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White Paper: An Efficient Workflow for Composite Design & Analysis Using LAP, CoDA & Laminate Tools with HyperMesh

The task is to define optimal composite material and laminate property data, using HyperMesh in combination with Anaglyph’s composites design and analysis software tools.

White Paper: Manufacturing Chain Modeling with Virfac® Using HyperMesh

Running simulations before production is often a credo for many industries using manufacturing processes like welding, machining, heat treatment, etc. Virfac®, which stands for Virtual Factory, is the perfect tool to predict, anticipate and optimize the thermal & mechanical behavior of the workpiece along the entire manufacturing chain. Please see hereafter a three-step chaining process, using a HyperMesh mesh, starting with a “T-joint” welding, followed by a machining process, and finally ends with a heat treatment.

Multi-physics Electric Motor Optimization for Noise Reduction

In an electric machine, the torque is generated by electromagnetic forces which also create some parasitic vibrations of the stator. These vibrations excite the mechanical structure on which the motor is fixed and generate sound. When designing the electric machine, this aspect has to be taken into account from the start since it depends on the harmonic content of the currents that feed the machine, on the shapes of the rotor and stator, and on the interaction of the electric frequencies with the natural mechanical modes of the structure. To simulate this phenomenon, a coupling between electromagnetic calculations and vibration analysis has to be set-up. Some optimization procedure can also be added in order to reduce the noise. In what follows, it is shown how Altair HyperWorks suite; specifically FluxTM, OptiStruct®, HyperMesh® and HyperStudy® products have been successfully used to perform a multi-physics optimization for noise reduction in a fuel pump permanent magnet motor.

White Paper: Optimizing Strain Gauge Placement with LW Finder & HyperMesh

This white paper demonstrates how to find the optimal locations to place strain gauges on a casted bracket in order to accurately measure loads.

Installation Guide: nanoFluidX 2.09

Brief installation instructions.

OptiStruct for Structural Analysis: Not Just for Optimizations Anymore

Reprint of Engineering.com article on OptiStruct as a structural analysis tool with built-in optimization capabilities

Tutorial: HW & Anaglyph Laminate Tools Integration

This document provides step-by-step instructions on how to use Anaglyph Laminate Tools within HyperWorks.

White Paper: One Source Solution for Short-Fiber Reinforced Materials in FEA

With use of today’s technology, FE simulation of the injection molding process is state of the art. Several unique solvers are available for this purpose. However, an appropriate coupling between the injection molding simulation and the mechanical simulation is required.

White Paper: Minimization of Forming Load of Gear Driver Forging Process with AFDEX and HyperStudy

In this paper, a workflow is presented that integrates the functionalities of a metal forming simulation software, AFDEX and a multidisciplinary optimization software, HyperStudy. Using this approach, the forming load of a gear driver used in an automotive transmission is minimized and two die design parameters are optimized.

Whitepaper: A Design-Validation-Production Workflow for Aerospace Additive Manufacturing

Additive manufacturing coupled with topology optimization allows the design-and-analysis and manufacturing iterations to be reduced significantly, or even eliminated. To ensure that the part will perform as simulated, a mid-stage validation is conducted on a standardized part before creating the final products.

Global-Local Analysis Using StressCheck, HyperMesh, HyperView and OptiStruct

This whitepaper describes the workflow for combining global and local analysis in structural development using StressCheck in combination with HyperWorks.

Design-Optimization of a Curved Layered Composite Panel Using Efficient Laminate Parameterization

In this paper, presented at the 2016 SAMPE Long Beach Conference, an aircraft door surround model is optimized with respect to the objectives and constraints typical for this type of component using HyperStudy and ESAComp.

A Design-Validation-Production Workflow for Aerospace Additive Manufacturing

There is a lot of hype these days regarding Additive Manufacturing (AM) or 3D Printing. Are companies seriously looking at this technology to make real parts for actual applications? For the aerospace industry, the hype is starting to become more real.

RADIOSS and MADYMO Coupling Tutorial

This document explains how to set up a RADIOSS coupling model using a MADYMO dummy model.

Design and optimization of a high performance C-Class catamaran with HyperWorks

Reprint of the article published on composite solutions magazine 2/2016.

