the laminate stacking sequence
the plies need to exist, just that there are same number of + and - plies.
A14 and A24 components for balanced laminates will always be zero and thus
exhibit no extensional shear coupling.
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vi - [0 / 45 / 45 / 0] [0 / 45]as
vii - [0 / 45 / 22.5 / 22.5 / 45 / 0] [0 / 45 / 22.5]as
viii - [0 / 45 / 45 / 45 / 45 / 0] [0 / 45 / 45]s
xi - [0 / 22.5 / 22.5 / 30 / 30]
d. Cross-Ply Laminates
A cross-ply laminate is defined as a laminate composed of only 0 and 90 plies.
o
A14, A24, D14, and D24 components for cross-ply laminates will always be zero and
thus exhibit no extensional shear or bending -twisting coupling.
xii - [0 / 90 / 90 / 0] [0 / 90]s
xiii - [90 / 0 / 90 / 0 / 90 / 0]
e. Angle-Ply Laminates
An angle-ply laminate is defined as a laminate composed of only + and - plies.
General Laminates
A general laminate is defined as a laminate which does not fall into any of the previous
categories of laminate definitions. General laminates can exhibit fully populated [ABD] matrices
and thus all types of coupling can exist including;
o
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Instability or Buckling
Matrix Crazing and Matrix Shear Yielding (See SIFT failure theory)
Fiber Fracture
Instability or Buckling
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Model Information
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PART a
Step 1: Build the S matrix for Plane Stress/3D for an orthotropic material:
Plane Stress
E11
[S ] = E112
0
3D
0
1
G12
12
E1
1
E2
E11
12
E1
E12
[S ] = 1
0
0
12
E1
12
E1
23
E2
1
E2
1
G12
0
0
1
G23
1
E2
23
E2
0
0
0
0
1
G12
[Q ] = [S ]
3D
[C ] = [S ]1
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PART b
Step 1: Calculate [TS ] for all angles (0, 45, -45):
1
cos2
[TS ] 1 = sin2
cos sin
Step 2: Calculate
2 cos sin
2 cos sin
cos2 sin 2
sin 2
2
cos
cos sin
2.00E+07
1.50E+07
Q_11
Q_12
Q_14
Q_22
Q_24
Q_44
1.00E+07
5.00E+06
0.00E+00
-100
-50
50
100
-5.00E+06
-1.00E+07
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Step 3: Calculate
[A], [B] and [D] for all layers, where it needs the appropriate
[Q] matrix:
n
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Chapter 2
Classical lamination theory is used to calculate effective stiffness and mass density of
the composite shell. This is done automatically within the code using the properties of individual
plies. The homogenized shell properties are then used in the analysis.
After the analysis, the stresses and strains in the individual layers and between the
layers can be calculated from the overall shell stresses and strains. These results may then be
used to assess the failure indices of individual plies and of the bonding matrix.
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PCOMP defines the structure and properties of a composite lay-up which is then
assigned to an element. The ply is only defined for that particular property and there is
no relationship of a ply that reaches across several properties.
PCOMPG defines the structure and properties of a composite lay-up allowing for global
ply identification which is then assigned to an element. Plies of different PCOMPG
definitions can have a relationship because of the use of global ply IDs.
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Both are defined as the (7th field for CQUAD or 6th field for CTRIA)
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Mpa
Mpa
mm/mm o
/C
E2 = E3 = 9650
23 = 0.6
G23 = 3100
2 = 3 = 18.0e-6
Mpa
MPa
mm/mm o
/C
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10. Create the load step with the constraints and loads.
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12. Pos-processing
?????
Results Representation: (Global x Analysis System)
o
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Laminate
Browser
Define/Edit
Pane
Review/Results
Pane
Menus
The HyperLaminate menu bar contains five menus that allow you to manage files, edit
materials, laminates, HLS loadcases and design variables, change views, and access on-line
help.
Toolbar
The HyperLaminate toolbar contains five tools that allow you to generate new materials,
laminates, HLS loadcases or design variables, and to cut, copy, paste, and delete entries in text
boxes.
Laminate Browser
This browser, located on the left side of the HyperLaminate window, provides a vertical tree
view of materials, laminates, HLS loadcases and size design variables in your model.
Left-clicking on an entity populates the Define/Edit and Review panes with details of that
branch.
Right-clicking on a branch offers context-sensitive operations for that branch.
Define/Edit Pane
This is the central pane of the HyperLaminate module. Here users may enter or change data
related to a material, laminate, HLS loadcase or design variable definition (depending on the
selected branch in the laminate browser).
Review Pane
This is the right-hand pane of the HyperLaminate module. The Review/Results pane has a
number of tabs that display the current state of the selected branch.
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1.
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(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
PCOMP
PID
Z0
NSM
SB
FT
TREF
GE
LAM
MID1
T1
MID3
T3
THETA3 SOUT3
T2
(10)
THETA2 SOUT2
etc.
DS
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Plies are listed from the bottom surface upwards, in respect to the elements normal direction.
Example
(1)
(2)
(3)
PCOMP
-0.5
0.2
0.2
(4)
(5)
(6)
(7)
1.E5
STRN
100.
0.0
YES
0.6
0.0
YES
(8)
(9)
90.0
NO
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(10)
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(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
PCOMPG
PID
Z0
NSM
SB
FT
TREF
GE
LAM
GPLYID1
MID1
T1
THETA1 SOUT1
GPLYID2
MID2
T2
THETA2 SOUT2
(10)
DS
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Plies are listed from the bottom surface upwards, in respect to the elements normal direction.
The image below, shows the stacking sequence for a non-symmetrical laminate.
Example
(1)
PCOMP
(2)
(3)
-0.5
101
2
103
(4)
(5)
(6)
(7)
1.E5
STRN
100.
0.2
0.0
YES
0.6
90.0
NO
0.2
0.0
YES
RADIOSS Composites 48
(8)
(9)
(10)
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(2)
(3)
(4)
(5)
(6)
(7)
(8)
PCOMPP
PID
Z0
NSM
SB
FT
TREF
GE
(9) (10)
1. The PCOMPP card is used in combination with the STACK and PLY cards to create
composite properties through the ply-based definition.
FIRST
SECOND
THIRD
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This process is similar to the process defined at section 2 of this chapter (2 How to Setup a
Composite in HyperMesh) that covers the setup using PCOMP or PCOMPG.
1. Follow the steps 1 thru 5 from the section 2.
2. Define the element sets that define each ply
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Ply(1) 0o
Ply(2) -45o
Ply(4) 90o
Ply(3) 45o
Problem description
Model Information
Geometry:
o
Force = 1N
Material:
E1 = 1.3e5
Mpa
12 = 13 = 0.3
G12 = G13 = 3450 Mpa
E2 = E3 = 9650
23 = 0.6
G23 = 3100
Mpa
MPa
Problem Setup
You should copy these Files: BEAM_COMPOSITE.hm;
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BEAM_COMPOSITE.hm.
