Chapter 71: Impact of a Rigid on Composite Laminate using GENOA PFA Material

Impact of a Rigid on
71 Composite Laminate using
GENOA PFA Material


Summary 1283

Introduction 1284

Requested Solution 1284

Model Details of Part 1 – Composite Shells 1284

Results 1285

Test versus Simulation 1286

Input File(s) 1286

Part 2 - Rigid Impact on Composite Foam Laminate using Genoa
Material 1287

Model Details – Composite shells and Solid Foam Material
1287
 Results of Part 2: 1288

Test versus Simulation 1288

Input File(s) 1288
 CHAPTER 71 1283
Impact of a Rigid on Composite Laminate using GENOA PFA Material

Summary
Title Chapter 71: Impact of a Rigid Body on Composite Laminate using GENOA PFA
Material
Features Using Genoa composite shell material for impact simulation
Geometry
Impactor
Plate

Material properties • Impactor (Rigid)

Mass = 0.138 lbf-s2/inch = 53.2 lbm
Diameter = 1 inch
• Plate (Deformable, GENOA 2D material)
G30-500/45 R6367: /-45/0/90/0/90/0/90/0/90/-45/45
Density = 1.962E-3 lbf-s2/inch4
12 layers (Details will be explained)
Analysis characteristics Transient explicit dynamic analysis (SOL700)
Boundary conditions Fixed boundary at sides of the plate
Applied loads Initial velocity of a rigid body
Element type 4-node shell element CQUAD4
FE results 1. Displacement and contact force time histories
2. Stress Distribution plot at the end
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CHAPTER 71

Introduction
MD Nastran predicts complex, large deformation composite behavior with extensive material degradation. GENOA
PFA (Progressive Failure Analysis) material model available in MD Nastran SOL700 allows prediction of complex
composite material behavior and degradation of the plies and laminates at micro-mechanical level. In the following
example which includes two parts, the simulation results are compared and correlated closely to those of test results
during a high velocity impact event. In part 1, the plate material is a composite laminate using shell elements while in
part2, the plate material is a combination of laminate composites and solid foam material.

Requested Solution
The displacement and contact force time histories are computed and compared with the test results.

Model Details of Part 1 – Composite Shells

The 10-inch width by 11-inch length composite panel is sandwitched by two supporting plates during impact
(Figure 71-1). The one-inch diameter impactor has a mass of 53.75 lbs with an impact velocity of 3.01 ft/sec resulting
in a impact energy of 7.58 ft-lbs. The panel was made with six layers of G30-500/R3676 fabric (in which the fiber
volume was 60 percent) with the ply lay-up of (45,-45), 4x(0,90),(45,-45). Each fabric ply is 0.014 inches thick and
the total thickness of the panel is 0.084 inches. For details of the test results, please refer to the paper, “Impact, and
Tension After Impact of Composite Launch Space Structure” (Frank Abdi, at al, Conference Paper 2001.).

Impactor
Fixture plate

A A
5.0 inch

11.00 inch

5.0 inch

10.0 inch Impacted panel

Figure 71-1 Test and Simulation Setup

The composite shell panel is modeled using PCOMP entry. The panel has 12 layers and the thickness of each layer is
0.007 inch. The panel is made with the ply lay-up of (45,-45), 4x(0,90),(45,-45) which is the same as the test model.
PCOMP 1
+ 1 .007 45.00000 1 .007 -45.
+ 1 .007 0.0 1 .007 90.00000
 CHAPTER 71 1285
Impact of a Rigid on Composite Laminate using GENOA PFA Material

+ 1 .007 0.0 1 .007 90.00000

+ 1 .007 90.00000 1 .007 0.0
+ 1 .007 90.00000 1 .007 0.0
+ 1 .007 -45. 1 .007 45.00000
The composite material is modeled using MAT1, MAT8, and MATM entries. MAT1 and MAT8 represent general isotropic
and orthotropic material properties, respectively. Both materials are referred by MATM material where the fiber/ply
and matrix properties of composite materials can be assigned. In addition, the failure criteria can also be defined in the
MATM material model.

MAT1 333 560000.0 0.33 1.962E-3

MATM 1 1 1 0 .6 0.0
+ PLY 1 33 333000.0266000.0333000.0266000.0333000.0
+ 266000.03846.0003846.0003846.000
+
+ MATRIX 333 11000. 55000. 21000. 2.00E-02 .05 4.00E-02
+ CRITICALS11T
+ NONCRIT S11C S22C S33T S33C S12S S23S S13S
+ MDE RROT CRSH DELM FMBK S22T
MAT8 33 3.400E+72500000.0.2 2500000.2500000.1000000.1.962E-3

Results
The results of the simulation were compared with those of the test. MD Nastran SOL700 generates Lagrangian time
history results into the binout binary and d3plot files while the Eulerian time history results are output in the THS file.
The following displacement time history is generated using SimXpert reading the results from d3plot.
Figure 71-2 shows the displacement time history result at node 1 which is located in the center of the panel and shows
the maximum displacement of 0.22 inches which correlates very closely to the maximum displacement from the test
of 0.20 inches.