Efficient Design and Analysis of Airborne Radomes



Computer Simulation's Role in Advancing Composite Aircraft Structures

Reprint of an article published on the December 2014 issue of Aerospace & Defense Technology magazine

Applications of Advanced Composite Simulation and Design Optimization

Usage of fiber reinforced composite material entered an new era when leading aircraft OEMs took an unprecedented step to design and manufacture essentially full composite airframe for commercial airliners. Composite structures offer unmatched design potential as the laminate material properties can be tailored almost continuously throughout the structure. However, this increased design freedom also brings new challenges for the design process and software. Moreover, as a relatively new material, composite behaviors are more complex and less fully understood by design engineers. Therefore, reliable simulation for highly complex events like bird strike and ditching can play an important role in shortening the product design cycle. This paper showcases two area of CAE tools for composite applications. On advanced simulation, bird strike simulation with Altair RADIOSS [1] is demonstrated on an aircraft underbelly fairing. On design optimization, an airplane wing structure is designed using an innovative composite optimization process implemented in Altair OptiStruct [1-3]. OptiStruct has seen increasing adoption among aerospace OEMs, as demonstrated in the Bombardier application process described in this paper.

Hawk T Mk2 - Arrestor Barrier (BAN MK2) Engagement Analysis

As the UK Ministry of Defence (MoD) Design Authority for Aircraft Arrestor Barrier Nets, AmSafe products are used to stop aircraft from over-running the end of the runway. The British Arrestor Net (BAN) Mk2 is suspended across the runway over-run area by two electrically driven stanchions and raised or lowered by remote control from the Air Traffic Control tower. This paper describes the process and results of a FE analysis of the engagement of the Hawk T Mk2 aircraft into a Type A Barrier (BAN Mk2). The analysis was performed using RADIOSS, an advanced non-linear explicit Finite Element solver.

Targeting Composite Wing Performance – Optimising the Composite Lay-Up Design

This paper shows how Altair OptiStruct, part of the HyperWorks suite, is used to provide a complete solution when designing with laminated composites, taking the design through concept stages to producing the final ply lay-up sequence. The technology is applied to the design of a laminated wing cover to produce a mass optimised design which meets the requested structural targets.

Resource Scaling for Antenna Placement Modeling on a SAAB JAS-39 Gripen Aircraft

This white paper demonstrates how resource requirements scale for the computational electromagnetic modeling of a modern fighter aircraft when the frequency increases. It also demonstrates how different simulation methods may be applied and how they scal relative to each other

Radar Cross Section of Aircraft with Engine Inlets

At radar frequencies, 1GHz and above, asymptotic methods are usually preferred to calculate the radar cross section (RCS) of targets like aircraft, since the main parts of the target are more than an order of magnitude larger than the wavelength. The challenge is how to combine these methods to compute the RCS. In this white paper the two-step method that obtains accurate results in limited time is detailed.

A shell facet model for preliminary design of cylindrical composite structures

The laminated composite lay-up design typically involves trade-offs between material selection, thickness of the layer, orientation of the layers, and the stacking sequence. Finding the right structural concept early in the design process leaves resources for the detailed design. Many structural members made of laminated composite materials have the form of thin walled cylindrical shells that are prone to buckling. Thus it is desirable to find structural designs that satisfy global requirements for structural stability early in the design phases. In this work, thin-walled cylindrical composite shells under different loading conditions have been studied for structural stability. The simulation is performed with a shell facet model implemented in the ESAComp software. Preliminary design tools for structural stability of thin-walled cylindrical composite shells are demonstrated and discussed.

Preliminary design of a wing spar bonded joint PrintE-mail

Fast tools such as the ESAComp module for bonded joints can be very efficient in the preliminary design of various joint configurations. In this example we consider a tip loaded wing of a small aircraft or wind turbine blade. The wing spar carries a constant in-plane shear (Nxy), which needs to be transferred from the joint laminates to the shear web.

Using Experimental Test Data In The Analysis Of Laminated Structures

Composite material systems have relatively large variation in their measured properties. A typical approach in engineering problems is deterministic, however. Material stiffness and strength, for example, are described with single values in linear-elastic analyses. Physical dimensions of the material, structural and environmental conditions in the laminate or uncertainties in material properties, for instance, require that several discrete definitions are needed for the material specification.

