ESAComp PDF

ESAComp Benchmark Cases
T H E C O M P O S I T E S D E S I G N S O F T W A R E B Y C O M P O N E E R I N G
for Version 4.5
01 - Material data bank
02 - Laminate stiffness
03 - Laminate load response
04 - ILS
05 - Failure NAFEMS
06 - Failure NCN Guide
07 - Sandwich beam
08 - Multiple point loads
09 - Sandwich panel
10 - Stiffened panel
11 - Panel natural frequency
12 - Aerofoil
Table of Contents
13 - Hat stiffeners
14 - Drive shaft
15 - Cyl shell axial buckling
16 - Underwater tank
17 - Bonded joint lap shear
18 - Bonded joint linear
19 - Notch
20 - Statistical data
21 - FE export
22 - Free edge mechanical
23 - Free edge thermal
ESAComp includes an extensive material data bank.
Data is sorted in a user-friendly way based on different
material classes (reinforced plies, different core
materials, adhesives, fibers, resins) and material types.
Sufficient data is provided for design purposes and the
data bank is constantly upgraded.
Users can create own data based on experimental tests
and micromechanical models are provided to define
engineering constants from the base materials.
In ESAComp users can store the following data:
engineering constants, failure stresses/strains, ultimate
failure values, expansion coefficients, thermal
conductivities, moisture diffusion parameters, strength
sets covering e.g. nominal and minimum strengths,
properties in different environments e.g. RT and
elevated temperature, and statistical data
ESAComp provides tools that make the material
specification easy. The example table is obtained from
[1].
Material data bank
[1] Space engineering - Buckling of structures, European Cooperation for
space standardization, ECSS-E-HB-32-24A, 24 March 2010
ESAComp laminate analysis calculates stiffness and
expansion coefficients in the plane of the laminate.
Laminate extension, bending and coupling between
these two phenomena are considered with classical
lamination theory. Out-of-plane shear stiffness values are
computed as well with other theory.
Different result items can be studied in numerous ways.
In the design studies laminate orientation theta can have
discrete value or multiple values can be given for the
orientation. Several laminates can be examined
simultaneously.
The image on right illustrates the deformation of various
laminate configurations under tensile load. Analyses have
been performed with ESAComp panel analysis. The
image also explains which elements of the compliance
matrix cause the different response: extension, shear,
bending and torsion.
The benchmark report [1] involves various stiffness
analysis for laminates. ESAComp results correspond with
the published data.
Laminate stiffness
[[1] Benchmarks for Membrane and Bending Analysis of Laminated Shells,
Part 1, Stiffness Matrix and Thermal Characteristics, 2005 NAFEMS Ltd
Case file:
BC2 Laminate stiffness.edf
Based on the classical lamination theory ESAComp
calculates hygrothermal expansion and curvature
coefficients for the laminate. Thermal and moisture loads
can be introduced assuming that these internal loads
vary linearly between the surfaces of the individual
layers.
Thermal strains and stresses are caused by temperature
differences between the analysis and reference
temperature.
ESAComp provides convenient and instructive
capabilities for the visualization of strains. For example,
free strains reveal how individual layers would expand if
they were not bonded together. Residual strains are the
difference between the actual strains and the strains in
free expansion. These strains cause the residual
stresses.
The benchmark report [1] involves various analysis for
the laminate thermal characteristics and load response
due to thermal loads. ESAComp results correspond with
the published data.
Laminate load response
[[1] Benchmarks for Membrane and Bending Analysis of Laminated Shells,
Part 1, Stiffness Matrix and Thermal Characteristics, 2005 NAFEMS Ltd
Case file:
BC3 NAFEMS Stiffness *.edf
Out-of-plane is the weak direction of the laminate and it
should be considered in practical applications.
ESAComp considers this by using the First Order
Shear Deformation (FSDT) theory. The computation of
the out-of-plane shear stress distribution and stiffness
is based on the advanced theory developed at German
Aerospace Center (DLR).
For the failure analysis ESAComp provides 3D failure
criteria, which include the terms for the out-of-plane
shear stresses. In addition, layer interface specific
strengths can be set in ESAComp.
In reference [1] shear stresses calculated using FSDT
and higher-order theory have been compared. When
laminate span to thickness ratio is 10 or higher the
stresses match very well. FSDT predicts ILS stresses
well also for antisymmetric composite structures that
have simply supported or clamped boundary condition.
In comparisons Abaqus was used as a reference code.
It should be noted that ESAComp produces identical
results to Abaqus.
