ANSYS Composite PrepPost

Modeling Composites the Simple Way

Composite Introduction

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 1. Composite Introduction

Agenda
• General Introduction Composites
• Classification of Composites
• Matrix and Fiber Materials
• Reinforcement Forms
• Manufacturing Methods
• Draping
• Ply Drop Offs
• Positive and Negative Features of Composites

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Agenda
• Raw Materials
• Numerical Approaches
• Single Plies
• Rules of Mixture
• Anisotropic, orthotropic, transversal isotropic
• From three dimensional stress state to plane stress
• Measurung Ply Properties
• Failure Indicator

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• Composite materials are made of multiple

layers of different materials.

• They are light weight and high in strength.

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Application Areas
• Aerospace
• Wind Energy
• Sports & Recreation
• Motorsport
• Construction
• Automotive
• Marine
• Defense
• … a d ore
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Terms
Fibers- Bonded or embedded
Matrix- A homogeneous base reinforcing fibers that are usually
material that forms the bulk of a responsible for the anisotropy of
composite material layer. the composite.
T

Lamina- A composite material in sheet form

usually referred to as a layer or ply. The
material properties of a layer is usually
determined through an equivalent
homogenization (smearing) process.
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Laminate- A stack of lamina joined
together in arbitrary directions,
referred to as a composite lay-up or
stacking-sequence.
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Classification of Composites Based on Reinforcement

Composite Materials can be classified by the type of
reinforcements used for the matrix material.
A. Particle Reinforced Composites
B. Fiber Reinforced Composites
• Short Fiber Reinforced
• Long Fiber Reinforced

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A. Particle Reinforced Composites

• Particle reinforced composites consist of particles of
one material dispersed in a matrix of a second
material. Particles may have any shape or size, but
are generally spherical,
ellipsoidal, polyhedral,
or irregular in shape.

Ceramic - Aluminum
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B. Fiber Reinforced Composites

• Fiber reinforced composites (FRC) are composites
where one material component (fiber) is used as a
reinforcing material for the matrix.

Carbon Fiber - Epoxy Glass Fiber - Epoxy

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B. Fiber Reinforced Composites

Short Fiber Reinforced Long Fiber Reinforced

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Random and oriented

short fiber reinforced
composites

Random and oriented

long fiber reinforced
composites

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Materials
• Matrix Materials
• Thermosets
• Thermoplastics
• Metals
• Ceramics
• Fiber Materials
• Glass
• Carbon
• Aramid (Kevlar)
• Boron
• Ceramics
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Gel Coats
Gel coats are specialized polyester
resins formulated to provide a
cosmetic outer surface on a
composite product.
They provide the high quality finish
for composite products and increase
the durability and resistance of the
outer surface.

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Reinforcement Forms
• Unidirectional
• Woven
• Mat
• Knit
• Stitched
• Braid Roving

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Reinforcement Forms

Unidirectional Woven Mat

Knits Stitched Braiding

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Manufacturing Methods
There are two general methods of manufacturing
composites. Open molding describes processes with
materials being exposed to the atmosphere during the
manufacturing process while closed molding processes
use two-sided mold sets or vacuum bags.
• Open Molding
• Closed Molding

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Manufacturing Methods
• Open Molding
• Hand Lay-Up
• Spray-up
• Filament Winding

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Manufacturing Methods
• Closed Molding
• Vacuum Bag Molding
• Vacuum Infusion Processing
• Compression molding
• Pultrusion
• Resin Transfer Molding (RTM)
• Reinforced Reaction Injection Molding (RRIM)
• Centrifugal Casting
• Continuous Lamination
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Manufacturing Methods
• Hand Lay-Up
• Composite layer are placed manually on a mold
• Resin is applied by pouring, brushing or spraying
• Layers are added to build laminate thickness
Low tooling costs and minimum
investments in equipment
Simple processing
Wide range of part sizes
Skilled operators allow good production
rates and consistent quality
Low volume and labor intensive
Hand Laying Carbon
Fiber
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Manufacturing Methods
• Using PrePreg Materials
• Fibers or fabrics with a pre-catalysed resin
system impregnated by a machine
• Resin system reacts slowly at room temperature
and is usually cured by heating at cure temperature
Higher fiber contents achievable
Allows strong resins with high viscosity