1,2,3,4
NULL
1,3,4
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1,2,4
2,4
3,4
o 1; 2; 3; 4 NULL.
It is a good procedure, if using PCOMP; isolate the elements in different components for
pos-processing.
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3. Assign the appropriate properties created above to the element of the beam components.
134
124
24
34
Global Results
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Step 4: Rerun the model and request now the CSTRESS and the CSTRAIN and
study the results for each ply
1. Save this model BEAM_PCOMP_CS.HM.
2. Run this model and call BEAM_PCOMP_CS.FEM
RESPONSE:
1. Which result it would be important to plot in addition to these?
The individual ply results as showed above.
2. What is the mainly difficult with PCOMP?
Pos-processing with different properties, mainly when the component has multiple
planes or regions, where there is no link between the common plies (GLOBAL PLY), with
PCOMPG this can be addressed.
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N (0,1,0)
N (-1,0,0)
N (0,-1,0)
Problem description
Ply (2)
45
Ply (3)
Ply (4)
-45
Ply (5)
90
Ply (6)
Ply (7)
45
Ply (8)
Ply (9)
-45
Ply (10)
90
Ply (11)
Ply (12)
45
Ply (13)
Ply (14)
-45
Ply (15)
90
Ply (16)
Ply (17)
45
Ply (18)
Ply (19)
-45
Ply (20)
90
Model Information
Geometry:
o
* Z is the main ply direction (Local 1) for all plies on this component
Clamped on Y=0.
Material:
E1 = 1.3e5
Mpa
E2 = E3 = 9650
Mpa
12 = 13 = 0.3
23 = 0.6
G12 = G13 = 3450 Mpa
G23 = 3100
MPa
Problem Setup: You should copy these Files: I_BEAM_COMPOSITE.hm;
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I_BEAM_COMPOSITE.hm.
TOP RIGHT
5, 4, 3,
2,
1]
TOP LEFT
5, 4, 3,
2,
1]
WEB
[20, 19, 18, 17, 16, 11, 12, 13, 14, 15]
7,
6]
BOTTOM LEFT
7,
6]
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2. Assign the appropriate properties created above to the element of the I beam component.
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Global Results
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Step 4: CSTRESS and the CSTRAIN and study the results for each ply
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N (0,1,0)
N (-1,0,0)
N (0,-1,0)
Problem description1.3E5
Model Information
Geometry:
o
* Z is the main ply direction (Local 1) for all plies on this component
Clamped on Y=0.
Material:
Mpa
E2 = E3 = 9650
Mpa
E1 = 1.3e5
12 = 13 = 0.3
23 = 0.6
G12 = G13 = 3450 Mpa
G23 = 3100
MPa
Problem Setup: You should copy these Files: I_BEAM_COMPOSITE_PCOMPP.hm;
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I_BEAM_COMPOSITE_PCOMPP.hm.
WEB (103)
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TOP
or 11
or 12
or 13
or 14
or 15
TOP_1
90
[1]
TOP_2
-45
[2]
TOP_3
[3]
TOP_4
45
[4]
TOP_5
[5]
TOP_6
90
[6]
TOP_7
-45
[7]
TOP_8
[8]
TOP_9
45
[9]
TOP_10
[10]
BOTTOM
20 or 15
19 or 14
18 or 13
17 or 12
16 or 11
10
9
8
7
6
BOTTOM_1
90
[11]
BOTTOM_2
-45
[12]
BOTTOM_3
[13]
BOTTOM_4
45
[14]
BOTTOM_5
[15]
BOTTOM_6
90
[16]
BOTTOM_7
-45
[17]
BOTTOM_8
[18]
BOTTOM_9
45
[19]
BOTTOM_10
[20]
WEB
WEB_1
20
19
18
17
16
11
12
13
14
15
90
[21]
WEB_2
-45
[22]
WEB_3
[23]
WEB_4
45
[24]
WEB_5
[25]
WEB_6
[26]
WEB_7
45
[27]
WEB_8
[28]
WEB_9
-45
[29]
WEB_10
90
[30]
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(1) TOP
[1, 2, 3, 4, 5, 6, 7, 8, 9, 10]
(2) BOTTOM
[11,12,13,14,15,16,17,18,19,20]
(3) WEB
[21,22,23,24,25,26,27,28,29,30]
Global Results
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Step 4: CSTRESS and the CSTRAIN and study the results for each ply
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Chapter 3
Composite Optimization
OptiStruct offers a comprehensive optimization package aimed at simplifying the design
of composite structures. This package includes the following optimization phases and
associated techniques:
o
Phase I Concept.
Free-sizing optimization is used to generate design concepts, while only considering
global responses and optional manufacturing constraints.
Phase II Dimension.
Sizing optimization with ply-based modeling is performed to control the thickness of
each ply bundle, while considering all design responses and optional manufacturing
constraints.
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1 What is Optimization?
Optimization on CAE can be described as the automatic search process for a min or a
max of a response. It can be formally defined as:
g j (x ) 0
xiL xi xiU
j = 1, L , m
i = 1, L , n
The objective function f(x) and the constraint functions gj(x) are structural responses
obtained from a finite element analysis. On OptiStruct the selection of the design variables x is
what define the type of optimization:
o
Size optimization (including free-size), the design variables are properties of structural
elements.
In topography and shape (including free-shape) optimization, the design variables are
the factors in a linear combination of shape perturbations.
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Design Variables
They are the parameters that can be varied to optimize system performance.
Design Space
It is the region where the responses are defined, for example in a topologic optimization
it is the volume where the material can be removed.
Response
It is any measure on the system performance that depend on the design variables
values. For example mass, volume, stress, displacement, etc
Feasible Design
It is a point or set of design variable values that satisfies all the constraints.
Infeasible Design
It is a point or set of design variable values that violates one or more constraint
functions.
Optimum Design
Set of design variables values that minimize (or maximize) the objective function and
that satisfy all the constraints.
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where (1.0 a)(1.0 b) represents the total volume of void in an element. It is easy to see that
a=b=0 represents the state of void for this element, and a=1 or b=1 implies that the element is
solid, i.e. filled with the 'real' material. Intermediate values of a and b represent fictitious
material.
The void size variables are considered to be continuous variables varying between 0
and 1. The void orientation of each element is also a continuous variable, which is determined
by the orientation of the principle strain. Note that while the real material is isotropic, the
fictitious material of intermediate density is anisotropic.
K ( ) = p K
where K and K represent the penalized and the real stiffness matrix of an element, respectively,
is the density and p the penalization factor which is always greater than 1.
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In addition, in order to neutralize the effect of stacking sequence, the SMEAR option is
usually a good choice for this design phase unless the user intended to follow through with the
stacking preference of the super-ply laminate model.
