ANSYS Composite PrepPost 18.

0
Workshop 7.1 – Solid Modeling

1 © 2017 ANSYS, Inc. July 13, 2017

 15. Workshop Solid Modeling

• This workshop will cover the solid model workflow using two
simple composite assemblies
• The composite part will be combined with metallic parts into an
assembly, and then analyzed

2 © 2017 ANSYS, Inc. July 13, 2017

 15. Workshop Solid Modeling

Agenda
• Create composite layup
• Extrude solid model using extrusion guidelines
• Add metal parts
• Transfer parts to ANSYS Mechanical
• Apply boundary conditions, loads and solve the model
• Evaluate solid model results in ANSYS Composite PrepPost

3 © 2017 ANSYS, Inc. July 13, 2017

 15.1 Workshop Solid Modeling
Start ANSYS Workbench and Restore Archive

1. Start ANSYS Workbench and restore Archive Solid_Modeling_FROM_START_18.0.wbpz

2. Save the Workbench project

4 © 2017 ANSYS, Inc. July 13, 2017

 15.1 Workshop Solid Modeling
The archived project contains two systems:
• ACP(Pre)  The system
with the composite part

• Metal Parts  The system

with the non composite
metal parts of the assembly
5 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling

• The composite part and the metal parts will be assembled later

• The solid composite model is generated based on a shell model and

extruded to a solid model

• This is the first step of the workshop

6 © 2017 ANSYS, Inc. July 13, 2017

 15.1 Workshop Solid Modeling
Open ANSYS Composite PrepPost Model

1. Open ANSYS Composite PrepPost; The shell mesh and materials are already defined

7 © 2017 ANSYS, Inc. July 13, 2017

 15.1 Workshop Solid Modeling
Create Fabrics

1. Create a new fabric using Epoxy Carbon Prepreg material

and a thickness of 0.008 in
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 15.1 Workshop Solid Modeling
Create Edge Wise Rosette

1
1. We will use an edge wise rosette to specify the fiber reference direction. Create a new edge wise
rosette based on Edge1. This edge has been defined as named selection in the model.
9 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling
Create Oriented Selection Set

1
1. Create a new Oriented Selection Set based on all elements. Use the edge wise rosette created in

10 © 2017 ANSYS, Inc. July 13, 2017

1
the previous step and an orientations direction as shown above.
 15.1 Workshop Solid Modeling
Create Plies

1
1. Create a new ply group
11 2.© 2017Create
ANSYS, Inc. six new layers (0°, 0°, -30°, 30°, 0°,0°)
July 13, 2017
 15.1 Workshop Solid Modeling
• When the composite layup is defined the solid model is created by
extrusion.
• We will use extrusion guides imported as CAD file to extrude the model
along a specific surface.

Extrusion guideline
(CAD geometry)

Solid model extrusion using Solid model extrusion without

extrusion guidelines using guidelines in surface normal
12 © 2017 ANSYS, Inc. July 13, 2017
direction
 15.1 Workshop Solid Modeling
• The unit system of the CAD file imported for the extrusion guide
is US Customary (inch), please change the unit system of ACP
(Pre)

Extrusion guideline
(CAD geometry)

Solid model extrusion using

extrusion guidelines
13 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling
Import CAD Geometry

1 3

2
1. Insert Geometry from the Component Systems
2. Link Geometry to Setup of ACP (Pre)

1 3.

