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ACP

(ANSYS Composite Prep/Post)

Jim Kosloski

ACP Background

ANSYS Composite PrepPost is an add-on module dedicated to the modeling of layered composite structures.

ACP is now included with the Mechanical Enterprise licenses

of layered composite structures.  ACP is now included with the Mechanical Enterprise licenses www.caeai.com 2

Typical ACP Usage

A shell element model is developed in Mechanical

Meshing shell geometry, applying loads and boundary conditions.

Can be in ANSYS Mechanical or Mechanical APDL

Define materials (Engineering Data, or APDL)

Import the models in ANSYS Composite PrepPost

Define Composite Fabrics:

Fabric: a material and a thickness

Composite Fabrics: • Fabric: a material and a thickness • Laminate: an assembly of fabrics (with

Laminate: an assembly of fabrics (with orientations)

Define the element orientation (so as to properly orient

materials)

Define the ply sequence for groups of elements (usually corresponding to faces of the geometry)

Solve the model - computed by the standard ANSYS

solver, in batch mode.

Post-process the results in ACP: deformations, thicknesses and failure criteria.

in batch mode.  Post-process the results in ACP: deformations, thicknesses and failure criteria. www.caeai.com 3

Incorporation into WB Architecture

ACP is incorporated directly into the WB architecture.

 ACP is incorporated directly into the WB architecture. Define composite material properties Set-up composite

Define

composite

material

properties

the WB architecture. Define composite material properties Set-up composite material fabric definitions, element

Set-up composite material fabric

definitions, element

orientations, ply layup, etc

fabric definitions, element orientations, ply layup, etc Import/Generate surface geometry Generate Shell Mesh

Import/Generate

surface

geometry

Generate

Shell Mesh

Composite Materials

In Engineering Data, there is now a composite materials library.

Show Libraries

there is now a composite materials library. Show Libraries Material does not need to be assigned
Material does not need to be assigned to bodies in Mechanical. Material assignment is done
Material does not need to be assigned to
bodies in Mechanical. Material
assignment is done in ACP.
All materials in Engineering Data are
brought into ACP.
Material assignment is done in ACP. All materials in Engineering Data are brought into ACP. www.caeai.com

Starting ACP

Once shell mesh is generated and materials defined, ACP can be started by right click: Edit…

ACP  Once shell mesh is generated and materials defined, ACP can be started by right
ACP  Once shell mesh is generated and materials defined, ACP can be started by right

Solving and Post-processing

Once the model is setup in APC(Pre) it can be linked to whatever type of analyses you need to solve:

be linked to whatever type of analyses you need to solve:  Then connect ACP(Post) to

Then connect ACP(Post) to the Solution of that analysis.

type of analyses you need to solve:  Then connect ACP(Post) to the Solution of that

ACP Modeling Capabilities

Multiple oriented element sets allow for multi-laminate build-up.

ACP Modeling Capabilities  Multiple oriented element sets allow for multi-laminate build-up. www.caeai.com 8
ACP Modeling Capabilities  Multiple oriented element sets allow for multi-laminate build-up. www.caeai.com 8
ACP Modeling Capabilities  Multiple oriented element sets allow for multi-laminate build-up. www.caeai.com 8

Parametric Modeling of Composites

Since ACP is integrated into Workbench, the composite data from ACP will be updated with any parameter changes in WB.

Example below shows parametric changes of doubler width shown in red.

any parameter changes in WB.  Example below shows parametric changes of doubler width shown in
any parameter changes in WB.  Example below shows parametric changes of doubler width shown in
any parameter changes in WB.  Example below shows parametric changes of doubler width shown in
any parameter changes in WB.  Example below shows parametric changes of doubler width shown in

Post-processing of Composite Results

Efficient post-processing of composite-specific results quantities.

New Sampling Element post-processing.

Plot worst case failure criteria over all layers. Pick element and see stress/strain and failure through the thickness

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Post-processing of Composite Results

Make thru-thickness stress plots and account for interlaminar normal stresses with shells.

Traditional shell approaches can not account for interlaminar normal stress (shown in blue curve)

ANSYS Composite PrepPost can predict these base on the work of Roos, Kress, & Ermanni

predict these base on the work of Roos, Kress, & Ermanni Critical Stresses in Bend Thru-Thickness

Critical Stresses in Bend

work of Roos, Kress, & Ermanni Critical Stresses in Bend Thru-Thickness ILS & ILN Stress Plots
work of Roos, Kress, & Ermanni Critical Stresses in Bend Thru-Thickness ILS & ILN Stress Plots

Thru-Thickness ILS & ILN Stress Plots Solids

Bend Thru-Thickness ILS & ILN Stress Plots – Solids Thru-Thickness ILS & ILN Stress Plots –

Thru-Thickness ILS & ILN Stress Plots Shells

Post-processing of Composite Results

Sandwich Construction Post-processing.

