LM2001 2

PAT325: MSC.Laminate Modeler, Course Notes Copyright (C) MSC.
SOFTWARE 2001
1
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=
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xy
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xy
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k
k
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Z
Q S
Q Q
Q Q Q
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14 12 11
View Direction
Reference
Direction
Reference
Angle
Application Region
Application Point
PAT325:
MSC.Laminate Modeler
Course Notes

Release 2001, Revision 2
PAT325: MSC.Laminate Modeler, Course Notes Copyright (C) MSC.SOFTWARE 2001
2
Andrew Main
MSC.Software
14/5/01
3
Objective
Show outlines of composites materials theory and the integration
between FEM and composites materials. Illustrate the basic functions
of MSC.Patran and MSC.Laminate Modeler in Composite design.

Who should attend
Engineers and material scientists involved in the design, analysis and
manufacture of composite components and structures.

Prerequisites
A degree in engineering, material science or equivalent experience.
Familiarity with MSC.Patran and a knowledge of composite materials.

The course is specifically written for the MSC.Nastran solver,
although only smaller deviations are found if running other solvers
such as MSC.Marc or HKS/Abaqus.

GENERAL INFO
4
TABLE OF CONTENTS
1 INTRODUCTION
2 ELASTIC BEHAVIOR OF MATERIALS
3 CLASSICAL LAMINATION THEORY
4 BUILDING COMPOSITE MODELS WITH PATRAN
5 FAILURE CRITERIA FOR COMPOSITES
6 MAKING PLIES WITH LAMINATE MODELER
7 MAKING LAYUPS WITH LAMINATE MODELER
8 PLIES ON DOUBLY CURVED SURFACES
9 INTRODUCING SPLITS IN PLIES
10 MODELLING TECHNIQUES FOR SANDWICH
PANELS
11 IMPORT/EXPORT OPTIONS
12 MANUFACTURING INTEGRATION

5
APPENDIX

A HINTS AND TIPS
B LAMINATE DEFINITION IN NASTRAN
C OPTIMISATION OF COMPOSITES IN NASTRAN
D R2001 NEW FEATURES
E MISC. SOLVER RELATED ITEMS
F BASIC COMPOSITE PRODUCTION METHODS
6
1 INTRODUCTION

7
Aerospace
F-111 horizontal stabilizer was the first flight worthy composite
component (1964)

8
Aerospace
Voyager Aircraft (1986)
First non-stop around the world 9 days flight.
Empty airframe weight only 9% of full weight - fully composite.

9
Aerospace
Cabin floors on Boeing aircraft

All composite fin main spar for Airbus A310-300

Fokker all composite airliner wing. Tested in lab in 2000, not flown

Japanese F-16 derivative first fighter composite wing

Comanche attack helicopter (1998)

10
Laminate Modeler, Automotive
Most Formula 1 teams use Laminate Modeler

11
General
Composites development is a multi-faceted process where design,
analysis and manufacture must be considered simultaneously.

The aim of simultaneous engineering is to use various analysis results
to drive the optimization of a structure and its manufacturing process.

MSC offers a range of CAE products which can enhance the
concurrent engineering of composites:
MSC.Patran
MSC.Nastran, MSC.Marc and MSC.Dytran

12
Laminate Tools from MSC
MSC.Patran
Analysis Integration Environment
Flexible Geometry Access (IGES, STEP, Catia, Pro/Engineer,
Unigraphics)
Flexible analysis preferences
Result Processing

Ply-based Modelling
Drape Analysis
Visualization

MSC.Nastran, MSC.Marc and MSC.Dytran
Structural Analysis

13
Composite Material, Definition
Two or more materials combined on a macroscopic scale, for
example fibre and resin

Highly directional Properties

Highly variable Properties, particularly strength

14
A composite material which exists in sheet form, whose thickness is
small compared with any other dimension

Each discrete lamina is usually referred to as a layer or ply.
Through this course we will use the word ply

May consist of several fibre directions wowen into each other,
usually two but sometimes one or three

Usually has a main direction,
or at least a reference direction
Composite Lamina, Definition
2
3
1
15
From textile weaving, the following definitions are used:
Warp fibers are aligned along the direction of the roll of cloth. They
tend to be straight because of the tension they are placed in

Weft fibres are the sideways fibres in the roll

Warp and Weft, Definition
16
Laminate, Definition
A stack of lamina joined together in arbitrary directions,
usually referred to as a composite or lay-up.
Through this course we will use the word lay-up

The laminate material is often converted into an equivalent
anisotropic homogeneous material for analysis purposes.

A laminated material is an artifice to aid analysis and usually has no
physical counterpart.

2
3
1
17
Composite Structure, Definition
A part or an assembly made up of laminates

18
2 ELASTIC BEHAVIOR OF
MATERIALS

19
The most general form of the linear elastic stress-strain relationship is:

The stress and strain tensors both contain 9 components, while the
Elastic modulus matrix contains 81 components!

In order for the material to conserver energy in real life, the
mathematical stiffness matrix must be symmetrical.

So, we can simplify the above equation to...
Generalized Material
kl ijkl ij
C c o =
i,j=1,2,3
20
Anisotropic Material
No planes of material property symmetry
21 independent elastic constants
The S in the lower left corner denotes that the matrix is symmetric
about its diagonal.

(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
=
(
(
(
(
(
(
(
(
zx
yz
xy
z
y
x
zx
yz
xy
z
y
x
C S
C C
C C C
C C C C
C C C C C
C C C C C C
c
c
c
t
t
t
o
o
o
66
56 55
46 45 44
36 35 34 33
26 25 24 23 22
16 15 14 13 12 11
21
Orthotropic Material
Three orthogonal planes of material property symmetry
9 independent elastic constants (E
1
, E
2
, E
3
, v
12
, v
23
, v
13
, G
12
, G
23
, G
31
)
No interaction between normal and shear stresses

(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
=
(
(
(
(
(
(
(
(
zx
yz
xy
z
y
x
zx
yz
xy
z
y
x
C S
C
C
C
C C
C C C
c
c
c
t
t
t
o
o
o
66
55
44
33
23 22
13 12 11
0
0 0
0 0 0
0 0 0
0 0 0
22
Orthotropic Material, 2
Solved for the strains:

(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(

=
(
(
(
(
(
(
(
(
zx
yz
xy
z
y
x
zx
yz
xy
z
y
x
G
S
G
G
E
E E
E E E
t
t
t
o
o
o
v
v v
c
c
c
31
23
12
3
2
23
2
1
13
1
12
1
1
0
1
0 0
1
0 0 0
1
0 0 0
1
0 0 0
1
23
Isotropic Material
Infinite number of planes of material property symmetry
Two independent elastic constraints (E and v)

