Post on 18-Feb-2022
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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
Copyright 2012 MSC.Software Corporation
Curing and Shrinkage
during
Manufacturing
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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
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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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
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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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
– Load case 1 ---- Heating and Forming • Boundary conditions:
– Pressure
– Vacuum
– Temperature
Pressure Vacuum Temperature
Laminate Forming Example
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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
– 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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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
– 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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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
History Plot:
Degree of Cure & Degree of Cure Shrinkage
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Composites Technology Day, February 2012
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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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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
• A. With Curing
• B. Without Curing
A B
Residual Stresses (After Springback)
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Copyright 2012 MSC.Software Corporation
0°/90°, +/- 45° Orthotropic Layup
Case Study : Sikorsky S-92 Helicopter
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Copyright 2012 MSC.Software Corporation
Case Study
.345” predicted
Springback
.35” actual
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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
Draping and CAD Interface
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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
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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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
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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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
Ply Draping Simulation Example
• Ply layup on hemisphere improved with splits
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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
Direct CAD Interface - FiberSIM
Layup info
FiberSIM
CATIA
Patran/LM
Optimization
Analysis
PCOMPs
Nastran
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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
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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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
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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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
Source: Frank Doerner, MSC 2011 User’s Conference Keynote Speaker
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Composites Technology Day, February 2012
Copyright 2012 MSC.Software Corporation
Thank You!