MSC Confidential

MSC Virtual Product Development

Solution In Aeronautic Industry

State of the Art of Composites Modeling / Simulation

EMEA Aerospace Center of Competence (May 2009)
 MSC Confidential

Composites Structures:
Satellites Applications

Intelsat VII Hubble Space Telescope

Mars Global Surveyor

Mars Global Surveyor

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Composites Structures:
Launchers Applications

Ariane 5 Evolution

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Composites Structures:
Civil Airplanes Applications

Boeing 787 Airbus A350

Bombardier LearJet 85

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Composites Structures:
Military Airplanes Applications

Airbus A400M Lockheed Martin F-35

F-111 Eurofighter Typhoon

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Composites Structures:
Air Missiles Applications

Joint Air to Surface Standoff Missile

(JASSM) Composite Body

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Composites Structures:
Helicopters Applications

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The progressive use of Composite on

Commercial Aircraft

In black the composite parts

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Introduction to Composites

• A COMPOSITE MATERIAL is a macroscopic

combination of two or more distinct materials, having a
recognizable interface between them.
• The resulting composite material has a balance of
structural properties that is superior to either constituent
material alone.
• "Composite material" commonly means arrangements of
fibres of a resistant material (reinforcing material) which
are embedded in a material with a much lower strength
(matrix), and stiffness.

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Products

• SimXpert the fully integrated multidiscipline simulation

environment. Integrated with MSC's advanced multidiscipline
(MD) solver technologies.
• MD Nastran the MSC's multidiscipline solver (MD) to ensure
the highest levels of accuracy on composite structures
• CATIA V5 to capture a truly complete digital product
definition.
• FiberSIM goes beyond CAD, enables you to ‘work how you
think’ when designing innovative composite structures

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SimX Laminate Definition and Verification

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SimX Laminate Composite Editor

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SimX Verify Tools

Verify the Material Coordinate System to determine the 0 direction

Verify the element normals to determine the location of ply 1

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SimX Verify Tools

Plot of ply angles and associated plies

Plot of each ply’s relative thickness

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SimEnterprise Composite WorkFlow

• Streamline composite Design

product development
• Design
• Verification
• Optimization

Connect
• Connect Design and
Analysis
Analysis
Common definition
• Zones
• Plies

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SimX FiberSim Integration

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FiberSim Connect

• FiberSIM/SimXpert interoperability
– SimXpert does FEM model definitions (mesh, LBC, analysis setup, ..)
– FiberSIM does PCOMP property calculation from zones and layup
definition
• Composite property verification in SimXpert
• Analysis ready full access to MD Nastran composite analysis

SimXpert

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Composite Interface

• FiberSim interface
• Interface for users to automatically generate corresponding
PCOMP entries based on the zones & layup information
previously defined in FiberSIM
• All user interactions related to composite definitions will be
performed in the standalone CATIA/FiberSIM environment
• All FEM model definitions (mesh, LBC, analysis setup, ..) will be
done in core SimXpert
• Values
• Instant access to zone & layup info currently available in CATIA-
FiberSIM environment
• Composite property definition is calculated with SimXpert
generated mesh data
• Analysis ready
• Completely open to all SimXpert MD solutions

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FiberSim:
FiberSim: Zone Based Design

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FiberSim: Laminate Zone Definition

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FiberSim: Laminate Zone Definition

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Import zone properties

Revision 1

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SimXpert: Mesh Geometry and export

Element information to FiberSim

Next Material ID

Element
Next PCOMP ID
1
1
1 -1.27940e+001 2.69369e+002 -3.32930e+002 3.50059e-002 -5.28049e-001 8.48492e-001 1.74349e-004 8.49016e-001 5.28367e-001
2 -1.26829e+001 2.47728e+002 -3.46025e+002 3.32297e-002 -5.03280e-001 8.63484e-001 2.28378e-004 8.63965e-001 5.03552e-001
3 1.26207e+001 2.69648e+002 -3.32769e+002 -3.04822e-002 -5.28117e-001 8.48624e-001 -1.74349e-004 -8.49016e-001 -5.28367e-001

