Introduction

The purpose of this document is to provide guidelines by which to analyze a

model aircraft wing structure in Abaqus. The guide assumes that the user
has little experience with Abaqus and/or may not have encountered many of
the features used. The design of the structure is based largely on previous
semesters of AERO 402-Aircraft. It is assumed that the user has already
created a working assembly of the wing structure using CAD software. This
document will assume that the CAD software used is SolidWorks.
The layout of the wing structure used in this example is shown below with the
upper surface skin and sheeting removed. The wing uses the NACA 63-210
airfoil and has a leading edge sweep of 30 degrees. There is a 12 inch root
chord with a taper ratio of 0.5. There is a root incidence angle of 2 degrees
and a wing twist of -2.5 degrees. The tip therefore has an incidence of -0.5
degrees. These parameters were chosen in order to demonstrate the
techniques that will allow students to analyze a wide variety of wing

structures whether simpler or more complex than this example.

Importing the SolidWorks Model

The model must be saved in a format that is most compatible to be used by
Abaqus. Although there are many formats which can be imported into
Abaqus, it should be noted that geometric features created in Abaqus CAE
are stored in ACIS (.sat) format. The Abaqus documentation therefore
suggests using this format for part imports.
Using the ACIS format, every part in an
assembly can be imported into Abaqus
at once whereas importing other part
formats may require each individual
part to be saved and imported. In the
case of this structure there are 60
individual parts that must be imported.
Furthermore, the geometry in stored to
an accuracy of 1*10-6 in ACIS
formatting, but according to the
Abaqus documentation other available
formats can be much less accurate.
In SolidWorks, open the wing structure
assembly to be analyzed. Go to File>Save As and use the pull-down arrow

to select ACIS (*.sat) in the Save as type: field. Use the Options button in
the bottom right of the Save As window.

Ensure that Solid/Surface geometry

is selected for the Output as: option
and check that the units are as
desired. Check that the highest
number is selected for Version. Click
OK and save the file.

Open a new model database in Abaqus

CAE. Under the model tree, right click
on Parts and select Import. Ensure that
ACIS is selected for the File Filter and
locate the assembly file that was
exported from SolidWorks. If an error
is given that the file is not a valid ACIS
file, return to SolidWorks and resave
the file with the next lower Version in
the Export Options and re-import the
new file.

Import all parts as 3D, Deformable Solids

and in general do not scale the parts.
Select OK and Abaqus will create a new
part for every member of the assembly.
If an error or warning is given that any of
the parts have imprecise geometry,

there are two logical courses of action. The first is to use the Convert to
precise representation geometry option when importing. Typically the best
action however is to return to the CAD program and carefully check the parts
for errors. Possible errors include regions of overlapping volume or selfintersection as well as minute slivers of material that may be left when using
cut features.

Because wing structural assemblies typically consist of numerous individual

parts (in this example there are 60), it is recommended for each part to right
click and rename each part with a more descriptive name, i.e. Rib 1 Center,
Front Top Spar Cap, etc.

Partitioning
Partitioning parts is generally recommended when a single part makes
contact in a joint with two or more parts. Partitioning is especially necessary
when multiple parts contact a single surface of another part. Later when
contact constraints are added to the model, the need for partitioning
becomes evident and which parts require partitions
becomes clearer.
Observe the joints shown to the right. The rib has a
partition where it will join the shear web of the rear shear
web because the spar caps also join the web and the rib.
The top spar cap is removed to show the partitions on the
shear web segments. Note that the web segments are
partitioned for the joints with the caps as well as with one another.

To partition for the joints, first select one of the

shear web segments in the part module. Select
Partition Face: Sketch. Select the front face (the

face with normal vector approximately in the negative x-direction) and click
done.

Choose to select an edge to appear vertical

and on the left and select the left edge.

Sketch a simple vertical line, press escape if

prompted to enter the next point, and click done at
the Sketch partition geometry prompt.

For the joints between web segments, it is

necessary that the part itself be partitioned into
cells rather than just partitioning the face. To do
this, select Partition Cell: Extrude/Sweep Edges
as shown.

Select the edge that was created by the face partition, click Done, and
select Extrude Along Direction. Select the edge shown to the right for the
extrude direction and click OK then click Create Partition and Done. Use
these steps to partition cells on each shear web segment where it will join
another web segment. Also partition cells on the rear of the central rib
segments as shown at the beginning of this section. Partition the front faces
of all rear shear web segments as shown at the beginning of the section.