Figure 71-2 Displacement Time History at Node 1

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CHAPTER 71

To generate the contact force time histories, an ASCII file is generated. This is because XY plots generation from
binout binary file is not currently supported in SimXpert or Patran at this time. Alternatively, LS-Post can be used to
generate the XY plot by reading the binout file directly.
To generate the ASCII file from binout file, a convertor tool called I2a is used. l2a is an executable that resides in
the MD Nastran SOL 700 installation directories and reads in the binout binary file and generates an equivalent ASCII
file. The command is:
l2a filename.dytr.binout0000
After running this command, several ASCII files are generated that include nodal forces (ncforc), contact forces (rcforc), element
forces (elout), etc.

In the rcforc file, the slave and master time history contact forces are recorded. The magnitude of contact forces on
slave and master bodies are the same but with opposite signs. Using a contact force time history of the master contact
body, the Figure 71-3 is generated by sorting the data first and then using MS xl for actual plot. The maximum
z-contact force is 878.6 lbf compared to 897 lbf from the test results.

Figure 71-3 Contact Forces in Z-direction

Test versus Simulation

Test Simulation
Maximum displacement (in) 0.20 0.22
Maximum contact force (lbf) 897 878.6

Input File(s)
Files Description
E1-Impact.bdf MD Nastran input for composite shells
 CHAPTER 71 1287
Impact of a Rigid on Composite Laminate using GENOA PFA Material

Part 2 - Rigid Impact on Composite Foam Laminate using

Genoa Material

Model Details – Composite shells and Solid Foam Material

The 10-inch wide by 11-inch high panel was fully fixed at each side. The one-inch diameter impactor had mass of
53.75 lbs and impact velocity of 62.04 inch/sec. The panel was made with a composite foam, adhesive and skin
composite fabric (Skin: G30-500/R3676, adhesive; FM-300, foam core: Rohacel 200WF.) The panel was laid up by
skin, adhesive, foam core, adhesive and skin from the bottom surface. Each skin fabric ply is 0.014 inch thick and the
total thickness of the skin ply is 0.056 inches (upper skin ply lay-up angle: -45, 45, 90, 0 and lower skin ply lay-up
angle: 0, 90, 45, -45). The thickness of the FM300 adhesive layer is 0.01 inch and the thickness of the core foam is
0.37 inch. To get the test results, please refer the report, (Dade Huang, Frank Abdi, Mohsen Khatiblou “Progressive
Failure Analysis (PFA) and Verification of Composite Test Panel Under Impact and Compression After Impact (CAI)
Loading Using GENOA”. Alpha STAR Technical Report to Boeing 12/14/1999. Filename: 2-99_Report-
impact_compression.)
The composite shell is modeled using PCOMP entry and the solid composite foam is modeled using PCOMPLS entry.
PCOMP 8
+ 1 1.4E-02 0.00 1 1.4E-02 90.0
+ 1 1.4E-02 45.0 1 1.4E-02 -45.
PCOMPLS 6
+ 1 2 1.0E-02 0.00
+ 2 3 2.4E-02 0.00
+ 3 3 2.4E-02 0.00
+ 4 3 2.4E-02 0.00
+ 5 3 2.4E-02 0.00
+ 6 3 2.4E-02 0.00
To predict the progressive fracture, the material is modeled using MAT1, MAT8, and MATM entries. MAT1 and MAT8
represent general isotropic and orthotropic material properties, respectively. Both materials are referred by MATM
material. The fiber/ply and matrix properties of composite materials and their failure criteria can be assigned by using
the MATM entry shown below:
MAT1 333 560000.01 0.33 1.308-4
MATM 1 1 0 .6 0.01
+ PLY 1 33 333000. 266000. 333000. 266000. 333000.
+ 266000.03846.0003846.0003846.0001.00E-021.00E-021.00E-02
+ 1.00E-021.00E-021.00E-021.00E-021.00E-021.00E-02
+ 0.03 0.03
+ MATRIX 333 11000. 55000. 21000. 1.00E-02 .01 1.00E-02
+ CRITICALS11T
+ NONCRIT S11C S22C S33T S33C S12S S23S S13S
+ MDE RROT CRSH DELM FMBK S22T
MAT8 33 3.400E+72500000.0.2 2500000.2500000.1000000. 1.632-4
1288 MD Demonstration Problems
CHAPTER 71

Results of Part 2:
The results of the simulation were compared with those of the test. To plot the results, same methodology as Part 1
was followed.

Figure 71-4 Contact Force Time History

The maximum z-contact force is 1510 lbf compared to 1514 lbf from the test results.

Test versus Simulation

Test Simulation
Maximum contact force 1510 lbf 1514 lbf

Input File(s)
Files Description
E2-Impact-Foam.bdf MD Nastran input for composite shells and solid foam material