composide | case study · cmdb addon material groups adhesives plies woods & plywoods metals...

Converting Metallic Structures to Composites

& Laminate Optimization

Julien Sellier – Managing Director Jonathan Evans - Application Engineer

CompoSIDE | Case Study

Copyright CompoSIDE Ltd 2016

O b j e c t i ve s

Introduction to Case Study ¤ Initial Assessment

¤ Evaluation of composite potential

¤ Optimisation of composite structures

Introduction to CompoSIDE and CMDB

CMDB Questions & Answers

Case Study and Live Demo

Questions & Answers

Slide 2 Copyright CompoSIDE Ltd 2016

G e t s t a r t e d !

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C a s e S t u d y I n t ro d u c t i o n

6m Radius Architectural Sphere Segments: ¤ Aluminium Alloy

¤ Weight = 656.6 kg

¤ Requirement to reduce weight retaining stiffness.

Goal: What is the feasibility of a composite design?


C a s e S t u d y O b j e c t i ve s

How to assess my composite structural concept?

What are the associated material quantities?

Cost & Time

Strength

(Process)

Weight

(Material)

What technology and materials to select to achieve a lighter solution?


C a s e S t u d y Wo r k p l a n

Which material should I use?

Where can I get the properties?

How should I orient my fibres / plies?

How do I ensure compliance of my laminate?

Are there opportunities to optimize?

How can I compare total material costs?


W h a t M a t e r i a l s S h a l l I u s e ?

Manufacturing Process

Fibres

Cores

Resins

Adhesives


W h a t P ro c e s s S h o u l d I u s e ?

Wet lamination Press Infusion

Pultrusion Prepreg/Resin Film

Infusion Automation


S h a l l I d o S o m e Te st i n g ?


Te st i n g C o st

Testing for certification purposes must be conducted by approved test houses. Below is a rough guide to the cost of basic static and fatigue testing for 1 material i.e. 1 fibre, 1 matrix, 1 process…

Aerospace qualifications can cost in excess of > €100k for a single material

Material sourcing and coupon manufacture Fibre volume content Tensile tests Compression tests ILSS Fatigue

€1,500 €6,500 for static tests >€45,000 for fatigue tests up to 5 million cycles

Minimum properties required to start a

design


Do I real ly need to spend many thousands € before start ing

design with composites?

T h e Te st i n g P y ra m i d

CompoSIDE CMDB Addon


W h a t d a t a i s i n C M D B A d d o n ?

Testing

Characteristic Values

Project Design Allowables

Statistical Analysis

Industry Partial Safety Factors

CompoSIDE CMDB Addon


H o w C M D B A d d o n Re d u c e s M a t e r i a l Te st i n g C o st s ?

The CompoSIDE CMDB Addon library is a consolidated set of data that enables a quick and easy start with your projects

This enables you to assess the viability of composites as a solution as an alternative to investing lots of time and money.

Material testing becomes validation rather than investigation


M AT E R I A L S

P R O C E S S

E N G I N E E R I N G

D e s i g n i n g w i t h C o m p o s i t e s

C M D B

S E C T I O N S p a c e

L A M I N A S p a c e

F E S p a c e

B O M G e n


U s i n g C M D B

Manual material

¤ Test data

¤ Reference materials

¤ CMDB Addon Materials

PLYGen materials

¤ Micromechanics

Layered Materials

¤ Classical Laminate Theory


M a t e r i a l D a t a H a n d l i n g

Material post-processing

¤ Properties for calculation

¤ Materials selection

¤ Data Comparison

¤ Scatter Plots

¤ Materials export (Xls)

Link to FEA Formats

¤ Ansys

¤ Nastran

¤ Radioss OptiStrut

¤ More to come


M a t e r i a l L i b ra r i e s

CS Material Library: The CMDB Addon which can be used across your projects

My Company Materials: Your own private materials library which can be used across your projects

Active Project Materials: All materials used within your active project

Project materials can be grouped into selections for easier material data management


C M D B A d d o n

W h a t d o I ge t ?