To determine the optimum laminate OptiStruct uses the SMEAR technology that
captures the stacking sequence effects:
o
B = 0 (Symmetric)
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above, for instance, the design concept would offer enough alternative ply orientations to break
the succession of plies of the same orientation if the percentage of each fiber orientation is
controlled (e.g. no ply orientation should drop below 15%). In addition, balancing of a pair of ply
orientations could be useful for practical reasons. For example, balancing 45 and -45 plies
would eliminate twisting of a plate bended along the 0 axis. In order to address these needs,
the following manufacturing constraints are made available for composite free-sizing:
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Cantilever Plate
The next figure shows the final results of topology and free-size optimization as
performed on this plate, side by side. As expected, the topology result created a design with
70% cavity, while the free-size optimization arrived at a result with a zone of variable thickness
panel.
Topology result
Free-size result
It is not surprising to see that the free-size design outperforms the topology design in
terms of compliance since continuous variation of thickness offers more design freedom.
It should be emphasized that free-size offers a concept design tool alternative to
topology optimization for structures modeled with 2-D elements. It does not replace a detailed
size optimization that would fine tune the size parameters of an FEA model of the final product.
To illustrate the close relationship between free-size and topology formulation, consider
a 3-D model of the same cantilever plate shown previously. The thickness of the plate is
modeled in 10 layers of 3-D elements.
The topology design of the 3-D model shown above looks similar to the free-size results
shown previously. This should not be surprising because when the plate is modeled in 3-D, a
variable thickness distribution becomes possible under the topology formulation that seeks a
discrete density value of either 0 or 1 for each element. If infinitely fine 3-D elements are used,
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a continuous variable thickness of the plate can be achieved via topology optimization. The
motivation for the introduction of free-size is based on the conviction that limitations due to 2-D
modeling should not become a barrier for optimization formulation. In regards to the 3-D
modeling of shell, topology optimization is equivalent to the application of extrusion constraint(s)
in the thickness direction of a 3-D modeled shell.
It is important to point out that while free-size often creates variable thickness shells
without extensive cavity, it does not prevent cavity if the optimizer demands it. For the example
already shown, we can see cavity in the free-size result in the 45 degree region, adjacent to the
support, and in the upper and lower corners of the free end.
Free-size optimization is defined through the DSIZE bulk data entry that is supported in
the HyperMesh optimization panel. Features available for free-size include: minimum member
size control, symmetry, pattern grouping and pattern repetition, and stress constraints applied to
von Mises stresses of the entire structure.
Involving both topology and free-size in the same optimization problem is not
recommended since penalization on topology components creates a bias that could lead to suboptimal solutions.
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Problem Formulation
For a composite shell element (shown in the figure below), the thickness it of each ply is
a variable between 0 and Ti defined on the PCOMP card.
Composite element
The only difference between topology and free-size here is that the former targets a
discrete final solution of 0 (or Ti) for it, while free-size allows it to vary freely between 0 and Ti.
The discrete solution is achieved by penalizing intermediate thickness. Most general
characteristics of regular shell topology and free-size optimization also apply to composite.
3 Size Optimization
In finite elements, the behavior of structural elements (as opposed to continuum
elements), such as shells, beams, rods, springs, and concentrated masses, are defined by input
parameters, such as shell thickness, cross-sectional properties, and stiffness. Those
parameters are modified in a size optimization. Some structural elements have several
parameters depending on each other; like beams in which the area, moments of inertia, and
torsional constants depend on the geometry of the cross-section.
The property itself is not the design variable in size optimization, but the property is
defined as a function of design variables. The simplest definition, as defined by the designvariable-to-property relationship DVPREL1, is a linear combination of design variables defined
on a DESVAR statement such that
p = C0 + DVi Ci
where p is the property to be optimized, and Ci are linear factors associated to the design
variable DVi.
Using the equation utility DEQATN, more complicated functional dependencies using
even trigonometric functions can be established. Such design-variable-to-property relations are
then defined using the DVPREL2 statement.
For a simple gage optimization of a shell structure, the design-variable-to-property relationship
turns into
t = DVi
where the gage thickness t is identical to the design variable DVi.
RADIOSS Composites 78
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The stacking sequence should not contain any section with more than a given number of
successive plies of same orientation.
The cover and/or core sections should follow a predefined stacking sequence.
HyperWorks 9.0
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RADIOSS Composites 80
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To achieve this optimum design we will introduce you the process called Optimization
Driven Design for Composite. It is divided in 3 phases:
o
Model Information:
E1 = 18.7e6 psi
N12 = 0.321
E2 = 1.40e6 psi
HyperWorks 9.0
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PCOMP_PLATE.hm.
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HyperWorks 9.0
Note that there are only 4 plies that are 1 inch thick each for a total thickness of
4 inches.
For this model the plies are all the same thickness and composite material.
HyperWorks 9.0
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HyperWorks 9.0
It makes that each plies of 45 or -45 will be in a pair with one off the other one.
10. This constraint requires that the 45.0 degree plies be in balance with the -45.0
degree plies.
11. Return to the free size composite page.
12. Click update to apply changes.
13. Click return to exit the panel.
Step 3: Create the 2 responses (mass and disp1211) for the optimization.
1. Enter the response panel.
2. Enter disp1211 in the response= field.
3. Select static displacement for the response type.
4. Select the node where the load is applied or by ID node # 1211.
5. Select total disp
6. Click create
7. Create a second response called volume.
8. Select volume for the response type.
9. Click create
10. Return to the optimization page.
HyperWorks 9.0
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Note that second request will create a FILENAME_sizing.fem file that will have
incorporated ply and element set information that includes ply patch configurations
for each ply type.
a. The default is to repeat the super ply 4 times for each ply defined on the
PCOMP(G) property that will give a total of 16 plies.
b. This is the default value and can be changed to adding the number of
desired ply sequence repetitions at the end of the line in *.fem file. For
example: OUTPUT,FSTOSZ,YES,5 This request would result in the
PCOMP ply sequence being repeated 5 times for a total of 20 plies.
RADIOSS Composites 86
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HyperWorks 9.0
Optimization History
It shows that the model had converged for a feasible solution with an
optimum volume.
3. One important result is the total element thickness using HyperView select the
last iteration on the file, it should be understood as the topography of the
laminate.
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4. Now it is important to see the individual angle plies thickness, it will be used per
OptiStruct to define the shape of the individual ply, this plot can be saw again
as a topographic plot of the stack for each angle ply:
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HyperWorks 9.0
PCOMP_PLATE_sizing.fem
ELEM SET cards will list what elements will be used for each ply,
Element sets for 45 degree angle plies (9, 10, 11 and 12)
Element sets for 90 degree angle plies (13, 14, 15 and 16)
HyperWorks 9.0
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Note that the PLY cards have the individual ply description
DESVAR cards will provide the initial, minimum and maximum thickness for
each ply.
