Evaluating the Realistic Behavior of

Laminated Composites

Copyright 2007 Dassault Systèmes

 2

Industry trends

• Composites usage is increasing in all industries

• Aerospace
• Boeing 787 – first large jet with a majority of composites by weight
• Airbus 350WX - over 60% of airframe made of new materials
• UAVs – primarily composite construction
• Automotive
• F1 race teams – composite shells
• Toyota's Tundra pickup has a composite box
• Nissan Concept uses carbon-fiber components
• Civil
• Composite-wrapped bridge structures
• Dentistry
• Fiber-reinforced composite dental bridges!

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
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Industry needs

• Current simulation methodology is not up to the task

• Verification of composites relies on testing
• Expensive, time consuming
• Current methodology has not evolved since the 1980s
• Typical simulation uses linear methods to estimate first failure
• Current composites interfaces are not up to the task
• It is very time consuming to define composites and post-process
composites in today's CAE tools
• Some CAD/CAE/PLM packages do not support progressive failure,
delamination, or material damage
• With linear methods, design margins for composite parts today are
often too high – the part is too expensive and heavy as a result
• This reduces the value of the use of composites and blunts the cost
advantages that composites can provide to a product

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 4

Abaqus Composites Solution

Our solution allows customers to:

• Perform advanced composites simulations including static and dynamic
analysis that includes linear, nonlinear, and damage / fracture / failure
within a single environment

• Predict the stiffness, first-failure, strength, and post-failure behavior at

the component and full-vehicle structural scale of complex composite
products

• Simulate low- (from tool drop or hail), medium- (from runway debris), or
high-velocity (ballistic penetration) events including Barely Visible Impact
Damage (BVID) and Bird Strike

• Have the very best in composite modeling, visualization, and post-

processing through Abaqus/CAE's new ply-based interfaces

As a complete product for composites modeling & simulation,

Abaqus has no peer.
Realistic Simulation of Composites
Copyright 2007 Dassault Systèmes
 5

Composites Technology and Features

• Features
• Ease-of-use and efficiency features
• NEW interface for pre-processing
• NEW post-processing options
• NEW Interface to CATIA CPD
• Technology
• Abaqus can solve a variety of problems
• Ballistic impact on unidirectional composite
• Barely Visible Impact Damage (BVID)
• Woven fabric composite beam crush
• Composite plate post-buckling behavior
• Skin-stringer debonding using VCCT
• Delamination using cohesive elements
• Draping simulation

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 6

NEW Interface for Definition of Composites

• New forms… new graphics… new visualization

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 7

Modeling Composite Structures

• In reality, composite structures are built by laying-up fabrics on top of

each other in patterns to create the part

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 8

Modeling Composite Structures

• In reality, composite structures are built by laying-up fabrics on top of

each other in patterns to create the part
• In the FEA world, users have to define various sections to represent the
different regions of the composite
• Time consuming and difficult for complicated components

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
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Modeling Composite Structures

• In reality, composite structures are built by laying-up fabrics on top of

each other in patterns to create the part
• In the FEA world, users have to define various sections to represent the
different regions of the composite
• Time consuming and difficult for complicated components
• This also results in post-processing difficulties
• Element layers and section points to not directly correspond to a
consistent piece of material

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 10

In V6.7, Uses Can Now Model in Terms of Plies

• Think in terms of “plies”

• Representation of the materials as placed in a mold
• User supplied ply name is available in ODB and Abaqus/Viewer
for easy tracking in post-processing operations
• Plies defined on picked regions or named sets of partitioned
geometry or orphan mesh parts

Ply-1 Ply-2 Ply-3

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
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Composites Modeling in V6.7

• Composite Layup Object

• Part level replacement for
multiple sections, section
assignments and material
orientations for layered
composites - in one dialog
box
• Advantages:
• Ply-based
• More intuitive definition of
ply regions than “artificial”
section assignments
• Output requests can be defined by composite layup
• Suppressible
• Supports shell, layered continuum shell and layered solid elements