ILS
1] A higher-order plate element for accurate prediction of interlaminar
stresses in laminated composite plates, Ramesh S., Wang C, Reddy J.N.,
Ang K., Composite Structures 91 (2009) 337357
Case file:
BC4 Reddy.edf
The failure behavior of reinforced plastics is influenced
by three major components namely fibers, matrix and
bonds between fibers and matrix. These components
have very different material properties. Therefore, the
failure behavior is characterized by a variety of failure
modes. Failure analysis is based on failure functions.
ESAComp provides three classes of failure criteria
which are based on independent conditions, polynomial
combined expressions and physically based conditions.
In ESAComp failure criteria selection is related to
material types. For example, for UDs and fabrics
different criteria can be used simultaneously. Failure
analyses are available both in the laminate level and in
the component level. In the laminate level multiple
criteria can be used for comparative studies. Failure
analysis is also supported in case of laminate thermal
loads.
The benchmark report [1] involves various strength
analysis for laminates. ESAComp results correspond
with the published data.
Failure NAFEMS
1] Benchmarks for Membrane and Bending Analysis of Laminated Shells,
Part 2, Strength Analysis, 2005 NAFEMS Ltd
Case file:
BC5 NAFEMS Strength *.edf
Transverse shear deformation plays significant role in the
load response of the sandwich panel. ESAComp considers
this by using the First Order Shear Deformation theory. The
core material can be orthotropic like honeycombs or isotropic
like foams.
When using the ESAComp panel analysis user has versatile
way to configure panel boundary conditions and introduce
both in-plane and out-of-plane loads.
The load response analysis shows displacements (on top)
and also laminate stress resultant like out-of-plane shear
forces (middle) and moments per unit length. These post
processing capabilities help to understand the load transfer
trough-out the panel.
ESAComp failure analysis (bottom) considers sandwich
specific failure modes like core shear and face sheet
wrinkling. Very detailed information can be obtained by
selecting element/s from the model for local analyses.
Different laminate analysis and design tools have been
evaluated by independent organization in [1] (images from
the case study).
Failure NCN Guide
[1] Design Tools for Fibre Reinforced Polymer Structures - National
Composites Network Best Practice Guide, Meunier M. and Knibbs S.
Case file:
BC6 Failure NCN.edf
In sandwich panel applications it may be useful to
understand, which part of the deformation is due to the
core shear. ESAComp beam analysis allows to choose if
the shear deformation is included or not.
In the classical approach the deformation is due to
bending. By default the shear deformation is included. In
such a case, an additional shear term is included in the
equation of the displacement. The computation of the
out-of-plane shear stiffness is based on the advanced
theory. The corrected shear stiffness can be studied by
using the cross section analysis.
Analytical solutions for the deformation for different
boundary and loading conditions can be found in the
literature, e.g. in [1]. ESAComp results are in line with the
published data.
The beam analysis also provides a reverse engineering
approach for the determination of EI and GA from the
experimental tests. 4-point bending is typically used in
that case.
Sandwich beam
[1] Handbook of composites, Lubin G. and Peters S., Springer, 1998
In special cases the loading condition may be quite complex.
ESAComp beam and panel analyses allow to specify any
type of transverse load distribution with multiple point loads.
Beam analysis is defined by the cross section and length
definition, support and loading conditions. Multiple point
loads can be combined with distributed loads and end
moments. The analysis solves e.g. force and moment
distributions, deflection and the load bearing capability.
Classical benchmark has been presented in [1]. Thick tree
layer solid laminate is subjected to sinusoidal load. When
comparing the maximum deflection to the elasticity solution
of Pagano it can be concluded that ESAComp result is 12%
stiffer. On the other, the maximum transverse shear stress is
5% higher when compared to the elasticity solution. Stress
result is very much in line with the Abaqus result [2].
Transverse shear stresses can be visualized locally with the
panel analysis.
Multiple point loads
[1] Pagano NJ. Exact solutions for composite laminates in cylindrical
bending. J Compos Mater 1969;3:398411
[2] Abaqus Benchmarks Manual, v6.8
Case file:
BC8 Pagano.edf
With ESAComp sandwich panels can be simulated.
Layer-wise structure may include multiple core plies.
Model definition can be made either in SI or British
unit system. During the work process unit systems
can be switched.
Several possibilities are provided for the definition of
loads and boundary conditions. For example, hinged
supports is one of the pre-defined edge constraints.
Symmetry can be used when applicable.
With ESAComp the engineer can study the global
behavior of the structure in terms of displacements,
for example. Element/s of interest can be selected
from the model for detailed post processing.
Numerical layer-wise stress results are often needed
for reporting.
The benchmark case is illustrated (image on top) in
[1]. The study involves a quarter of the three-layer
sandwich shell under uniform pressure load [2].
