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Introduction to Composite Material Modeling with SolidWorks Simulation Premium

Helping Designers make the right choice

Henri Dos Santos

Presentation Outline

Introduction Characterisation of Composite Materials Composite Applications SolidWorks Simulation Premium Composite Positioning SolidWorks Simulation Premium Functional Composite Specifications Composite Sandwich principle Composite failure Composite Modelling in SolidWorks

Quality of our results

Conclusion

Introduction - What is a composite Material?

Four basic categories of structural materials : Metals

Polymers
Ceramics

And Composites

Definition : Composite materials consist of two or more separate materials combined in a macroscopic structural unit

Introduction

1+1 = 3 2
improved specific properties not obtainable by any of the original components acting alone

Introduction - History facts/ Did you know?

Introduction - History facts/ Did you know?

The ancient Egyptians were the first people known to make use of plywood

reinforced concrete invented by the Romans approx. 1000 BC (opus caementicium)

Advantages and Disadvantages of Composites

Advantages Lightweight High specific stiffness High specific strength Tailored properties Excellent fatigue endurance Excellent weather/Water resistance Can be radar and sonar transparent Low thermal expansion Good Damping

Disadvantages Cost of materials Long development time Manufacturing difficulties Temperature limits Hidden Damage

Advantages and Disadvantages of composites

Types of composite
Composites include :

Fibrous : Composed of fibers, in a matrix Laminar : layers of materials Particulate : Composed or particles or flakes, in a matrix Hybrid : combinations of any of the above

Roles of the matrix and Reinforcement in a composite :

Matrix Give shape to the composite Protects the reinforcements from the environment Transfers loads to the reinforcements Contribute to properties such as toughness

Reinforcements

Give strengh and stiffness Dominate other properties such as coefficient of thermal expansion, conductivity

Types of composite

High Strength fiber

Glass fiber Quartz fiber Organic fiber Carbon fiber Boron fiber Ceramic fiber

Matrix
Thermo set resins Polyester Vinlyester Epoxy Etc Thermoplastics PPS PEEK PEI Metals Glass Ceramics Carbon

Types of composite
Fiber reinforced plastics (FRP) Sandwich structures

FRP facings, aluminum facings, steel facings and core (foam, honeycomb, etc)

Multi-layer laminates Metal Matrix Composites (MMC's)

Glass matrix composites

Ceramic Matrix Composites Ceramic Ceramic Composites Carbon Carbon Composites etc.

Use of composites today

Use of composites today

25% of the A380's airframe by weight

Carbon-fibre reinforced plastic (CFRP)

glass-fibre reinforced plastic (GFRP)

quartz-fibre reinforced plastic (QFRP) GLARE (GLAss-REinforced fibre metal laminate)

But also

Use of composites today

Positioning & Marketing

Composite Material modeling has been added to SolidWorks Simulation Premium

Scoped to be a tool for Design Engineers who wish to:

Explore the use of composites as a replacement for sheet metal, thin walled castings, or other homogenous thin walled materials Evaluate the benefits and/or sensitivity of material, thickness, number of plys, or orientation in an existing thin walled composite material application

Functional Specifications
Composite formulations supported:

3-layer Sandwich Multi-layer Symmetric and Asymmetric (50 layers max.) (laminates)

Study Types supported:

Static Frequency

Buckling

Material supported :

Each layer can be isotropic or orthotropic

Output supported:

Tsai-Hill, Tsai-Wu, Max Principal Stress FOS plots Interlaminar Shear Stress General Stress and Displacement output per shells

Sandwich

Core Foam Balsa wood Composite honeycomb

Skins Sheet metal Glass FRC

Theorical Symmetric Sandwich Beam principle bending stiffness ???

Theories for Predicting Failure of Composite Laminates A variety of failure criteria exist to predict the ply level ultimate strength in polymer matrix composites. Maximum Stress simply compare macroscopic (ply level) stresses in each coordinate direction to maximum values.

Tsai-Hill and Tsai-Wu use quadratic (and tensor in the case of Tsai-Wu) combinations of the stresses to account for stress interaction.

SolidWorks 2009
Improve the Quality of Your Design

Goals
Minimize deflexion Max (<15 mm) Minimize weight of the part (<300 g) Geometry/global shape cant be changed !!

Force= 50N

Free to change thickness and materials

SolidWorks 2009

Current design :
Material used is orthotropic

Thickness is 3 mm
deflexion Max is 18.2 mm weight is 733 g

SolidWorks 2009

New design :
composite Sandwich definition with a foam material Same previous material for skins Total Thickness is 5.5 mm deflexion Max is 13.7 mm weight is 204 g

Benefits :

SolidWorks 2009 Composite support

Conclusion Composite materials have great potential in the next decades

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SolidWorks Simulation add Value & Strength to Your Products
Thank You
Helping Designers make the right choice

Henri Dos Santos