Wrinkling

Local buckling of a face sheet under compression

Failure indicator available using shell modeling of sandwich

Core Failure

Local failure of core in shear or tensile loading

Failure indicator available using shell modeling of sandwich

of core in shear or tensile loading • Failure indicator available using shell modeling of sandwich
of core in shear or tensile loading • Failure indicator available using shell modeling of sandwich
of core in shear or tensile loading • Failure indicator available using shell modeling of sandwich
of core in shear or tensile loading • Failure indicator available using shell modeling of sandwich
of core in shear or tensile loading • Failure indicator available using shell modeling of sandwich

Advanced ACP Capabilities

Fiber orientation prediction and modification.

Use internal ACP draping simulation to compute orientation changes due to geometry curvature, develop flat pattern.

Modify the fiber orientation to something that is actually observed on the manufacturing floor through alignment with local rosettes.

something that is actually observed on the manufacturing floor through alignment with local rosettes. www.caeai.com 13
something that is actually observed on the manufacturing floor through alignment with local rosettes. www.caeai.com 13
something that is actually observed on the manufacturing floor through alignment with local rosettes. www.caeai.com 13

Advanced ACP Capabilities

3D Solid Modeling:

If a composite part is thick and bulky a shell mesh may not be sufficient to predict accurate results.

One of ACP(Pre) strengths is that the 2D shell mesh can be extruded into a 3D solid model.

CAD support: STEP and IGES geometries can be imported to define thick cores or use as guides for 3D extrusions.

STEP and IGES geometries can be imported to define thick cores or use as guides for

Advanced ACP Capabilities

Even more…

Map composite thickness and angles through table look-up. Build complex assemblies including contact.

Customize layups using scripts and tables (Filament winding)

Multiple solid models can be combined through links to MAPDL.

2-Way FSI with composites

— Multiple solid models can be combined through links to MAPDL. — 2-Way FSI with composites
— Multiple solid models can be combined through links to MAPDL. — 2-Way FSI with composites
— Multiple solid models can be combined through links to MAPDL. — 2-Way FSI with composites

ACP v17.0 Enhancements

Variable Material Data

The temperature-, shear-, and degradation factor-dependent material data functionality has been extended.

In release 17.0, the composite material elasticity and strength properties can depend on any scalar user-defined field.

This allows you to account for not only basic effects like temperature or ply- shearing due to draping on the composite behavior of the simulation, but any other factor such as void content, degree of curing, or humidity.

behavior of the simulation, but any other factor such as void content, degree of curing, or

ACP v17.0 Enhancements

Enhanced Composite Workflows

Multiple ACP-Pre systems and Mechanical Models can now be assembled in one analysis system.

This functionality can be used in design studies where the composite definition remains the same but different geometries are evaluated.

Submodeling is another situation where this functionality can be used. In a scenario where two models are to share the same ACP (Pre) Setup, one setup cell is

dragged on to the other.

ACP maps as much information onto the second model as possible. It is advised to use common Named Selections as well as the same Engineering

second model as possible. It is advised to use common Named Selections as well as the

ACP v17.0 Enhancements

Enhanced Composite Workflows

Composite workflows for shell and solid element analyses have been streamlined.

Composite shells and composite solids follow the same workflow logic and composite shell models can now be combined with composite solid models.

the same workflow logic and composite shell models can now be combined with composite solid models.

ACP v17.0 Enhancements

Interactive Lay-up Definition in Excel

A new Excel Link interface allows for efficient, live, spreadsheet-based definition and data exchange on composite lay-ups in ACP.

for efficient, live, spreadsheet-based definition and data exchange on composite lay-ups in ACP. www.caeai.com 19

Mechanical Composites Enhancements

The following composite enhancements have been made at Release 17.0 for working with composite (layered) elements directly in Mechanical:

Additional Result Types for Composite Analysis.

Mechanical now supports ply-based User Defined results and Elemental Coordinate System results. These results are supported through traditional Details view scoping as well as through the automated context menu (right-click) option when you select one or more Ply objects.

as through the automated context menu (right-click) option when you select one or more Ply objects.
as through the automated context menu (right-click) option when you select one or more Ply objects.

Mechanical Composites Enhancements

Specifying Ply-based Named Selections using Worksheet Criteria.

You can now define ply-based Named Selection using the Criterion option of the Worksheet.

— You can now define ply-based Named Selection using the Criterion option of the Worksheet. www.caeai.com

Mechanical Composites Enhancements

Ply Graphics Options.

In addition to Ply fiber direction, transverse direction, and Element Normal direction, Mechanical now enables you to view Ply normal direction as well as Element reference direction using new toolbar options.

you to view Ply normal direction as well as Element reference direction using new toolbar options.

Element Orientation

1.

Element Orientations can be applied via manual element selection or using a Named Selection.

2.

Element Orientations can be defined using different coordinate systems

within the same body.

3.

Element triad display can be controlled using the element orientation toolbar.

1. 2.
1.
2.

3.

3. Element triad display can be controlled using the element orientation toolbar. 1. 2. 3. www.caeai.com
3. Element triad display can be controlled using the element orientation toolbar. 1. 2. 3. www.caeai.com
3. Element triad display can be controlled using the element orientation toolbar. 1. 2. 3. www.caeai.com