WORKSHOP 4 MAKING PLIES AND LAYUP FOR A FAIRING COMPONENT WS4-1 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation

WS4-2 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation

WS4-3 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Problem Description This workshop is mainly about creating plies/lamina on a set of surfaces. The creation of the first part of the model involves reading two MSC.Patran session files, then creating displacement constraints and pressure loading. In the MSC.Laminate Modeler a material property is to be created. Then, 10 plies/lamina are to be created. Some of them are draped on the under-side of surfaces, and others are draped on the top- side of surfaces. Doing this workshop will help develop the ability to understand such terms as application region(select area), start point, application direction, reference direction, and reference angle, all terms used during the creation of plies. The 10 plies are to be used to create a single layup. Using the sequence of selecting plies and ply application direction, experience will be gained stacking plies. Finally, after completing an MSC.Nastran analysis, the stress results will be viewed before and after processing the data with MSC.Laminate Modeler to create ply-wise stress data.

WS4-4 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Suggested Exercise Steps: 1. Create a new database. 2. Create the geometry and FEs by reading session file 3. Create displacement constraints at nodes 4. Create pressure loading. 5. Create 2D orthotropic material properties using session file 6. Create a new MSC.Laminate Modeler layup file 7. Create an MSC.Laminate Modeler material 8. Create plies using MSC.Laminate Modeler 9. Define MSC.Laminate Modeler layup by stacking all piles 10. Check the plies using MSC.Laminate Modeler 11. Check the layup using MSC.Laminate Modeler 12. Run the analysis and access results 13. Display results in MSC.Patran 14. Postprocess the ply stress using MSC.Laminate Modeler 15. Postprocess the ply stress under Results 16. Optional exercise material

WS4-5 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a b c Create a new database. a.File / New. b.Enter fairing as the file name. c.Click OK. d.Click OK. Step 1. Create a New Database d

WS4-6 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Step 2. Create the Geometry and FEs by Reading Session File Read(play) the session file. a.File / Session. b.Click Play. c.Select fairing_geom.ses as the File name. d.Click -Apply-. (This action will cause the session file to be read; all the PCL commands will be executed. Please do not interrupt it.) d c b a

WS4-7 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Apply boundary conditions. a.Loads/BCs : Create / Displacement / Nodal. b.Enter Bottom_of_leg as the New Set Name. c.Click Input Data. d.Enter for the Translations. e.Click OK. f.Click Select Application Region. Step 3. Create Displacement Constraints at Nodes a b c f e d

WS4-8 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Select Curve or Edge icon. b.Select edge Surface 7.3. c.Click Add. d.Click OK. e.Click –Apply-. a c b d e Step 3. Create Displacement Constraints at Nodes (Cont.) b

WS4-9 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Enter Top_of_leg as the New Set Name. b.Click Input Data. c.Enter for the Translations. d.Click OK. e.Click Select Application Region. a b e d c Step 3. Create Displacement Constraints at Nodes (Cont.)

WS4-10 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Select Curve or Edge icon. b.Select Surface 7.1. c.Click Add. d.Click OK. e.Click –Apply-. c b d e a Step 3. Create Displacement Constraints at Nodes (Cont.) b

WS4-11 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Step 4. Create Pressure Loading Apply pressure load. a.Loads/BCs : Create / Pressure / Element Uniform. b.Enter Top_pressure as the New Set Name. c.Select 2D as the Target Element Type. d.Click Input Data. e.Enter 0.1 for the Top Surf Pressure. f.Click OK. g.Click Select Application Region. a b c d e f g

WS4-12 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Select Surface or Face icon. b.Select Surface 1:6 (hold down the Shift key to select all 6 surfaces on the top). c.Click Add. d.Click OK. e.Click –Apply-. c b d e Step 4. Create Pressure Loading (Cont.) a b

WS4-13 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation The model should look like this. Step 4. Create Pressure Loading (Cont.)

