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You are on page 1of 76

MICMAC-FEA

January 14, 2009

1

MIC-MAC:

Uniform stress state; point design

Powerful for estimation

Ease of use

MIC-MAC, FEA AND MIC-MAC/FEA

FEA (FINITE ELEMENT ANALYSIS):

e.g., MD Nastran, Simulia Abaqus, etc.

Advanced tool for engineers and designers

Non-uniform stress state

Stress concentrations

Simple linear stress analysis to non-linear analysis

Progressive damage

Linear perturbation analysis

Buckling instability analysis

Mic-Mac/FEA:

Combines the simplicity of MicMac and the power of FEA.

Easy to use Excel interface

FEA runs in the background

Strength analysis, frequency calculations and buckling analysis

Chart-Quick and Lamrank for optimization

Failure envelope

2

How does Mic-Mac/FEA work?

Mic-Mac/FEA

(Excel Sheet)

FEA

(MD Nastranor

Simulia Abaqus)

Results

(Excel Sheet)

3

NON-UNIFORM STRESS STATE

Coupon under tension applied without grips

Effect of text fixtures on coupon strength (R/FPF)

Coupon under tension applied with grips

4

NON-UNIFORM STRESS STATE

Effect of text fixtures on coupon strength (R/FPF)- UD specimen

Laminate: [0]

s

Hotspots are indicated by red color.

Strength ratio contour for

a coupon without grips

Strength

(3500 MPa)

Strength ratio contour for

a coupon with grips

Strength

(3347 MPa)

A reduction of 4%

5

Strength

(562 MPa)

NON-UNIFORM STRESS STATE

Effect of text fixtures on coupon strength (R/FPF) : UD off-axis specimen

Laminate: [10]

s

Hotspots are indicated by red color.

Strength ratio contour for

a coupon without grips

Strength ratio contour for

a coupon with grips

Strength

(496 MPa)

A reduction of 12%

6

NON-UNIFORM STRESS STATE

Determination of critical regions in an open hole specimen

Material: Im6/epoxy [SI]

Laminate: [0/90/45]

s

7

NON-UNIFORM STRESS STATE

Determination of critical regions in an open hole specimen

Here shown in terms of failure index for FPF (k, reciprocal of the strength ratio, R).

Zoomed views of contour plots for the failure index

(spectrum: blue to red color for the lowest to the highest k values).

k = 0.98 k=0.3 k=0.95 k=1

Does max of all max strain components point to all of the actual hot-spots? No

Map

k = 1

Map e

o

1

4.6e

-3

Map e

o

2

-2e

-3

Map e

o

6

5.4e

-3

8

OPTIMIZATION USING CHART-QUICK

Determination of an optimal laminate definition with respect to the strength for LPF

Material: T300/N5208 [SI]

Laminate: [q]

s

Rigid Body rotation

9

OPTIMIZATION USING CHART-QUICK

Determination of an optimal laminate definition with respect to the strength for LPF

[ 20]

s

is the optimal laminate.

0

10

20

30

40

50

60

70

80

90

0 10 20 30 40 50 60 70 80 90 100

R/LPF

q

10

BUCKLING ANALYSIS

Determination of critical loads for buckling.

Material: Im6/epoxy [SI] Intact

Laminate: [0/90]

s

(a) (b)

11

BUCKLING ANALYSIS

Determination of critical loads for buckling.

BUCKLING (Eigen values)

Mode # Eigen values

Critical loads

(N/m)

1 0.003878 3.87767

2 0.013765 13.7652

3 0.034872 34.8715

4 0.035738 35.7383

5 0.089439 89.4392

Mode 1

Mode 2

Mode 3

Mode 5

Mode 4

12

OPTIMIZATION USING LAMRANK

Choice of optimal laminate (in terms of R/FPF) from LamRank.

Material: Im6/epoxy [Eng] Intact

Laminate: [q

1

/q

2

]

s

Angles to be chosen from a pool of {0, 30, 60}.

500 k/in

1000 k.in

10 in

5

0

i

n

2 in

5 in

25 in

13

OPTIMIZATION USING LAMRANK

Choice of optimal laminate (in terms of R/FPF) from LamRank.

LamRank Intact [FPF]

theta/1 theta/2 theta/3

Rank 0 30 60

min(R/Intact)

minimum value of

Strength ratio

Repeat

for failsafe

design.

Ceil(Repeat) Relat.

1 1 0 1 0.039 25.951 26 1.049

2 1 1 0 0.037 27.361 28 0.995

3 0 1 1 0.036 27.779 28 0.980

4 0 2 0 0.035 28.589 29 0.952

5 2 0 0 0.035 28.943 29 0.941

6 0 0 2 0.027 36.371 37 0.749

14

VIBRATION

Calculation of first few vibration modes and natural frequencies.