( )
( )
( )
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
=
(
(
(
(
(
(
(
(
zx
yz
xy
z
y
x
zx
yz
xy
z
y
x
C C S
C C
C C
C
C C
C C C
c
c
c
t
t
t
o
o
o
2
12 11
2
12 11
2
12 11
11
23 22
13 12 11
0
0 0
0 0 0
0 0 0
0 0 0
24
Isotropic Material, 2
Solved for the Strains:

(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
+
+
+

=
(
(
(
(
(
(
(
(
zx
yz
xy
z
y
x
zx
yz
xy
z
y
x
E
v
S
E
v
E
v
E
E
v
E
E
v
E
V
E
t
t
t
o
o
o
c
c
c
) 1 ( 2
0
) 1 ( 2
0 0
) 1 ( 2
0 0 0
1
0 0 0
1
0 0 0
1
) 2 1 )( 1 (
1
u u +
= V
25
3 CLASSICAL
LAMINATION
THEORY

26
Laminate Shell Element Definition
To determine the stiffness of our Laminated Shell Element, we need to
calculate the relationship between force and response in the plate

Assumptions:
Lamina are in a state of plane stress (
z
= 0)

Lamina are perfectly bonded

Linear variation of strain through the thickness

27
Forces and Moments Action on a plate
x
z
y
M
y

F
xy

V
y

M
y

F
y

M
xy

F
xy

M
xy

F
x

M
x

V
x

F
xy

M
xy

F
y

V
y

F
x

M
xy

M
x

V
x

F
xy

28
Approach

Calculate the stiffness of each lamina in the lamina coordinate system

Transform the stiffness into the laminate coordinate system as required

Add up stiffness for each lamina to obtain the laminate stiffness

Calculate stress in lamina as a function of reference strain and
curvature

29
General stiffness relation for anisotropic material
Our starting point is:

(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
=
(
(
(
(
(
(
(
(
zx
yz
xy
z
y
x
zx
yz
xy
z
y
x
C S
C
C
C
C C
C C C
c
c
c
t
t
t
o
o
o
66
55
44
33
23 22
13 12 11
0
0 0
0 0 0
0 0 0
0 0 0
30
Reduced Stiffness for Plane Stress Conditions
The assumptions reduce our matrix to:

This is valid for one lamina in its local coordinate system.

Q
ij
are the reduced stiffness of the lamina in plane stress:
(
(
(
(
(
(
=
(
(
(
xy
y
x
xy
y
x
Q S
Q Q
Q Q Q
c
c
o
o
44
24 22
14 12 11
33
3 3
C
C C C
Q
j i ij
ij

=
31
Transforming Reduced Stiffness
The lamina stiffness must be transformed into the coordinate system of the
Laminate. This is done by an ordinary coordinate transform
X (lamina)
X (laminate)
Y
Y
Z, Z
-u
-u
32
Calculating total Laminate Stiffness
The contributions from the different laminas to the total laminate stiffness
is classified into three groups:
A
ij
Extensional Laminate Stiffness
B
ij
Coupling Stiffness
C
ij
Bending Stiffness

The stiffness correlation becomes:

(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
=
(
(
(
(
(
(
(
z
y
x
z
y
x
zx
yz
xy
z
y
x
D S
D D
D D D
B B B A
B B B A A
B B B A A A
M
M
M
N
N
N
_
_
_
c
c
c
0
0
0
44
24 22
14 12 11
44 24 14 44
24 22 12 24 22
14 12 11 14 12 11
33
Calculating Stresses in Lamina
The local in-plane stresses anywhere in the plate element can now be
found as a function of the global strains:

Where Z is the distance from the neutral plane to the relevant point in the
ply, and _ is the curvature.
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+
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=
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xy
y
x
xy
y
x
xy
y
x
Z
Q S
Q Q
Q Q Q
_
_
_
c
c
t
o
o
44
24 22
14 12 11
34
4 BUILDING COMPOSITE
MODELS WITH
MSC.PATRAN

35
Calculation Approach
MSC.Patran, MSC.Nastran and most common analysis codes have similar
approach to composites:

Based on laminate material representation of the lay-up

Within each laminate material, the lamina sequence, material, thickness
and orientation are constant

Orientations of the laminate material can be defined relative to edges of
elements, vectors projected onto elements or relative to coordinate
systems

36
Example of how to create a Composite Model
Material:

Directional strength [Pa]
E
11
= 40E6 E
22
= 1E6
v
12
= 0.25
G
12
= G
13
= 0.6E6 G
23
= 0.5E6

Ply thickness
0.01 and 0.0125

Ply orientations
0 and 90
u= 90 t=0.0125
u= 0 t=0.01
u= 0 t=0.01
u= 0 t=0.01
u= 0 t=0.01
u=0 t=0.01
u= 90 t=0.0125
u= 90 t=0.0125
u= 90 t=0.0125
x
z
y
u
37
STEP 1: Creating a Composite Material
In Patran Materials menu
Create a new orthotropic material
...and enter the
Material properties
38
STEP 2: Creating a Ply Lay-up
Still in the Materials menu...
Create a new Lay-up
...by stacking
plies
39
STEP 3: Create the Composite Structure
In Patran Property menu...
..associate the
Laminate Material
with its parent
geometry region
40
STEP 4: Request ply stress data
In the Output Requests
submenu in the
Analysis menu

...request ply stress
data as output

1
2
3
41
STEP 5: Calculate the results
In Patran Analysis menu...