ESAComp displacement and stress results correlate
extremely well with the published data.
Sandwich panel
[1] Abaqus Benchmarks Manual, v6.8
[2] Test R0031 1/3, NAFEMS publication R0031, "Composites
Benchmarks", Feb 1995
Case file:
BC9 Nafems_R0031-3.edf
With ESAComp solid, sandwich and stiffened panels
can be simulated. Internally, an FE solver is used.
Regular stiffeners are modeled with beam elements.
The beam stiffener cross section is defined by specifying
the main dimensions and selecting laminate structures
for the different parts of the section. In the panel
specification locations of the stiffeners are specified.
Panel natural frequency analysis calculates ten lowest
natural frequencies and associated mode shapes.
The benchmark [1] case involves the study of the natural
frequencies for two kinds of composite panels.
ESAComp results correlate extremely well with the
published data for the solid panel. For the rib stiffened
panels results are also in line with the published data.
Deviation is less than 5% for all five lowest natural
frequencies.
Stiffened panel
[1] Rikards R., Chate A. and Ozolinsh O., Analysis for buckling and
vibrations of composite stiffened shells and plates, Composite Structures
51 (2001) 361-370
Case file:
BC10 Stiffened panel.edf
With ESAComp one can design flat and
curved composite panels. The panel is
simply defined by its dimensions and the
selection of the laminate.
ESAComp laminate lay-up tool allows
efficient creation of laminates from the
previously defined plies.
Boundary conditions can be configured
independently for each edge and corners.
The benchmark [1] study involves the
natural frequency analysis of the cross ply
laminate in the free boundary conditions.
Analysis results of ESAComp very well
correlate with the published data in terms of
frequency and mode shapes.
Panel natural frequency
[1] Ullah I. and Sinha J., Dynamics of Composite Plate by Experiment and
Finite Element Analysis, European Journal of Scientific Research, ISSN
1450-216X Vol.55 No.2 (2011), pp.207-219
Case file:
BC11 Natural frequency.edf
With ESAComp rectangular, curved, composite panels
can be simulated. Accompanied by axial in-plane
loads and simply supported boundary conditions is a
widely used approach for the preliminary design of
wind turbine blades.
Curved panels are defined by the main dimensions
and the radius of curvature. Then, laminate is selected
for the panel. Various load combinations and boundary
conditions can be defined in the cylindrical coordinate
system.
ESAComp can be used to calculate the critical
buckling load. With the determined load level the load
response analysis can be performed to estimate the
strain levels.
The benchmark [1] case involves the study of different
approaches for the stability analysis of wind turbine
blades. It shows that the simplified approach is
feasible and slightly conservative. An isotropic material
system was used for simplicity. ESAComp results
extremely well correlate with the published data.
Aerofoil
[1] Gaudern N. and Symons D., Comparison of Theoretical and Numerical
Buckling Loads for Wind Turbine Blade Panels, WIND ENGINEERING
VOLUME 34, NO. 2, 2010 PP 193206
Case file:
BC12 Aerofoil.edf
With ESAComp user can make trade-off studies between
different panel configurations. Solid, sandwich and
stiffened panels are defined by the main dimensions and
the selection of the laminate/s.
Several possibilities are provided for the definition of loads
and boundary conditions. For example, in-plane normal
and shear forces can be defined for the edges of the panel.
Each edge is handled independently and the forces can
vary linearly. Combination of different load components is
supported.
Stability analysis of ESAComp calculates the first ten
buckling load factors and the associated mode shapes.
The benchmark study [1] involves a buckling simulation for
various composite panels loaded with in-plane normal
force. For the solid panel analysis results of ESAComp
extremely well correlate with the published data in terms of
the buckling load and mode shape. For the hat stiffened
panel ESAComp results are conservative with the
difference of 15%. This is due to the different approach for
boundary conditions.
Hat stiffeners
[1] Roberts J.C., Bao G., and White G.J., Experimental, numerical and
analytical results for bending and buckling of rectangular orthotropic plates,
Composite Structures 43 (1999) 289-299
Case file:
BC13 Hat stiffeners.edf
With ESAComp a drive shaft with constant or axially
varying laminate lay-up can be efficiently defined. The
shaft can be reinforced locally. Also, conical shafts can
be modeled.
The shaft can be loaded with torque, axial force and
initial eccentricity of the shaft, for example.
Analysis tools allow to find optimal flexibility and
sufficient safety in terms of ply failure and global
stability. Natural frequency analysis can be used in the
design process to avoid exciting the structure in the
application environment.