4.
Import the cad file extrusion_guide.stp, the step file we will import can be
found in the workshop folder.
Update ACP (Pre) setup and return to ACP (Pre)
14 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling
Import CAD Geometry 3

1
2
1. The CAD file imported before is present in CAD Geometries
2
2. Create a new virtual geometry (Right mouse button on Virtual
Geometries
 Create Virtual Geometry)
3. Check whether your unit system is US Customary (in, lbm, lbf, s),

15
the unit system of the imported CAD is US Customary
© 2017 ANSYS, Inc. July 13, 2017
3
 15.1 Workshop Solid Modeling
Create a Solid Model

2
3
1
4
1. Create a new Solid Model (Right Mouse button on Solid Models
 Create Solid Model)
2. Select All Elements in element sets
3. Select extrusion method Analysis Ply Wise
16
4. © 2017
Select
ANSYS, Inc.
Resin Epoxy as Global Drop-Off Material
July 13, 2017
 15.1 Workshop Solid Modeling
Create a Solid Model
23
2 4

1 1.
2.
Insert a new Extrusion Guide
Select Edge1 for the first extrusion guide
3. Select Type Geometry
4. Select the imported CAD geometry
17 © 2017 ANSYS, Inc. July 13, 2017
5. Repeat Steps 1-4 for Edge Set Edge2 using same geometry
 15.1 Workshop Solid Modeling
• The solid model has been extruded by ANSYS Composite
PrepPost and can now be used for different analyses.

• In the next steps we will

assemble composite
and metal parts within
ANSYS Mechanical.

18 © 2017 ANSYS, Inc. July 13, 2017

 15.1 Workshop Solid Modeling
Transfer composite and metal parts to ANSYS Mechanical

1
2

1. Update the ACP (Pre) Setup

2. Drag and Drop a new Static Structural system into the project schematic. Do not drop the new
system onto any of the existing systems.
19 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling
Transfer composite and metal parts to ANSYS Mechanical

1
3
2
1. Drag and Drop Setup of ACP (Pre) onto Model of the new Static Structural
(select Transfer Solid Composite Data)
2. Drag and Drop Model of Metal Parts onto Model of the new Static Structural
20 3. ©Update Model of theJulynew
2017 ANSYS, Inc. Static Structural
13, 2017
 15.1 Workshop Solid Modeling
Open ANSYS Mechanical

1. Open ANSYS Mechanical by double-clicking Model of the new Analysis System

2. Meshes and materials of the solid composite and of the metal parts are imported from the ACP
21
(Pre) and Metal
© 2017 ANSYS, Inc.
Parts analysis systems, they can not be modified here
July 13, 2017
 15.1 Workshop Solid Modeling
Check Automatically Defined Contacts

1. The contact regions for the assembly have been automatically defined by ANSYS
Mechanical. Please check both contact regions. Bonded contacts are used to
22 connect
© 2017 ANSYS, Inc. the metal parts to the composite specimen.
July 13, 2017
 15.1 Workshop Solid Modeling
Apply Boundary Conditions

1
1. Apply a fixed support to one end
and a remote displacement to the
other end. Define a displacement
of 0.01 inch in x-direction and fix
all other displacements and
rotations.
23 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling
Solve the Model
2
1

1
1. Add Total Deformation to the solution
2. Solve the Model
24 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling
Postprocessing in ANSYS Composite PrepPost

2
1
1. Drag and Drop ACP (Post) onto Model of ACP (Pre) system
25
2. ©Drag and Drop Solution
2017 ANSYS, Inc. July 13, 2017
of Static Structural analysis system onto Results of new ACP (Post) system
 15.1 Workshop Solid Modeling 2

2
1. Update and open Results of new ACP (Post) system and update Model in ANSYS Composite PrepPost.
2. Add Failure Criteria to Definitions (the more failure criteria are evaluated the more resources are used
26
for postprocessing)
© 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling
• Interlaminar strains and stresses for solid models are calculated by
ANSYS and automatically available in ANSYS Composite PrepPost.