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Manufacturing Methods
• Autoclave Curing
• Curing of thermoset composites uses
mechanical and chemical processes
• Pressure is applied to remove trapped air and volatiles
• Plies and fiber are consolidated by pressure
• Crosslink reaction, usually initiated by heating,
is necessary to cure material
• Autoclave controls temperature and pressure
Allows high strength to weight ratios

Construction of a composite
fuselage section (Boeing 787)
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Manufacturing Methods
• Spray Up
• Chopped fiber reinforcements and catalyzed resin is placed onto a
mold surface using a chopper/spray gun
• Laminate is rolled to compact chop
• Woven or knitted fabrics can be added
Simple processing
Low-cost tooling
Portable equipment
No part size limitations
Chopped fibers

Sealine spray layup from

Motor Boat & Yachting
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Manufacturing Methods
• Filament Winding Filament winding of a subsea
sphere by Windtec.no
• Resin impregnated fibers or laminates are
wound around a mandrel in predefined pattern
• Fibers and laminates can be pre-impregnated
or running through a resin bath before wound
• Composite is usually cured using autoclaves or ovens
High strength to weight ratios
Good control over uniformity and fiber orientation
Allows highly engineered products and strict tolerances
Automatic process
Limited designs (although new developments
allow non cylindrical and non spherical designs)
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Manufacturing Methods
• Vacuum Bag Molding
• Improves mechanical properties of open mold processes
• A release film is placed over the laminate
• Followed by a bleeder ply of fiberglass cloth, non-woven nylon,
polyester cloth, or other material that absorbs excess resin from
the laminate
• A breather ply of a non-woven fabric is placed over the bleeder ply
• A vacuum bag is mounted over the entire assembly
• Vacuum is applied and the atmospheric pressure eliminates voids
and excess resin

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Manufacturing Methods
• Vacuum Bag Molding
More uniform consolidation
Removing entrapped air
Avoids hand layups being resin rich How-To Use a Vacuum Bag

Improved core-bonding

• Vacuum Infusion
• The resin is introduced into the mold after the vacuum has pulled
the bag down and compacted the laminate
• Resin completely saturates the reinforcements
No resin excess offers substantial emission reductions

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Manufacturing Methods
• Compression Molding
• A mechanical or hydraulic press with heated molds forms
composite parts using sheet molding compound, bulk molding
compound or liquid composite molding
• Sheet Molding Compound (SMC); Fiber reinforced polyester
material using long strands of chopped fibers (> 1 inch)
• Bulk Molding Compound (BMC); Highly filled resin paste combined
with short fibers (0.125- 0.5 inch)
• Liquid Composite Molding (LMC); Uses preforms matching the
finished design or mats (in case of plane shapes). Resin is added
into the open dies. High strength to weight ratios

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Manufacturing Methods
• Compression Molding
Fast molding cycles
High part uniformity
Good surfaces available
Automatic process
Chopped fibers or
preforming necessary

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Manufacturing Methods
• Pultrusion
• Continuous method to manufacture composite parts having a
uniform cross section
• Rovings or fiber mats are pulled through
resin bath and then formed and cured in
a heated die
• Cured parts are cut into desired lengths The Pultrusion Process

Continuous process
High strengths
Limited to uniform cross sections
Pultrusion

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Manufacturing Methods
• Combining Braiding & Pultrusion
• combines the braiding performing technique and composite
pultrusion process to fabricate constant cross-section products
• Fiber angles can be oriented in the braiding process to achieve a
specific angle along to the beam axis
Continuous process
High strengths
Orientation of fiber angles
Limited to uniform cross sections

Braid-Trusion of an L-shaped
thermoplastic composite beam
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Manufacturing Methods
• Resin Transfer Molding (RTM)
• Reinforcement material (can be continuous fibers, mats, preforms,
or woven fabrics) is placed between two matching mold surfaces
• Resin is injected into the mold and wets out all surfaces of the
reinforcing materials
• Curing at room temperature or by heated molds (cycle time)
• Vacuum can be applied to increase resin flow
High quality finish
Fast production
Allows complex surface designs
High tooling costs Resin
Limited part sizes
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Manufacturing Methods
• Reinforced Reaction Injection Molding (RRIM)
• Reinforcement material and resin are mixed and injected into a
closed mold
• Short fibers or flakes are usually used to create a more isotropic
material behavior

• Structural Reaction Injection Molding (SRIM)

• This process uses two resin components which are combined and
mixed together, then injected into a mold cavity containing
reinforcement. In the mold cavity, the resin rapidly reacts and
cures to form the composite part