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HyperWorks 9.0
The second request in output will make OptiStruct export the input file
PCOMP_PLATE_shuffling.fem prepared to perform the PHASE 3 Shuffle.
4. Click return.
5. Click next until you see STACK and click it.
6. Change SMEAR to blank
RADIOSS Composites 91
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8. From the Analysis page enter the optimization panel then the size subpanel.
9. Double click the desvar= button
Edit the upper bound for each design variables to give more Design Space to the
upper bound predefined per OptiStruct:
DV
ID
NAME
X0
Xmin
Xmax
DESVAR
1010100
autoply
0.12
0.00
0.30
DESVAR
1010200
autoply.1
0.34
0.00
0.80
DESVAR
1010300
autoply.2
0.48
0.00
1.00
DESVAR
1010400
autoply.3
0.06
0.00
0.20
DESVAR
1020100
autoply.4
0.17
0.00
0.40
DESVAR
1020200
autoply.5
0.12
0.00
0.30
DESVAR
1020300
autoply.6
0.13
0.00
0.30
DESVAR
1020400
autoply.7
0.58
0.00
0.80
DESVAR
1030100
autoply.8
0.17
0.00
0.40
DESVAR
1030200
autoply.9
0.12
0.00
0.30
DESVAR
1030300
autoply.10
0.13
0.00
0.30
DESVAR
1030400
autoply.11
0.58
0.00
0.80
DESVAR
1040100
autoply.12
0.08
0.00
0.20
DESVAR
1040200
autoply.13
0.05
0.00
0.20
DESVAR
1040300
autoply.14
0.07
0.00
0.20
DESVAR
1040400
autoply.15
0.80
0.00
1.00
ANGLE(o)
-45
45
90
13. Include the stress constrain and edit the DCONADD as on the image bellow:
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HyperWorks 9.0
15. Run OptiStruct directly using the RADIOSS manager or load the model into
HyperMesh and run OptiStruct from it.
16. First it is interesting to look at the optimization history to understand the design
evolution, it can be done opening the file .hgdata to plot the displacement:
Optimization History
It shows that the model had converged for a feasible solution with an
optimum volume.
The Composite stress response is not available on the history on 9.0, but
can be reviewed for example on the .out file:
HyperWorks 9.0
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ID
NAME
X0
Xmin
Xmax
OPTIM
DESVAR
1010100
autoply
0.12
0.00
0.30
0.10
DESVAR
1010200
autoply.1
0.34
0.00
0.80
0.40
DESVAR
1010300
autoply.2
0.48
0.00
1.00
1.00
DESVAR
1010400
autoply.3
0.06
0.00
0.20
0.05
DESVAR
1020100
autoply.4
0.17
0.00
0.40
0.15
DESVAR
1020200
autoply.5
0.12
0.00
0.30
0.10
DESVAR
1020300
autoply.6
0.13
0.00
0.30
0.10
DESVAR
1020400
autoply.7
0.58
0.00
0.80
0.15
DESVAR
1030100
autoply.8
0.17
0.00
0.40
0.15
DESVAR
1030200
autoply.9
0.12
0.00
0.30
0.10
DESVAR
1030300
autoply.10
0.13
0.00
0.30
0.10
DESVAR
1030400
autoply.11
0.58
0.00
0.80
0.15
DESVAR
1040100
autoply.12
0.08
0.00
0.20
0.20
DESVAR
1040200
autoply.13
0.05
0.00
0.20
0.20
DESVAR
1040300
autoply.14
0.07
0.00
0.20
0.05
DESVAR
1040400
autoply.15
0.80
0.00
1.00
0.05
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ANGLE(o)
-45
45
90
HyperWorks 9.0
MAXSUCC: limits the number of plies of the same type (orientation) that are
adjacent to each other.
The second shuffling constraint, PAIR, constrains each 45.0 degree ply to be
adjacent to a -45.0 degree ply.
RADIOSS Composites 95
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0o Plies
-45o Plies
1010101
1010102
1020101
1020102
1020103
1030101
1030102
1030103
1040101
1040102
1040103
1040104
1010201
1010202
1010203
1010204
1010205
1010206
1010207
1010208
1020201
1020202
1030201
1030202
1040201
1040202
1040203
1040204
1010301
1010302
1010303
1010304
1010305
1010306
1010307
1010308
1010309
1010310
1010311
1010312
1010313
1010314
1010315
1010316
1010317
1010318
1010319
1010320
1020301
1020302
1030301
1030302
1040301
1010401
1020401
1020402
1020403
1030401
1030402
1030403
1040401
1030101
1020101
1010101
1010102
1010201
1040101
1010202
1030102
1020102
1010203
1010204
1040102
1010205
1030103
1020103
1010206
1010207
1040103
1010208
1030201
1020201
1010301
1010302
1040104
1010303
1030202
1020202
1010304
1010305
1040201
1010306
1030301
1020301
1010307
1010308
1040202
1010309
1030302
1020302
1010310
1010311
1040203
1010312
1030401
1020401
1010313
1010314
1040204
1010315
1030402
1020402
1010316
1010317
1040301
1010318
1030403
1020403
1010319
1010320
1040401
1010401
1040401
1040201
1040102
1040101
1030201
1020201
1010101
1010102
1010201
1010202
1030102
1020102
1010306
1010203
1010204
1010205
1030103
1020103
1010307
1010206
1010207
1010208
1030302
1020302
1040203
1040103
1030403
1020403
1010308
1010301
1010302
1010303
1040104
1030401
1020401
1010310
1010309
1010304
1010305
1030101
1020101
1030202
1020202
1010311
1010312
1010313
1010314
1040204
1010401
1010315
1010316
1010317
1040202
1040301
1030301
1020301
1010318
1010319
1010320
1030402
1020402
45o Plies
1040401
1040201
1040102
1040101
1030201
1020201
1010101
1010102
1010201
1010202
1030102
1020102
1010306
1010203
1010204
1010205
1030103
1020103
1010307
1010206
1010207
1010208
1030302
1020302
1040203
1040103
1030403
1020403
1010308
1010301
1010302
1010303
1040104
1030202
1020202
1030401
1020401
1010310
1010309
1010304
1010305
1030101
1020101
1010311
1010312
1010313
1010314
1040204
1030402
1020402
1010401
1010315
1010316
1010317
1040202
1040301
1030301
1020301
1010318
1010319
1010320
1040401
1040201
1040102
1040101
1030201
1020201
1010101
1010102
1010201
1010202
1030102
1020102
1010306
1010203
1010204
1010205
1030103
1020103
1010307
1010206
1010207
1010208
1030302
1020302
1040203
1040103
1030403
1020403
1010308
1010301
1010302
1010303
1030401
1020401
1040104
1030202
1020202
1010310
1010309
1010304
1010305
1030101
1020101
1010311
1010312
1010313
1010314
1040204
1030402
1020402
1010401
1010315
1010316
1010317
1040202
1040301
1030301
1020301
1010318
1010319
1010320
90o Plie
1040401
1040201
1040102
1040101
1030201
1020201
1010101
1010102
1010201
1010202
1030102
1020102
1010306
1010203
1010204
1010205
1030103
1020103
1010307
1010206
1010207
1010208
1030302
1020302
1040203
1040103
1030403
1020403
1010308
1010301
1010302
1010303
1030401
1020401
1040104
1030202
1020202
1010310
1010309
1010304
1010305
1030101
1020101
1010311
1010312
1010313
1010314
1040204
1030402
1020402
1010401
1010315
1010316
1010317
1040202
1040301
1030301
1020301
1010318
1010319
1010320
The table shows the shuffling iterations from beginning to the last.