Te c h n i c a l O ve r v i e w o f C M D B

Characteristic Values

Materials Data Fit for Design

Industry Proven Values

Across Hundreds of Products

Full Datasets

Fit for FEA

Transferable

Export to FEA


C M D B A d d o n M a t e r i a l G ro u p s

Adhesives

Plies

Woods & Plywoods

Metals

Resins

Fibres

1277 Materials


Cores

C o re s

212 Core Materials

Wide Range of Densities Available

Most Commonly Used Materials Available

¤ Honeycomb

• N636

• Nomex

¤ Balsa

¤ PVC Foams

¤ PET Foams

¤ San Foams

¤ PMI Foams

¤ PUR Foams

¤ Linear PVC Foams

¤ Flow Mediums


P l i e s

No Standards in Composite Industry

One Material One Test Campaign

P l y P r o p e r t i e s

Resin Manufacturing

Process

Fibre Grade

Fibre Sizing Fabric Type

Fibre Type


P l i e s

9 Fibre Types

7 Fabric Types

¤ UD

¤ Woven

¤ Biaxial

¤ Triaxial

10 Different Matrixes

8 Manufacturing Methods

¤ Quadraxial

¤ Mats

¤ Stack-ups (Combos)

890 Different Plies


M a t e r i a l s S e l e c t i o n


… n o t e n o u g h ?


C re a t e Yo u r O w n P l i e s w i t h P l y G e n

PLYGen Material

Reference Material

Resin Manufacturing

Process

Fibre Type Fabric Type


N o m e n c l a t u re Fo r C M D B

Fabric Type

¤ U= Unidirectional,

¤ X= Biaxial,

¤ W= Woven

¤ Q= Quadraxial

¤ Y=Triaxial

¤ CSM= Chopped Strand Mat

Fibre Type

¤ C=Carbon

¤ G=Glass

¤ A=Aramid

Fibre Grade

¤ LM= Low Modulus

¤ SM=Standard Modulus

¤ IM=Intermediate Modulus

¤ HM=High Modulus

¤ E=E-glass

¤ S=S-Glass

Matrix Type

¤ UP=Unsaturated Isophthalic Polyester

¤ EP=Epoxy

¤ V=Vinylester

¤ Ph=Phenolic

¤ Bi=Bismaleimide


¤ HL=Hand Layup

¤ VW=Vacuum Wet

¤ SU=Spray-Up

¤ VIN=Vacuum Infusion

¤ FW = Filament Winding

¤ PP=Pre-Preg

¤ PPA=Pre-Preg Autoclaved

¤ CM=Compression Moulding

Fabric Type

Fibre Grade

Matrix Type


Fibre Type

Reinforcement Weight

UC-HM400-EP-VIN


Questions so Far?

Let ’s design!

M AT E R I A L S

P R O C E S S

E N G I N E E R I N G

Approach with CompoSIDE

C M D B

S E C T I O N S p a c e

L A M I N A S p a c e

F E S p a c e

B O M G e n


C a s e S t u d y

6m Radius Architectural Sphere Segments: ¤ Aluminium Alloy

¤ Aluminium Weight = 656.6 kg

¤ Requirement to reduce weight retaining stiffness.

Requirements ¤ Structure to withstand gravity and wind

loading

¤ Maximum deflection = 10mm MAX.

¤ Ensure sufficient strength


C o m p o S I D E Wo r k f l o w

Outputs

Select Materials

Create 2D Sections

Create 3D Model using sections and analyse

Baseline Design

Analysis



Outputs

Select Materials

Create 2D Sections


Baseline Design

Analysis

Replace Material in 2D section with composite

Replace Section and analyse

with composite

Composite Analysis

Select Materials


B u s i n e s s C a s e C o m p a r i s o n S u m m a r y F i rs t A n a l y s i s

Weight Comparison

¤ Weight Saving of 40%!

Lets look at optimising the laminate.

Material Material Weight

Aluminium 656.6 kg

Carbon Fibre – Single Skin 396.5 kg



Outputs

Select Materials

Create 2D Sections


Baseline Design

Analysis



with composite

Composite Analysis

Select Materials



with composite

Composite Optimisation

Select Materials

Optimise Laminates


B u s i n e s s C a s e C o m p a r i s o n S u m m a r y F i n a l A n a l y s i s

Weight Comparison

¤ Total Weight Saving of 52%!

The structure can still be further optimised from here using the same process

Material Weight

Aluminium 656.6 kg

Carbon Fibre – Single Skin 396.5 kg

Carbon Fibre – Sandwich 314.6 kg


Summary

C o m p o S I D E


C a s e S t u d y S u m m a r y W h a t p ro b l e m s d i d w e s o l ve ?

Which material should I use? ¤ CMDB can help in the selection of the materials

Where can I get the properties? ¤ CMDB Addon provides 1,200+ Materials Data

How should I orient my fibres / plies? ¤ Quick optimization loops within CompoSIDE

How can I compare total material quantities? ¤ BoMGen automatically provides costs and weights


G e t s t a r t e d !

Sign up for 30 days free trial!!


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