Material Properties
The structure of this example consists of materials that are primarily used in
creating model aircraft: balsa wood, birch ply-wood, and Monokote skin.
Because wood is highly orthotropic, it is critical that orthotropic material
properties be specified for all wooden components and that material
directions be specified to simulate the wood grain directions.

Use the pull-down arrow to go to the

Property module and create a new
material for each of balsa, birch, and
Monokote.

Choose to define elastic

mechanical properties as shown.

For the woods, select Type:

Orthotropic using the pull-down
menu.

Orthotropic material behavior is defined by:

Where the D matrix for balsa is given using values from the USDA
Enycyclopedia of Wood as:
544477.0317
8464.503486
15429.48139
0
0
0

8464.503486
9609.681717
5447.54364
0
0
0

15429.48139
5447.54364
260031.5336
0
0
0

0
0
0
1.99E+04
0
0

0
0
0
0
2.91E+04
0

0
0
0
0
0
2.70E+03

Similarly the D matrix for birch, calculated using values from the USDA, is:
2306606.945
138833.8032
195951.2595
0
0
0

138833.8032
161031.5298
79197.24615
0
0
0

195951.2595
79197.24615
253126.8765
0
0
0

0
0
0
1.50E+05
0
0

0
0
0
0
1.64E+05
0

0
0
0
0
0
3.76E+04

If basswood should instead be used for any components, the D matrix using
USDA values is:
1657603.957
81770.03951
130932.8106
0
0
0

81770.03951
64579.6542
40144.71305
0
0
0

130932.8106
40144.71305
158411.8644
0
0
0

0
0
0
7.39E+04
0
0

0
0
0
0
8.99E+04
0

0
0
0
0
0
1.61E+04

After using the above properties to define the wood materials, create
Monokote as an isotropic material with the properties shown. Distributors of
Monokote acknowledge that it is a Mylar film, but will not provide specific
properties. The properties shown are therefore taken from information for
Mylar films manufactured by DuPont Teijin Films.

Material Libraries
In Abaqus versions 6.7EF and later, material properties
can managed through the use of Material Libraries.
Material Libraries allow the use of consistent material
properties without the need to research properties for
each individual material. Because of the number of
values required to define orthotropic materials, libraries
are especially useful for these materials. While in
the Property module, note that there is a tab for
Material Library.

In the work directory create a folder named

abaqus_plugins if there is not one already there.
Go to the Material Library tab and use the Material Library Manager button.

Create a new Material Library using the

Create button. Select each material
and use the < button to add the
material to the library. Save the library
and the materials in it can be added to
any other project. Again, this is
primarily to ensure consistent properties
are used and to save time in finding the
necessary parameters.

To use materials from a library in a project, first ensure

that the .lib file is saved in the abaqus_plugins folder.

In the Material Library Tab use the pull-down arrow to select the desired
library (if there are multiple in the plugin folder). Select the material and use
the Add Material to Curent Model button.

Material Directions
In order to accurately apply the material properties to
the parts, material directions must be assigned for each
orthotropic part. To demonstrate this, first go to the
model tab and find one of the spar caps in the Parts list,
right click on it, and select Switch Context.

Use the Create Datum CSYS: 3 Points button

as shown and choose to create a Rectangular
coordinate system.

Choose the origin as any point along one of

the long edges of the part. When prompted
to select a point along the x-axis, choose any
other point that lies along the same edge as
already chosen. Choose the third point as
any point on an edge which is parallel to the
edge already chosen. The desired result is
that the x-axis should lie along the
longitudinal direction of the part. All other
spar caps and all stringers should have
datum coordinate systems added in a like
manner. Each piece of the upper surface and
lower surface sheets for each leading edge
and trailing edge should have coordinate
systems added in a similar manner.

For each spar cap, stringer, and leading and trailing

edge sheets go to the Property module and choose to
Assign Material Orientation.

Select the part as the highlighted region,

click on the Datum CSYS List button in
the bottom right, and select the datum
coordinate system that was created with
the three points. Leave the default
options in the Edit Material Orientation
window and click OK.

Adding material directions for

the center rib segments and
leading edge segments can also
be accomplished with the same
procedure. As shown, the corner
notches provide the three points
to define the coordinate system.

As the trailing edge segments do not

have such notches, other techniques
can be used to create logical material
directions. For the trailing edge
segments, the desired material
directions are such that one axis lies along the left edge, one axis lies
perpendicular to that edge and in the plane of the face shown, and one axis
is normal to the face shown.