The benchmark [1] case involves the study of the
shear buckling for various composite drive shafts
under torsion. ESAComp results are in line with the
published data. When the simulation is reproduced in
Ansys using respective composite shell element, it can
be stated that the buckling mode shapes are identical
and ESAComp predicts on average 5% higher
buckling load for the 5 shaft configurations.
Drive shaft
[1] Shokrieh M., Hasani A. and Lessard L., Shear buckling of a composite
drive shaft under torsion, Composite Structures 64 (2004) 6369.
Case file:
BC14 Drive shaft.edf
With ESAComp one can design straight and
conical composite tubes with circular cross
section. Performance of the structure can be
studied under various conditions.
ESAComp provides extensive data bank for
commercial material grades. Laminate
designs can base on the existing materials
and own material systems can be created.
In ESAComp the model creation is easy and
fast. Engineering can focus on the laminate
design rather than FEA modeling.
The benchmark [1] study involves the
stability analysis of the axially loaded thin-
walled composite cylinder. Linear static
analysis results of ESAComp very well
correlate with the published data.
Cyl shell axial buckling
[1] Hhne C. et al., A new approach for robust design of composite
cylindrical shells under axial compression, Proceedings of the European
Conference on Spacecraft Structures, Materials & Mechanical Testing
2005, SP-581 - September 2005.
Case file:
BC15 Cylindrical shell.edf
With ESAComp open composite cylindrical shells can be
simulated. As a special case this tool can be used to
simulate pressure vessels.
Constant pressure over the surfaces of the shell can be
applied. This generates hoop forces and bending at the ends
of the shell. The pressure vessel option sets axial membrane
forces that correspond the reaction force from the virtual end
plate or end cap.
Both ends can be rigidly mounted but more realistic
approach is obtained when the other end is free. This is
particularly important for the stability analysis to allow axial
deformation. To prevent radial deformation steel ring
idealizing the end plate can be used.
The benchmark [1] case involves the study of the buckling
for various thick (R/t ~20) carbon composite wound tanks.
ESAComp results are in line with the published data.
ESAComp predicts on average 12% higher buckling loads
for the 3 tanks when using simulation results as a reference.
Reference models had flat end plate. Deviation from the test
results were 33%.
Underwater tank
[1] Buckling of filament-wound composite cylinders subjected to hydrostatic
pressure for underwater vehicle applications, Moon C-J, Kim I-H, Choi B-H,
Kweon J-H, Choi J-H, Composite Structures 92 (2010) 22412251
Case file:
BC16 Underwater tank.edf
A qualitative measure for the adhesive can be
obtained with the standard lap shear test.
Nevertheless, the assumption for the constant shear
stress distribution is wrong. ESAComp calculates
accurately transverse shear and peeling stresses for
various bonded joints.
The stress-strain curve of the typical structural
adhesive consists of linear and nonlinear parts. In
ESAComp, this type of behavior can be modeled with
bi-linear material model.
Using the reverse engineering approach one can start
from the measured lap shear strength and end up
defining what is the ultimate failure strain of the
adhesive by using the nonlinear material model for the
adhesive.
In the reference [1] study a single-lap joint subjected to
end moments is considered with two different
approaches. Transverse shear and peeling stresses
are identical and match with those calculated by
ESAComp.
Bonded joint lap shear
[1] Analytical and Numerical Results for an Adhesively Bonded Joint
Subjected to Pure Bending, Smeltzer S. and Lundgren E., 47th
AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and
Materials Conference, AIAA 2006
Case file:
BC17 Bonded joint.edf
FEA is flexible approach for the bonded joint
problems. Drawbacks are the effort needed
in preprocessing, long solution times and
convergence issues. ESAComp solution for
bonded joints is based on semi-analytical
approach. It tackles the challenges of the
FEA approach and therefore, is valuable tool
in the preliminary design.
Bonded joint analysis computes the
response (displacement and stresses) of the
joint and evaluates margin to failure for
various joint configurations: single lap, single
strap, double lap, double strap, single scarf,
double scarf, bonded doubler
In the reference [1] study bonded doubler
and double strap joints are used for
benchmarking. Both joints are subjected to
uniaxial tension. Presented transverse shear
and peeling stress distributions very well
match with those calculated by ESAComp.
Bonded joint linear
[1] Analysis Tools for Adhesively Bonded Composite Joints, Part 1: Higher-
Order Theory, Bednarcyk B., Zhang J., Collier C., Bansal Y. and Pindera
M., AIAA JOURNAL Vol. 44, No. 1, January 2006
Case file:
BC18 Bonded joint.edf
Stress concentrations around the laminate cut-outs
need to be carefully considered. ESAComp notched
laminate analysis computes the stresses and
strains in the surroundings of the cut-out due to a
specified in-plane load and evaluates how the
laminate is able to withstand the load. Stress
concentration factors are also specified.