Issue the Analysis to MSC.Nastran

Wait for the analysis to complete

Link the results file to MSC.Patran

42
STEP 6: Postprocess the Results
In Patran Results menu...

Visualize stresses for each ply, now called layer

Layer 1 is always at bottom of element

Beware of drop-offs or reversed elements

43
Lay-up, User Interface
An alternative tool for building lay-ups is situated in the Utilities Menu,
under Materials, Laminate Builder Tool. It is worth trying out...
44
Perform Lesson 1, Composite Model of Loaded Flat Plate in your
Exercise Workbook

Be sure to ask for help on anything you dont understand
Exercise
45
5 FAILURE
CRITERIA FOR
COMPOSITES

46
Calculating Material Strength
For isotropic materials, the resulting stress (or strains) are compared
with a single value characterising the allowable strength of the material.
Generally, the maximum shear stress (Tresca) or shear energy (Von
Mises) is used to predict yield of a metal

For orthotropic materials, strengths in different directions can vary
widely. For example, a unidirectional lamina could withstand a tension
of 2000 MPa along the fibres, but fail under a tension of 100 MPa
perpendicular to the fibres. This brings the need for special purpose
algorithms for calculating the allowable strength for composites

Failure criteria discussed here are limited to first-ply failure, giving a
conservative estimate of the strength of the laminate

Commonly used failure criteria are generally empirical, and do not
reflect micro-mechanical failure mechanisms

47
Failure Mechanisms of Unidirectional Lamina
Longitudinal
Tension -
Fiber
Failure
Longitudinal
Compression -
Fiber Failure
Transverse
Tension -
Matrix
Failure
Transverse
Compression -
Matrix Failure
In-Plane Shear -
Fiber-Matrix
Interface Failure
48
Strength Coefficients
For Orthotropic lamina under plane stress, up to eight strength
coefficients are commonly used to describe strengths:

Xt TX Tensile strength along the x-axis
Xc CX Compressive strength along the x-axis
Yt TY Tensile strength along the y-axis
Yc CY Compressive strength along the y-axis
S12 SXY Shear strength in the XY plane
S23 SYZ Shear strength in the YZ plane
S31 SXZ Shear strength in the XZ plane
F12 Interaction Term

The numbers should be input as absolute values

49
Definitions
o
x

o
y

a
b
Failure Surface
in Stress Space
Failure is calculated as a mathematical function of load vs. strength.
Several mathematical models exist to predict failure.

Failure Index (FI) is calculated based on the load and strength
according to several models, se later slides
Strength Ratio (SR) is the ratio by which the load must be factored
to achieve failure. It is usually derived from the Failure Index

Margin of Safety (MoS) is a reflection of the reserve strenght
b
a
SR =
1 = SR MoS ! 0 Safe MoS >
! 1 Failure SR <
! 1 Safe SR >
50
Maximum Stress Failure Criterion
Direct comparison of stresses and strength coefficients

Ignores interaction between loads in different directions

(

=
SXZ
abs
SYZ
abs
SXY
abs
CY TY CX TX
max FI
xz
yz xy
x
y
x x
) (
,
) (
,
) (
, , , ,
t
t t
o
o
o o
FI SR / 1 =
1 = SR MoS
51
Hill Failure Criterion
Where:
F
11
= 1 / TX
2
for
x
0 F
12
= -1 / (2TX
2
) for
x
y
0
1 / CX
2
for
x
< 0 -1 / (2TY
2
) for
x
y
< 0
F
22
=1 / TY
2
for
x
0 F
66
= 1 / SXY
2

1 / CY
2
for
x
< 0

2
66 12
2
22
2
11
2
xy y x y x
F F F F FI t o o o o + + + =

Does not automatically account for difference in tensile and
compressive strengths
FI SR / 1 =
1 = SR MoS
52
Hill Failure Criterion, 2
In MSC.Laminate Modeler the Hill Criteria is supplemented by a maximum
criterion for through-thickness shear loading causing matrix failure

SR
m
= 1 / FI
m

MoS
m
= SR
m
-1

The lower of the in-plane and through plane margins of safety is output.
(
=
SXZ
abs
SYZ
abs
max FI
xz
xy
m
) (
,
) (
t
t
53
Tsai-Wu Failure Criterion
Where:
F
1
= 1 / TX-1/CX F
22
= 1 / (TY CY)
F
2
= 1 / TY-1/CY F
12
= IXY / sqrt(TX CX TY CY)
F
11
= 1 / (TX CX) F
66
= 1 / SXY
2

IXY recommended = -0.5 (only important for multiaxial loading)

Where:

2
66 12
2
22
2
11 2 1
2
xy y x y x y x
F F F F F F FI t o o o o o o + + + + + =
a
a b b
SR
2
4
2
+ +
=
2
66 12
2
22
2
11
2
xy y x y x
F F F F a t o o o o + + + =
y x
F F b o o
2 1
+ =
1 = SR MoS

Accounts for different tensile and compressive strengths by
incorporating linear terms

54
Tsai-Wu Failure Criterion, 2
In MSC.Laminate Modeler the Tsai-Wu criteria is supplemented by a
maximum criterion for through-thickness shear loading causing matrix
failure

SR
m
= 1 / FI
m

MoS
m
= SR
m
- 1

The lower of the in-plane and through-thickness margins of safety is output

(
=
SXZ
abs
SYZ
abs
max FI
xz
xy
m
) (
,
) (
t
t
55
Comparison between Maximum and Tsai-Wu
o
y

o
x

TX
-CX
TY
-CY
Tsai-Wu
Maximum
56
Other Quadratic Failure Criteria
These are similar to Tsai-Wu criterion, except with different interaction
terms

HOFFMAN
F
12
= -0.5 / (TX CX)

HANKINSON
F
12
= 0.5 / (1 / (TX + CY) + 1 / (TY+CX) 1/ SXY
2
)

COWIN
F
12
= 1 / sqrt (TX CX TY CY) 0.5 / SXY
2

57
User-Defined Criteria
MSC.Laminate Modeler allows the user to define a custom failure
criterion

The user writes custom function (written in a PCL function) and selects
User failure criterion for calculation

The model could for example include microstructural failure models or
multiple sub-criteria models, each with a particular mechanism of failure

58
Strain-Based Criteria
All failure criteria can be based on strain rather than stress

Failure strain vary less than failure stress. Can make criteria more
stable

Allowables and results must use same measure of strain (I.E. Shear
strain allowables must be tensor shear strains and not engineering
shear strains)

59
User Interface, Patran
In the Materials menu in
Patran, set Input options to a
2d orthotropic material, change
the Constitutive Model to
Failure

60
User Interface, Patran
If a Failure Constitutive model is defined, MSC.Nastran would
automatically calculate the Failure Indices to the results file
The Failure information must be read into the Patran database through
an routine in Utilities, Results, Read MSC.N Failure Indices
61
User Interface, Laminate Modeler
In Laminate Modeler, Failure Calculation is
done in the Result menu...
Select output entities
Input Material allowables (see next slide)
Select Failure Criterion
Select Application Region (Surfaces or Elements)
Select the Proper Load and Subcases
62
User Interface, Laminate Modeler
NOTE:
If the constants are already entered in Patran, they will automatically
show up in Laminate Modeler as well!
63
Calculating Failure Criteria, Program Execution
Using Laminate Modeler, the Failure is done as post prosessing, based
on the solver results. This is a different approach compared to letting
the solver do the failure calculation as add-on simulation to the stress
and deflection calculation

This approch allows a quicker what-if study. In order to do a new
failure calculation, for example with a different criteria, it is not
neccesary to re-run the structural part of the analysis!