Element ID Centroid Normal Node 1-2 Direction

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FiberSim: PCOMP Evaluation

• FiberSIM PCOMP Evaluation

– Property (Material and PCOMP) file and Assignment file
– The Property file is a Nastran BDF containing MAT and PCOMP
data

Element ID Material Angle

(Radians)

PCOMP ID

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SimXpert: Automatically PCOMP created

by FiberSim

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CAE-CAD iterations
Modify the layup in SimX
Revision 2

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Modify the layup in SimX for Zone/PCOMP 6

Add 2 plies +45 and +45 to the zones 6 and

export to FiberSIM (revision2)

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FiberSIM Import Modified LayUp in SimX

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Validation

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FiberSIM Draping Simulation

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SimXpert FiberSim Connect Advantages

• Eliminate errors and inefficiencies of translating composite

data between design and analysis

• Define or update properties in Design or Analysis

• Use common definitions & methods for composite

properties

• Native CAD update (SimX & FiberSIM share common

native Catia V5rxx models )

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Access to MD Nastran Advanced Composite Solution

Extensive MD content now

– Structures workspace
• Linear Contact
• Non Linear Contact
• Progressive Failure Analysis
• Adv. Progressive Failure Analysis
• Fracture Mechanics and Delamination: VCCT
(Virtual Crack Closure Tecnique)
• Delamination: Cohesive Zone Modeling
• Delamination: Breaking glued contact
• 3D Composites

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Progressive Failure Analysis

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Progressive failure Analysis

• The progressive failure analysis is a method developed for

predicting the nonlinear response and failure of laminated
composite structures from initial loading to final failure.
• Failure is indicated by the failure criteria used.
• When failure occurs, the FEM element stiffness is degraded.
• The material will not heal; the damaged elements keep the
degraded properties after unloading.
• Investigations of effect of overloads on composite structures

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Progressive failure Analysis

• Once the strains and stresses are known throughout the composite laminate, a
failure theory is used to detect failures for each lamina at a given load level, when
failure index is larger than one, degrade material stiffnesses

• Available for existing criteria (maximum stress etc):

Hill
Tsai-Wu
Hoffman

• Available for NEW criteria:

These failure theory are able to predict the failure load and also the mode of failure
such as fiber failure and/or matrix failure.
Puck
Hashin
Hashin-tape
Hashin-fabric

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Progressive failure

• How does failure affect the different material moduli ?

• Assume
– 1-direction is fiber direction
– 2-direction is matrix direction in the plane of the ply
– 3-direction is through the ply thickness
• Fiber failure
– Reduce E1 and E3
• Matrix failure
– Reduce E2, G12, G23 and G31

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Progressive failure

Progressive Failure Analysis of a Plate with Hole

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Adv. Progressive Failure Analysis

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Genoa Integration:
Micromechanical Composite Material Definition

• GENOA is an integrated structural

analysis software suite to predict
strength, reliability and durability of
structural composite components
• The use of material library from
Genoa is available in MD Nastran.
• Based on constituent properties,
Fiber and Matrix, evaluates the
structural and material response
including degradation of material
properties due to initiation and growth
of damage.
• Over 20 Micro Mechanical Failure
Criteria Failure Criteria available with
MD Nastran Adv. PFA analysis

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Adv. Progressive Failure Analysis

• Analysis is set up and

post processed in
SimXpert environment. 3D Fiber

• It is a fully integrated
solution, Genoa material 2D Woven
stiffness evaluation is in
the increment loop, MD Vehicle Component
FEM Laminate
Nastran calls Genoa for Traditional FEM stops here Lamina
each element, damage GENOA goes down to micro-scale
reflected as modified
stiffness.
• At each individual load Micro-Scale Unit cell at node
FEM results carried down to
step, the stresses and micro scale Sliced unit cell
strains, obtained through Reduced properties propagated
up to vehicle scale
the composite micro-
stress analysis, are
checked according to
distinct failure criteria.
Takes full advantage of MD Nastran capabilities and Genoa material library

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Adv. Progressive Failure Analysis