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Manufacturing Methods
• Centrifugal Casting
• Used for making cylindrical, hollow shapes such as tanks, pipes
and poles
• Chopped strand mat is placed into a hollow, cylindrical mold, or
continuous roving is chopped and directed onto the inside walls of
the mold
• The resin is applied to the inside of the rotating mold

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Manufacturing Methods
• Continuous Lamination
• Creates composites in sheet form such as composite glazing,
corrugated or flat construction panels, and electrical insulating
materials
• Reinforcement is combined with resin and sandwiched between
two plastic carrier films
• Sheet takes shape under forming rollers, and the resin is cured to
form the composite

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Hand Layup Automated Prepreg Winding RTM

Geometry Complex Complex Near to rotational Complex

Holes/Inserts Possible Possible Difficult Possible

Stiffeners Possible Possible Difficult Possible

Back Tapering Possible Possible Not possible Difficult

Surface Moderate – Good1 Good1 Moderate1 Good2

Fiber Architecture Any Any Limited Any

Typ. Fiber Volume

40% 65% 50% 50%
Content

Mechanical Properties Middle High Middle Middle

Quality Moderate Very good Middle Good

Reproducability Moderate Very good Good Good

Tooling Costs Low Very High High High

According to Ermanni, ETH Zürich 1 only one side

2 both sides
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 1. Composite Introduction

From Fibers to Finished Composite Components

By SGL Group
The Carbon Company

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 1. Composite Introduction

Draping
• The ability to drape describes the formability of textile
preforms and how they adapt themselves to the contour of
3D surfaces
• Draping is simulated to avoid wrinkles or other undesired
effects and to consider changes of the fiber orientation

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Draping of a Ply

Inside a Ply In a Laminate

„Trellis“-Effect:
change of angle between fiber
directions due to shearing

Fiber Stretching:
curvature of woven fibers
changes due to tensile loading

Fiber Straining:
due to elasticity of fibers

Fiber Translation: Translation:

due to slipping, especially at translation of plies with respect
edges and corners to each other

According to Ermanni, ETH Zürich

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Draping
• High ability to drape and low
deformation resistance allow
draping of complex
geometries

high
2D-
Knitted Fabrics

Mats

Ability to Drape
2D-Wovens

3D-Wovens UD-Clutch
low

high low
Deformation Resistance

Plank, Wiesbaden 1992

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Ply Drop Offs

• Achieve gradual thickness changes and tapering
in composite laminates
• Introduces resin pockets, which may lead to
delamination failure

terminated plies

resin pocket

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Positive Features of Composite Designs

• Oriented stiffness and strength properties
• Material properties adjustable by engineers (material design)
• Parameters to modify e.g. type of fibers and matrix, fiber
volume fraction, fiber orientation, stacking sequence, layer
thickness, fabrication method
• Significant reduced weight compared to metals
• High stiffness and strength properties with respect to weight
• High fatigue resistance

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Positive Features of Composite Designs

• Specific material characteristics possible (e.g. thermal
stability due to negative coefficient of thermal expansion of
carbon fibers)
• Reduced corrosion tendency
• Low moisture absorption
• Damping of vibrations
• Less sensitive for imperfections (geometrical and physical)
• Electrical conductivity or non-conductivity
(depending on the materials used)

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Negative Features of Composite Designs

• Low stiffness and strength perpendicular to fiber direction
• Large thermal strains perpendicular to fiber direction
• Low interlaminar shear stiffness and strength
• Long time durability (especially concerning environmental
influence, e.g. heat, oisture, che ical, UV, agi g …
• Heat resistance (e.g. fire resistance of matrix material)
• Undesirable brittle failure behavior (safety concepts)

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Negative Features of Composite Designs

• Open questions concerning recycling
• Difficulties in damage detection (x-rays, ultra sonic, thermo
graphic, non-destructive methods)
• Open questions concerning reparability
• Relatively high material costs
• Problems with conventional joints (bolts, rivet, adhesive)
• Sensitive with respect to the fabrication process (flaws,
bubbles, dust)

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Raw Materials
• Composite materials are made of at least
two distinct materials
• One component (fiber) is used as a
Carbon Fiber - Epoxy
reinforcing material for the matrix
• The matrix holds fibers
• The matrix will guarantee a load transfer Matrix takes forces
in between fibers
in between the fibers as well as external
loadings into the fibers