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 12
Composite Lay-up Creation:
> Create new ply layer and select region for that ply

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
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Composite Lay-up Creation:
> Select material for the ply

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
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Composite Lay-up Creation:
> Set thickness and ply angle

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 15
Composite Lay-up Creation:
> Define second ply layer

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
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Composite Lay-up Creation:
> Define third ply layer

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 17

Composite Plies Manager Options

• Ply management via right mouse

menu
• Copy plies
• Move plies
• Delete plies
• Invert plies
• Read from and write to file

• Ply patterning
• Create
symmetric layup
• Copy plies
multiple times

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 18
Composite Query Shows Lay-up Thicknesses, Fiber
Directions, and Element Reference Plane

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 19

Ply-based Post-processing

• Ply-based results
• Choose particular ply for results
• Element layer numbering is
handled automatically
• Works with the existing section
points functionality
• Can show contours on top,
middle, bottom, or top and
bottom

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
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Envelope Calculations

• Show ply names

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
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Envelope Calculations

• Show quilt plot of critical plies

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 22

Thru-Thickness Plots

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 23

All Composites Features Are Open for Scripting

Full scripting support

def firstFail(criterion=['AZZIT','MSTRN', 'MSTRS',
'TSAIH', 'TSAIW',], saveHardcopy=1):

print "\n\nSTARTING..."

# Use the output database displayed in the current

viewport

vp = session.viewports[session.currentViewportName]
odb = vp.displayedObject
if type(odb) != visualization.OdbType:
raise 'An odb must be displayed in the current
viewport.'

# Find the maximum failure crits

bigList = [] for j in range(totalPlies):

bigDict = {}
try:
region1=p.sets[areaDic.get(areaId[j])]
fields = odb.steps['Step-1'].frames[-1].fieldOutputs #This
assumes the set exists!
t01 = time.time() except:
# counter = 0 print "SERROR: Set name " + areaDic.get(areaId[j])
+ " does
for field in fields.keys(): # O(len(keys)) not exist in the model :("
sys.exit()
...
compositeLayup.CompositePly(suppressed=FALSE,
plyName=plyName[j], region=region1,
material=matDic.get(matId[j]),
thicknessType=SPECIFY_THICKNESS,
thickness=float(thk[j]),
orientationType=SPECIFY_ORIENT, orientationValue=0.0,
numIntPoints=3)

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 24

NEW Draping Technology

• Simulayt’s “Composites Modeler for Abaqus” can be purchased as a

module of Abaqus/CAE
• Calculates local fiber directions when tape/cloth is draped over curved
geometry

• Predicts flat pattern to

ensure proposed plies
can be manufactured
• Allows legacy lay-ups
to be imported

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 25

NEW Link Between CATIA CPD and Abaqus

• Lay-up definitions in CATIA CPD can be passed to Abaqus/CAE

• If lay-ups are modified in Abaqus/CAE, updated definitions are passed
back to CATIA CPD

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 26

Composites Technology and Features

• Features
• Ease-of-use and efficiency features
• NEW interface for pre-processing
• NEW post-processing options
• Interface to CATIA CPD composites
• Technology
• Abaqus can solve a variety of problems
• Ballistic impact on unidirectional composite
• Barely Visible Impact Damage (BVID)
• Woven fabric composite beam crush
• Composite plate post-buckling behavior
• Skin-stringer debonding using VCCT
• Delamination using cohesive elements

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 27

Unidirectional Composite VUMAT

• Ballistic impact is a concern in many application areas, including road

and runway debris, bird strike, and armor design
• A unidirectional fiber composite damage and failure VUMAT for
Abaqus/Explicit is available for high speed impact problems
• Available in ABAQUS Answer 3123
• Elastic stress/strain relations are given by orthotropic damaged elasticity
• Four damage variables are introduced, two associated with fiber tension
and compression and two with matrix tension and compression
• Damage modeling can be combined with cohesive elements to predict
delamination

