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Homebuilt Projects Special

Samuel Ashton – Application Engineer | Jonathan Evans - Application Engineer

CompoSIDE | Webinar 18

Copyright CompoSIDE Ltd 2017 Slide 124/10/2017

O b j e c t i ve s

Introduction to composite design, materials and process selection

Testing and certification of composite materials

Design approach in CompoSIDE

Case Study (Architectural Panel)

Questions & Answers


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C a s e S t u d i e s

Typical home built engineered product¤ Automotive

¤ Aeronautical

¤ Marine

¤ Sports & Leisure

¤ Architectural

End goals Assess composite feasibility (weight, cost

etc..)

Ability to compare solutions

Be confident that structure works


C a s e S t u d y O b j e c t i ve s

How to assess my composite structural concept?

What are the associated material quantities?

Cost & Time

Strength

(Process)

Weight

(Material)

What technology and materials to select to achieve a lighter solution?


P ro d u c t A p p l i c a t i o n D e ve l o p m e n tTa r g e t U s e r s

Engineer – Design / Development

Manufacturer – Modification / Substitution

End User – Due Diligence


C a s e S t u d y Wo r k f l o w

Which material should I use?

Where can I get the properties?

How should I orient my fibres / plies?

How do I ensure compliance of my laminate?

Are there opportunities to optimize?

How can I compare total material costs?


W h a t M a t e r i a l s S h a l l I u s e ?


W h a t P ro c e s s S h o u l d I u s e ?

Wet lamination Press Infusion

PultrusionPrepreg/Resin Film

InfusionAutomation


S h a l l I d o S o m e Te st i n g ?


Te st i n g C o st

Testing for certification purposes must be conducted by approved test houses. Below is a rough guide to the cost of basic static and fatigue testing for 1 material i.e. 1 fibre, 1 matrix, 1 process…

Aerospace qualifications can cost in excess of > €100k for a single material

Material sourcing and coupon manufacture

Fibre volume contentTensile testsCompression testsILSS

Fatigue

€1,500

€6,500 for static tests

>€45,000 for fatigue tests up to 5 million cycles

Minimum properties required to start a

design


Do I real ly need to spend many thousands € before start ing

design with composites?


T h e Te st i n g P y ra m i d

CompoSIDE CMDB


W h a t d a t a i s i n C M D B ?

Testing

Characteristic Values

Project Design Allowables

Statistical Analysis

IndustryPartial Safety Factors

CompoSIDE CMDB


H o w C M D B A d d o n Re d u c e s M a t e r i a l Te s t i n g C o st s ?

The CompoSIDE CMDB Addon library is a consolidated set of data that enables a quick and easy start with your projects

This enables you to assess the viability of composites as a solution as an alternative to investing lots of time and money.

Material testing becomes validation rather than investigation


M AT E R I A L S

P R O C E S SE N G I N E E R I N G

D e s i g n i n g w i t h C o m p o s i t e s

C M D B

S E C T I O N S p a c e

L A M I N A S p a c e

F E S p a c e

B O M G e n


U s i n g C M D B


Manual materials

¤ Test data

¤ Reference materials

¤ CMDB Addon Materials

PLYGen materials

¤ Micromechanics

Layered Materials

¤ Classical Laminate Theory

M a t e r i a l D a t a H a n d l i n g

Material post-processing

¤ Properties for calculation

¤ Materials selection

¤ Data Comparison

¤ Scatter Plots

¤ Materials export (Xls)

Link to FEA Formats

¤ Ansys

¤ Nastran

¤ Radioss OptiStrut

¤ More to come


C M D B A d d o n

W h a t d o I ge t ?


Te c h n i c a l O ve r v i e w o f C M D B

Characteristic Values

Materials Data Fit for Design

Industry Proven Values

Across Hundreds of Products

Full Datasets

Fit for FEA

Transferable

Export to FEA


C M D B A d d o n M a t e r i a l G ro u p s

Adhesives

Plies

Woods & Plywoods

Metals

Resins

Fibres

1277 MaterialsCores


C o re s

212 Core Materials

Wide Range of Densities Available

Most Commonly Used Materials Available

¤ Honeycomb

• N636

• Nomex

¤ Balsa

¤ PVC Foams

¤ PET Foams

¤ San Foams

¤ PMI Foams

¤ PUR Foams

¤ Linear PVC Foams

¤ Flow Mediums


P l i e s

No Standards in Composite Industry

One Material One Test Campaign

P l y P r o p e r t i e s

ResinManufacturing

Process

Fibre Grade

Fibre SizingFabric Type

Fibre Type


P l i e s

9 Fibre Types

7 Fabric Types

¤ UD

¤ Woven

¤ Biaxial

¤ Triaxial

10 Different Matrixes

8 Manufacturing Methods

¤ Quadraxial

¤ Mats

¤ Stack-ups (Combos)

890 Different Plies


M a t e r i a l s S e l e c t i o n


… n o t e n o u g h ?


C re a t e Yo u r O w n P l i e s w i t h P l y G e n

PLYGen Material

Reference Material

ResinManufacturing

Process

Fibre Type Fabric Type


Let ’s Design!

24/10/2017 Copyright CompoSIDE Ltd 2017 Slide 28

Des ign Approach with CompoSIDE


C a s e S t u d y

6m Radius Architectural Sphere Segments:¤ Aluminium Alloy

¤ Aluminium Weight = 656.6 kg

¤ Requirement to reduce weight retaining stiffness.

Requirements¤ Structure to withstand gravity and wind

loading

¤ Maximum deflection = 10mm MAX.

¤ Ensure sufficient strength


C o m p o S I D E Wo r k f l o w

Outputs

Select Materials

Create 2D Sections

Create 3D Model using sections and analyse

Baseline Design

Analysis



Outputs

Select Materials

Create 2D Sections


Baseline Design

Analysis

Replace Material in 2D section with composite

Replace Section and analyse

with composite

CompositeAnalysis

Select Materials



Outputs

Select Materials

Create 2D Sections


Baseline Design

Analysis



with composite

CompositeAnalysis

Select Materials



with composite

CompositeOptimisation

Select Materials

Optimise Laminate

s


B u s i n e s s C a s e C o m p a r i s o n S u m m a r yF i n a l A n a l y s i s

Weight Comparison

The structure can still be further optimised from here using the same process

Material Weight

Aluminium 656.6 kg

Carbon Fibre – Sandwich 314.6 kg


Total Weight Saving of 52%!

Summary


C o m p o S I D E


C a s e S t u d y S u m m a r yW h a t p ro b l e m s d i d w e s o l ve ?

Which material should I use?¤ CMDB can help in the selection of the materials

Where can I get the properties? ¤ CMDB Addon provides 1,200+ Materials Data

How should I orient my fibres / plies?¤ Quick optimization loops within CompoSIDE

How can I compare total material quantities?¤ BoMGen automatically provides costs and weights


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S t a r t y o u r F R E E 3 0 D ay s Tr i a l N o w !

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CompoSIDE | Webinar 18€¦ · CompoSIDE | Webinar 18 ... ¤ Radioss OptiStrut ¤ More to come ... Video Tutorials Live Chat Support FAQs Webinars Knowledge Base Online Training