Material: Im6/epoxy [Eng] Intact

Laminate: [0/45/-45]

5s

20 in

1 in

15

VIBRATION

Calculation of first few vibration modes and natural frequencies.

FREQUENCY (Hz)

Mode # Intact

1 14.508

2 14.508

3 84.529

4 84.529

5 121.18

6 183.36

7 183.36

16

FAILURE ENVELOPE

Failure envelope for notched specimen.

0.05

0.05

0.02125

Material:

Im6/ep [SI]

Laminate:

[0/90/45/-45]s

All dimensions are in m

0.01

17

FAILURE ENVELOPES

Can one determine biaxial strength using uniaxial data? NO!

-400

-300

-200

-100

0

100

200

300

-400 -200 0 200 400

FPF Envelope

(FEA)

s

1

(MPa)

s

2

(MPa)

18

FAILURE ENVELOPES

ULTIMATE FAILURE ENVELOPE

-400

-200

0

200

400

600

800

-400 -200 0 200 400 600 800

FAILURE ENVELOPE

(ULT)

s

1

(MPa)

s

2

(MPa)

19

FAILURE ENVELOPES

Material:

Im6/ep [SI]

Laminate:

[0/90/45/-45]s

All dimensions are in m

0.05

0.05

0.0075

0.0025

0.02375

0.02125

Failure envelope for notched specimen.

20

-400

-200

0

200

400

600

800

-500 0 500 1000

FAILURE ENVELOPE

(ULT)

FAILURE ENVELOPES

Can one determine biaxial strength using uniaxial data? DEFINITELY NOT!

s

1

(MPa)

s

2

(MPa)

21

FAILURE ENVELOPES

Failure envelopes for smooth, open hole and open slot specimens.

s

1

(MPa)

s

2

(MPa)

-1500

-1000

-500

0

500

1000

1500

2000

-2000 -1000 0 1000 2000

NOTCHED SPECIMEN (OPEN

HOLE)

SMOOTH SPECIMEN

NOTCHED SPECIMEN (OBLONG

SLOT)

22

MIC-MAC/FEA: GETTING STARTED

If any question, send queries to :

pranavdhojshah@gmail.com

23

INSTALLING MIC-MAC/FEA

1) Download the latest version of Mic-Mac/FEA.

2) Unzip the file to a local folder.

3) Install proper version of Abaqus (Student edition -6.8 or full version -6.7).

4) Open the Mic-Mac/FEA Excel file.

24

USING MIC-MAC/FEA

25

USING MIC-MAC/FEA

26

USING MIC-MAC/FEA

27

USING MIC-MAC/FEA

Note: Loads are

always in MN/m or

kips/in. If moments,

they are in MN or

kips.

28

USING MIC-MAC/FEA

Note: Loads are

always in MN/m or

kips/in. If moments,

they are in MN or

kips.

29

USING MIC-MAC/FEA

30

USING MIC-MAC/FEA

31

USING MIC-MAC/FEA

32

USING MIC-MAC/FEA

33

USING MIC-MAC/FEA

34

LIVE DEMONSTRATION

Due to time constraint, a simplified problem set has been created and packaged with

the distributed MicMac/FEA.

This presentation is applicable for MicMac/FEA-Abaqus.

Please open MicMac/FEA in your desktop and follow the steps.

35

EXAMPLE: STATIC ANALYSIS

Material:

Im6/epoxy [SI]

Problem Set:

Example

Laminate:

[0/60/-60]

3s

Load:

N = {1,0,0} MN/m

Dimensions:

0.1x0.2 sq m

Run analyses as the followings:

1) Static analyses to fetch R/FPF and LPF

36

EXERCISE: FREQUENCY

Material:

Im6/epoxy [SI]

Problem Set:

Example

Laminate:

[0/60/-60]

3s

Load:

N = {1,0,0} MN/m

Dimensions:

0.1x0.2 sq m

Run analyses as the followings:

1) Vibration analysis to fetch natural frequencies for FPF

37

USING MIC-MAC/FEA

38

USING MIC-MAC/FEA

39

USING MIC-MAC/FEA

40

USING MIC-MAC/FEA

NOTE:

While running Chart-Quick GUI option should be turned off , unless

required. This will save computer run-time.

41

EXAMPLE :CHART-QUICK

42

Material:

Im6/epoxy [SI]

Problem Set:

Example

Laminate:

[f]

3s

Load:

N = {1,0.5,0.1} MN/m

Dimensions:

0.1x0.2 sq m

Run Chart-Quick analysis to obtain the optimal helical angle in terms of R/FPF.

