28.10.
2009
1
Simulation of Composite Structures with
Abaqus Unified FEA from SIMULIA
Martin Kssner
Dassault Systemes Simulia GmbH
[Link]@[Link]
DS Strategy: 3D virtual experience everywhere
2
28.10.2009
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DS Brands
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Experience
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MCAD
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Production
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Testing
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Product
PLM
Collaboration
User
Experience
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to-use 3D Design
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Intelligence
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Performance
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Simulation
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Excellence
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Abaqus Product Line
Abaqus/CAE
Interactive, parametric, finite element
modeler and results viewer
Abaqus/Standard
Linear and nonlinear statics, dynamics,
acoustics, and heat transfer
Abaqus/Explicit
Transient, very large deformation, highly
nonlinear simulations
Tightly integrated with Abaqus/Standard
Abaqus for CATIA V5
Access to Abaqus technology from within
the V5 environment
28.10.2009
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Industry trends
Composite usage is increasing in all industries
Aerospace
Boeing 787 1
st
large jet with a majority of composites by weight
Airbus 350WX - Over 60% of airframe made of new materials
UAVs primarily composite construction
Automotive
F1 race teams composite shells
Toyota's Tundra pickup has a composite box
Nissan Concept uses carbon-fiber components
Civil
Composite-wrapped bridge structures
Dentistry
Fiber-reinforced composite dental bridges!
Industry need customer pains
Current simulation methodology is not up to the task
Verification of composites relies on testing
Expensive, time consuming
Current methodology has not evolved since the 1980s
Typical simulation uses linear methods to estimate first failure
Current composite interfaces are not up to the task
It is very time consuming to define composites and post-process
composites in today's CAE tools
Some CAD/CAE/PLM packages do not support progressive failure,
delamination, or material damage
With linear methods, design margins for composite parts
today are often too high the part is too expensive and heavy
as a result
This reduces the value of the use of composites and blunts the cost
advantages that composites can provide to a product
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Abaqus Composite Solution mission statement
Abaqus solution for our customers:
Perform advanced composite simulations including static and
dynamic analysis that includes linear, nonlinear, and damage /
fracture /failure within a single environment
Predict the stiffness, first-failure, strength, and post-failure behavior
at the component and full-vehicle structural scale of complex
composite products
Simulate low- (from tool drop or hail), medium- (from runway debris),
or high-velocity (ballistic penetration) events including Barely Visible
Impact Damage (BVID) and Bird Strike
Have the very best in composite modeling, visualization, and post-
processing through /CAE's new ply-based interfaces
Composites - Technology and Features
Features
Ease-of-use and efficiency features
interface for pre-processing
post-processing options
Interface to CATIA CPD
Technology
Abaqus solvers can solve a variety of problems
Ballistic impact on unidirectional composite
Model damage in fiber-reinforced materials
Barely Visible Impact Damage (BVID)
Composite plate post-buckling behavior
Delamination using cohesive elements
Woven fabric composite beam crush
Skin-stringer debonding using VCCT
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Interface for Definition of Composites
Draping Technology
Simulayt Composite Modeler for Abaqus/CAE can be
purchased as a 3
rd
party product that runs as a module of
/CAE-Features
Determine the flat pattern needed
Draping simulation provides accurate material directions for laminate
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Modeling Composite Structures
In Reality, composite structures are built by laying-up fabrics on
top of each other in patterns to create the part
Modeling Composite Structures
In Reality, composite structures are built by laying-up fabrics on
top of each other in patterns to create the part
In the FEA world, users have to define various sections to
represent the different regions of the composite
Which is time consuming and very difficult for complicated components
This also results in very difficult post-processing
Element layers and section points do not directly correspond to a
consistent piece of material
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Users Can Now Model in Terms of Plies
Think in terms of Plies
Representation of the materials as placed in a mold
User supplied ply name is available in ODB and /Viewer for easy
tracking in post-processing operations
Plies defined on picked regions or named sets of partitioned
geometry or orphan mesh parts
Ply-1
Ply-2
Ply-3
Composite modeling in Abaqus
Advantages:
Ply-based
More intuitive definition of
ply regions than artificial
section assignments
Output requests can be
defined by composite layup
Suppressible
Composite Layup Object
Part level replacement for multiple sections, section assignments
and material orientations for layered composites - in one object
Supports shell, layered continuum shell and layered solid
elements
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Composite Plies Manager Options
Ply Management via right mouse menu
Copy plies
Move plies
Delete plies
Invert plies
Read from and write to file
Ply Patterning
Create symmetric layup
Copy plies multiple times
Composite Query
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Ply based postprocessing
Ply based results
Choose particular ply for
results
Element layer numbering is
handled automatically
Works with the existing section
points functionality
Can show contours on top,
middle, bottom or top and
bottom
Envelope calculations
Show ply names
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Advanced Simulation Capabilities
Ballistic impact on unidirectional composite
Model damage in fiber-reinforced materials
Barely Visible Impact Damage (BVID)
Composite plate postbuckling behavior
Delamination using cohesive elements
Unidirectional Composite VUMAT
Ballistic impact is a concern in many application areas, including road
and runway debris, bird strike, armor design, and many others
Abaqus has developed a unidirectional fiber composite damage and
failure VUMAT for Abaqus/Explicit specifically for high speed impact
problems
Available in Abaqus Answer 3123
This specific example will consider ballistic impact onto unidirectional
fiber composite plate
Geometry, material properties and experimental results are taken from
Kasano, H., Impact Perforation of Orthotropic and Quasi-isotropic
CFRP Laminates by a Steel Ball Projectile, Adv. Composite Mater., vol.