DSHUFFLE constrains to limit the number of like adjacent plies to a maximum
of four;
It guarantee that on the last iteration we have for every 45.0 degree (103xxxx,
green highlight) ply a -45.0 degree ply (102xxxx, yellow highlight).
SUMMARY
Composite optimization is a three phase task:
1. Begins with Free Size optimization that determines composite patch size, shape, and
location. On this phase OS output the input deck that is then used in the second phase,
2. Size optimization (ply bundle optimization), to determine optimum ply bundle thickness
and required number of plies per patch.
3. Shuffling optimization is the last phase used to optimize stacking sequence and meet
ply book rules, improve performance, and improve manufacturability.
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HyperWorks 9.0
Model Information
E = 76000 MPa
Nu=0.33
E1 = 150000 MPa
E2 = 9650 MPa
N12 = 0.321
E1 = 150000 MPa
E2 = 9650 MPa
N12 = 0.321
HyperWorks 9.0
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Wing_example.hm.
TopSkin
Normal
BottomSkin
Normal
Material Orientation (Skin components)
TopSkin
BottomSkin
Note that there are only 4 plies that are 0.4 thick each for a total thickness of 1.6.
For this model the plies are all the same thickness and composite material.
RADIOSS Composites 98
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The TopSkin differs only by a different material ID. Both materials for the TopSkin and
BottomSkin are identical for this exercise.
HyperWorks 9.0
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1 2
3
4
The numbers provided in this example are for training purposes only. Actual
manufacturing and design constraints are very dependent on the manufacturing
process and application.
HyperWorks 9.0
Proprietary Information of Altair Engineering, Inc.
2. Create the design constrain on the displacement response (MAXDISP < 50 mm)
With this card OptiStruct will generate the input for the next phase:
Wing_example_FREE_SIZE_freesizing.fem
Alternatively, the following line can be added to the *freesizing.fem file with the other output
lines located just above the case control section at the top of the file.
Ply and element set information that includes ply patch configurations for each
ply family.
It will also repeat the PCOMP ply sequence 4 times to give a total of 16 plies
each for the TopSkin and BottomSkin.
This is the default value and can be changed to adding the number of desired ply sequence
repetitions at the end of the line.
This request would result in the PCOMP ply sequence being repeated 5 times for
a total of 20 plies.
HyperWorks 9.0
Optimization history
Summary:
Min Mass = 0.11 ton = 110 kg.
Max Disp. (Max Torque) = 49.97 mm
TopSkin
BottomSkin
HyperWorks 9.0
Proprietary Information of Altair Engineering, Inc.
HyperWorks 9.0
TopSkin component
BottomSkin
These plies were created based on the PCOM or PCOMPG sequence we had, to better
understand it lets explain the number that identify them:
HyperWorks 9.0
Proprietary Information of Altair Engineering, Inc.
Ply 1010100
DV Seq.
Ply
Family
1
* This other example below is not present on the model, it just to show what happen if the
number of DV and plies is superior to 9.
Ply 10130400
DV Seq.
1
Ply
Family
3
8. Review the element Set that are used for representing each ply:
DV SEQ.
Definition
PLY
FREE SIZE
Definition DV SEQ.
01
01
1
01
01
01
01
2
01
01
01
01
3
01
01
01
01
4
01
01
02
02
1
02
02
02
02
2
02
02
02
02
3
02
02
02
02
4
02
02
HyperWorks 9.0
Ply
01
01
01
01
02
02
02
02
03
03
03
03
04
04
04
04
01
01
01
01
02
02
02
02
03
03
03
03
04
04
04
04
Bundle
(FSTOSZ)
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
ESET
ID
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
1010100
1010200
1010300
1010400
1020100
1020200
1020300
1020400
1030100
1030200
1030300
1030400
1040100
1040200
1040300
1040400
2010100
2010200
2010300
2010400
2020100
2020200
2020300
2020400
2030100
2030200
2030300
2030400
2040100
2040200
2040300
2040400
Remember each set is a shape that will be manufactured then it needs to have a clear
topology, we will now show how to improve the shape we got from the FREE SIZE
optimization:
Ply 1010100
o
o
o
o
Ply 1010200
o
o
o
o
Ply 1010300
o
o
o
o
o
o
o
o
Ply 1010400
This should be done for every shape (TopSkin and BottomSkin) that has ill-defined shapes.
HyperWorks 9.0
Proprietary Information of Altair Engineering, Inc.
This command will make OS generate the input for the Phase III (Shuffle).
10. Change on the stack cards the third field LAM from SMEAR to blank.
11. Update the maximum value on the Design variables, this will give a little more room for OS
search a optimum design:
HyperWorks 9.0
ID
1010100
1010200
1010300
1010400
1020100
1020200
1020300
1020400
1030100
1030200
1030300
1030400
1040100
1040200
1040300
1040400
2010100
2010200
2010300
2010400
2020100
2020200
2020300
2020400
2030100
2030200
2030300
2030400
2040100
2040200
2040300
2040400
NAME
autoply
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
X0
3.22
3.00
3.54
0.40
0.98
1.89
3.20
4.10
0.98
1.89
3.20
4.10
0.79
0.89
1.49
6.99
3.23
2.98
3.54
0.42
1.00
1.88
3.31
3.97
1.00
1.88
3.31
3.97
0.80
0.92
1.60
6.84
Xmin
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Xmax
4.00
4.00
5.00
1.00
2.00
3.00
4.00
5.00
2.00
3.00
4.00
5.00
1.00
1.00
2.00
9.00
4.00
4.00
5.00
1.00
2.00
3.00
4.00
5.00
2.00
3.00
4.00
5.00
1.00
2.00
2.00
9.00
14. Run the optimization again with the DELSIZE =0.1 run as Wing_example_Size_0.1.fem.
We have a feasible solution on the initial Design (X0), then what we want is to give a smaller
step to see if around this point we can find a better solution. It can be done using the Opti
Control panel:
Mass = 132.7 Kg
Max Disp. = 46.95 mm
HyperWorks 9.0
Proprietary Information of Altair Engineering, Inc.