Failure Calculation can be done on user-specified local areas of the
model, there are no need to do an overall calculation

64
Perform Lesson 2, Failure Criteria for Flat Plate in your Exercise
Workbook and Lesson 3, Flatplate using Laminate Modeler

Exercise
65
6 MAKING PLIES WITH
LAMINATE MODELER

66
Particulars for Plies
Laminate material description of lay-up is only efficient for large, flat
structures
Composites are particularly effective when used to manufacture curved
surfaces, and most composite models involves curved surfaces
Fibre directions can change dramatically around a corner, requiring
multiple laminate materials (and element property regions)
Reinforcing patches dramatically increase number of laminate material
required

The conclusion to these four points is that the method presented up until
now has its severe restrictions, and is not practical to use for real world
applications!!!
The rest of this course will show how to better represent a laminate
material using the power of MSC.Laminate Modeler
67
Traditional simulation of Composite Structures
Calculation approach:
Lay-up definitions are done on an element-wise manner
Lamina directions are related to global coordinate axes and does not
follow surface curvatures

Results:
Changes are difficult to implement
Results difficult to interpret as present recovery is on the basis of
elements not lamina
Optimization difficult
Tedious work leads to simplifications and an inaccurate model
68
Example
A surface with 3 property sets...

69
Example, 2
..requires 6 property sets after one reinforcement ply

70
Example, 3
With more than limited curvature, several materials needs to be defined!
Model Ply #1 Ply #2
Thicknesses (4) Materials (5)
Properties ( 36)
71
Ply representation in MSC.Laminate Modeler
Build model on basis of plies, analogous to manufacturing situation
Rapid modification of lay-up possible, allowing optimisation

Conventional Laminate
Material Representation of
Lay-up
Laminate Modeler:
Descriptive Ply-based
Representation of Lay-up
72
Creating Ply Materials, User Input
In Laminate Modeler Material menu...
You have now made a ...
Enter additional properties, these are dependent on
sheet material construction
Select material (made in Patran material menu)
Enter the name of the material being made,
or keep the default
73
Creating Plies, Definitions
Application Region
Specifies the region on the model where the ply shall be applied

Application Direction
Specifies the surface normal of the undeformed flat ply.
This is default set as the view direction

Application Point
Specifies the point where application shall start

Reference Direction
Specifies the direction of the fibre.
If wanted, the ply fibre may be rotated
an angle relative to this direction,
called the Reference Angle
View Direction
Reference
Direction
Reference
Angle
Application Region
Application Point
74
Creating Plies, User Interface

In Laminate Modeler Ply menu
Enter Reference Direction for application method
Enter Ply orientation at starting point
Enter starting point of application
Enter Application Region (elements or surfaces)
Enter the name of the Ply being made
Enter Reference Angle for ply direction
75
Working procedure
The procedure explained is repeated until all plies are described,
remember that a ply may be used several times in the lay-up.

We might, though, want to return here later after running an analysis to
make new plies or alter the existing plies somewhat.

Now, the next step is to build a lay-up of the plies we have made
76
7 MAKING LAYUPS WITH
LAMINATE MODELER

77
Particulars for Lay-ups
Lay-ups are composed of a list of plies

The list is the chronological order in which plies are applied to the
model

Plies are applied from the direction used when creating the plies

Plies may be used repeatedly in a lay-up

78
Creating Lay-ups, User Interface
In Laminate Modeler Lay-up menu...

The Lay-up definition is done in four steps:
These four submenus will now be shown
4: Specify Tolerance for properties translation
3: Select Element Type
2: Defining Offset relative to the application
region
1: Build a Lay-up out of an existing set of plies
79
STEP 1: Lay-up, User Interface
The difference between
this lay-up builder tool and
the tools in Patran is that
here we have already
asigned thickness,
material and directions to
the ply
80
STEP 1: Lay-up, User Interface
Copy current definition below the bottom layer
Copy current definition
Make current definition symmetrical about the bottom layer
Make the current definition symmetrical

Cut
Copy
Paste
Paste Mirrored
Undo
81
STEP 2: Offset Definition and User Interface
MIDDLE
BOTTOM
TOP
Shell Surface
Offset Value
Shell Surface
Offset Value
Shell Surface
Offset Value
Default is Middle (no offset)

82
STEP 2: Offset Definition and User Interface
Offsets, when used correctly can improve the accuracy of your
analysis
When incorrectly used an offset can cause large reductions in
stiffness.
Understand the load paths
How are the bending moments from the offset reacted?
Do not fix offset elements in translation only

Do not use offsets when performing buckling analysis.
The differential stiffness calculations do not consider offsets and will
therefore be incorrect
Run analysis as non-linear?
83
STEP 3: Element Type, User Interface
Select either Standard or Revised Shell
Element Type.
It is recommended to use the standard
element, and this is the default.

84
Laminate Modeler has a default global
tolerance that is used by the program in
order to judge how many materials
property sets it needs to create in Patran.
If the user wants, he can change this
tolerance, or create local tolerance
requirements

STEP 4: Tolerance, Definition and User Interface
Global Region
Local
Region
85
Verifying Lay-up
The created lay-up could (and should) be verified
visually to see that it became what we wanted.
86
Translating from Ply to Laminate Material
When hitting Apply in the Lay-up menu, the Plies are automatically
converted to Laminate Material in the traditional sense

This is done automatically by MSC.Laminate Modeler when executing
an analysis
This is an internal program function, and is really what we want to avoid
doing manually
Actual description Apparent description
87
Translating from Ply to Laminate Material, 2
A minimum set of laminate materials is calculated to model the fibre
angles within the user-defined tolerances

If the tolerance is zero, there may be one laminate material per
element

A property set is made for every laminate material generated

A group is made for each ply containing its application region for
reference purposes

The user is informed about the number of materials and property
sets that are defined

88
Enhancing Lay-up Definition
Ply angles in Laminate modeler lay-ups are calculated from the
edge of the elements first 2 nodes. This is only one of the
methods for defining ply angles that exist within Nastran.
To use alternative definitions Laminate Modeller has the Create
Laminate menu. This menu allows ply angles to be defined
relative to a vector or a coordinate system projected onto the
element. Secondary Vectors or coordinates are used for the
elements which are nearly normal to the vector being used.
89
Create Laminate Form
Select element Type (Normally
2D_Stan.Lam for Nastran)
Select the method for defining the zero
degree direction

90
Verifying Laminate Material
It is possible to investigate the Laminate created in the
Lay-up process.
Different options in the Display Method, will give
different types of plot.
91
Verifying Laminate Material, 2
Display Method XY Plot shows either thickness and orientation of the
plies graphically.
92
Transforming results back to ply sort
When the analysis results are read into MSC.Patran the results are on
Laminate Material form. When these results are presented in
MSC.Patran, stresses pertaining to a single layer is shown - NOT
PLYWISE! It is not possible to gather information about how results are
in each of the plies.

