2008 International ANSYS Conference. Lay-Up Evaluation of Composite Tubes

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1 2008 International ANSYS Conference Lay-Up Evaluation of Composite Tubes Paulo Roberto Rocha Aguiar Guilherme Pinto Guimarães Centro Tecnológico do Exército CTEx Brazilian Army Technological Center 2008 ANSYS. Inc. All rights reserved. 1 ANSYS. Inc. Proprietary

1 Introduction Brazilian Army Technological Center (CTEx) Guaratiba / Rio de Janeiro Major adoption of composite materials in aerospace. defense.

3 1 Introduction Brazilian Army Technological Center (CTEx) Guaratiba / Rio de Janeiro Major adoption of composite materials in aerospace. defense. off-shore and other industries Use of composite materials: High strength / Low weight Composite tubes applications in defence: Light weapons Prototypes production and testing 2008 ANSYS. Inc. All rights reserved. 3 ANSYS. Inc. Proprietary

Particles or fibers Fiber reinforced composite materials: different strengths in directions aligned with fibers and transversely to it.

4 Introduction Composite Materials Two or more different materials Materials present different physical properties New composite material: homogeneous in macroscopic scale Constitution of FIBER REINFORCED composite materials: Matrices Reinforcement materials Particles or fibers Fiber reinforced composite materials: different strengths in directions aligned with fibers and transversely to it. Several constitutive relations: Orthotropic behavior Transversely isotropic behavior 2008 ANSYS. Inc. All rights reserved. 4 ANSYS. Inc. Proprietary

5 Introduction Composite Materials Fiber reinforced laminated tubular structures production: Filament winding process Layered composite tubes: Stacking of several long-fibers reinforced layers Total number of layers Total tube thickness (Sum of individual layer s thickness) Layer material (Matrix and fibers) Winding angle Tailored design of composite structures: Add-on layers with different fibers directions To form a Laminate Overview of strength requirements to withstand service loads: Internal blast pressures and tractions Axial-torsional coupling behaviour of laminates 2008 ANSYS. Inc. All rights reserved. 5 ANSYS. Inc. Proprietary

Introduction Composite Materials Prototype production overview: Third-party production company First prototype tests (ORIGINAL lay-up purposed) New lay-up configurations: Improve strengths to

6 Introduction Composite Materials Prototype production overview: Third-party production company First prototype tests (ORIGINAL lay-up purposed) New lay-up configurations: Improve strengths to in-service loads and production winding times and costs Winding directions 1 and 2: Radial and Longitudinal Traction real tests to analyze longitudinal strengths New lay-up (Remodeled) consider different winding angles for several layers Same total thickness for every lay-up configuration 2008 ANSYS. Inc. All rights reserved. 6 ANSYS. Inc. Proprietary

7 2 Objectives Finite element modeling of composite tubes: Technical support to prototypes design Virtual testing to several lay-up configurations and loading scenarios Virtual representation of real testing scenarios Objectives of this presentation Represent real traction test on tube prototype-1 (Partial length) Represent and compare blast and traction tests on tube prototype-2 (Total tube length) Comparison of two layup configurations: (Original) lay-up configuration (Remodeled) lay-up configuration 2008 ANSYS. Inc. All rights reserved. 7 ANSYS. Inc. Proprietary

reinforced laminate composite materials Two different test scenarios: TEST-1 and TEST-2 configurations

8 3 Prototype Modeling Filament winding capabilities: Tube longitudinal direction winding (Direction-1) Tube transverse direction winding (Direction-2) Prototype tube finite element model: SHELL99 Tube made of fiber reinforced laminate composite materials Two different test scenarios: TEST-1 and TEST-2 configurations ANSYS/Multiphysics 7.0 Help System SHELL99 finite element 2008 ANSYS. Inc. All rights reserved. 8 ANSYS. Inc. Proprietary

9 Prototype Modeling Material Models Orthotropic and/or Transversely Isotropic material models Failure criteria for individual layers Material data required for every single layer (Fiber reinforced composite layer): Layer density Fiber longitudinal elasticity modulus Fiber transverse elasticity modulus Layer shear modulus Layer poisson s ratio Traction strength limits (Longitudinal and transverse) Compression strength limits (Longitudinal and transverse) Shear strength limit Max deformation data in traction (Longitudinal and transverse) Max shear deformation (Longitudinal and transverse) 2008 ANSYS. Inc. All rights reserved. 9 ANSYS. Inc. Proprietary

Thermal effects not considered TEST-1 finite element model Boundary conditions and mesh discretization Colors show

10 4 Test Configurations and Finite Element Models TEST-1 configurations: Failure criteria: Maximum stress Boundary condition: Fixation of one of tube s edges Load: Static analysis Longitudinal traction applied in tube s free edge Thermal effects not considered TEST-1 finite element model Boundary conditions and mesh discretization Colors show different real constant sets Wall thickness and lay-up configurations 2008 ANSYS. Inc. All rights reserved. 10 ANSYS. Inc. Proprietary

4 Test Configurations and Finite Element Models TEST-2 configurations: Failure criteria: Maximum stress Boundary condition: Fixation in two regions Load: Transient dynamic Internal pressure and