The user can modify this initial step to see how it affects the solution, on this example any
step higher than 0.15 tends to drive the solution to an unfeasible point. For values small
than 0.01 the number of iterations can be to high, and the optimum it will be always around
132 Kg.
Other test that the user can do on this case is changing the initial values for some plies and
measures the effects.
The solution for each shape is:
DV
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
HyperWorks 9.0
ID
1010100
1010200
1010300
1010400
1020100
1020200
1020300
1020400
1030100
1030200
1030300
1030400
1040100
1040200
1040300
1040400
2010100
2010200
2010300
2010400
2020100
2020200
2020300
2020400
2030100
2030200
2030300
2030400
2040100
2040200
2040300
2040400
NAME
autoply
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
X0
3.22
3.00
3.54
0.40
0.98
1.89
3.20
4.10
0.98
1.89
3.20
4.10
0.79
0.89
1.49
6.99
3.23
2.98
3.54
0.42
1.00
1.88
3.31
3.97
1.00
1.88
3.31
3.97
0.80
0.92
1.60
6.84
Xmin
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Xmax
4.00
4.00
5.00
1.00
2.00
3.00
4.00
5.00
2.00
3.00
4.00
5.00
1.00
1.00
2.00
9.00
4.00
4.00
5.00
1.00
2.00
3.00
4.00
5.00
2.00
3.00
4.00
5.00
1.00
2.00
2.00
9.00
OPTIM
2.54E+00
2.54E+00
3.81E+00
0.00E+00
1.27E+00
1.27E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
1.27E+00
5.08E+00
2.54E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
1.27E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
1.27E+00
5.08E+00
ANGLE(o)
0
45
-45
90
45
-45
90
TOPSKIN
HyperWorks 9.0
Proprietary Information of Altair Engineering, Inc.
BOTTOMSKIN
HyperWorks 9.0
This command will make OS export the property settings for the last iteration on
file_name.prop.
5. Define the DEBUG card to help on understand the shuffle steps:
DEBUG,SHUFHTML,1
This will generate a file in a HTML format with a table with the shuffle iterations:
Wing_example_suffle_shuf.hist.html
DEBUG,SHUFTEXT,1
This will generate a text file with the stack sequences during the shuffle iterations:
Wing_example_suffle.shuf
HyperWorks 9.0
Proprietary Information of Altair Engineering, Inc.
The first shuffling constraint, MAXSUCC, limits the number of plies of the same
type (orientation) that are adjacent to each other.
The second shuffling constraint, PAIR, constrains each 45.0 degree ply to be
adjacent to a -45.0 degree ply.
7. Run the final optimization to determine the optimum stack sequence for the two skin.
8. Open the HTML to analyze the shuffle process.
The table below shows the shuffling iterations from beginning to the last. Note how the
DSHUFFLE constraints to limit the number of like adjacent plies to a maximum of four and how
the 45.0 degree (103xxxx, yellow highlight) and -45.0 degree (102xxxx, green highlight) plies
are paired together in the last iteration in the far right column.
0o Plies
TopSkin
- 45o Plies
45o Plies
90o Plies
BottomSkin
SUMMARY
HyperWorks 9.0
Instructor Name
Revised Nov. 2008
Altair Proprietary and Confidential Information
Agenda
Theoretical introduction
Composite Pre-processing Analysis
Composite Optimization
Composite Material
How does the displacement look like for the same load in y-direction?
3 E
=
12 0
23 0
13 0
E
1
E
1
E
1
G
1
G
0 1
0 2
0 3
0 12
0 23
1
G
13
G=
Altair Proprietary and Confidential Information
E
2(1 + )
1 E11
12
2 E1
3 E13
= 1
12 0
23 0
13 0
21
E2
31
E3
32
E3
0
0
1
E3
1
G12
0
0
0
0
0
0
1
G 23
1
E2
23
E2
0 1
0 2
0 3
0 12
0 23
1
G13
13
where:
G12 =
E1
2(1 + 12 )
G23 =
E2
2(1 + 23 )
G13 =
E3
2(1+ 13 )
3 = 13 = 23 = 0
1 E11
12
2 = E1
0
12
with:
ij ji
Ej
12
E1
1
E2
i, j =1,2,3.
Ej
i j
0 1
0 2
1
G12 12
3 = 12 1 + 23 2
E2
E1
OR
i = Cij ( j j T )
i, j = 1 6
Total strains are the summation of both the free thermal and
mechanical strains.
T
M
= +
T
Free thermal
, strains are the strains caused by free thermal
expansion or contraction.
t , j = j T
Mechanical strains are the strains which cause stress
M = T
Altair Proprietary and Confidential Information
i = Cij ( j j T )
{ x } = [TS ]1 [Q ][TS ]T ({ x } { x }T )
OR
{ x } = [Q ]({ x } { x }T )
Where
[Q ] = [TS ]
[Q ][TS ]T
N y = y dz
N t / 2
xy
xy
n
N y = y dz
N k =1 z k 1
xy
xy
Copyright 2008 Altair Engineering, Inc. All rights reserved.
For a homogenous single ply plate of constant thickness the midplane moments can be written in terms of stress variation through
the thickness of the plate as:
M x t / 2 x
M y = z y dz
M t / 2
xy
xy
n
M y = z y dz
M k =1 z k 1
xy
xy
Stress-Strain relationship:
[ ] ({ } { } T )
{ x }k
{ x } = [Q ]({ x } { x }T )
=Q
x k
x k
zk
{N x } = ([Q ]k ({ x
k =1 z k 1
} + z {k } { } T ))dz
k
x k
OR
{N x } = [A]{ x
}+ [B]{k } {N }
T
x
zk
{M x } = ([Q ]k ({ x
} + z {k } { } T ))zdz
k
k =1 z k 1
x k
OR
{M x } = [B]{ x
}+ [D]{k } {M }
T
x
Where:
n
N A B 0 N T
=
k T
M
B
D
M
N A B 0 N T
=
k T
M
B
D
M
The [A] matrix relates mid-plane forces to mid-plane strains defining
the extensional behavior of the laminate.
A14 and A24 terms represent extensional shear coupling
between the mid-plane forces and midplane shear strain.
The [A] matrix is stacking sequence independent
N A B 0 N T
=
k T
M
B
D
M
The [B] matrix relates mid-plane forces to plate curvatures and midplane moments to mid-plane strains.
Both above relations represents extensional bending and
shear - twist coupling.
The [B] matrix is zero for symmetric laminates
N A B 0 N T
=
k T
M
B
D
M
The [D] matrix relates mid-plane moments to plate curvatures
defining the extensional behavior of the laminate
D14 and D24 terms represent bending twist coupling between
the mid-plane moments and plate curvatures.