So, we need to translate back to a plywise representation!
93
After linking the result file to MSC.Patran, the
results can be translated back to a ply-wise
representation - as shown to the left.
Note that this is not done automatically, but is
done at user request in Laminate Modeler.

Note that load case, subcase and layered
results must be chosen.
Transforming results back to ply sort, User Interface
94
Example, Model
A composite plate is reinforced
with two perpendicular strips
of material, as shown to the right.
It is clamped along the left edge
And two point loads acts on the free end.
The FE shell model is shown below.
95
Example, Model 2
Traditional Modelling
Two Materials and three layered Property sets are created in Patran. The
Property Sets are created on an element layer basics, and has no physical
Counterpart.

Laminate Modeler Modelling
One material and no properties are created in Patran.
Three plies are created with different directions and application regions in
Laminate Modeler. They are stacked to form a lay-up.
96
Example, Results
Traditional Results
Layer 1 Layer 2 Layer 3

Lamiante Modeler Results
Ply 1 Ply 2 Ply 3
97
Example, Modifications
Discussion
We now want to change the thickness of one of the reinforcement patches.
We also want to add another set of reinforcement patches on the bottom of
the plate.

What do we need to do in the two different approaches to solve this?
98
Perform Lesson 4, Making Plies and Lay-up on a Fairing
Component in your Exercise Workbook

Exercise
99
8 PLIES ON
DOUBLY CURVED
SURFACES

100
Composites on Curved Surfaces
Composites achieve maximum efficiency when used to
manufacture curved surfaces

For curved surfaces, the fibre orientations and flat pattern profiles
of a ply is not obvious

MSC.Laminate Modeler has extensive tools to simulate the
application of plies to flat, single curved and double curved
surfaces

101
Definition of Surface types
Flat surfaces
Orientation is a constant vector in space

Specifying a fibre orientation at one point of the surface gives a unique
solution for the fibre orientation at every point on the surface, and a
unique flat pattern

No shearing of material during application of plies and the flat pattern is
the same shape as the surface
102
Definition of Surface types, 2
Singly curved surfaces
Has one constant orientated vector, one variable

Specifying a fibre orientation at one point of the surface gives a unique
solution for the fibre orientation at every point on the surface, and a
unique flat pattern

No shearing of material during application of plies and the flat pattern is
the same shape as the surface
103
Definition of Surfaces types, 3
Doubly curved surfaces
Has two variable vectors in space

Can be covered by a fabric in an infinite number of ways.

Shearing happens when ply is drawn over the surface. The amount of
shearing is greatly dependent of the application starting point and fibre
direction.
104
Gaussian Curvature
A factor called the Gaussian Curvature, K, is used to describe the degree
and type of curvature on any surface.

The Gaussian Curvature is the product of the principal curvatures at that
point.

Z
2
1
1/k
1
1/k
2
105
Positive Gaussian Curvature
Dome-like surfaces have positive Gaussian curvature because the
principal curvatures have the same direction

Geodesic lines on the surface parallel at some point will tend to converge

106
Zero Gaussian Curvature
Cylindrical surfaces have Zero Gaussian curvature because there is
zero curvature in one direction.

Geodesic lines on the surface parallel at some point will remain parallel

107
Negative Gaussian Curvature
Saddle like surfaces have negative Gaussian curvature

Geodesic lines on the surface parallel at some point will tend to diverge
108
Visualization of Gaussian Curvature
Positive Gaussian
curvature:
Insufficient
material to form a
disc
Zero Gaussian
curvature:
Correct material
to form a disc

Negative Gaussian
curvature:
Excess material to
form a disc
We have draped a
disc/formed ply
onto a surface...
..and then
flattened it out
again
109
Applying the ply, Considerations
We need to tell how our ply material shears when drawn over a curved
surface. There are two different shear algorithms: Scissor and Slide.
This is a material-specific behaviour.

We need to tell how the ply is forced into contact with the surfaces. This
is called draping, and is a manufacturing method.

We need to give a starting point of fibre application on the surface, and
the initial fibre direction at this point.
110
Scissor Shear Algorithm
An originally square piece of material shears in a trellis like mode about
its vertical to form a rhombus

This simulates how woven fabric behaves

a
a
o
111
Slide Shear Algorithm
Two opposite sides of a square material element slide parallel to each
other while their separation remains constant

This simulates how unidirectional materials behaves

a o a
112
Shear Algorithm, User Interface
The Shear Algorithm is set when making the
material in Laminate Modeler.
Select either Scissor or Slide from the pull-down
menu

Shear builds up more rapidly using the slide draping
algorithm. This reflects actual manufacturing
experience that woven fabrics are more drapable
than unidirectional materials. Therefore the scissor
draping method is default.
For small deformations, predictions are identical.

113
Draping Algorithms
Selects the way that material is draped on surface at a macroscopic
level.

Different algorithms on a doubly curved surface give different results.

Remember there is no unique drape for a ply!

Draping starts by defining two perpendicular axis with zero shear on the
draped area, it then proceeds by extension.
114
Geodesic lines are drawn from the start point, one being parallel to the
referenced angle of the application direction

This method can be unsuitable for highly curved surfaces and corners.
This is the default axis type
Geodesic Axis
View
Direction
Principal
Axes
Application
Direction
Reference
Angle
115
Planar Axis
Two planes are drawn that are perpendicular to each other and to the
draped surface at the application point. One of the planes is collinear with
the application direction. The principal axes are defined as the intersection
of the two planes and the surface, and have zero shear.

This method is appropriate for symmetrical surfaces
View
Direction
Principal
Planes
Application
Direction
Reference
Angle
116
No Axis
Fabric grows from start point and outwards by extension only, without the
use of geodesic lines

117
Energy Extension
Fabric grows from start point in a direction which minimizes the
instantaneous strain deformation energy

This method is suited for highly-curved, deep-drawn surface - but
draping is less well controlled than previous methods

118
Angle Extension
Fabric grows from start point in a direction which minimizes the
instantaneous shear angle

119
Draping Algorithm, User Interface
The menu for selecting the
appropriate Draping Algorithm is
situated in the Laminate Modeler Ply
menu, under Additional controls,
Geometry
Select Axis Type
Select Extension Type
120
Projecting and Painting
We can chose to project or paint the ply onto the surface.
This is totally different from draping.