Fibers take forces

in fiber direction
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Relative Importance of Fibers and Matrix

Fiber Matrix
Mechanical Properties
Stiffness

Strength

Fatigue

Damage tolerance

Impact behavior

Thermo-mechanical properties

Fiber-matrix bonding
Ermanni, ETH Zürich

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No Importance High Importance
 1. Composite Introduction

Relative Importance of Fibers and Matrix

Fiber Matrix
Physical Properties
Corrosion Behavior

Thermal Stability

Chemical Stability

Electrical properties
Ermanni, ETH Zürich

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No Importance High Importance
 1. Composite Introduction

Glass Fibers
• Basically silica(SiO2)
• Isotropic properties
• E-glass „electrical“ glass
• Most common fiber
• Moderate stiffness, high strength
• Relatively heavy
• Good chemical, environmental Glass Fiber Roving
conditions and fire resistance
• inexpensive

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Glass Fibers
• R-, S-glass „stre gth“ glass, other
chemical mixture)
• higher stiffness (+20%) and
strength compared to E-glass
• expensive

Glass Fiber Roving

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Carbon Fibers
• Orthotropic properties
• Many different types available
• Expensive to extremely expensive
• Low density
• Low ductility in impact
• Coefficient of thermal
expansion nearly zero
Carbon Fiber Sandwich
• Electrically conductive

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Carbon Fibers
• PAN (polyacrylnitrile)-fiber
• Low stiffness
• Very high tensile & compressive strength
(HT-, HS-, HM-fibers)
• Pitch-fiber
• High to ultra high stiffness (HM-, UHM-fiber)
• High tensile and low compressive strength
• Large scatter in material properties

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Aramid Fibers (also known as Kevlar, Twaron)

• Orthotropic properties
• Lowest density of all fibers
• Higher stiffness compared
to glass fiber
• High tensile strength
• Low compressive strength
• Highly ductile in impact Woven Aramid
• Negative coefficient of thermal expansion
• Moisture absorption  decreases material properties
• Available with low stiffness (life vests, robes, etc.)
• Moderately expensive
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Other Fiber Materials

• For special application, e.g. embedded in
ceramic or metal matrix
• Boron
• Silicon Carbide (SiC)
• Silicon Oxide (SiO2)
• Aluminum Oxide (Al2O3)
• others

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Thermosets as Matrix Material

• Isotropic properties
• Polyester (unsaturated)
• Most common resin
• Good resistance against chemicals and
UV-light
• Catalytic reaction, short curing time,
emits styrene
• Large shrinkage during curing
• Inexpensive

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Thermosets as Matrix Material

• Epoxy
• Most often used resin for high
quality composite materials
• Very good strength properties,
good gluing properties
• Curing with hardener through
polyaddition is critical in view
Epoxy Resin
of health and Hardener
• Low shrinkage
• Expensive

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Thermosets as Matrix Material

• Vinyl ester
• Properties in between Polyester and Epoxy
• Very good chemical resistance
• Low shrinkage
• Moderate price

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Thermoplastics as Matrix Material

• Different production process
necessary (valid for mass production)
• Needs heat to be formed
and solidified
• Creeps at larger
temperatures
• Larger ductility then
thermosetting

Press for Thermoplastics,

University Kaiserslautern
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Thermoplastics as Matrix Material

• PP (Polypropylene), PE (Polyethylene),
PA (Polyamide), PEEK (Polyether ether ketone)
• High ductile resistance
• Good mechanical properties
• Temperature resistance (up to max. 250 °C)
• Expensive
• Polyamide
• Less thermal resistance but less expensive
• PTFE (Teflon)
• Temperature resistant

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Non-Polymer Matrix Materials

• Metal-Matrix-Composites (MMC)
• Aluminum
• Titanium
• Copper
• Magnesium
• Ceramics-Matrix-Composites (CMC) Ceramic Particles in
Aluminum
• Aluminum oxide
• Mullite
• Carbon
• Silicon carbide
• Concrete
Steel Fiber Reinforced Bor Fibers in Aluminum
59 © 2011 ANSYS, Inc. February 7, 2013 Concrete
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Core Materials
• Foam
• Polyurethane PU
• Polyvinylchloride PVC
• Polystyrene PS
• Honeycombs Foam

• Aluminum
• Plastic (Nomex)
• Glass / Penol
• Paper Nomex
• Wood Honeycomb

• Balsa
• Prestressed wooden cores
Balsa
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Numerical Approaches
Get a feeling for size.