WS4-14 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Step 5. Create 2D Orthotropic Material Properties Using Session File c b a Generate 2D orthotropic material properties, to be used to create ply material properties. They are created by reading a session file into MSC.Patran. a.File / Session. b.Click Play. c.Select materials.ses as the File name. d.Click -Apply-. (This action will read the session file. Please do not interrupt it.) d

WS4-15 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Tools / Laminate Modeler / Layup/Laminate. b.Click New Layup File. c.Enter fairing as the file name. d.Click OK. b a Step 6. Create a New MSC.Laminate Modeler Layup File c d

WS4-16 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Create / LM_Material / Add. b.Select ud_t300_n5208 as the Analysis Material. c.Enter 0.25 for the Thickness. d.Click –Apply-. a d b c Step 7. Create an MSC.Laminate Modeler Material

WS4-17 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Step 7. Create an MSC.Laminate Modeler Material (Cont.) Before creating the plies, display the labels for the surfaces and points.

WS4-18 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Step 8. Create Plies Using MSC.Laminate Modeler b c d f h a j e Use the laminate modeler and the laminate modeler material to create the plies. a.Laminate Modeler : Create / LM_Ply / Add. b.Select Mat_1 as the LM_Material. c.Enter Surface as the Select Area. d.Enter Point 1 as the Start Point. e.Enter – in front of the Application Direction vector(*). f.Click in Reference Direction box g.Select Tip and base points icon. h.Select Point 1 and Point 2 for the Reference Direction. i.Enter 0 for the Reference Angle. j.Click –Apply-. g * By adding a negative sign in front of the vector its direction is reversed, hence it is on the underside of the surface, as shown. The ply is applied to the underside of the surface. i

WS4-19 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Enter 45 for the Reference Angle. b.Click –Apply-. c.Remove the contents of the Application Direction input data box (*) d.Enter Surface as the Select Area. e.Enter Point 2 as the Start Point. f.Enter – in front of the Application Direction vector. g.Enter 0 for the Reference Angle. h.Click –Apply-. i.Enter 45 for the Reference Angle. j.Click –Apply-. * Having the vector entered automatically will only occur if the Application Direction box is empty before selecting the Starting Point. a b e f g h i d c j Step 8. Create Plies Using MSC.Laminate Modeler (Cont.) For the second ply use the same input as for the first ply, except change the reference angle to 45 degrees. For the fourth ply use the same input as for the third ply, except change the reference angle to 45 degrees.

WS4-20 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Make sure that the Application Direction vector is pointing upward. If not, check to see if there is a negative sign in front of the vector. Ply 2Ply 3 Ply 4 Step 8. Create Plies Using MSC.Laminate Modeler (Cont.)

WS4-21 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Plies 1 through 4 have been draped across the bottom of the T shape. The next plies need to be added to the top. Remember the layup sequence is used with the ply application direction to give the stack of material. The layup is created by MSC.Laminate Modeler the same way a physical layup is created. It would be difficult to do this as a single cure component. The next plies are to be applied to the top of the T. Use the same reference direction, and make sure the application direction is correct Step 8. Create Plies Using MSC.Laminate Modeler (Cont.)

WS4-22 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Remove the contents of the Application Direction input data box b.Enter Surface as the Select Area. c.Enter Point 1 as the Start Point. d.Enter 0 for the Reference Angle. e.Click –Apply-. f.Enter 45 for the Reference Angle. g.Click –Apply-. c a d e b f g Step 8. Create Plies Using MSC.Laminate Modeler (Cont.) For the sixth ply use the same input as for the fifth ply, except change the reference angle to 45 degrees.

WS4-23 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Remove the contents of the Application Direction input data box b.Enter Surface as the Select Area. c.Enter point 4 as the Start Point. d.Click in Reference Direction input box. e.Select Tip and base points icon. f.Select Point 4 and Point 6 for the Reference Direction. g.Enter 0 for the Reference Angle. h.Click –Apply-. c a g h b d Notice that point of application is now at Point 4 Step 8. Create Plies Using MSC.Laminate Modeler (Cont.) e f Ply 7

WS4-24 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a b a.Enter 45 for the Reference Angle. b.Click –Apply-. Step 8. Create Plies Using MSC.Laminate Modeler (Cont.) For the eight ply use the same input as for the seventh ply, except change the reference angle to 45 degrees.

