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1 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Simulation solution for Composite ManufacturingBenjamin Lehugeur
Technical Account Manager, Airbus Group
2 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ANSYS Composite Manufacturing Solutions
ANSYS Workbench
Forming
Fabric Deformation
Draping / Explicit
ANSYS LSDyna
ANSYS Mechanical
Impregnation
Resin flow calculation
/ Warping
PlanetsX
Curing
Residual Stresses
/ Distorsion
ANSYS Mechanical
ANSYS Composite Cure (ACCS)
Heat load / Autoclave
ANSYS Fluent
Strength Analysis
Falling
Collision, Shock
ANSYS Mechanical
ANSYS LSDyna
Lightning Strike
ANSYS HFSS
ANSYS Composite
PrePostVariable Material Fields:
Degradation Factor, Temperature,
Void content, …
Multiscale
Simulation
3 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ANSYS Composite Manufacturing Solutions
ANSYS Workbench
Forming
Fabric Deformation
Draping / Explicit
ANSYS LSDyna
ANSYS Mechanical
Impregnation
Resin flow calculation
/ Warping
PlanetsX
Curing
Residual Stresses
/ Distorsion
ANSYS Mechanical
ANSYS Composite Cure (ACCS)
Heat load / Autoclave
ANSYS Fluent
Strength Analysis
Falling
Collision, Shock
ANSYS Mechanical
ANSYS LSDyna
Lightning Strike
ANSYS HFSS
ANSYS Composite
PrePostVariable Material Fields:
Degradation Factor, Temperature,
Void content, …
Multiscale
Simulation
4 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ANSYS Composite Pre-post (ACP)
• “Model as you build it” approach
• Parametric modeling of plies– Material properties, ply thickness– Number of layers– Fiber direction– Ply dimension and outline (ACP Rules)– Complex layouts of plies can be automated using
interactive layup definition in EXCEL
• Direct model review– Check the stacking on the fly– Look at area coverage– Produce plybooks for manufacturing
• “Thick-walled” composites structures– ACP offers Shell or Solid Element Modeling– Accurately model out-of-plane stresses
5 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ACP Workflow
Can be used with several solvers:• ANSYS Implicit / Transient• ANSYS Explicit: LS-DYNA, Autodyn• Any others via ACT (for RTM for instance)
6 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ACP / Variable Material Fields
• Each composite structure has its individual challenges!
• Consider degraded material properties in region with low fiber volume content, voids and folding
• Analyse draping shear angle and fiber orientation
• Consider environmental conditions such as temparature and humidity (resin)
7 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ACP / Draping
• Draping simulation or direct measurements allow you to include the shear distortion effect of a fabric in your simulation.
Composite draping: shear and wrinkling(Dr M Sutcliffe, University of Cambridge, UK)
No shear
E1 = E2
E1 ≠ E2
30° shear
8 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ACP / Draping
• Draping allows you to evaluate the shear angle by
- Simulation: Shear angle is estimated using energy algorithm assuming shear modulus distributed uniformly.
- External data: LookUp Table (CSV)
9 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ACP / Draping
• Deformation analysis based on simple geometrical interpretation (without considering blank-sheet’s stiffness).
– Location of folds after forming
– Optimum form of blank sheet before forming
10 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Implicit Simulation / ANSYS Mechanical
• Temperature dependency
• Real forming velocity
• Parametrization of the tooling geometry quickly to optimize the forming process (reduce number of folds)
11 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Explicit Simulation / ANSYS Mechanical – LS Dyna
12 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Multiscale SimulationMultiMech ACT Extension for Mechanical
• MultiMech'sbreakthrough multiscale analysis techniques completely within ANSYS Workbench + ACP
• No longer need to perform destructive testing or use curve-fitting techniques to capture the unique, nonlinear behavior of composite materials.
13 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Multiscale SimulationMultiMech ACT Extension for Mechanical
Main features in the MultiMech App :
• Two-way coupled multiscale Finite Element solver, dynamically linked to ANSYS
• Automatic cracking and composite damage mechanisms
• Automatic composite microstructure generator
• Supports any composite type, orientation, and damage mechanism
• Robust post- processing features to let users “zoom” into microstructural behavior
14 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ANSYS Composite Manufacturing Solutions
ANSYS Workbench
Forming
Fabric Deformation
Draping / Explicit
ANSYS LSDyna
ANSYS Mechanical
Impregnation
Resin flow calculation
/ Warping
PlanetsX
Curing
Residual Stresses
/ Distorsion
ANSYS Mechanical
ANSYS Composite Cure (ACCS)
Heat load / Autoclave
ANSYS Fluent
Strength Analysis
Falling
Collision, Shock
ANSYS Mechanical
ANSYS LSDyna
Lightning Strike
ANSYS HFSS
ANSYS Composite
PrePostVariable Material Fields:
Degradation Factor, Temperature,
Void content, …
Multiscale
Simulation
15 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Infusion / RTM
• PlanetsX intregration insideANSYS Workench
– Coupled to ACP and Mechanicalfor Fabric Deformation and Warpage calculation
16 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Infusion / RTM
17 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Infusion / RTM
• Close-up
– Relation between folds and permability
– Possibility of air trap (void) generation
18 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ANSYS Composite Manufacturing Solutions
ANSYS Workbench
Forming
Fabric Deformation
