ACP - Intro - 14.5 - S01 - Composite - Introduction PDF

ANSYS Composite PrepPost
Modeling Composites the Simple Way
Composite Introduction
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1. Composite Introduction
Agenda
General Introduction Composites

Classification of Composites
Matrix and Fiber Materials
Reinforcement Forms
Manufacturing Methods
Draping
Ply Drop Offs
Positive and Negative Features of Composites
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Agenda
Raw Materials
Numerical Approaches
Single Plies
Rules of Mixture
Anisotropic, orthotropic, transversal isotropic
From three dimensional stress state to plane stress
Measurung Ply Properties
Failure Indicator
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Composite materials are made of multiple

layers of different materials.
They are light weight and high in strength.
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Application Areas
Aerospace
Wind Energy
Sports & Recreation
Motorsport
Construction
Automotive
Marine
Defense
and more
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Terms
Fibers- Bonded or embedded
reinforcing fibers that are usually
responsible for the anisotropy of
the composite.
Matrix- A homogeneous base

material that forms the bulk of a
composite material layer.
L
Lamina- A composite material in sheet form
usually referred to as a layer or ply. The
material properties of a layer is usually
determined through an equivalent
homogenization (smearing) process.
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Laminate- A stack of lamina joined

together in arbitrary directions,
referred to as a composite lay-up or
stacking-sequence.
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Classification of Composites Based on Reinforcement
Composite Materials can be classified by the type of
reinforcements used for the matrix material.
A. Particle Reinforced Composites
B. Fiber Reinforced Composites
Short Fiber Reinforced
Long Fiber Reinforced
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A. Particle Reinforced Composites
Particle reinforced composites consist of particles of
one material dispersed in a matrix of a second
material. Particles may have any shape or size, but
are generally spherical,
ellipsoidal, polyhedral,
or irregular in shape.
Ceramic - Aluminum
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Fiber reinforced composites (FRC) are composites
where one material component (fiber) is used as a
reinforcing material for the matrix.
Carbon Fiber - Epoxy

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Glass Fiber - Epoxy
Short Fiber Reinforced
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Long Fiber Reinforced
Random and oriented

short fiber reinforced
composites
Random and oriented

long fiber reinforced
composites
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Materials
Matrix Materials
Thermosets
Thermoplastics
Metals
Ceramics
Fiber Materials
Glass
Carbon
Aramid (Kevlar)
Boron
Ceramics
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Gel Coats
Gel coats are specialized polyester
resins formulated to provide a
cosmetic outer surface on a
composite product.
They provide the high quality finish
for composite products and increase
the durability and resistance of the
outer surface.
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Reinforcement Forms
Unidirectional
Woven
Mat
Knit
Stitched
Braid
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Roving
Reinforcement Forms
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Unidirectional
Woven
Mat
Knits
Stitched
Braiding
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There are two general methods of manufacturing
composites. Open molding describes processes with
materials being exposed to the atmosphere during the
manufacturing process while closed molding processes
use two-sided mold sets or vacuum bags.
Open Molding
Closed Molding
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Open Molding
Hand Lay-Up
Spray-up
Filament Winding
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Closed Molding
Vacuum Bag Molding
Vacuum Infusion Processing
Compression molding
Pultrusion
Resin Transfer Molding (RTM)
Reinforced Reaction Injection Molding (RRIM)
Centrifugal Casting
Continuous Lamination
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Hand Lay-Up
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Composite layer are placed manually on a mold

Resin is applied by pouring, brushing or spraying
Layers are added to build laminate thickness
Low tooling costs and minimum
investments in equipment
Simple processing
Wide range of part sizes
Skilled operators allow good production
rates and consistent quality
Low volume and labor intensive
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Hand Laying Carbon

Fiber
Using PrePreg Materials
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Fibers or fabrics with a pre-catalysed resin

system impregnated by a machine
Resin system reacts slowly at room temperature
and is usually cured by heating at cure temperature
Higher fiber contents achievable
Allows strong resins with high viscosity
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Autoclave Curing
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Curing of thermoset composites uses

mechanical and chemical processes
Pressure is applied to remove trapped air and volatiles
Plies and fiber are consolidated by pressure
Crosslink reaction, usually initiated by heating,
is necessary to cure material
Autoclave controls temperature and pressure
Allows high strength to weight ratios
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Construction of a composite
fuselage section (Boeing 787)
Spray Up
Chopped fiber reinforcements and catalyzed resin is placed onto a