5.000.000 : 1
Scale relation
geometry to fiber
diameter

Rotor Diameter 82m

Hub Height up to 100m
(Figure Coutesy by REpower Systems SE )

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Numerical Approaches

• Micro-Scale Approach

• Meso-Scale (Laminate Level)

Approach

• Macro-Scale Approach

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Numerical Approaches
• The most detailed approach describes the micro-structure
of the composite. This includes fiber shape, fiber location
and material properties of reinforcement and matrix.
• If only displacements, buckling loads, or vibration
frequencies and modes are required, the laminate can be
analyzed as a homogeneous shell using a macro-scale
approach. In this case the stress distribution can not be
obtained.

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Numerical Approaches
• Analyzing strains, stresses and failure criteria of the
composite laminate requires to model the single layers a
composite design is built up by. This method is called
meso-scale approach. It requires material properties and
thicknesses for each layer of the design.
• ANSYS Composite PrepPost is mainly used to prepare and
evaluate composite specific results of a design using the
meso-scale approach.

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Single Plies
• The Ply Coordinate System
• 1-Direction: Parallel to fiber direction
(also II-direction, L-direction or x-direction)
•
(also  direction, T-direction or y-direction)
2-Direction: Perpendicular to fiber direction

• 3-Direction: Normal to ply

also „out of pla e“ or z-direction)

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Unidirectional Plies

• Fiber Volume Fraction

 F  Total Volume  V F 
Fibers Matrix
Fiber Volume A
AF  AM
F

V tot
• Fiber Weight Fraction
 A
A  A 
  
Fiber Weight G F F F
F Total Weight Gtot F M
F M

• Matrix Weight Fraction

 A 
A  A 
  
Matrix Weight G M M M
M Total Weight Gtot F F M M


• Conversion
  1  1

1

1 F 
 M  M 
F

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Unidirectional Plies
• Fiber volume fraction, fiber mass and the ply thickness
are dependent values
• Wovens and Fabrics:

  M
• Fiber volume fraction for  kg 
 
 t  2
m 
F
F M F

specific ply thickness F t arg et

• Ply thickness for a specific

t  Mt arg et
F

fiber volume fraction F F

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Rules of Mixture
• Rules of mixture are used to estimate material properties
(Young's modulus in the 1 and 2 direction) of a composite
based on the fiber and matrix material properties
• Multiple different rules of mixture exist in literature, all of
them are an estimation
• Using the rules of mixture we simplify the mechanics of
the composites layers

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Rules of Mixture, Halpin-Tsai Equations

• Semi-empirical model
• Contiguity factor  usually defined empirical by curve
fitting. See recommended values on next slide.

1   1   1  

E1  E2  G12 
1   1   1  
EM 1 EM 2 GM 12

1 1 1
EF 1 EF 2 GF 12

  M1   M2   M 12
E E G
1 1 1
EF 1 EF 2 GF 12
EM 1 EM 2 GM 12

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Rules of Mixture, Halpin-Tsai Equations

Contiguity factor 
E1 for perfectly aligned continuous fibers =
E1 for imperfectly (or wavy) aligned <
continuous fibers (often in range of 100-1000)
E1 for aligned discontinuous fibers  = 2  fiber aspect ratio

=2
E2 for aligned continuous or
discontinuous fibers

=1
G12 for aligned continuous or
discontinuous fibers
(Source: Fire properties of polymer composite materials by A. P. Mouritz,A. G. Gibson)

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Rules of Mixture, Jones

EM  E F 2
E1    EF1  (1   )  EM E2 
  EM  (1   )  EF 2
GM  GF 12
G12 
  GM  (1   )  GF12

 12    F12  (1   )  M

 21   12
E2
E1

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Rules of Mixture, Puck

• Empirical modification with respect to experimental
values using a nonlinear approach according to Puck
E1    EF1  (1   )  EM

EM  (1  0.85 2 )
E2  EM 
*

1  M2
* EM

  (1   )1.25
*
EM
EF 2

GM (1  0.6  0.5)
G12 
  M  (1   )1.25
G
GF 12

 12    F12  (1   )  M  21   12
E2
E1
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Homogeneous and Heterogeneous Materials

• Heterogeneous materials have varying properties at
different locations within the material
• In contrast, properties for homogeneous materials (e.g
steel) are the same at every location within the material
• Composite laminate material is considered
predominantly as a homogenous material for simulations
on a laminate level.