First choose to create a point using Create Datum Point: Project Point On
Line.

Choose the point shown and

the left edge. The use the
projected point, the original
point, and another point along
the left edge to define the
datum coordinate system.
Assign material directions with
the same steps as above.

Define material coordinates for the leading edge

dowel such that the x-axis coincides with the
longitudinal direction of the part.

Sections and Composite Layups

In the Property module, use the
Create Section button to create a
Solid, Homogeneous section of
balsa material. Assign this section
to each spar cap and to each
stringer. Create another Solid,
Homogeneous section of birch and
assign it to the leading edge dowel
rod

For the leading and trailing edge

sheets, create a Homogeneous, Shell

section and note that it is considered to be type: Continuum Shell. Since the
sheets are 1/32 inch balsa, enter .03125 for the thickness and balsa material.
Since this is a Continuum Shell section, the true thickness is calculated based
on the dimensions of the part to which it is assigned. The entered value is
considered an initial value for the calculations. Assign this section to each of
the upper and lower surface leading and trailing edge sheets. Create another
Continuum Shell section for the shear webs. Use a thickness of 1/16 inch
(.0625) and balsa material. Assign this section to each of the three segments
of the front shear web and the three segments of the rear shear web. Create
a Continuum Shell section with 0.002 thickness and Monokote/Mylar material.
Assign this section to the wing skin.

The rib segments should be modeled as 1/16 inch thickness birch plywood
with 3 plies oriented at 0-90-0 degrees. The most accurate way to model
these therefore is to use the composite layup feature in Abaqus. In the
property module, select Create Composite Layup as shown

Create a 3-ply Continuum Shell layup.

Right click the Region box, select Edit

Region, highlight the entire part, and
click done to set the entire column.
Right click the Material box, select birch,
and click OK to set the entire column.
Since the part is 1/16 inch thick, assign
0.020833, 0.020834, and 0.020833 for
the thicknesses. Near the top of the
window, use the pull-down arrow to set
Definitition: Coordinate system. Click
the Select button, choose Datum
CSYS List, select the datum coordinate
system previously defined, and click OK.
Set the rotation angles for the plies to 0,

90, and 0. Click OK and the part is now defined as a 3-ply composite. Use
the same sequence of steps to apply composite layups to each leading edge
rib segment and each trailing edge rib segment.

Meshing
Notice that of all the parts that compose the structural assembly, the
majority of them are plate-like, thin structures. All of the ribs and shear web
segments are simple flat plates while the leading and trailing edge sheeting
and the skin are curved shell structures. All of these type components can be
analyzed in Abaqus using Continuum Shell Elements.
To use Continuum Shells in the analysis, mesh controls
must be assigned to each part that will use the shell
elements. For each plate-like and shell-like part, go to
the Mesh modules and select Assign Mesh Controls

Highlight the entire part and click done. Make

sure that the technique to be used is Sweep.
On parts such as the rib segments, Sweep
meshing may have been selected as the
default.

Choose Assign Element Type, highlight the entire

part, and click done.

Choose Continuum Shell, Hex and

leave the other options at the default
settings. Note that on parts that

contain a cusp such as on the trailing edge sheets, it is often desirable to

partition the cusp from the rest of the part. Continuum Shell, Wedge
elements can then be applied to the cusp in order to provide a better quality
mesh than if only hex elements were used.

Apply this sequence of steps to each of the rib segments, the shear web
segments, the sheeting and the skin. The stringers, spar caps, and leading
edge dowel can simply be assigned 3D Stress elements.

The parts of this example can be seeded

by specifying the approximate global
size as shown. Avoid meshing too finely
on the ribs segments as the Academic
Teaching License is limited to 100000
nodes for the entire assembly. The
curvature of the wing skin will dictate a
very fine mesh that will easily lead to a
node count near that limit. Higher
quality meshes can often be obtained
using careful partitioning and edge
seeds, but doing so can be quite tedious and often yields little benefits to the
analysis.

Assembly
The first step in assembling the model is to create an Instance for each and
every part.

Go to the Assembly module, right click

on Instances, and select Create
Instance as shown. Left click on the
first part in the list, scroll to the

bottom, hold the Shift key, and left click on the bottom-most part. Choose
Dependent Instance Type and click OK. This will create all 60 Instances at
once

At this point each of the parts will be

placed in the position that the part
held in the SolidWorks assembly and
therefore in the ACIS .sat file that was
used to import the geometry. By
default, all of the datum coordinate
systems that were created for the
material directions are also shown in
the assembly. This clutter can make
assigning constraints
more annoying.

