CCM has been creating unique design and analysis software solutions for composite structures for more than two decades. The software is continu-ously upgraded to reflect new research findings as well as to capitalize on advances in computing technology. Software applications such as CDS2.0, LIMS and MAT162 are used extensively by researchers at UD-CCM and industri-al sponsors to predict material properties and behavior during processing as well as study failure of composites under dynamic loading.

CDS v3.0 - Composite Design and Simulation SoftwareThe newest release of our structural design tool: CDS3.0 builds upon previ-ous versions with integrated parametric design and analysis of composite lami-nates and cylinders, material ranking, and drag and drop functionality with standard spreadsheet import and export. The software consolidates UD-CCM’s current composite solid mechanics appli-cations into a single environment that conducts effective property predictions,

plate and cylinder analysis with integrated material property management, as well as thermal and pro-cess simulation, all with real time results. The materials database structure has been updated to allow easy drag-and-drop, sorting, duplication and export in multiple for-mats. Users can plot sorted Ashby and tabular data to easily compare and rank properties, including mechanical and physical properties, micromechan-ics parameters, cure kinet-

ics, and damage and failure properties, as well as non-linear and MAT162 (LS-DYNA) properties. The user can modify properties “on the fly” and see laminate effective properties, stresses, strains, and progressive failure in real time. The new parametric design fea-tures allow users to directly compare and rank properties for multiple microme-chanics or laminate solutions. CDS3.0 is available to industrial con-sortium members through consortium agreements tailored to program require-ments and duration of contracts. Demonstration versions of the CDS suite can be made available to potential mem-bers with training work-shops at CCM. The soft-ware is PC based and can run on non-networked PC’s running Windows®.To learn more about CDS3.0, visit http://www.ccm.udel.edu/CDS/

LIMS - Liquid Injection Molding Simulation Liquid Injection Molding Simulation (LIMS) is a software tool that simulates the mold filling stage of liquid compos-ite molding processes such as resin transfer molding (RTM), vacuum assist-ed resin transfer molding (VARTM) and related processes by modeling flow through porous media by the finite ele-ment/control volume method. It provides a cost-effective way to verify and opti-mize mold design by providing a “virtu-al” mold filling process to reduce or eliminate time- and resource-consuming trial-and-error manufacturing approach-es. The simulation allows the user to monitor flow progression, pressure dis-tribution, and resin flow rates during the mold filling process, providing full virtu-al “instrumentation” of the mold. Full scripting control of the virtual filling process is provided within LIMS. Both the inlet parameters, including injection and vent locations, and material proper-ties can be changed during the virtual filling. This allows users to emulate real injection hardware limitations and infu-sion control algorithms. Consequently, LIMS has been successfully used to design and simulate an intelligent or adaptive filling process and even to sim-ulate additional physical phenomena

Technical Contacts

John TierneyCDSPhone: 302.831.0548jtierney@udel.edu

Pavel Simacek LIMS Phone: 302.831.6454psimacek@udel.edu

Bazle Haque MAT 162 Phone: 302.831.6805gama@udel.edu

such as dual scale flow or preform deformation. LIMS allows combination of 1D, 2D and 3D zones within a single model mesh. This allows easy addition of flow disturbances, such as racetracking--the tendency for resin to flow much faster around corners to the part model. It also allows placement of the distribution media in VARTM type processes on the existing part mesh and to handle element aspect ratio issues more effectively. To practically utilize this capability, LIMS graphical user interface (LimsUI) allows creation of these features based on the mesh topology by a simple point and click method. Obviously, it also pro-vides the more mundane operations such as effortless modification of the material and injection parameters, simulation execution, simulation results visualiza-tion, and change or add injection and vent locations. All of these operations are adjusted to handle the specific needs of LCM modeling, such as highly aniso-tropic materials. For those interested in utilizing the simulation engine in their own program, for example, for the purpose of optimi-zation, there is a slave version controlled through a dynamically linkable library that can be included in the user program. Currently, LIMS is supported for the 32- and 64-bit Windows environment, XP and later. The simulation engine also runs on 32-and 64-bit Linux systems. To learn more about LIMS, visit http://www.ccm.udel.edu/Pubs/tech-briefs/LIMS.pdf

MAT162 in LS-DYNA: Progressive Damage Modeling of Composites In collaboration with Materials Sciences Corporation, CCM has devel-oped a progressive composite damage model (pCDM) for uni-directional (UD) and plain-weave (PW) fabric compos-ites, known as MAT162 and implement-ed in LS-DYNA. MAT162 is the state-

of-the-art in three-dimensional high strain rate progressive damage modeling of UD and PW composites using solid elements and was developed on the foundation of earlier orthotropic com-posite models MAT02 and MAT59. Based on Hashin's theory, five quadratic failure criteria for UD composites and seven failure criteria for PW composites are defined to model different composite damage modes, for example, matrix cracking, delamination, fiber tension shear, fiber compression, fiber shear, and composite crush. MAT162 has the capability of model-ing the post-damage softening behavior of composites as well as simulating the material degradation that occurs with various damage modes.

MAT162 requires a series of soften-ing and rate parameters in addition to elastic constants and strength properties. CCM has developed a series of model experiments to determine these parame-ters by conducting a series of parametric simulations of quasi-static punch shear, dynamic punch shear, and ballistic exper-iments. CCM is now developing pCDM for 2D and 3D fabric composites of vari-ous weaving architectures. In order to bridge the gap from micro- to meso- to macro-mechanics based damage model, CCM will incorporate different failure theories in different scales. MAT162 progressive damage is now available in explicit FEA code LS-Dyna; however, the codes are being implement-ed in ABAQUS for implicit and structur-al analysis. To learn more about MAT162, visit http://www.ccm.udel.edu/Tech/MAT162/Intro.htm