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 28

Unidirectional Composite VUMAT (cont’d)

• This example shows ballistic impact

onto unidirectional fiber composite
plate

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 29

Barely Visible Impact Damage

• Non-visible damage to composite

structures is a significant concern in the
aerospace industry
• Issues such as maintenance tool drop,
hail impact and other sources of damage
must be dealt with as part of composite
structure design
• How much residual strength does a
structure maintain when small flaws in
the structure are present?

from McGowan, D.M., and Ambur, D.R., NASA TM-110303

Damage-Tolerance Characteristics of Composite Fuselage
Sandwich Structures With Thick Facesheets

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 30

Barely Visible Impact Damage (cont’d)

• ABAQUS/Explicit used to model

low speed impact
• Residual displacements used as
initial condition in ABAQUS/Standard
• Hashin damage model available in
ABAQUS/Explicit

Crushing Force

200,000
Undamaged
180,000 Damaged

160,000

140,000

120,000

Load (lb) 100,000

80,000

60,000

40,000

20,000

0
0.00 0.02 0.04 0.06 0.08 0.10 0.12
Displacement (in)

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
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Woven Fabric Composites VUMAT

• Woven fabrics are used extensively

in crashworthiness applications
• Helicopter sub-floor systems make
use of these materials
• Automotive uses include steering
column crash absorbers as well as
front and rear crash boxes Steering column crash absorber

from Kindervater, Christof The Crashworthiness of

Composite Aerospace Structures, Workshop -
Crashworthiness of Composite Transportation Structures
TRL, Crowthorne, 3rd October 2002
Realistic Simulation of Composites
Copyright 2007 Dassault Systèmes
 32

Woven Fabric Composites (cont’d)

• Woven fabrics dissipate energy efficiently
during crushing
• Kinetic energy is converted into fracture
energy, breaking fibers and crushing
matrix material
• This energy is absorbed by the vehicle
structure rather than the pilot’s spine, or
the driver’s sternum
• Abaqus/Explicit can successfully model
this behavior

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 33

Postbuckling Behavior of Composites

• Buckling and postbuckling behavior of
composite panels is an important design
consideration in many industries
• This example uses eigenvalue buckling and
Riks analysis capabilities
from Smith, F.A. and Hopkins, P.M., Boeing Rotorcraft,
Philadelphia, PA, Non-linear Internal Loads Modeling
Methods, ABAQUS User’s Conference 2006, Boston, MA

Post-buckled
stiffness
Buckling load

Pre-buckled
stiffness

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 34

Postbuckling Behavior of Composites (cont’d)

• The composite lay-up has a significant effect on the panel buckling

behavior

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 35

Debonding Using VCCT

• Boeing selected SIMULIA to commercialize their proprietary

implementation of the Virtual Crack Closure Technique (VCCT)
• SIMULIA has productized Boeing’s technology for commercial usage
based on the existing debonding functionality (2D and extended for 3D)
• Apply linear elastic fracture mechanics to bondlines and interfaces

•2D and 3D delaminations •Multiple cracks

•Propagation •Non-linear behavior (e.g., postbuckling)
•Mode separation •Composite structure

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 36

Debonding Using VCCT

• VCCT for Abaqus

• Runs during an Abaqus analysis
• Utilizes the existing “debond” contact
architecture in Abaqus/Standard,
suitably extended
• Does not utilize overlapped user
elements as the basis for the
implementation
• Does not require matched meshes
across bonded surfaces
• Includes post-failure ramp-down of
crack tip force
• Includes post-failure penetration prevention
• Includes post-processing capabilities within Abaqus/Viewer
• Includes analysis stabilization algorithms to help stabilize running cracks in
Abaqus/Standard
• Is compatible with existing Abaqus elements and material, incrementation and
convergence controls, and stress-based procedures

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 37

Debonding Using VCCT (Skin-Stringer Example)