The [D] matrix is stacking sequence dependent and is most affected
by the location of zero degree plies in the stacking sequence.
Material Data:
E1 = 18.7e6psi
E2 = E3 = 1.40e6psi
12 = 13 = 0.3
23 = 0.6
G12 = G13 = 0.5e6psi
G23 = 0.45e6 psi
2.00E+07
1.50E+07
Q_11
Q_12
Q_14
Q_22
Q_24
Q_44
1.00E+07
E11
[S ] = E121
0
12
E1
1
E2
0
1
G12
5.00E+06
0.00E+00
-100
-50
50
100
-5.00E+06
[Q ] = [S ]1
-1.00E+07
[Q]
= [TS ] [Q ][TS ]
1
N A B 0 N T
=
T
M B D k M
Copyright 2008 Altair Engineering, Inc. All rights reserved.
Laminate Matrices.
3
Laminate Matrices.
Specific PrePre-processing
Majority of the real life parts are modeled with shell elements.
Element
Property
(PCOMP)
Ply 1
Ply 2
.
.
.
Ply n
Analysis
Ply results
(Stress & strain
for individual ply)
Shell results
(Stress and strain)
Ply Failure
(Ply failure or
matrix failure)
Altair Proprietary and Confidential Information
Both are defined as the (7th field for CQUAD or 6th field for CTRIA)
12. Pos-processing
Define the element normal to establish the reference for defining ply
stacking
Ply material, Ply thickness (number of plies), Ply angle, Order of stacking
Modeling Flow
Material Property
(MAT8)
Element Property
(PCOMP)
Material
Orientation
Element Normal
Element
(CQUAD4 )
Material Property
(MAT8)
E1 = 18.7e6 psi
12 = 13= 0.3
a1 = 1.0e-7
in/in/oC
E2 = E3 = 1.4e6 psi
23 = 0.6
a2 = a3 = 18.0e-6
in/in/oC
Material Property
(MAT8)
12 = 13= 0.3
a1 = 1.0e-7
in/in/oC
E2 = E3 = 1.4e6 psi
23 = 0.6
a2 = a3 = 18.0e-6
in/in/oC
Failure Theory
Ply 2
Ply 1
Ply 4
Ply 3
Altair Proprietary and Confidential Information
Element Normal
Plies are listed from the bottom surface upwards, with respect to
the elements normal direction
Material Orientation
E2 = E3 = 9650 Mpa
12 = 13 = 0.3
23 = 0.6
a1 = 1.0e-7mm/mm/oC
a2 = a3 = 18.0e-6 mm/mm/oC
The x-axis of the element coordinate is aligned with side 1-2 (or
direction from G1 G2) of the shell element and z-axis is aligned
with the normal of the shell element.
Z = Element Normal
HyperLaminate
HyperLaminate is an interactive
tool for pre-processing of
composites.
LIVE DEMO
PCOMP defines all the laminate properties like ply material, thickness and
orientation and also the stacking sequence.
Through the global ply identification number, plies that are part of
many regions can be tracked across the regions, reducing the effort
for keeping track of the ply properties and stacking information.
Ply definition, stacking and the property are defined separtely through
independent cards (PLY, STACK and PCOMPP).
(replacing
Ply
ID
MID
THETA
SOUT
TMANUF
ESID1
ESID2
ESID3
ESID4
ESID5
ESID6
ESID7
ESID8
ESID9
PLYID1
PLYID2
PLYID3
PLYID4
PLYID5
PLYID6
STACK
ID
LAM
PLYID7
+
Altair Proprietary and Confidential Information
Defining PCOMPP
Define all the ply definitions separately using PLY cards (Angle,
Elements Sets, Thickness, etc)
PCOMPG
PCOMPP
1.
1.
MID-Plane (Z0)
1.
MID-Plane (Z0)
FT (Hill, TSAI,...)
MID-Plane (Z0)
2.
FT (Hill, TSAI,...)
2.
FT (Hill, TSAI,...)
2.
3.
3.
PLY
4.
4.
5.
Ti (Ply thickness)
5.
Ti (Ply thickness)
6.
6.
1.
2.
3.
7. GPLYID
STACK
1. LAM (SMEAR, SYM,...)
What is Optimization?
min f (x ) = f (x1 , x1 ,..., x n )
xiL xi xiU
j = 1, L , m
active
g j (x ) 0
inactive
i = 1, L , n
violated
Feasible
Design
Optimum
Design
Design Space (0 - 1)
Infeasible
Design
Topologic optimization
Homogenization method
K ( ) = p K
Size Optimization
Number of Plies?
t = DVi
Ply Bundle Sizing!
p = C 0 + DVi Ci
Sizing
optimization
VS
Challenges
Design Complexity: how to optimally
Manufacturing
Costs
Integrated ribs
Ply drop-offs
Complex stacking
Manufacturing
Complexity
Plate design
Ply drop-offs
Complex stacking
Plate design
One laminate
Complex stacking
Plate design
One laminate
Quasi isotropic
[0, 90, +-45]nS
Mechanical
efficiency
Altair Proprietary and Confidential Information
Design
complexity
CAE upfront
Optimization
Process automation
Integration of design
and performance
evaluation
OptiStruct 9.0
Solution for concept and pre-design of complex composite structures
Stream-lined process based on structural optimization and process automation
Altair Proprietary and Confidential Information
Geometry
definition
Virtual
verification
Design
(CAD)
Design
(CAD)
Verification
(CAE)
Verification
(CAE)
Structural
optimization
(CAE)
Optimization
(CAE)
Physical
verification
Physical Test
(a)
Physical Test
Design
(CAD)
Integrated design
and analysis
Verification
(CAE)
Physical Test
(c)
(b)
Manufacturing constraints
Phase II Dimension:
Ply-Bundle Sizing with ply-based FEA modeling
Manufacturing constraints
nP
e s ig
m
roble
Phase 1
Tailoring?
Phase 2
Number of Plies?
Phase 3
y
x
Laminate Stacking?
Free Sizing!
0
Rule based
Automation
Automation
45
-45
ply shuffling
90
Patch Interpretation
Automation
Automation
45
-45
0
0
45
-45
90
90
-45
45
0
0
-45
45
Optimized Stacking
Sequence!
Terminology
Tailoring
Super Ply
Ply Bundle
Shuffling
Terminology
0
0Super Ply
90
45
-45
Ply Bundle 4
Free Sizing
Ply Bundle 3
Initial Laminate Definition
consisting 4 Super-Plies
OUTPUT,FSTOSZ,YES,4
Ply Bundle 2
Basically each bundle consists of several plies so that the thickness (number of
plies) can be sized. The bundles do not have to be resulted from free-size, though
it would be the recommended approach.
