Composite Modeling with FiberSim

April 10 2012

Innovation Intelligence

Composites Overview within HyperWorks

CAD & Mfg Interoperability

Geometry
HyperMesh
Modern Ply Based
Composites Pre-Processing

Visualizations
Visually Verify the Math Model

Realizations
Export Ply Based Models to
Solver Zone Based Models

OptiStruct/RADIOSS
Composites
Design Optimization & Analysis

HyperLaminate Solver
Classical Lamination Theory

HyperView
Composites
Post-Processing & Failure Analysis

HyperWorks Partners
Detailed Compoiste Material
Modeling & Structural Modeling

Process of FiberSim- Hypermesh interoperability

Import CAD model

Create mesh
Import Equivalent
Fibersim model

Read CAD part ,surface from Catia , UG etc ,geometry etc.

Geometry clean up on imported CAD model

Mesh the part ,check element quality etc.

Extract composite data - Ply, stacking , material info , system definition

Drape data , triangulation data (ply shapes ) etc as table in HM .

Geometric ply shape

realization

Template properties

Contains additional FE required for design/analysis but not required for manufacturing/documentation

Realize geometric shapes to FE ply shapes - Two methods , simple , advanced

Extract elements for each Ply.
Do result Map, result interpolation
Correct the drape angles

Stack & Material

orientation

Defines the stacking sequence direction and the reference material orientation

Review & Modify

Visually verify math model via 3D visualizations (Ply shapes/orientation/thickness, Stacking sequence)

Ply based model

realization

Conversion of ply to zone based modeling

Laminate realization.

Export & Solve

Export to any supported solver

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Step 1: CAD geometry import

Basic CAD model geometry for the part is imported
HM support all the major CAD systems and Neutral formats

CATIA V5, V4

UG-Nx

PTC

Parasolid

IGEs

STEP

At this stage, we import the geometry data only

Ply or Composite data is not imported

Use Optistruct Use profile in Hypermesh

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Import CAD geometry

Do not us this composite data

toggle for Fibersim

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

STEP 2: Mesh the CAD Geometry

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

STEP 3: Import FiberSim Composite Data ( HDF5 file *.h5)

Use File/ Import /Geometry
Select FiberSim file filter
Import the HDF5 file

*.h5

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

FimberSim Model import.

This process will import and
populate HM data base with

Laminate data ( ply book ply

stacking data,

Composite Material data

Each ply data (triangular elements

spanning a single ply)

Master Rosette ( coordinate system

for the model ) for stacking direction

If the Ply is woven / fabrics HM

create additional plies for each
direction (P003_1 , P003_2) two
plies

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Imported FiberSim Data----Laminate Table.

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

SETP3 Correction of Element Normals

Based on the Stacking direction ( Rosette Z direction), element
normal's are changed to match the Z direction
Use tools/Normal panel in HM to reverse the normal/ or correct the
flipped few elements Red color is in the positive normal direction

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

STEP4 Realize FibersSIm Geometry plies in FE

Plies .. (PLY-> Realize)
This step converts the FiberSim Ply entities to Finite element Mesh
created in HM.

This process takes each FiberSim Ply date and finds the FE elements which are
bounded by the ply boundaries and transfer the ply directions, draping data, ply
orientation into FE elements. Geometry plies are converted to FE plies.

HM uses two mapping approaches..

Simple mapping Based on proximity checks of the FE elements to ply.

Advance Mapping Use correct interpolation to fine the FE element for a ply and transfer
the data.

Right Mouse click on the Ply entity on the Browser to activate the realize

dialog box

FiberSIM HM integration

Ply realization ( converting geom representation to Fe representation) .

Derive ply boundary from triangulations mesh data.
Project the ply boundary /region on the actual mesh in HM .

What is draping data ?

Corrections to thickness and fiber direction of every element within a

Ply.

Mapping Fibersim Draping data to HM.

Final fiber Direction from Fibersim

N4

N3
Ply Fiber Direction

Corrected Theta for OS

interface as Drape card
Material Direction
Theta on element

N1

Vector provided by
Fibersim on every
element.

N2

Element Material/local axis

From N1-N2

Results of realization Transfer FiberSim composite data to

FE based data in HM STEP4 results
Create FE plies from the mesh model
Elements inside a ply boundary is grouped into individual FE plies

Draping table is created

Each ply FE element will contain the Drape data

The change in ply thickness due to draping ( scale factor)

Change in fiber angle due to draping

STEP 4 -- results
Ply sets are created.. Set containing FE elements for each plies

STEP 5: Verification of FE plies, thickness and orientation in

HM
First step is to create Ply property PCOMPP
HM support ply based model as default ( not Zone based model)

Assign this property to all the FE elements

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

STEP5 -- Ply Visualization

Set the display to By Property

Set the Visualization mode to

Hide/ show each ply from the

Browser

STEP 5 Ply angle Visualization on FE model

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

STEP5 --- Ply thickness visualization -3D representation

Turn on 3D representation Mode

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

STEP 6: Exporting into Solver Specific Zone models..

Altair solvers Optistruct / Radioss supports Ply based models
Nastran ( 11.0.130)/ Abaqus (11.0.140 only) and other solvers support
Zone Based models
The following step Laminate Realize shall convert Ply based model to
Zone base model

This will create PCOMPG for Nastran

Or *SHELLSECTION_COMPOSITE cards for Abaqus.(11.0.140)