Painting is only valid for isotropic materials. For composites it might
be honeycomb or paint.

Projecting is done in one of two ways, either project by an axis or by a
plane. It is not true draping and is similar to methods used in Patran.
121
Axis Projecting Algorithm
A Global axis is projected normally onto the element at the first node.
This axis is then rotated an angle o in the counter-clockwise direction
from the viewing point. (Note that o is generally not equal to u)

Select from three guiding axis:
X-axis
Y-axis
Z-axis
x
z
y
o
u
Parallel X-axis
Projected X-axis
122
Plane Projecting Algorithm, 2
The material angle is parallel to the intersection of a certain plane with the
first edge of the element.

Select from three different plane definitions:
Plane X-axis: Plane through the Z-axis rotated an angle o from the X-axis
Plane Y-axis: Plane through the X-axis rotated an angle o from the Y-axis
Plane Z-axis: Plane through the Y-axis rotated an angle o from the Z-axis
x
z
o
123
Projection and Painting, User Interface
The menu for selecting the Projection or Paint
Algorithm is situated in the Laminate Modeler
Ply menu

If Projection is chosen, the projection method
must be chosen here
124
Plies - OVERVIEW
Where in UI

Type Scissor Slide Project LM_Material
menu

Method Geodesic Geodesic Axis LM_Ply
Planar Energy Plane menu
Energy Maximum
Maximum
None
125
The resulting ply pattern is viewed on-screen with colour coding for the
degree of shear angle. The shear angle spectrum values are default 0-5
for red, 5-10 for green, and so on. (The values are really just fractions of
the Maximum Strain (Degrees) value defined for the material).

If shear is excessive, try
Reducing the coverage area
Moving the starting point

This is the time you start using the Laminate modeler interactively to figure
out how to drape your model with the best possible result!
Visualization of Ply Pattern Result
126
The numeric extremes are shown in the upper
left corner.

The resulting shear in the
ply is colour coded on the model

Visualization of Ply Pattern Result
127
Ply Menu Toggle ON/OFF Display Icons
Reference and Application Direction vectors
Boundary Visualisation (explained later)
Outline (debugging tool, not intended for customer use)
Draped Pattern
Flat Pattern
Maximum strain and shear values etc in number form
Visualisation of the element by element fibre directions
Materials
Close Draped Pattern
128
Perform Lesson 5, Draping a doubly curved surface in your Exercise
Workbook

Exercise
129
9 INTRODUCING SPLITS
IN THE PLIES

130
Curved Composites Particulars
We have seen that fabric must shear to cover a doubly-curved surface
The amount of shear distortion increases with the degree of double
curvature and the area covered
The amount of shear is dependent on the starting point and initial fibre
orientation

The material can shear up to a point at which the warp and weft fibers lock
The point at which locking occurs varies with material and type of weave. A
highly drapable material allows a large shear before locking. High shear
during draping will lead to problems like wrinkling. In practice a laminator
will introduce a cut in the material to remove excess material.

Laminate Modeler introduces splits in exactly the same way
131
Creating Splits, User Interface
The menu for introducing cuts is situated in the
Laminate Modeler Ply menu, under Additional
Controls, Control Parameter Boundaries
Preview the Split on the model to check whether
you got it right. The splits show up on both the
model and the flat pattern
Select Split location. Application
region either elements or geometry
132
Creating Splits, Example

The quarter section is by one ply, starting in the middle of the lower
edge. The resulting shear is massive and totally unacceptable.

133

By introducing two cuts, as shown below to the left, the resulting drape is
much better (but could still need some more cuts in it).
134

By comparing the flat patterns, we can see that excess material is
removed by introducing the splits. Without the splits, this excess material
must be distributed by shearing the ply.
135
Creating Splits, Conclusion

We have seen that:
Splits reduce shear in doubly curved plies
Splits makes any surface drapable

The best location for the splits is greatly dependent on the ply settings and
the surface to be draped.

You need to alter the different settings in order to create an acceptable ply.
These settings can be difficult to identify on beforehand. You need to play
around interactively in order to do this. Ask your laminator what he would
do!

MSC.Laminate Modeler is a tool that enables you to do this!
136
Possible Draping Problems
Sharp corners
Use split

Holes in Surfaces
The holes must be meshed, but does not need to have an property
assigned. Laminate Modeler will automatically detect these dummy
elements.
137
Possible Draping Problems, 2
Incomplete boundary definition
Define artificial boundaries using split

T-Sections
Watch the element selection and surface normals
138
Pattern does not cover entire application region
Increase step lengths (step length is distance between lines and can either
be in physical units (explicit) or multiples of Laminate Modelers best
estimate step length (implicit))
139
An error and message file is created called <filename>.lm_msg.
Investigate this file for further details. View it interactively as shown below.
140
Perform Lesson 6, Draping with Splits in your Exercise Workbook

Exercise
141
10 MODELLING
TECHNIQUES FOR
SANDWICH PANELS

142
Sandwich Panel Design
In order to increase bending and shear stiffness panels are often
constructed using face-skins bonded onto honeycomb or foam
core.
Face-skins provide most strength and stiffness
Core gives sufficient strength and stiffness to hold face-skins apart
Core is usually very thick in comparison with face-skins

Does a sandwich panel obey the assumptions for classical
laminate theory?
How thick is the sandwich relative to the smallest dimension of the
panel?
Is shear deflection important?
143
Modelling core as a ply in a lay-up
This is the simplest way to model
a sandwich.
Shear behaviour is not accurately
defined.
Design may be insensitive to core
properties
In Nastran stress and strain
results are only given mid-ply.
If stresses at top and bottom of
core are needed, put in a thin ply
of core on either side of the main
core ply
Core Ply
Core Ply
Core Plies for stress recovery
144
Modelling Core With Solids
Gives better shear prediction
Gives better modelling of corners
Outside face skin has more
material than inside faceskin
Doubles the number of nodes in
model
Use a 3D orthotropic material for
core if it has different shear
stiffness in 2 directions.

Solid Core
Element
Shell Elements
For Face-skins
145
Perform Lesson 7, Modelling Honeycomb in your Exercise Workbook

Exercise
146
11 IMPORTING PLIES AND
MODELS

147
Importing Plies Onto A New Mesh
Laminate Modeler stores a definition of the
mesh in the Lay-up File and uses this to
create the properties on each element.
If you change your mesh then the lay-up file
becomes invalid.
How can we salvage the lay-up file?