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 38

Delamination with Cohesive Elements

T
• Delamination applications N
• Traction separation law
• Typically characterized by peak
strength (N) and fracture energy
(GTC) GT C
• Mode dependent
• Linear elasticity with damage 
• Available in both Abaqus Typical traction-separation response
/Standard and /Explicit
7
• Modeling of damage under the 6 Shear mode
general framework used for other
material models in Abaqus 5

4 Normal mode

GTC
• Damage initiation 3

• Traction or separation- 2

based criterion 1

0
• Damage evolution 0 0.2 0.4 0.6 0.8 1

Mode Mix
• Removal of elements
Dependence of fracture toughness on mode mix

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 39

Delamination with Cohesive Elements (cont’d)

• Cohesive elements have the benefit of not requiring the specification of

crack initiation within the structure
• Therefore, initiation of delamination can be modeled
• An example is given here of a skin/stiffener debonding. The example is
available as Problem 1.4.5 in the Abaqus Example Problems manual
• Results of interest include stress concentrations at stiffener
terminations, residual thermal strains at the interface, effects of
residual strains on debonding, and how delamination propagates

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 40

Delamination with Cohesive Elements (cont’d)

• Angle beam with three layers connected with adhesive

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 41

Summary
The Abaqus Composites Solution allows customers to:
• Perform advanced composites simulations including static and dynamic
analysis that includes linear, nonlinear, and damage / fracture /failure
within a single environment

• Predict the stiffness, first-failure, strength, and post-failure behavior at

the component and full-vehicle structural scale of complex composite
products

• Simulate low- (from tool drop or hail), medium- (from runway debris), or
high-velocity (ballistic penetration) events including Barely Visible Impact
Damage (BVID) and Bird Strike

• Have the very best in composite modeling, visualization, and post-

processing through Abaqus/CAE's new ply-based interfaces

As a complete product for composites modeling & simulation,

Abaqus has no peer.

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
Case Study

Copyright 2007 Dassault Systèmes

 43

Example (Payload Fairing)

• “The payload fairing is the

equipment used to protect the
spacecraft and the upper
stage during the early portion
of the boost phase when the
aerodynamic forces from the
atmosphere could affect the
rocket,” NASA.com.

• The image here shows the

payload fairing for the NASA
Mars Exploration Rover
mission

Image courtesy of NASA

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 44

Example (Payload Fairing)

• Composite Aeroshell Model (built in CAE v6.7PR4)

• Aluminum ribs / stiffeners shown in purple
• Composite sections showing local reinforcement regions around
access doors

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 45

Example (Payload Fairing)

New Composite Layup GUI

Side-doubler region

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 46

Example (Payload Fairing)

Query on panel shows composite layup,

thicknesses, and orientations in /Viewer

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 47

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 48

Example (Payload Fairing)

• Pressure load = 20 x (cos2psi under side only

Note: strain discontinuities in

doubler region

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 49

Example (Payload Fairing)

• Ply-based post-processing in /Viewer Ply : CLOTH-1

Ply : CLOTH-3

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 50

Example (Payload Fairing)

Max Principal Envelope Contour

Max Principal Envelope Ply ID where MAX occurs

Envelope plots to view which

layer has the peak strain

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 51

Example (Payload Fairing)

• Composites supported in both Abaqus/Standard and /Explicit

Abaqus/Standard (20 psi) Abaqus/Explicit (20 psi)

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 52

Example (Payload Fairing)

• Composites supported in both Abaqus/Standard and /Explicit

Abaqus/Standard (20 psi) Abaqus/Explicit (20 psi)

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes
 53

Example (Payload Fairing)

• Analysis in Abaqus/Explicit carried out to collapse of structure

Applied Load = 50 psi over 1.0 second

P = 42.5 psi (t = 0.85)

Nose Tip Displacement

Realistic Simulation of Composites

Copyright 2007 Dassault Systèmes