ACP Training ACP Key features and Functionality ANSYS Switzerland GmbH Technoparkstrasse 1 8005 Zurich Switzerland Phone: Fax: Mail: Web: +41 (0) 44 500 93 60 +41 (0) 44 500 93 61 [email protected] www.ansys.com Difficulties in Simulating Layered Composites ● Material properties americascup.com ● Efficient layup Reference direction Stacking sequence Tapering Fiber orientations/draping ● ● Shell versus Solid Elements Efficient evaluation of state-of-the-art Failure Criteria carbon.at carbon fibre - epoxy composite frailure Contents Shell-based Composite Analysis ● ACP in Workbench Work-Flow ● From Materials to Plies ● Layup and Fiber Directions ● Advanced Modeling of Fiber Directions and Ply Thickness ● Stacking Visualization ● Postprocessing Solid Composite Analysis ● ACP in Workbench Work-Flow ● Assembly of a Track Rod ● Solid Model Extrusion ● Solid Model Postprocessing Shell-based Composite Analysis in ANSYS Workbench „Model as You Build It“ Logic Work-Flow Source: class40.it From Materials to Plies Typical Fabric: Carbon UD Material Level Ply Level Fabric Single ply, UD or Woven Typical Stackup: Non-crimped fabric me es sa m i t 3 c fabri Stackup Prearranged combination of fabrics Sub Laminate Collection of fabrics or stackups From Materials to Plies Material Level Ply Level Modeling Ply (MP) Defines ACP layup ● s me i t 3- ● ● Material: fabric, stackup, sublaminate Number of layers (repetitions) Orientation Production Ply (PP) Manufacturing resolution Analysis Ply (AP) Simulation resolution of plies 1 Fabric = 1 PP = 1 AP 1 Stackup = 1 PP = x APs 1 Sub Laminate = y PPs = x*y APs Layup Direction How to manage arbitrary layup directions? ● ● stringer Define Oriented Element Sets based on ANSYS Named Selections Define multiple Layup Directions per Element bonding port bonding starboard Fiber Directions – 1 Rosette ● ● Reference direction Rosette 1 Cartesian, cylindrical, spherical and edge-wise rosettes Combination methods Fiber Directions – Superposed Rosettes Rosette 3 Rosette 2 Rosette 1 Fiber Directions – Edge-wise Rosette Edge set Edge-wise rosettes are very handy to define the reference direction along an edge guide Advanced Fiber Directions - Draping Draping Algorithm is fast, intuitive and capable of handling complex shapes Draping Algorithms determine draped fiber orientations Draping Mesh shows shear induced by draping Flatwrap visualization can be exported for ply-cutter Advanced Fiber Directions - Table Based E.g. for filament winding Advanced Ply Thickness Core thickness set by CAD geometry Core edge taper Ply thickness entered with a Look Up Table CAD-geometry Visualization of Stackings ● ● Stacking sequence and composite thickness can be displayed on arbitrarily Sections or the entire model Sampling elements are a powerful tool to analyze the layup Shell Postprocessing Assess utilization of each ply with a Sampling Element IRF plot of entire structure Analyze structure ply-by-ply Tw(15)(2): Tsai-Wu Layer 16, Loadcase 3 Gain an overview of critical failure mode, layer and load case Why Solid Modeling? Account for ● out-of-plane normal stresses ● out-of-plane shear stresses Relevant for ● „thick-walled“ composite structures ● e.g. buckling analyses of such ● proper modeling or assemblies, e.g. with contacts gurit.com gereports.com wind-watch.org Solid Composite Analysis in ANSYS Workbench Assembly of Composite Track Rod with Fittings New in R14.5 Solid Model in ACP Metal inserts site o p Com Analysis result By courtesy of: Sauber F1 Team ure t c u str Solid Model Extrusion Monolithic Material-wise Analysis Ply-wise Solid Model Extrusion Continued Drop-Offs • Model drop-offs with homogeneous resin elements • Optional removal of bad elements • Caching computed solid models allows to quickly restore them on reload and update of the ACP model. Solid Model Extrusion: Extrusion Guides With Extrusion-Guide Along Geometry Along Direction Solid Model Extrusion: Advanced Features An Extruded Solid Model can be additionally shaped with external geometries to generate desired shapes Start with shell geometry and composite layup Define extrusion guides and snap to geometry Specifiy element thickness and extrude Solid Model Solid Model Postprocessing All features of Shell-Model Postpsrocessing are retained IRF plot for entire Solid Model pd(8) Puck delamination in layer 8 Projection of the critical layer (IRF) onto the reference shell Sampling element
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