WS4-25 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Notice that point of application is now at Point 5 a.Remove the contents of the Application Direction input data box b.Enter Surface 3 5 as the Select Area. c.Enter Point 5 as the Start Point. d.Click in Reference Direction input data box. e.Select Tip and base points icon. f.Select Point 5 and Point 7 for the Reference Direction. g.Enter 0 for the Reference Angle. h.Click –Apply-. c a g h b d Step 8. Create Plies Using MSC.Laminate Modeler (Cont.) e f

WS4-26 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Enter 45 for the Reference Angle. b.Click –Apply-. a b Ply 10 Step 8. Create Plies Using MSC.Laminate Modeler (Cont.) For the tenth ply use the same input as for the ninth ply, except change the reference angle to 45 degrees.

WS4-27 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Create the layup. Define the layup by stacking piles 1 through 10. a.Laminate Modeler : Create / LM_Layup / Add. b.Click Layup Definition. c.Select Ply 1 through 10 in order. d.Click OK. e.Click –Apply-. f.Click OK to accept. Step 9. Define MSC.Laminate Modeler Layup by Stacking all Piles b c a Use no offset, standard element type, and default tolerance. e d

WS4-28 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Step 10. Check the Plies Using MSC.Laminate Modeler Check the plies (fiber direction and application region) using the Laminate Modeler. a.Laminate Modeler : Show / LM_Ply / Graphics. b.Select Ply_10. c.Click –Apply-. Select other plies to check the fiber direction and application region. a b c

WS4-29 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Ply 1 Ply 9 Ply 7 Ply 4 Click Reset Graphics after viewing Step 10. Check the Plies Using MSC.Laminate Modeler (Cont.)

WS4-30 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Show / LM_Layup / Exploded View. b.Select fairing 1 through 10. c.Click –Apply-. d.Click Reset Graphics. b c d a One ply(fairing) can be viewed at a time. Step 11. Check the Layup Using MSC.Laminate Modeler

WS4-31 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Analyze the problem and retrieve the results. a.Analysis : Analyze / Entire Model / Full Run. b.Click Subcases. Step 12. Run the Analysis and Access Results a b

WS4-32 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation b a.Select Default from Available Subcases. b.Click Output Requests. c.Select STRESS from Output Requests. d.Select Ply Stresses e.Click OK. f.Click Apply. g.Click Cancel. f a g Step 12. Run the Analysis and Access Results (Cont.) c d

WS4-33 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Click Apply. b.Access Results / Attach XDB / Result Entities. c.Click Select Results File. d.Select faring.xdb. e.Click OK. f.Click Apply. a b c d e f Step 12. Run the Analysis and Access Results (Cont.)

WS4-34 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Step 13. Display Results in MSC.Patran Postprocess the layer results. a.Results : Create / Quick Plot. b.Select Stress Tensor. c.Select Displacements, Translational. d.Click Apply. a c b d This has no physical counterpart! We do not have any layer of composite that corresponds to what we are able to postprocess! We might be able to get some layers identical to plies, but that is purely by coincidence. In our case layers 5 to 8 correspond to physical plies. This is unusual for anything other than a simple model like this.

WS4-35 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a.Create / Results / LM_Ply Sort. b.Select SC1:DEFAULT, A1:Static Subcase. c.Select Stress Tensor. d.Click –Apply-. b a c d MSC.Laminate Modeler re-sorts the results to be ply-wise. If the results are in an.XDB file, the ply results are created as a new result case. If the results are in an old.OP2 format file, the ply results are created as a new result in the existing result case. Step 14. Postprocess the Ply Stress Using MSC.Laminate Modeler

WS4-36 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation a a.Results : Create / Quick Plot. b.Select SC1:DEFAULT, a2:Static Subcase. c.Select LM_Sort, All Global Plies, MSCNASTRAN. d.Click Apply. b c d The stress results should look like that shown above. The plot that has a physical meaning. Without the capability of MSC.Laminate Modeler, the composite results cannot be fully post-processed. The position (at faring i (ply i)) can be set to see the different results. Fairing(ply) 1 Step 15. Postprocess the Ply Stress Under Results

WS4-37 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation Step 16. Optional Exercise Material In the Layup menu, change the Tolerance Definition to 20 degrees and re-create the layup. Notice that Laminate Modeler now creates significantly fewer property regions and laminate materials. This is however at the cost of accuracy. MSC.Nastran run times will not be affected significently. If you have any difficulty with this exercise, examine or play the session file fairing.ses after opening a new database. Please do not hesitate to ask for help if you have any questions!

WS4-38 PAT325, Workshop 4, February 2004 Copyright 2004 MSC.Software Corporation