04 Composites

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

3
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

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.
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

6
NEW Interface for Definition of Composites
• New forms… new graphics… new visualization

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

8

• 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

9

• 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

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

11
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

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

13
> Select material for the ply

14
> Set thickness and ply angle

15
> Define second ply layer

16
> Define third ply layer

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

18
Composite Query Shows Lay-up Thicknesses, Fiber
Directions, and Element Reference Plane

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

20
Envelope Calculations
• Show ply names

21
Envelope Calculations
• Show quilt plot of critical plies

22
Thru-Thickness Plots

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)

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

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

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

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

28
Unidirectional Composite VUMAT (cont’d)
• This example shows ballistic impact

onto unidirectional fiber composite
plate

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

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)

31
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
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

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

34
Postbuckling Behavior of Composites (cont’d)
• The composite lay-up has a significant effect on the panel buckling

behavior

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

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

37
Debonding Using VCCT (Skin-Stringer Example)

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

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

40
Delamination with Cohesive Elements (cont’d)
• Angle beam with three layers connected with adhesive

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.

Case Study

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

44
• Composite Aeroshell Model (built in CAE v6.7PR4)

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

45
New Composite Layup GUI
Side-doubler region

46
Query on panel shows composite layup,

thicknesses, and orientations in /Viewer

47

48
• Pressure load = 20 x (cos2psi under side only
Note: strain discontinuities in

doubler region

49
• Ply-based post-processing in /Viewer Ply : CLOTH-1
Ply : CLOTH-3

50

Max Principal Envelope Contour
Max Principal Envelope Ply ID where MAX occurs
Envelope plots to view which

layer has the peak strain

51
• Composites supported in both Abaqus/Standard and /Explicit

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

52
• Composites supported in both Abaqus/Standard and /Explicit

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

53
• 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


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Evaluating the Realistic Behavior of

Copyright 2007 Dassault Systèmes

• Composites usage is increasing in all industries

Realistic Simulation of Composites

• Current simulation methodology is not up to the task

Realistic Simulation of Composites

Abaqus Composites Solution

Our solution allows customers to:

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

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

As a complete product for composites modeling & simulation,

Composites Technology and Features

Realistic Simulation of Composites

NEW Interface for Definition of Composites

• New forms… new graphics… new visualization

Realistic Simulation of Composites

Modeling Composite Structures

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

Realistic Simulation of Composites

Modeling Composite Structures

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

Realistic Simulation of Composites

Modeling Composite Structures

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

Realistic Simulation of Composites

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

• Think in terms of “plies”

Ply-1 Ply-2 Ply-3

Realistic Simulation of Composites

Composites Modeling in V6.7

• Composite Layup Object

Realistic Simulation of Composites

Realistic Simulation of Composites

Realistic Simulation of Composites

Realistic Simulation of Composites

Realistic Simulation of Composites

Realistic Simulation of Composites

Composite Plies Manager Options

• Ply management via right mouse

Realistic Simulation of Composites

Realistic Simulation of Composites

Realistic Simulation of Composites

• Show ply names

Realistic Simulation of Composites

• Show quilt plot of critical plies

Realistic Simulation of Composites

Realistic Simulation of Composites

All Composites Features Are Open for Scripting

Full scripting support

# Use the output database displayed in the current

# Find the maximum failure crits

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

Realistic Simulation of Composites

NEW Draping Technology

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

• Predicts flat pattern to

Realistic Simulation of Composites

NEW Link Between CATIA CPD and Abaqus

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