• The following failure criteria should be switched to 3D: Maximum

Strain, Maximum Stress, Tsai-Wu, Tsai-Hill, Hashin, Puck, Cuntze

• All failure criteria can be evaluated at the same time

(If hardware resources allow this, ANYS Composite PrepPost utilizes
multiple CPUs to evaluate failure criteria)
27 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling

1. Select failure criteria

2. Configure failure criteria and switch failure criteria to 3D (if available)
28 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling

1
1. Add Failure Plot to Solution 1
2. show failure criteria ply wise
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 15.1 Workshop Solid Modeling
Show plies as solid elements

• Select element edges

• Select surface highlighting
• Select element highlighting
• Select solid element highlighting

• Sometimes it is necessary to reselect plies

30 © 2017 ANSYS, Inc. July 13, 2017
 15.1 Workshop Solid Modeling
Show inner plies as solid elements

31 • To analyze inner plies

© 2017 ANSYS, Inc. unselect element edges and surface highlighting
July 13, 2017
 15.1 Workshop Solid Modeling
Failure criteria for different plies by selecting plies in the model tree

32 © 2017 ANSYS, Inc. July 13, 2017

 15.1 Workshop Solid Modeling

• Compare 2D Failure Criteria evaluation vs. 3D Failure Criteria

evaluation

Tsai-Wu and Tsai-Hill

Tsai-Wu and Tsai-Hill 3D Evaluation
2D Evaluation
33 © 2017 ANSYS, Inc. July 13, 2017
 15.2 Workshop Solid Modeling
Start ANSYS Workbench and Restore Archive

1. Start ANSYS Workbench and restore Archive pressure_vessel_from_start_18.0.wbpz

2. Save the Workbench project

34 © 2017 ANSYS, Inc. July 13, 2017

 15.2 Workshop Solid Modeling

1
2 2

1. Drag and Drop ACP (Pre) in the project schematic

2. Connect the Geometry Cells

35 © 2017 ANSYS, Inc. July 13, 2017

 15.2 Workshop Solid Modeling

1 2
2

1. In Engineering Data add composite material

2
properties,Epoxy_Carbon_UD_230GPa_Prepreg,
2. Double click Model of ACP (Pre), add mesh
and specify the resin material, Resin_Epoxy
properties for cap and lateral cylinder, generate
36 © 2017 ANSYS, Inc. July 13, 2017 the mesh on the surface
 15.2 Workshop Solid Modeling
1
1
2 3
2
3
Double click setup of ACP (Pre), define (1) a fabric material, (2) a new rosette, and (3) an oriented selection set as shown in
this slide
37 © 2017 ANSYS, Inc. July 13, 2017
 15.2 Workshop Solid Modeling

1 1

1. Create a Modeling Group and add 5 plies with fibers oriented in the cylinder tangential direction
38 © 2017 ANSYS, Inc. July 13, 2017
 15.2 Workshop Solid Modeling

1
1. Extrude a solid model, extrusion method Analysis Ply Wise,

1 Resin_Epoxy as global drop-off material

2. Update the model and leave ACP (Pre)

39 © 2017 ANSYS, Inc. July 13, 2017

 15.2 Workshop Solid Modeling

1. Add Static Structural to the project schematic and connect to the ACP (Pre) model of the
vessel and the mechanical model of the supports
2. Open Mechanical in the Static Structural box
40 © 2017 ANSYS, Inc. July 13, 2017
 15.2 Workshop Solid Modeling

1 1
3 2
1
4
1. Add bonded contact between the vessel and the two supports in the connections
2. Fix the bottom of the two supports and the rim of the cap
3. Apply pressure on the inside surface of the vessel
41
4. Add total deformation in the solution for plotting purposes. Solve the model.
© 2017 ANSYS, Inc. July 13, 2017
 15.2 Workshop Solid Modeling

1
2

1. Check the total deformation in Mechanical

2. Drag and Drop ACP (Post) on ACP (Pre) in the project schematic and connect its Results cell
with Solution of the Static Structural Analysis
42
3. Update the project and open ACP (Post) to check the different laminae of the composite
© 2017 ANSYS, Inc. July 13, 2017
 15.2 Workshop Solid Modeling

1 2
2

1
1. Add Max Strain and Max Stress in the Failure Criteria Definition
2. Insert Failure in the solution, the maximum IRF element wise. The critical spot is near the
vessel cap (need to introduce a fillet in the geometry to reduce stress concentration)
43 © 2017 ANSYS, Inc. July 13, 2017