Laminate Modeler projects the draping
results from one mesh onto the new mesh.
This causes approximation and quantum
effects in the new lay-up. A ply with a
straight edge may become one with a jagged
edge.
The Angle and Distance tolerances control
how far or rotated the new element has to be
relative to the original for LM to map the ply.

148
Extracting A Model From A Lay-up File
Opening a new database and then opening an existing file gives the
following error
We can continue using the 2
nd
option and import the model into a clean
database

149
Extracting A Model From A Lay-up File

In Laminate Modeler go to Import/Model/File
Select Mesh to import nodes and elements
Select group if you want a group made of
the imported elements
Select Materials to import materials

150
Perform Lesson 8, Importing Lay-up Files in your Exercise Workbook

Exercise
151
12 MANUFACTURING
INTEGRATION

152
Integration Overview
On-screen visualisation of the draping results
Export draped pattern
Export flat pattern
Export mould surface
General analysis data

Simulation is rapid, so results can be used to alter ply specification
immediately
You need an integrated process to be efficient in your work.
MSC.Laminate Modeler provides several outputs to aid the design and
manufacturing process:
153
Export of Draped Pattern Surface
Import it into a CAD system to form a record of fibre orientations
Used it in a ply-book as a manufacturing aid
Use it to project or mark onto mould tools to facilitate initial placement
and subsequent forming
The draped pattern can be exported in IGES and DXF formats.
You can then...
154
Export of Flat Pattern Surface
Plot it on paper to use as guideline for manual cutting using scissors or
a knife
Export it to a CAM system to create plies automatically
The flat pattern can also be exported in IGES and DXF formats
You can then...
155
Export of Flat Pattern Surface, 2
There is an significant time saving compared with conventional experiment
method of flat pattern generation:

Average part has 50 plies
Flat pattern generated manually using paper, manually digitised
2 man-days per ply
100 man-days per component
At USD 50/hour, labour cost is USD 40000
Target is 15 minutes/ply
At USD 50/hour, labour cost is less than USD 1000
Some components have 600 plies or more.
156
Export of Mould Surfaces
The mould Surfaces are created based on the lay-up of plies. The
routine creates both the top and bottom mould surfaces.

The surfaces are faceted, each facet is generated based on element
faces
157
Export, User Interface
Information about the plies, flat
patterns and draped patterns can
be exported when creating a Ply
Book
A Ply Book is a set of reference
for what has been modelled. It
can be used both by designers
and lay-up workers
The Ply Book is on Postscript
format
The ply shapes are exported as
separate files

158
Export, User Interface 2
The mould shape could be exported, as
shown to the left.
This must be done prior to making the lay-up.
Alternatively the option can be enabled and
the lay-up can be re-created or modified with
no actual changes.

159
Fabric Thickening
When material shears, the fabric typically thickens

This is calculated on the basis of constant volume

Changes fibre volume fraction in standard closed moulds, causing
fibre breakage or resin starvation

The Amount of Fabric Thickening is stated after a ply is made

Fabric thickening is taken into account when making the mould
surfaces

160
Springback Analysis
A common problem in the composites industry is the high cure
temperatures

Thermal effects have two sources. Firstly the mould tool will expand
when heated so there may be an overall increase in component size.
When cooling to room temperature, the component also experiences
deformation due to the anisotropic thermal expansion properties of the
composite material.

The solution to this is to compensate for the springback in the mould
surface shape. This can avoid having costly tooling mistakes or
needing to have adjustable mould tools.

MSC.Laminate Modeler is capable of doing springback analysis in
order to make a compensated tool.
161
Anisotropic Thermal Properties
The governing equation when incorporating thermal effects in an
orthotropic material looks like:

T is the current temperature, T
REF
the reference temperature.
The thermal expansion coefficients are o
1
, o
2
and o
3

(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(

=
|
|
|
|
|
|
|
|
.
|
\
|

|
|
|
|
|
|
|
|
.
|
\
|
|
|
|
|
|
|
|
|
.
|
\
|
zx
yz
xy
z
y
x
REF
zx
yz
xy
z
y
x
G
S
G
G
E
E
v
E
E
v
E
v
E
T T
t
t
t
o
o
o
o
o
o
c
c
c
31
23
12
3
2
23
2
1
13
1
12
1
3
2
1
1
0
1
0 0
1
0 0 0
1
0 0 0
1
0 0 0
1
) (
0
0
0
162
Springback Analysis Procedure
Springback analysis is performed as a linear statics thermal run
on the nominal model shape
Reference temperature set to the cure temperature
Component temperature set to ambient. (20 C)

Displacements from the analysis are the component springback
Subtract displacements from model to give compensated mould shape

To compensate for mould expansion scale model by
( ) ( )
ambient cure
T T o 1
163
Perform Lesson 9, Springback analysis of an jet engine cowling
in your Exercise Workbook

Exercise
164
APPENDIX A
HINTS AND TIPS

165
Think of how the item will be laminated
Think of how you want to change design and understand
consequences on Laminate Modeler
Dont change the mesh after you start a lay-up file - but remember
to equivalence the nodes!
Be consistent with application direction
Use multiple lay-up files rather than trying to get everything into one
Plan your work
166
Use session files to record all the inputs
Create a library of materials in a session file
Use geometric entities as application regions rather than FEM
entities
Use of Session files
167
Try new features on small test models
Check your solver output-files for warnings and error messages

Tell MSC of any problems or bits you want added to make your life
easier!
Miscellaneous
168
APPENDIX B
LAMINATE DEFINITION
IN NASTRAN