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Anisotropic Material
• Isotropic material (e.g. steel) has the same properties in any
direction.
• Anisotropic material has properties (mechanical, etc.) that
vary with the orientation.
• The stiffness of an isotropic material is described by two
properties, the odulus of elasticity E a d Poisso ’s ratio ν,
whereas anisotropic material requires up to 21 properties

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Anisotropic Material
• Material definition requires the full 6×6 elastic coefficient
matrix [D]
 xx   D11   xx 
   D symmetry   
 yy   21 D22   yy 
 zz   D31   zz 
   
D32 D33
 xy   D41   xy 
 yz   D51   yz 
D42 D43 D44

     
D52 D53 D54 D55
 xz   D61 D62 D63 D64 D65 D66   xz 

   D  

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Orthotropic Material
• An orthotropic material has three planes of material symmetry
• A unidirectional fiber-reinforced composite may be
considered to be orthotropic
• One plane of symmetry is perpendicular to the fiber direction,
and the other two can be any pair of plane orthogonal to the
fiber direction Z
Fibers Matrix

X
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Orthotropic Material Fibers Matrix

• Nine constants are required to describe an orthotropic material

E x , E y , E z , xy , yz , xz , Gxy , G yz , Gxz

 xx   D11   xx 
   D   
D12 D13
 yy   21 D22 D23   yy 
 zz   D31   zz 
   
D32 D33
 xy     xy 
 yz     yz 
D44

     
D55
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 xz   D66   xz 
 1. Composite Introduction

Orthotropic Material Fibers Matrix

• The compliance matrix    S    S   D1  is defined as

 E1 
 yx
 Ezxz 
 xx   x   xx 
   Exy 
 zy
  
Ey

 yy    x   yy 
1

 zz    Exzx    zz 
 yz
Ey Ez

     
1

 xy  
Ey Ez

  xy 
 yz     yz 
1
G xy

     
 xz     xz 
1
G yz

 
1
G xz
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Transversal Isotropic Material

• Transversal isotropic materials are orthotropic materials
characterized by isotropic material behavior in one material
symmetry plane
• A unidirectional layer has transversal isotropic material behavior
with the fiber direction as symmetry axis
• A woven fabric has transversal isotropic material behavior with
the out of plane normal direction as symmetry axis
• The number of constants to define is reduced to 5

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Transversal Isotropic Material

• Unidirectional Layer
E y  Ez  xy   xz
Gxy  Gxz
2  1  yz 
G yz 
Ey

Unidirectional

• Woven Fabrics
Ex  E y  yz   xz
G yz  Gxz
2  1  xy 
Gxy 
Ex

Woven

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Isotropic Material
• Most common materials of industrial use are isotropic
(aluminum, steel, etc.)
• Isotropic materials have an infinite number of planes of
symmetry, meaning that the properties are independent of the
orientation
• Two constants (Young modulus and Poisso ’s Ratio) are
necessary to represent the elastic properties of isotropic
material

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From Three Dimensional to Plane Stress State

• Composite materials are often used in form of plates and
shells, which have two dimensions (length and width) much
larger than the third dimension (thickness). When the
thickness of a plate is small compared to the other dimension,
it is reasonable to assume that the transverse stress is zero
(σZ=σ3=0).

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From Three Dimensional to Compliance Matrix    S   

  x   S11   x 
      
S12
  y    S12   y
Plane Stress State
   S 66   xy 
S 22
 xy  
 z  0,  yz  0,  xz  0
S11  , S 22  , S 66 
1 1 1

 xx   S11   xx 
E1 E2 G12
 12
   S   
S12 S13 S12  S 21  

 yy   21   yy 
E1
S 22 S 23
 zz   S31   zz  Stiffness Matrix    D   
   
S32 S33
 xy     xy    x   D11   x 
 yz     yz 
S 44
      
D12
  y    D12   y
         D66   xy 
S55 D22

 xz   S 66   xz   xy  

D11  , D22  2 , D66  G12

E1 E
 
 E
S12  S 21   12 2

  1  2  12
E 2

E1
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Transformation to the Global Coordinate System