11 4 Test Configurations and Finite Element Models TEST-2 configurations: Failure criteria: Maximum stress Boundary condition: Fixation in two regions Load: Transient dynamic Internal pressure and longitudinal internal traction Thermal effects not considered TEST-2 finite element model Boundary conditions and mesh discretization Colors show different real constant sets Wall thickness and lay-up configurations 2008 ANSYS. Inc. All rights reserved. 11 ANSYS. Inc. Proprietary

12 Test Configurations and FE Models Test-2 Loading Configurations Two lay-up configurations considered in both tests: Original lay-up Remodelled lay-up Transient dynamic loading data: Load Step Time (ms) Time Inc. (ms) Tube Length (%) Internal Pressure (%) Internal Traction (%) ANSYS. Inc. All rights reserved. 12 ANSYS. Inc. Proprietary

13 5 Simulation Results TEST-1 configurations output data: Selected layers to be shown: Longitudinal displacements Fiber longitudinal direction stress (S1) Fiber transverse direction stress (S2) Comparison between ORIGINAL and REMODELLED lay-ups TEST-2 configurations output data: Same selected layers as TEST-1 Load Step vs. Stresses (S1/S2) graphics Including strength limits Longitudinal displacements and S1 stress results to compare ORIGINAL and REMODELLED lay-up configurations for layers , for load steps ANSYS. Inc. All rights reserved. 13 ANSYS. Inc. Proprietary

14 Simulation Results TEST-1 Configurations Original Remodelled lay-ups: Longitudinal displacements (mm) Original Remodelled lay-ups: S1 (Pa) Layer ANSYS. Inc. All rights reserved. 14 ANSYS. Inc. Proprietary

Simulation Results TEST-1 Configurations Original Remodelled lay-ups: S1 (Pa) Layer 4 Original

Remodelled lay-ups: S1 (Pa) Layer 24 2008 ANSYS.

Simulation Results TEST-2 Configurations S1 Results (Pa) Layer 24 Over load steps S2 Results

Simulation Results TEST-2 Configurations S2

Results (Pa) Layer 5 Over load steps 2008

22 Simulation Results TEST-2 Configurations Original Remodelled lay-ups: Longitudinal displacements (mm) Load Step 1 Original Remodelled lay-ups: Longitudinal displacements (mm) Load Step ANSYS. Inc. All rights reserved. 22 ANSYS. Inc. Proprietary

23 Simulation Results TEST-2 Configurations Original / Remodelled S1 results (Pa) Layer 1 / L.S. 1 Original / Remodelled S1 results (Pa) Layer 5 / L.S ANSYS. Inc. All rights reserved. 23 ANSYS. Inc. Proprietary

24 Simulation Results TEST-2 Configurations Original / Remodelled S1 results (Pa) Layer 11 / L.S. 1 Original / Remodelled S1 results (Pa) Layer 24 / L.S ANSYS. Inc. All rights reserved. 24 ANSYS. Inc. Proprietary

25 Simulation Results TEST-2 Configurations Original / Remodelled S1 results (Pa) Layer 1 / L.S. 3 Original / Remodelled S1 results (Pa) Layer 5 / L.S ANSYS. Inc. All rights reserved. 25 ANSYS. Inc. Proprietary

26 Simulation Results TEST-2 Configurations Original / Remodelled S1 results (Pa) Layer 11 / L.S. 3 Original / Remodelled S1 results (Pa) Layer 24 / L.S ANSYS. Inc. All rights reserved. 26 ANSYS. Inc. Proprietary

27 5 Conclusions Successful modeling of fibrous laminates in ANSYS Powerful capabilities in post-processing the results Transient results from structure analysis for specified layer vs. load step Results show failures in some layers, as expected from the original lay-up Results also show improvements in structural performance with remodeled lay-up Prototype production time with remodeled lay-up reduced by ~3 hours Gains of time and costs Test firings with both lay-ups show overall tube thickness successfully survive 2008 ANSYS. Inc. All rights reserved. 27 ANSYS. Inc. Proprietary

Acknowledgements and Institution s Contacts Marcelo Soares Brisola / André Luiz Tenório

Tecnológico do Exército Av. das Américas 28705 Guaratiba Rio de Janeiro/RJ Brazil.

28 Acknowledgements and Institution s Contacts Marcelo Soares Brisola / André Luiz Tenório Rezende / Othon Sampaio dos Santos CTEx Ricardo Damian / Marcus Reis ESSS CTEx: Centro Tecnológico do Exército Av. das Américas Guaratiba Rio de Janeiro/RJ Brazil. ZIP Brazilian Army web-site: Paulo Aguiar: paguiar@ctex.eb.br Guilherme Guimarães: gguimara@ctex.eb.br Phones: +55(21) / THANKS FOR ATTENTION 2008 ANSYS. Inc. All rights reserved. 28 ANSYS. Inc. Proprietary

Analysis of Composite Structure Using HM12.0/Radioss

Analysis of Composite Structure Using HM12.0/Radioss Anil M.Sutar Design Engineer Citec Engineering India Pvt. Ltd. Yerwada, Pune 411 006 anil.sutar@citec.com Abbreviations: FE- Finite Element, GRP-Glass