Modeling composite materials at constituent level

• Typically failure is assessed at

laminate/lamina scales
• But failure has its source at micro scale
fiber/matrix
• Failure is indicated by the Micro
Mechanical failure criteria selected
• When failure occurs degrade Fiber and
Matrix stiffnesses

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Adv. Progressive Failure Analysis

Modeling composite materials at Ply Level

• Failure is indicated by the

Micro Mechanical failure
criteria selected
• With lamina or ply properties
as input: the ply stress is
compared to the strength limit
of the ply directly without
going through the
constituents and fiber of
matrix volume ratios.
• When failure occurs degrade
plies properties

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Modeling composite materials:

Composite architectures

• UD tape
• Woven fiber
• 3-D braided

• Using fiber angles and volume fractions in both in-plane

and out-of-plane directions

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Modeling composite materials:

HoneyComb

• Predicts damage resistance, durability and damage tolerance

of honeycomb composite structures
• Uses an advanced theory to predict the various failure
mechanisms in honeycomb composite structures
• Cell geometry definition

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Failure theories for Adv. Progressive Failure Analysis

• Longitudinal tension • Fiber micro-buckling

• Longitudinal compression
• Transverse tension
• Transverse compression
• Normal tension
• Normal compression
• In-plane shear
• Transverse normal shear
• Longitudinal normal shear
• Modified distortion energy
• Inter-ply relative rotation
• Tsai-Wu theory
• Hill theory
• Hoffman theory
• Maximum stresses theory
• Maximum strain theory
• First strain invariant failure
theory
• Inter-ply relative rotation
• Fiber crashing

Honeycomb failure modes recognized

Wrinkling Crimping Dimpling

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Genoa Integration: Modeling composite

materials at constituent Level
Fusolage Stiffened Panel Adv. Progressive Failure Analysis with Micromecanical material definition (Fiber / Matrix)

Stress Strain Micromechanical Damage Index

Glued Contact between frames and panel

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3D Composites

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3D Composites
• Needed for detailed out-of plane stress recovery

NAFEMS: Three-point bending test

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3D Composites
Detailed out-of plane stress recovery

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Fracture Mechanics and Delamination

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Delamination Introduction
• Delamination is one of the main failure mechanisms in laminated
composites
• Possible reasons for delamination are:
Manufacturing defects and stress
Gradients near geometric discontinuities (like stiffener terminations and bolted
joints)
• Delamination may result in local failure or even a significant loss of the
structural integrity
• Three different approach available:
VCCT
CZM
Breaking glued contact

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Fracture Mechanichs with VCCT

(Virtual Crack Closure Tecnique)
• The VCCT is the fracture mechanics approach for studying
delamination and crack initiation and growth.
• It is used for calculating the energy release rate of single or
multiple cracks. The results will be obtained for each crack
separately. Each crack consists of a crack tip grid for shells
and a crack front for solids.

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Delamination of NASA Test Specimen

(Virtual Crack Closure Tecnique)

VCCT

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Delamination of NASA Test Specimen

(Virtual Crack Closure Tecnique)

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Delamination:
Cohesive Zone Modeling (CZM)
• The interface elements can be modeled between 2D and 3D
structural finite elements:
• The cohesive material models are defined in terms of relative
displacements (between the top and bottom edges/faces)
versus tractions

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Delamination of NASA Test Specimen

Cohesive Zone Modeling (CZM)

Cohesive Zone Modeling

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Delamination of NASA Test Specimen

Cohesive Zone Modeling (CZM)

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Delamination:
Breaking glued contact

• Release glued contact when stress

criteria is satisfied:

• Use contact normal and tangential

stress
• After break, do regular contact with
friction and separation

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Delamination:
Breaking glued contact

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Computational Performance

• Fast Shell Integration PCOMPF Card

• Composite shell elements with a large number of layers
may need a large amount of CPU time and memory
because of:
– the integration in thickness direction to determine the generalized
stress-strain law and the generalized stresses
– storage of stresses and strains on a layer basis
• Results should be the same as with standard integration

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Virtual Product Development

http://www.mscsoftware.com/

Armando Mete
Technical Consultant
EMEA Center of Competence Aerospace
+39 06 42272249
+39 335 7851319
armando.mete@mscsoftware.com

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