The analysis approach supports both circular and
elliptic notches and it is applicable when the panel
width to notch diameter ratios equal to or are
greater than 4.
The analysis can be made at the notch boundary or
at the user specified characteristic distance from
the edge. Stresses and strains can be studied in the
normal direction as well.
In the reference [1] study 45 laminate subjected to
a tensile load has been considered. Different strain
components at the edge of the notch exactly match
with those computed by ESAComp.
Notch
[1] Hufenbach W., Gottwald R., Grber B., Lepper M. and Zhou B., Stress
concentration analysis of thick-walled laminate composites with a loaded
circular cut-out by using a first-order shear deformation theory, Composites
Science and Technology (2008)
Case file:
BC19 Notch.edf
Engineering design problems include always
uncertainties such as variation in material
properties or incomplete statistical data to generate
input. ESAComp allows to treat material properties
as random variables with mean value, standard
deviation and specific distribution type.
Experimental tests can be used to create the
statistical data. When the data does not exist
estimates can be made.
ESAComp probabilistic laminate analysis is using
Monte Carlo method, which is based on the same
deterministic equations that are used in the normal
design. In the process a high number of laminate
designs are evaluated and for each design material
properties are independently defined based on their
statistical data.
This approach answers if some specific material
property has high importance in the laminate level.
The approach has been described in [1] and it
covers various types of laminate analyses.
Statistical data
[1] Probabilistic laminate analysis using ESAComp software, Wallin M. and
Leppnen P., Proceedings of the European Conference on Spacecraft
Structures, Materials & Mechanical Testing 2005, SP-581 - September
2005.
ESAComp material data bank and various analysis
and design capabilities can efficiently be used in the
conceptual and preliminary design phases of the
product development. Often, general purpose FEA
tools are needed for more detailed simulation.
The FE export interface allows transferring
ESAComp laminate definitions together with the
associated material data into the major FE software.
Various FE software specific formats are supported.
Options are both for mechanical and thermal
analyses. ESAComp writes laminate and material
definitions in the user specified unit system in to a
ascii file (image on right: python script for ANSYS
Composites PrepPost), which is then used in the FE
model.
Thanks to these interfaces ESAComp can be used
as a material database for FEA. ESAComp analysis
tools can be used for cross-checking the FE model
with simplified structure. Also, design enhancements
with ESAComp can be made in the design loop.
FE export
At the free edges of a laminate out-of-plane stresses
arise even when the laminate is subjected to in-
plane loading. Out-of-plane stresses are caused by
the mismatch in material properties of bonded
adjacent layers.
The CLT assumes a plane state of stress, which is
reasonable assumption in the middle of the laminate.
However, CLT gives erroneous layer level stresses
y
and
xy
at free edges, since these stresses should
be zero.
In the ESAComp approach the analysis is made with
FEA using a special element that makes it possible
to use just the cross section (greyed section in top
image) of the laminate in the simulation.
In the reference [1] study a cross-ply laminate is
subjected to the tensile load. Out-of-plane stresses
z
and
yz
are in-line with those calculated by
ESAComp.
Free edge mechanical
[1] Pagano N.J. (editor), Interlaminar Response of Composite Materials,
Composite Materials Series 5, Elsevier Science Publishers B.V., 1989.
Case file:
BC22 Free edge.edf
ESAComp free edge analysis computes the out-
of-plane stresses developed near the edge
region. The analysis is made for a selected
laminate and the load object can be a
combination of uniaxial in-plane and flexural
loads and hygrothermal loads varying in the
thickness direction.
The out-of-plane shear stress
yz
originates from
y
through force balance. For perfectly bonded
plies, displacement continuity at layer interfaces
requires the existence of non-zero
yz
. Similarly,
xz
is developed from
xy
. Out-of-plane normal
stress
z
originates from
y
through moment
balance.
In the reference [1, 2] studies an angle-ply
laminate is subjected to the thermal load. Out-of-
plane stresses
z
and
xz
are in-line with those
calculated by ESAComp.
Free edge thermal
[1] Whitcomp J.D. and Raju I.S., Superposition Method for Analysis of Free-
Edge Stresses, Journal of Composite Materials, Vol.17, pp.492-507, 1983.
[2] Wang A. S. D. and Crossman F. W., Edge effects on thermally induced
stresses in composite laminates, Journal of Composite Materials, July 1977,
Vol. 11, no.3 pp. 300-312
Case file:
BC23 Free edge.edf

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ESAComp Benchmark Cases

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