Design-Optimization Of Cylindrical, Layered Composite Structures Using Efficient Laminate Parameterization

For many years, layered composites have proven essential for the successful design of high-performance space structures, such as launchers or satellites. A generic cylindrical composite structure for a launcher application was optimized with respect to objectives and constraints typical for space applications. The studies included the structural stability, laminate load response and failure analyses. Several types of cylinders (with and without stiffeners) were considered and optimized using different lay-up parameterizations. Results for the best designs are presented and discussed.

Engineering oriented formulation for laminate lay-up optimization

The concept of elementary laminates is used to formulate the design problem for a laminated composite structure. A parameterized laminate is divided into stacks with periodic patterns of elementary laminates. With elementary laminates desired regularity for the laminate lay-ups is achieved, which is practical for multi-layer laminates. Due to the reduced design space solution time can be considerably reduced. Two laminate lay-up formulation concepts are presented and their performance is evaluated. The design problem used as a reference case involved the optimization of the stacking sequences to maximize plate buckling loads using a genetic algorithm.

PROBABILISTIC LAMINATE ANALYSIS USING ESACOMP SOFTWARE

Engineering design problems include always uncertainties such as variation in material properties or environment, incomplete statistical data to generate input, modelling and human errors. Yet, the design in general relies on single numbers obtained from engineering equations. In case of strength prediction the material strength is derived using statistical methods and the uncertainties is included in the design value (A or B-value).

CFRP Electronics Housing for a Satellite (ESA 2005)

The drive for continuous mass reductions in spacecraft structures has promoted the use of carbon fibre reinforced plastics. CFRP has excellent specific stiffness and strength, which makes it possible to construct lightweight structures. CFRP is typically used in applications where electrical, thermal and radiation protection properties are not decisive.

Transverse shear in Laminate Analysis

This paper describes the method for transverse shear analysis to be applied in the composites design program ESAComp. The correlation of the method to the formulations used in the commercial finite element programs is presented and the results from the selected method are compared to the exact elasticity results. The results show good agreement with the exact solutions for cross-ply and unsymmetric angle-ply laminates. Symmetric angle-ply laminates create bending twisting coupling that the theory cannot accurately model.

FACILITIES IN ESACOMP FOR ANALYSIS AND DESIGN OF ADHESIVE BONDED JOINTS

This paper presents a newly developed analysis and design module for adhesive bonded joints implemented in ESAComp, software for analysis and design of composite laminates and laminated structures.

Pressure vessels: The composite solution from ComposicaD and ESAComp

With composite pressure vessels foreseen as a significant industrial growth sector, Mike Skinner, from Seifert and Skinner & Associates, talks us through their approach and how the composite solution offered by ComposicaD and ESAComp provides efficient design and analysis to meet the emerging markets.

Considering large deflections in panels - ESAComp 4.4 introduces nonlinear analysis

In composite panels with large support spans, deflections are primarily due to bending. Out-of-plane shear can also play a significant role in sandwich structures. While these deformation types are considered in the typically used linear static analyses, the results are not accurate when going beyond the small deflections regime. When a panel is firmly fixed at its edges, it starts to carry loads partly like a membrane already at low load levels. The panel exhibits stress stiffening. Consequently, with an appropriate analysis approach more efficient structures can be designed.

ESAComp meets challenging marine applications

In this article we learn about ESAComp's role in the design-development of a carbon composite RIB "Rigid-hulled Inflatable Boat", the latest project from Dr. Luca Olivari, a naval architect, founder and owner of the Italian company Olivari Composites Engineering.

At the origins of delamination stresses - Free edge analysis gives insight

When you make a tensile test for [±45/0/90]s and [90/±45/0]s laminates you may observe different failure strengths. This may seem first surprising since the laminates are basically the same - only the stacking sequence is different, which should not influence on the in-plane values.

Anisogrid Payload Adaptor Structure For Vega Launcher

In the framework of a development project promoted by the European Space Agency (ESA/ESTEC), Airbus Defence & Space (EADS CASA Espacio, ECE) has designed, manufactured and tested a technology demonstrator representative of the payload adaptor (PLA) of VEGA Launcher, by using an anisogrid concept, called anisogrid payload adaptor (APA).

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