To remove the clutter

from the assembly, go to
View->Assembly Display
Options. Go to the Datum
tab and unselect Show
datum coordinate
system.

Changing the View Manipulation Options can

often make constraining the assembly much less
of an annoyance. To do this, go to Tools>Options. There one can set the mouse controls
to coincide with controls in a number of CAD

programs with which the user may be more familiar such as SolidWorks or
Catia.

Properly constraining the assembly requires a

rather lengthy sequence of constraints between
the various parts. It is generally easier to work
with constraining some parts when other parts not
in the view. In the Model tree, under Instances
right click on the upper surface piece of the wing
skin and select Suppress. Do the same for the
two pieces of upper surface sheeting. This will
allow the underlying structure to be visible. To add
each part back to the assembly, simply right click
and select Resume.

To assign the constraints, the parts should be

separated enough to select the contact surfaces. For
example, select the Translate Instance shown.

Select the top cap of the front spar, click done,

enter (0,0,0) for the translation vector start
point, enter (0,3,0) for the translation vector
end point, and click OK.

In the Interaction module, use the Create Constraint button to create a Tie
Constraint.

Click continue, choose Surface for the master

type, and left click on the bottom surface of
the spar cap.

Choose Surface for the slave type and select

the top surface for each of the front shear web
segments. Also select the top surface of the
corner notch on each leading edge rib
segment and center rib segment as shown. To
select multiple surfaces simply click a surface,
hold the Shift key, and left click the next
surface. To deselect one of the surfaces hold
the Ctrl key and left click on the undesired
surface.

Click Done to access the Edit Constraint window. The Position Tolerance
option should be set based upon the manner in which the parts are
assembled. In many cases the computed default is sufficient especially when
this is no separation or negligible separation. In some assemblies, however,
the convergence calculations are helped by instead adding a small separation
between parts and then specifying the Position Tolerance as slightly larger
than the separation. In many cases the Adjust slave surface initial position
option will aid the calculations. However, care should be taken especially in
contact between curved or complex surfaces as this option may occasionally
cause errors due to Negative Element Volume.

Once the constraint is completed the part should be

translated back to its original position. Constraints
should then be added in the same manner to define
each joint between parts. As was shown previously,
a single constraint can be added to define several
joints that a single part has with several others.
Multiple master surfaces can also be chosen in
defining a single constraint, thereby further
reducing the number of individual constraints which
are to be used in defining the assembly. The list of
constraints which were used in creating this
example is shown to the right in order to
demonstrate a possible combination of constraints
to define the assembly. One primary concern in
defining the constraints is that no node should have
more than one master, although a master node may
have any number of slave nodes.

Loads and Boundary Conditions

The loads and boundary conditions chosen for this example were somewhat
simple.

Go to the Step module and use the Create Step

button to create a Static, General Step. The default
options are sufficient to conduct basic analysis.

Go to the Load Module and use the Create

Load button to create a concentrated force in
the Step that was just created.

Make the load a 2lb force at the tip,

centered about the quarter-chord by
selecting the two points shown and
entering a magnitude of 1 for CF2.

Use the Create Boundary Condition button

to create a boundary condition in the same
step. Select the Mechanical Category and
Choose Symmetry/Antisymmetry/Encastre.

Select the regions shown and choose

the Encastre boundary condition.

Stresses and Strains in Local Part Coordinate Directions

In the job module create a job and simply use the
default options.

Submit the job for analysis. Once the analysis is complete, right
click to view the results. The Plot Contours on Deformed
Shape button is quite useful for locating stress concentrations
and areas of high strain. Use Result-> Field Output to choose
which variable is displayed. The invariant variables can be of
particular interest.

Because the global coordinate system is used in

expressing the stress and strain components, these
variables typically are not useful. Instead it is much more
useful to consider the stress and strain components of
various parts in context of the material coordinate
systems which were previously defined. To obtain these
values, first use the Create Field Output From Fields.

In the Create Field

Output window select
whether which set of
variables to transform
(stress or strain or
others). Select
Transformation for the
Function and the select
the coordinate system
to which the variables
should be transformed.

Clicking OK creates a Session Step in the

Output Database tree. In this Session Step
using Results->Field Output allows one to
instead plot the variable components in the
transformed material direction. This
information is invaluable in any analysis which
incorporates material grain directions.