Draping / Explicit
ANSYS LSDyna
ANSYS Mechanical
Impregnation
Resin flow calculation
/ Warping
PlanetsX
Curing
Residual Stresses
/ Distorsion
ANSYS Mechanical
ANSYS Composite Cure (ACCS)
Heat load / Autoclave
ANSYS Fluent
Strength Analysis
Falling
Collision, Shock
ANSYS Mechanical
ANSYS LSDyna
Lightning Strike
ANSYS HFSS
ANSYS Composite
PrePostVariable Material Fields:
Degradation Factor, Temperature,
Void content, …
Multiscale
Simulation
19 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Curing / ANSYS Composite Cure Simulation (ACCS)
• Residual Stresses during Cure lead to distortion/cracking
• Spring-in, Cure Shrinkage, Consolidation
• Enthalpy, Tool Part interaction
• Design inverted tooling surface
The ACCS chemical solver is embedded within transient thermal module and simulates development of polimerisation, glass transition temperature as well as internal heat generation
related to exothermic cross-linking reactions
20 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Geometry and material
properties input
ANSYS Thermal Cure Simulation
Calculate temperature and cure gradients, degree of
cure, cure rate, viscosity, glass transition
temperature and exotherms
ANSYS Structural Cure SimulationCalculate development of stresses and predict part
distortion
Structural model based on the semi empirical approach
Supported heating methods
Convection
Conduction
Microwave
Electromagnetic induction
The analysis is semi coupled. First we evaluate temperature and degree of cure using thermal solver and then degree of cure and temperature is passed to structural simulation to analyse development of stresses and distortions
Compensated
tooling surface
Curing / ANSYS Composite Cure Simulation (ACCS)
21 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Example problems where ACCS was used
Tooling corrections for landing flap nose caps
Tooling corrections for flaps including ribs, skins and spars
Tooling design corrections for rear spars
Tooling modifications to fan track liners
Tooling design and compensation for the leading edges. Optimisation of the bonding process
Over 100 tooling surfaces were designed with this technology for the A350 -900 and -1000.
Other references: PRIMUS/Triumph Aerospaces (Fairing Angles), GKN Aerospace (trailing spars, landing flaps,
leading edges), CTRM (nose caps, landing flap ribs), Bombardier Aerospace (Spars, skins), Agusta-Westland (door frames), AVIC China (satellite components, radomes), VESTAS (50m long tooling for spars, skins, design and optimisations of heating systems, design of the bonding process).
22 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Curing / Autoclave
• CFD Analysis to get accurate Air flow and Thermal map inside autoclave
– Produce more parts in same time
– Produce less scrap when thermicallyoptimized
– Boundary condition for ACCS !
23 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ANSYS Composite Manufacturing Solutions
ANSYS Workbench
Forming
Fabric Deformation
Draping / Explicit
ANSYS LSDyna
ANSYS Mechanical
Impregnation
Resin flow calculation
/ Warping
PlanetsX
Curing
Residual Stresses
/ Distorsion
ANSYS Mechanical
ANSYS Composite Cure (ACCS)
Heat load / Autoclave
ANSYS Fluent
Strength Analysis
Falling
Collision, Shock
ANSYS Mechanical
ANSYS LSDyna
Lightning Strike
ANSYS HFSS
ANSYS Composite
PrePostVariable Material Fields:
Degradation Factor, Temperature,
Void content, …
Multiscale
Simulation
24 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ACP / Postprocessing
• Combined /Extensive failure criteria– Max. Strain & Max. Stress
– Tsai-Wu
– Tsai-Hill
– Hashin
– Puck (delamination)
– LaRC
– Cuntze
– Face Sheet Wrinkling
– Core Failure
– Hoffman
– …
• Advanced failure modes such as crack propagation, progressive damage, interface delamination, …
Crack propagation
Initial crack
25 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Strengh Analysis
• Advanced failure modes such as
– Crack propagation,
– Progressive damage,
– Interface delamination,
– Shock …
CHARPY IMPACT TESTLSDYNA COMPOSITE MAT54
26 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Lightning Strike
• Multifunctional simulations for composites
Strike at wingtip
Exit at tail PeakH at 1HzPenetrates the wings and fuselage
Predator UAV with Carbon Fiber Shell
27 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
Lightning Strike
• Predict destruction of samplesof part of plane under lightningstrike test
– Specific design workflow couplingEmag and Mechanical solver
– Including composite + grid
– Plasma thermal condition; Conduccion, radiation and convection of the arc
• Specific failure criteria easilyimplemented as user-definedcriteria (Python)
28 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ANSYS Composite Manufacturing Solutions
Simulate the full composite manufacturing process with:
• A single Simulation Platform, open to third party tools (via ACT)
• ANSYS Composite Prepost all along the chain• Best in class specific solvers: accuracy and speed
for structural, resin injection, curing and lightning strike
• Remove Material characterization bottleneck and accurate damage mechanisms with Multiscale approach
29 © 2015 ANSYS, Inc. March 12, 2017 ANSYS Confidential
ANSYS Composite Manufacturing Solutions
ANSYS Workbench
Forming
Fabric Deformation
Draping / Explicit
ANSYS LSDyna
ANSYS Mechanical
Impregnation
Resin flow calculation
/ Warping
PlanetsX
Curing
Residual Stresses
/ Distorsion
ANSYS Mechanical
ANSYS Composite Cure (ACCS)
Heat load / Autoclave
ANSYS Fluent
Strength Analysis
Falling
Collision, Shock
ANSYS Mechanical
ANSYS LSDyna
Lightning Strike
ANSYS HFSS
ANSYS Composite
PrePostVariable Material Fields:
Degradation Factor, Temperature,
Void content, …
Multiscale
Simulation