USING MIC-MAC/FEA

43

USING MIC-MAC/FEA

44

USING MIC-MAC/FEA

45

USING MIC-MAC/FEA

46

USING MIC-MAC/FEA

NOTE:

While running Lamrank, only run one problem at a time (e.g. do not run

buckling and static analysis, first run the static analysis and obtain results.

Then run the buckling analysis.

Running multiple problems at a time might crash Mic-Mac/FEA.

While running Lamrank, turn off the GUI option unless necessary.

47

EXAMPLE : LAM RANK

48

Material:

Im6/epoxy [SI]

Problem Set:

Example

Laminate:

To be chosen from a pool of 30, 60 and 45

[f

1

, f

2

]

s

Load:

N/A

Dimensions:

0.1x0.2 sq m

Run Lamrankanalysis to obtain the optimal laminate in terms of the first natural

freqency.

USING MIC-MAC/FEA

49

USING MIC-MAC/FEA

50

USING MIC-MAC/FEA

51

USING MIC-MAC/FEA

NOTE:

While running Failure Envelope, at least 5 increments should be defined (value in

Cell G63>=5). Specify odd number of the increments.

Results are in MPa or ksi.

While running Failure Envelope, turn off the GUI option unless necessary.

52

USING MIC-MAC/FEA

NOTE:

Since MicMac/FEA saves the Excel file every time it runs, make sure that all the

input fields are reset when a new analysis is started.

Material, laminate, geometry, etc. should be defined every time a new analysis is

started.

53

EXAMPLE : FAILURE ENVELOPE

54

Material:

Im6/epoxy [SI]

Problem Set:

Example

Laminate:

[0,90,45,-45]

s

Load:

N/A

Dimensions:

0.1x0.2 sq m

Plot failure envelope in sigma-1,2 axes

MIC-MAC/FEA PROBLEM SET

The following problem sets are currently distributed with Mic-Mac/FEA. More

problem sets can be added in future and updates will be issued as a new

release of Mic-Mac/FEA version 4.x.

Units:

Input loads are in MN/m or kips/inch.

Input moments are in MN or kips.

Dimensions are in m or inch.

55

MIC-MAC/FEA PROBLEM SET

Load 1

Load 2

Width

L

e

n

g

t

h

Load 1

Load 2

Width

L

e

n

g

t

h

Rectangular Plate1 Rectangular Plate2

56

MIC-MAC/FEA PROBLEM SET

Load 1

Load 1

Width

L

e

n

g

t

h

Load 1

Width

L

e

n

g

t

h

Smooth Coupon1

Coupon2

Load 1

57

MIC-MAC/FEA PROBLEM SET

Width

L

e

n

g

t

h

Plate4

Moment 1

M

o

m

e

n

t

2

58

MIC-MAC/FEA PROBLEM SET

Load 1

Width

L

e

n

g

t

h

Plate5

All sides constrained in out-of-

plane direction.

Load 2

Load 1

Load 2

59

MIC-MAC/FEA PROBLEM SET

Load 1

Width

L

e

n

g

t

h

Plate 8

P

r

e

s

s

u

r

e

60

MIC-MAC/FEA PROBLEM SET

Width

L

e

n

g

t

h

Plate 9

P

r

e

s

s

u

r

e

61

MIC-MAC/FEA PROBLEM SET

Load 1

Load 2

Width

L

e

n

g

t

h

Load 1

Load 2

Width

L

e

n

g

t

h

OpenHole1

OpenHole2

Radius (center hole)

Radius (center hole)

d1

d2

d1

d2

62

MIC-MAC/FEA PROBLEM SET

Width

L

e

n

g

t

h

OpenHole3

Moment 1

M

o

m

e

n

t

2

Radius (center hole)

d1

d2

63

MIC-MAC/FEA PROBLEM SET

Load 1

Width

L

e

n

g

t

h

OpenHole4

Load 2

Load 1

Load 2

Radius (center hole)

d1

d2

64

MIC-MAC/FEA PROBLEM SET

Load 3

Load 1

Width

L

e

n

g

t

h

OpenHole5

Load 1

L

o

a

d

2

d2

Radius (center hole)

d1

65

MIC-MAC/FEA PROBLEM SET

Load 3

Load 1

Width

L

e

n

g

t

h

OpenHole6

L

o

a

d

2

Load 1

d2

Radius (center hole)

d1

66

MIC-MAC/FEA PROBLEM SET

Width

L

e

n

g

t

h

OpenHole8

Constrained in out-of-plane direction at

sides

d2

Radius (center hole)

d1

Load 1

Load 1

OpenHole8 (end conditions for

buckling analysis)

Constrained in out-of-plane direction

at bottom only

Width

L

e

n

g

t

h

d2

Radius (center hole)

d1

Load 1

67

MIC-MAC/FEA PROBLEM SET

HollowShaft1

(for buckling analysis, only torsion is considered)

Layup is out to in.

