This was a 2012 Americas HTC Composites training presentation given by Shan Nageswaran. This presentation focuses on Zone-based vs. Ply-based HyperWorks composite modeling approach, CATIA - CPD based composite modeling, Fibersim Interface, Conventional shell vs. Continuum shell / solid composite modeling, and optimization and future HyperWorks enhancements. HyperWorks tips for Ply based-PCOMPP and Zone based (PCOMP/PCOMPG) modeling for Multi laminate structures are also covered.

1. Composite Modeling with FiberSim
April 10 2012
Innovation Intelligence®

2. Composites Overview within HyperWorks
CAD & Mfg Interoperability
Geometry
HyperMesh
Modern Ply Based
Composites Pre-Processing
Visualizations Realizations
Visually Verify the Math Model Export Ply Based Models to
Solver Zone Based Models
OptiStruct/RADIOSS
Composites
Design Optimization & Analysis
HyperLaminate Solver HyperView
Classical Lamination Theory Composites
Post-Processing & Failure Analysis HyperWorks Partners
Detailed Compoiste Material
Modeling & Structural Modeling

3. Process of FiberSim- Hypermesh interoperability
Import CAD model • Read CAD part ,surface from Catia , UG etc ,geometry etc.
• Geometry clean up on imported CAD model
Create mesh • Mesh the part ,check element quality etc.
Import Equivalent • Extract composite data - Ply, stacking , material info , system definition
• Drape data , triangulation data (ply shapes ) etc as table in HM .
Fibersim model
Geometric ply shape •
•
Realize geometric shapes to FE ply shapes - Two methods , ‘simple’ , ‘advanced’
Extract elements for each Ply.
• Do result Map, result interpolation
realization • Correct the drape angles
Template properties • Contains additional FE required for design/analysis but not required for manufacturing/documentation
Stack & Material • Defines the stacking sequence direction and the reference material orientation
orientation
Review & Modify • Visually verify math model via 3D visualizations (Ply shapes/orientation/thickness, Stacking sequence)
Ply based model • Conversion of ply to zone based modeling
• Laminate realization.
realization
Export & Solve • Export to any supported solver

4. 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

5. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Import CAD geometry
Do not us this composite data
toggle for Fibersim

6. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
STEP 2: Mesh the CAD Geometry…

7. 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

8. 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

9. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Imported FiberSim Data----Laminate Table….

10. 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

11. 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

12. 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 .
.

13. What is draping data ?
• Corrections to thickness and fiber direction of every element within a
Ply.

14. 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
Element Material/local axis
From N1-N2
N1 Vector provided by N2
Fibersim on every
element.

15. 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

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

17. 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

18. 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

19. STEP 5…… Ply angle Visualization on FE model

20. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
STEP5 --- Ply thickness visualization -3D representation
• Turn on 3D representation Mode

21. 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)