• Layers are defined with different specific fiber angles
• In order to build a stiffness matrix for the complete layup the
stiffness matrixes for each layer are transformed from the
layers x,y,z or 1,2,3 coordinate system into the global
coordinate system using a transformation matrix
 cos 2  sin 2  2 sin  cos  
T    sin 2  cos 2   2 sin  cos  
 X
 sin  cos  sin  cos  cos 2   sin 2  

x
y z
 cos 2  sin 2   2 sin  cos  
T 1   sin 2  
Y
cos 2  2 sin  cos   Z
sin  cos   sin  cos  cos 2   sin 2  


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Transformation to the Global Coordinate System

 x   X   X   x 
  y   T    Y    Y   T     y 
      1   X
       
 xy   XY   XY   xy 
x

 x   X   X   x 
y z

  y   T    Y    Y   T     y 
      1   Y

       
Z
 xy   XY   XY   xy 

Compliance Matrix

S  
  X   S11   X 
     
T 1 S  T 
S12
  Y    S12    Y 
   S 66   XY 
S 22
 XY  

Stiffness Matrix

D 
  X   D11 D12   X 
  
  Y    D12 D22
  
   Y  T 1 D T 
   D66   XY 
 XY  
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 1. Composite Introduction

Layered Shell-Elements in ANSYS

4-Node Structural Shell 8-Node Structural Shell

• Structural shell elements require the definition of the

following mechanical material properties per layer
• Young's Modulus in X, Y and Z direction
• Shear Modulus in the XY, YZ and XZ plane
• Poisson's Ratio in the XY, YZ and XZ plane
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Element Technology in ANSYS

• A layup can also be defined for solid elements (SOLID185,
SOLID186) and solid like shell elements (SOLSH190) in ANSYS
• Furthermore discrete reinforcements (REINF264) are possible
for shell and solid elements
• Please see the ANSYS Theory Reference in the ANSYS Help
(// Theory Reference) for more information on element
technology in ANSYS

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Measuring Ply Properties

• Mechanical properties of composite materials depend on the production
process and the specific material properties of the basic materials used as
well as on the manufacturing process of the composite design
• General material databases are available (ESAComp has a comprehensive
material database) but the data provided are standard material data
• For individual material data ask your material manufacturer about data,
recommended tests and/or recommended test laboratories
• Contact test laboratories offering standard test (ISO or ASTM) and non
standard tests

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Measuring Ply Properties

• International Organization for Standardization

The International Organization for “tandardization is an international

standard-setting body composed of representatives from various national
standards organizations.

Examples:
• ISO 14125:1998 fiber-reinforced plastic composites -- Determination of
flexural properties
• ISO 527-5:2009 Plastics -- Determination of tensile properties -- Part 5:
Test conditions for unidirectional fiber-reinforced plastic composites

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Measuring Ply Properties

• American Society for Testing and Materials (ASTM)

A“TM International is an international standards organization that develops

and publishes voluntary consensus technical standards for a wide range of
materials, products, systems, and services.
Examples:
• Committee D30 on Composite Materials
• ASTM D7205 / D7205M - 06 Standard Test Method for Tensile Properties
of Fiber Reinforced Polymer Matrix Composite Bars
• ASTM D7617 / D7617M - 11 Standard Test Method for Transverse Shear
Strength of Fiber-reinforced Polymer Matrix Composite Bars
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Tension Tests and Failure Mode

Unidirectional
Composite Tensile Test

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Compression Tests and Failure Mode

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In-Plane Shear Tests and Failure Modes

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Failure Indicator
FPF – First-Ply-Failure Indicator
• Mathematical equations indicating first failure of any ply
• Indicates the occurring failure mode: fiber tension, fiber
compression, matrix tension, matrix compression
• Determines reserve factor, inverse reserve factor, margin of
safety
• Typical criteria: Max. Stress, Max. Strain, Tsai-Wu, Tsai-Hill,
Hashin, Puck2D, Puck3D, Cuntze

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Failure Indicator
LPF – Last-Ply-Failure (Progressive Damage)
• Further loading beyond FPF until ultimate failure of laminate.
• Post-failure formulations needed (ply-discount method)
• May also include energy dissipating methods

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Delamination
• Interface failure between two plies in normal direction
 Interlaminar Failure
• Driven by normal stress in thickness direction

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 1. Composite Introduction

Debonding
• Interface failure between face sheet and core
of sandwich structures.
• Only predictable when core and sheet are
separately modeled.

Compression Test

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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

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