Load 1

Load 2

Load 3, shear flow

Length

Radius

68

MIC-MAC/FEA PROBLEM SET

Load 1

Width

L

e

n

g

t

h

Example file is for quick-run only. It may not produce acceptable results as it has a very

coarse mesh (4 nodes only).

Load 2

Load 1

Load 2

Load 1

Width

L

e

n

g

t

h

End conditions for buckling

for Example case.

Example

69

MIC-MAC/FEA ADDING A NEW PROBLEM SET

Adding a new problem set in Mic-Mac/FEA requires familiarity with AbaqusCAE

environment.

Create a CAE file such that:

1) Geometry is defined.

(If orientation is not defined, global orientation is taken as the default)

2) Only 2D conventional shell element is accepted.

3) Mesh is defined (if using Student edition, maximum number of nodes is 1000).

4) Boundary condition is defined.

5) Load is defined (1 MN/m or kips/in or in case of bending MN or kips)

6) A Job is created as Job-1.

7) Save the CAE file to the following directory:

AbaqusMM>caefiles>CaseFiles

AbaqusMM

cae_files

CaseFiles

70

MIC-MAC/FEA ADDING A NEW PROBLEM SET

Register the new problem set with MicMac/FEA Abaqus

1) Open MicMac/FEA and click on Raw Interface to go to ABAQUS sheet where the new

problem set can be registered.

2) Refer to the following slides to input variables in appropriate cell. Note that currently a

maximum of 50 problem sets can be registered (can be expanded).

71

MIC-MAC/FEA ADDING A NEW PROBLEM SET

Number

Probl em

Name

Description

Predefi ned

Load1

Description:

e.g., 1000 N/m

Uni t (N/m or

l bf/i n)

Predefi ned

Load2

Description:

If non exi stent:

N/A

Predefi ned

Load3

Description:

If non exi stent:

N/A

Fi l e for static

analysis.

Fi l es are in

cae_fi les folder

Fi l e for buckling

analysis wi th same or

si milar BC of static

analysis.

Ei gen vector would be

l oad defined as load 1, 2

or 3.

e.g., 1000N/m

compressive

If does not exi st N/A

Frequency file.

If does not

exi st N/A

Di mension

updateable?

Y: Yes

N: No

72

MIC-MAC/FEA ADDING A NEW PROBLEM SET

Di mension1

Legend.

Description

Predefi ned

Load1

Description:

e.g., 1MN/m

Uni t (MN/m or

ki ps/in)

Predefi ned

Load2

Description:

If non exi stent:

N/A

Di mension1 value. Do not

change thi s formula here

(l i nks to i nput di mension

val ue i n Mi cMac/FEA sheet

Can di mension be updated.

If Yes, i nput Y. For such

di mensions you need to

know the sequence (Di m1

wi l l be di m[0] i n Abaqus

sequence. El se, i f the

di mension is fi xed, i nput N.

73

MIC-MAC/FEA ADDING A NEW PROBLEM SET

Di mension2 value. Do not

change thi s formula here

(l i nks to i nput di mension

val ue i n Mi cMac/FEA sheet

Di mension 2 l egend. If not

exi sting write N/A

Up to 7 di mensi ons can be

defi ned

Dimensions are in m or inch

74

MIC-MAC/FEA ADDING A NEW PROBLEM SET

Ignore

Depth val ue; di scontinued

for now.

Ignore

Twi st value; discontinued

for now.

Is failure plot enabled?

Yes or No

If enabl ed, in the static file,

l oads should have been

defi ned (e.g., si gma1,

si gma2)

Ignore

Mask and seed (for

meshi ng) discontinued for

now.

75

TROUBLESHOOTING

The program stops running in the middle:

Do not run other programs while running Mic-Mac/FEA. Always keep the Excel window in the

front (do not minimize it).

Check if the dimensions are defined correctly.

Do not define more than 50 number of plies. Excessive number of plies will slow down or even

crash the computer depending upon its capacity.

Error of abq682.bat or abq671.bat not found is displayed.

Make sure the correct version of Abaqus is installed.

Check if the path in the environment file is defined properly.

Try reinstalling Abaqus.

If your computer lies in a network, unzip the Mic-Mac/FEA to a local folder (such as

desktop or C: ).

76

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