169
MSC.Patran MSC.Nastran

LAMINA MATERIAL
Isotropic MAT1/2/8
2D Orthotropic
2D Anisotropic

Laminate Material
Lamina Material PCOMP
Thickness
Orientation

Property Material
Laminate Material PCOMP
Orientation

Elements QUAD4/8, TRI3/6
170
PCOMP PROPERTY CARD
$1------$2------$3------$4------$5------$6------$7------$8------$9------$10-----
PCOMP PID Z0 NSM SB FT TREF GE LAM +AM1
+AM1 MID1 T1 THETA1 SOUT1 MID2 T2 THETA2 SOUT2 +AM2
+AM2 MID3 T3 THETA3 SOUT3 ..ETC
1/2 line per ply definition
PID Property ID
Z0 Offset from grid points to first ply (default -1/2 element thickness)
NSM Non-Structural Mass
SB Allowable inter-laminar shear
FT Failure Theory, Hill, Hoffman, Tsai-Wu, max strain
TREF Reference temperature. (Overrules MATi TREF)
GE Element damping coefficient
LAM SYM indicates only 1/2 plies defined and symmetry is used
MIDi, Ti, THETAi Material, thickness and angle of ply
SOUTi YES gives stress output at this ply
171
2D ORTHOTROPIC MATERIALS IN NASTRAN
$1------$2------$3------$4------$5------$6------$7------$8------$9------$10-----
MAT8 MID E1 E2 NU12 G12 G1Z G2Z RHO +AM1
+AM1 A1 A2 TREF Xt Xc Yt Yc S +AM2
+AM2 GE F12 STRN
MID Material ID
E1,E2 Modulus of Elasticity Along and Across Fibres
NU12 Poisson's Ratio (c2/ c1 for load in direction 1)
G12 In-plane shear modulus
G1Z Shear modulus in 1-Z plane
G2Z Shear modulus in 2-Z plane
RHO Density
A1,A2 Coefficient of thermal expansion in 1 and 2 directions
TREF Ignored for pcomp entry
Xt,Xc,Yt,Yc Tensile and compressive strengths in 1 and 2 directions
S Shear strength
GE Ignored for pcomp entry
F12 Failure theory interaction term
STRN Set to 1.0 if Xt, Xc, Yt, Yc and S are strains instead of stresses
172
COMPOSITE OUTPUT FROM NASTRAN
PARAM, NOCOMPS,-1
EQUIVALENT HOMOGENEOUS STRESSES OUTPUT
PARAM, NOCOMPS, 1
PLY STRESSES AND FAILURE INDICES OUTPUT
MATERIAL ALLOWABLES NEEDED FOR FAILURE INDEX OUTPUT
PARAM, NOCOMPS, 0
BOTH HOMOGENEOUS AND PLY OUTPUT GIVEN

173
APPENDIX C
OPTIMISATION OF
COMPOSITES IN NASTRAN

174
Composite Optimization
What can optimisation do?
Design improvement
Making Infeasible designs work
Correlation with test
Identify sensitive design areas

NOTE: Optimization of composites is not supported in either pre or
post in Patran or Laminate Modeler. It is only possible through
manual editing of the Nastran input file. Optimization is not feasibly
possible for curved plies that have multiple of materials and properties
assigned to them, since these cannot be changed individually.
175
Design Model and Analysis Model
Nastran optimisation uses a standard Nastran model which is called the
analysis model.
In addition a design model is created to specify how the optimisation will
run. This consists of:

Design variables (Thicknesses, ply angles, etc)

Design responses (Mass, stress, displacement etc)

Design objective (One design response which can be minimised or
maximised. Commonly minimise mass)

Design constraints (Limits which design variables or responses must
stay within)
176
Composite Optimization Techniques
Problems
Varying number of plies is currently not possible. Nastran V2001 will
be able to! (Using discrete property optimisation)
Varying ply angles can result in instability in the optimisation routines
due to low sensitivity.

Solution
Model with plies at different angles and make thickness of each ply a
design variable.
Use the thickness of each ply to decide on physically how many plies
will be needed at each angle.

177
OPTIMISATION EXAMPLE
1323 Nodes, 1392 Elements
21 property Entries
84 Design Variables
Minimise Mass
Static Pressure Loading
Constraint on failure Indices

Zo must be defined as a
secondary design variable using
an equation otherwise optimiser
will not work.
178
OPTIMISATION EXAMPLE
0,00
100,00
200,00
300,00
400,00
500,00
600,00
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Design Cycle
M
a
s
s
-0,20
0,00
0,20
0,40
0,60
0,80
1,00
1,20
1,40
1,60
0 5 10 15 20 25 30 35 40 45
Design cycle
C
o
n
s
t
r
a
i
n
t

V
a
l
u
e
0,00E+00
2,00E-01
4,00E-01
6,00E-01
8,00E-01
1,00E+00
1,20E+00
0 5 10 15 20 25 30 35 40 45 50
Design Cycle
T
h
i
c
k
n
e
s
s
179
FAILURE INDEX RESULTS
Initial Design Final Design
Mass: 500 Mass: 200
Max failure index: 0.246 Max failure index: 0.987
180
APPENDIX D
Laminate Modeler 2001
NEW FEATURES

181
Product Enhancements And New Features, V2001
Ability to create solid elements from an existing lay-up
Modified anisotropic properties for sheared materials
Modifications to ply shear display
Enhancements to Ply-book creation
Enhancements to show LM_layup
Transform LM_layup Mirror
Import/Export information into LAP
182
APPENDIX E
MISC. SOLVER RELATED
ITEMS

183
Specifics using the MARC solver and LM
Supported Element Types are:

Type 22 is a second order quadrilateral element
Type 75 is a first order quadrilateral element
Type 72 is a second order quadrilateral element
Types 49 and 50 are second order triangular elements
184
Specifics using the DYTRAN solver and LM
185
Specifics using the ABAQUS solver and LM
Offsets does not work in the LM user interface
Failure Calculation is ON pr. default
Three results are requested : Top, Middle and Bottom
Results pr. ply is ON pr. default

186
Specifics using the ABAQUS solver and LM
187
Specifics using the ANSYS solver and LM
188
APPENDIX F
Basic Composite
Production Methods

189
Background
This Appendix is not intended to be a complete discussion of
composite manufacturing, but a brief description of the typical
procedure for a hand-made high quality component.
Alternative manufacturing methods include
Filament winding
Resin Transfer Moulding (RTM)

190
Mould Tool Production
Moulds can be made from a variety of materials
Epoxy resin blocks
Reinforced composite
Wood
Plaster
Graphite Blocks
Metal
Mould tool treated with release coating to stop
component sticking
191
Composite Lay-up
Individual plies of material added onto mould
If a lot of plies are added the material is consolidated using
a vacuum
192
Vacuum Consolidation
A layer of peel ply is applied over the component to prevent it
sticking to the vacuum bagging. Peel ply may be a glass cloth
coated with PTFE.
Sometimes a layer of bleeder cloth is put over the peel ply to
soak up excess resin
An impervious sheet or vacuum bag is applied over everything
and sealed around the edges. A vacuum is achieved by sucking
the air out through a port. This
Vacuum Port
Bleeder
Peel ply
Vacuum Bag
193
Curing
Moulded component is now cured in an oven or autoclave (under
pressure)
After curing, vacuum bagging materials are removed and
component is removed from mould. (Hopefully not with a chisel!)

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