10, no. 4, pp. 309318, 2001
Videoclip
28.10.2009
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Unidirectional Composite VUMAT (contd)
Summary
Damage and failure modeling in
Abaqus/Explicit can be used to
assess ballistic limit velocities and
composite fiber and matrix damage
Damage modeling can be combined
with cohesive elements to predict
delamination as well (as we will
see soon)
MODE III: matrix tension
Damage Initiation (Hashins Criteria)
1 0 ,
2
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where
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L C T
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S Y S
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Y X S , , - material strengths
22
MODE I: fiber tension
MODE II: fiber compression MODE IV: matrix compression
28.10.2009
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Assessment of Barely Visible Impact Damage (BVID)
New Abaqus composites damage capabilities allow
users to simulate non-visible or barely visible damage
Goals:
Simulate low speed impact to composite surface
Predict residual damage in composite facesheet
X-45 Assembly: Image courtesy of NASA
Abaqus Simulation Recreates NASA Langley Test
NASA Langley paper reports the damage
characteristics results from experimental
composite fuselage keel sandwich structure
subjected to low-speed impact damage
D. McGowan, D. Ambur, Damage Tolerance
Characteristics of Composite Fuselage
Sandwich Structures with Thick Facesheets,
NASA Langley Research Center, NASA
Technical Memorandum 110303, Hampton,
VA, Feb. 1997
28.10.2009
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Finite Element Model of Test Specimen
10
5
122 radius
36 layer AS4/8552 graphite-epoxy facesheet modeled with
linear thin shell elements
Honeycomb core modeled with linear brick elements
Impact tool modeled with parabolic tetrahedron elements
Abaqus Predicted Impact Loads
I
m
p
a
c
t
F
o
r
c
e
(
l
b
)
Explicit analysis predicted
dynamic impact of specimen
Impact forces and
displacements were recovered
from the explicit solve
The maximum nodal
displacement was applied to the
impact tool in a static analysis
Impact forces at ball center, 0.25
from center and 0.35 from center
VM Stress in honeycomb shows
impact area
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Damage Analysis Results
Red area shows where fiber
compressive damage occurs
(Damage variable output at
top facesheet, outer layer)
Red area shows where matrix
tensile damage occurs
(Damage variable output at
top facesheet, inner layer)
Damage Analysis Results - Crushed without Impact
Matrix compressive damage
at peak compression load
(Damage variable output)
Matrix compressive damage
after panel failure
(Damage variable output)
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Damage Analysis Results - Impacted Section
Matrix compressive damage
at peak compression load
(Damage variable output)
Matrix compressive damage
after panel failure
(Damage variable output)
Damage Analysis Results
0
20.000
40.000
60.000
80.000
100.000
120.000
140.000
160.000
180.000
200.000
0,00 0,02 0,04 0,06 0,08 0,10 0,12
L
o
a
d
(
l
b
)
Displacement (in)
Crushing Force
Undamaged
Damaged
28.10.2009
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Postbuckling Behavior of Composites
Buckling and postbuckling behavior of composite
panels is an important design consideration in many
industries
This example uses Buckling and Riks analysis capabilities
Buckling load
Prebuckled
stiffness
Postbuckled
stiffness
Postbuckling Behavior of Composites (contd)
The composite lay-up has a significant effect on the panel
buckling behavior
Videoclip
28.10.2009
17
Delamination of a composite with cohesive elements
This model is a representative of
composite delamination
It comprises of 3 layers of composite
with adhesive layers applied between
composite layers.
The composite delaminates under the
impact of a heavy mass displayed in
light greenish shade in the animation.
Continuum shell elements layers
Cohesive layers
Delamination of a composite with cohesive elements
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Delamination with Cohesive Elements (contd)
And a final example that is a bit academic
but makes for a great animation
35
Simulation of Composite Structures with
Abaqus Unified FEA from SIMULIA
Martin Kssner
Dassault Systemes Simulia GmbH
[Link]@[Link]