Altair Proprietary and Confidential Information
Ply Bundle 1
Terminology
Ply Bundle 4
Ply Bundle 3
Ply Bundle 2
Z
Ply Bundle 1
0Plies
90Plies
+45Plies
Linked with
Manufacturing
Constraint
-45Plies
Terminology
Tailoring Cutting the ply patch shapes
PHASE I - Concept
Concept: Free-Size or Topology Optimization
Optimization Setup
Min (Mass)
Manufacturing Constraints
+45
-45
90
Superply Level
Balanced 45Plies
Smeared Superply
Level
If no stiffness is needed for 90Ply in Element X, the variable T90will reduce or become zero.
T0
F
0
123
90
45
-45
3
T-45
PCOMP
Variable: Ti of each Super-Ply-Element
90
Altair Proprietary
and Confidential Information
0
Material Definition
Property Definition
DSIZE
Free Size Design Variable Definition
Static Displacement
Total Disp
Node ID 2669
Objective Function
90
Balance Constraint
0
Altair Proprietary and Confidential Information
90
Element Thickness
Ply2 (90)
Element Thickness
Ply3 (+45)
LINKED by Constraint
Element Thickness
Ply4 (-45)
Altair Proprietary and Confidential Information
45
T = Ply4 (nom)
90
T = Ply3 (nom)
-45
T = Ply2 (nom)
T = Ply1 (nom)
T = Ply1 (nom)
-45
T = Ply2 (nom)
90
T = Ply3 (nom)
45
T = Ply4 (nom)
T_45Ply (1)
T_90Ply (1)
Ply90%
=
Min/Max =
Sum(T_0Ply)
T_0Ply Constant
T_Laminate
T_Laminate Min/Max
Balance_45Ply,
T_45Ply (1) = T_45Ply (2)
Sum(T_90Ply)/T_Laminate
PCOMP
T_90Ply (2)
T_45Ply (1)
0 DEG
90 DEG
45 DEG
- 45 DEG
90
0 DEG
90 DEG
45 DEG
- 45 DEG
45
-45
0
90
45
OUTPUT,FSTOSZ,YES,VALUE
FreeSize to Size
Creates a new *.sizing.fem deck
Level setting Ply-Bundles: 0plies
Bundle1
Bundle3
Activate output
Bundle2
Bundle1
Bundle4
Bundle3
-45
Bundle2
Bundle4
Bundle1
Bundle3
Bundle2
Bundle4
*
*
*
*
*
Ply1010200 (0-Bundle2)
*
Ply1010300 (0-Bundle3)
*
Fig. Set Browser
Ply1010400 (0-Bundle4)
90Ply
OUTPUT,FSTOSZ,YES,8
45Ply
0Ply
90Ply
45Ply
PHASE II Dimension
System: Ply-Bundle Sizing with ply-based FEA modeling
Manufacturing constraints
Phase II Dimension
Ply-Bundle Concept
PLY
STACK
Element properties
Phase II Dimension
Level setting Ply-Bundles: 0plies
Phase II Dimension
Level setting Ply-Bundles: +/- 45plies
Phase II Dimension
Level setting Ply-Bundles: 90plies
Ply
ID
MID
THETA
SOUT
TMANUF
ESID1
ESID2
ESID3
ESID4
ESID5
ESID6
ESID7
ESID8
ESID9
PLYID1
PLYID2
PLYID3
PLYID4
PLYID5
PLYID6
STACK
ID
LAM
PLYID7
Manufacturing Ply-Book
Optimization definition
PLY 4
PLY 3
PLY 2
PLY 1
PLY 4
PLY 3
STACK1
PLY 2
PLY 1
DCOMP
Ply based sizing design variable definition
OUTPUT,SZTOSH,YES
Size to Shuffle
Creates a new *.shuffling.fem deck
Altair Proprietary and Confidential Information
Activate output
Copyright 2008 Altair Engineering, Inc. All rights reserved.
0 DEG
45 DEG
90 DEG
- 45 DEG
PHASE III
Detail: Stacking Sequence Optimization
45
-45
90
45
-45
0
0
45
-45
90
90
-45
45
0
0
-45
45
Ply Shuffling
-45
+45
-45
+45
-45
Ply Pairing
+45
-45
The lay-up sequence should contain no sections with more than a given
number of successive plies with the same angle (typically 3 or 4)
+45
DSHUFFLE
Design Variable Definition for Composite Ply Shuffling Optimization
Formulation from Sizing Optimization phase is maintained
Automatically created after the Sizing Optimization phase with
OUTPUT,SZTOSH,YES
Initial
No rules
Successive
ply limit = 3
Successive
ply limit = 2
Pairing
constraint 45 -45
Reversed Pairing
constraint 45 -45
Core 0
45 -45 90
90
90
45
90
-45
-45
90
-45
45
90
45
45
45
45
-45
45
-45
45
45
-45
-45
45
45
45
45
45
45
-45
-45
45
-45
45
90
-45
45
45
45
-45
-45
90
45
45
45
-45
-45
-45
45
45
45
-45
-45
90
-45
-45
45
-45
-45
45
-45
90
45
-45
-45
-45
-45
-45
45
90
-45
90
90
90
90
90
90
45
90
90
90
90
90
-45
90
90
90
-45
90
90
45
90
90
-45
90
90
90
90
Cover 0
45 -45 90
If each run takes 6 seconds, testing all available combinations would take:
8.35E+25 years!
STACK
OUTPUT,FSTOSZ
OUTPUT,SZTOSH
PCOMP
Free-sizing
optimization
Sizing optimization
ID
NAME
X0
Xmin
Xmax
DESVAR
1010100
autoply
0.12
0.00
0.30
DESVAR
1010200
autoply.1
0.34
0.00
0.80
DESVAR
1010300
autoply.2
0.48
0.00
1.00
DESVAR
1010400
autoply.3
0.06
0.00
0.20
DESVAR
1020100
autoply.4
0.17
0.00
0.40
DESVAR
1020200
autoply.5
0.12
0.00
0.30
DESVAR
1020300
autoply.6
0.13
0.00
0.30
DESVAR
1020400
autoply.7
0.58
0.00
0.80
DESVAR
1030100
autoply.8
0.17
0.00
0.40
DESVAR
1030200
autoply.9
0.12
0.00
0.30
DESVAR
1030300
autoply.10
0.13
0.00
0.30
DESVAR
1030400
autoply.11
0.58
0.00
0.80
DESVAR
1040100
autoply.12
0.08
0.00
0.20
DESVAR
1040200
autoply.13
0.05
0.00
0.20
DESVAR
1040300
autoply.14
0.07
0.00
0.20
DESVAR
1040400
autoply.15
0.80
0.00
1.00
ANGLE(o)
-45
45
90
Conclusions
The benefits of this process are even more significant for applications with
Successful application of this process at various OEMs and suppliers for different
commercial aero projects.
Responsiveness to implement new rules into the algorithm for stacking sequence
optimization.