section 5 curing, draping, and cad interface - msc...
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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
Section 5
Curing, Draping, and CAD Interface
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Composites Technology Day, February 2012
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Curing and Shrinkage
during
Manufacturing
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MSC Composite Curing Capability
• Cure-induced heating and curing shrinkage
– Thermal heat generation due to curing
– Shrinkage strains associated with curing
– Causes distortion and residual stress in parts
– Prediction is critical for predicting final shape
• Coupled thermo-mechanical analysis
– Critical capability for process development
– Available for solid and shell elements
– Marc has this unique capability in the industry
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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
• Cure analysis is done to evaluate the degree of cure and curing reaction heat flux
• Cure rate evaluation is based on temperature and curing kinetics models
• Curing heat flux term due to the change of degree of cure is added to RHS of heat transfer pass
• An iterative time integration scheme has been developed so that the degree of cure is accurately calculated for the heat transfer pass
• Fraction of cure and temperatures are transferred to Mechanical pass
• Volumetric Resin Shrinkage is incorporated in the Mechanical pass
• Degree of Shrinkage is defined as function of degree of cure and
temperature
• Curing Shrinkage Strain Components are calculated based on the
volumetric resin shrinkage
• Post processing data includes degree of cure, curing heat flux, resin
shrinkage strains
• User subroutine support for curing kinetics and curing shrinkage
models
Thermal-Cure-Mechanical Analysis
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Start of Thermal Cycle
(Cure pass)
Mechanical
pass
Thermal pass End of Thermal Cycle
Cure rate
Reaction Heat
flux
Converged?
Yes
No Degree of
cure
Temperatures
Thermal-Cure-Mechanical Analysis Flow
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– Load case 1 ---- Heating and Forming • Boundary conditions:
– Pressure
– Vacuum
– Temperature
Pressure Vacuum Temperature
Laminate Forming Example
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– Load case 2 ---- Base movement • Boundary conditions:
– Pressure
– Vacuum
– Temperature
– Base move Base
Dx=0.002
Dy=0.002
Dx
Dy
Laminate Forming Example
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– Load case 3 ---- Spring-back • Boundary conditions:
– Pressure
– Vacuum
– Temperature
– Release_x
– Release_y
– Fix_z
Release_x Release_y
Laminate Forming Example
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History Plot:
Degree of Cure & Degree of Cure Shrinkage
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Shrinkage Strain
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• A. With Curing
• B. Without Curing
A
B
Residual Stresses (Before Springback)
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• A. With Curing
• B. Without Curing
A B
Residual Stresses (After Springback)
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0°/90°, +/- 45° Orthotropic Layup
Case Study : Sikorsky S-92 Helicopter
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Case Study
.345” predicted
Springback
.35” actual
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Draping and CAD Interface
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Laminate Modeler
• An add-on to Patran
• Process simulation
– Ply based approach
– Ply draping
• Ply management allows for
rapid modifications during
model development
• Account for thickness and
fiber direction changes in
draped plies
• Model manufactured
component accurately
including splits/darts
• Direct interface to CAD
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Why Laminate Modeler?
• Real structures aren’t flat
plates …
– Complex curvature requires
draping
• Manufacturing: Flat
pattern development
• Analysis: Accurate
orientation information
– Complex layups require ply
management
• Countless plies
• Ply drop-off
• Element CID misalignment
• Results in countless
PCOMPs and changes
become … costly …
Fiber orientations
Ply E
Ply D
Ply C
Ply B
Ply A
Layer 5
Layer 4
Layer 3
Layer 2
Layer 1
PCOMP 1 PCOMP 2 PCOMP 3
PC
OM
P L
ayers
Glo
bal P
lies
PCOMP 4
Elements
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Ply Draping Simulation Example
• Ply layup on hemisphere improved with splits
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Direct CAD Interface - FiberSIM
Layup info
FiberSIM
CATIA
Patran/LM
Optimization
Analysis
PCOMPs
Nastran
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Interface to FiberSIM
• Directly access layup data from
FiberSIM
– FiberSIM plies and layup files are
imported and mapped onto analysis
mesh
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Concluding Remarks
• MSC has a strong composites solution meeting
your end-to-end product development process
simulation needs
• Nastran/Patran/Laminate Modeler supports this
composites solution workflow
• As required, Marc can easily be incorporated
into this workflow to provide additional
capabilities
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Source: Frank Doerner, MSC 2011 User’s Conference Keynote Speaker
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Thank You!