mold surface using a chopper/spray gun
Laminate is rolled to compact chop
Woven or knitted fabrics can be added
Simple processing
Low-cost tooling
Portable equipment
No part size limitations
Chopped fibers
Sealine spray layup from
Motor Boat & Yachting
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Filament Winding
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Filament winding of a subsea

sphere by Windtec.no
Resin impregnated fibers or laminates are

wound around a mandrel in predefined pattern
Fibers and laminates can be pre-impregnated
or running through a resin bath before wound
Composite is usually cured using autoclaves or ovens
High strength to weight ratios
Good control over uniformity and fiber orientation
Allows highly engineered products and strict tolerances
Automatic process
Limited designs (although new developments
allow non cylindrical and non spherical designs)
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Vacuum Bag Molding
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Improves mechanical properties of open mold processes

A release film is placed over the laminate
Followed by a bleeder ply of fiberglass cloth, non-woven nylon,
polyester cloth, or other material that absorbs excess resin from
the laminate
A breather ply of a non-woven fabric is placed over the bleeder ply
A vacuum bag is mounted over the entire assembly
Vacuum is applied and the atmospheric pressure eliminates voids
and excess resin
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Vacuum Bag Molding
More uniform consolidation
Removing entrapped air
Avoids hand layups being resin rich
Improved core-bonding
How-To Use a Vacuum Bag
Vacuum Infusion
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The resin is introduced into the mold after the vacuum has pulled
the bag down and compacted the laminate
Resin completely saturates the reinforcements
No resin excess offers substantial emission reductions
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Compression Molding
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A mechanical or hydraulic press with heated molds forms

composite parts using sheet molding compound, bulk molding
compound or liquid composite molding
Sheet Molding Compound (SMC); Fiber reinforced polyester
material using long strands of chopped fibers (> 1 inch)
Bulk Molding Compound (BMC); Highly filled resin paste combined
with short fibers (0.125- 0.5 inch)
Liquid Composite Molding (LMC); Uses preforms matching the
finished design or mats (in case of plane shapes). Resin is added
into the open dies. High strength to weight ratios
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Compression Molding
Fast molding cycles
High part uniformity
Good surfaces available
Automatic process
Chopped fibers or
preforming necessary
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Pultrusion
Continuous method to manufacture composite parts having a

uniform cross section
Rovings or fiber mats are pulled through
resin bath and then formed and cured in
a heated die
The Pultrusion Process
Cured parts are cut into desired lengths
Continuous process
High strengths
Limited to uniform cross sections
Pultrusion
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Combining Braiding & Pultrusion
combines the braiding performing technique and composite

pultrusion process to fabricate constant cross-section products
Fiber angles can be oriented in the braiding process to achieve a
specific angle along to the beam axis
Continuous process
High strengths
Orientation of fiber angles
Limited to uniform cross sections
Braid-Trusion of an L-shaped
thermoplastic composite beam
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Resin Transfer Molding (RTM)
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Reinforcement material (can be continuous fibers, mats, preforms,

or woven fabrics) is placed between two matching mold surfaces
Resin is injected into the mold and wets out all surfaces of the
reinforcing materials
Curing at room temperature or by heated molds (cycle time)
Vacuum can be applied to increase resin flow
High quality finish
Fast production
Allows complex surface designs
High tooling costs
Resin
Limited part sizes
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Reinforced Reaction Injection Molding (RRIM)
Reinforcement material and resin are mixed and injected into a

closed mold
Short fibers or flakes are usually used to create a more isotropic
material behavior
Structural Reaction Injection Molding (SRIM)
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This process uses two resin components which are combined and
mixed together, then injected into a mold cavity containing
reinforcement. In the mold cavity, the resin rapidly reacts and
cures to form the composite part
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Centrifugal Casting
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Used for making cylindrical, hollow shapes such as tanks, pipes

and poles
Chopped strand mat is placed into a hollow, cylindrical mold, or
continuous roving is chopped and directed onto the inside walls of
the mold
The resin is applied to the inside of the rotating mold
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Continuous Lamination
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Creates composites in sheet form such as composite glazing,

corrugated or flat construction panels, and electrical insulating
materials
Reinforcement is combined with resin and sandwiched between
two plastic carrier films
Sheet takes shape under forming rollers, and the resin is cured to
form the composite
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Hand Layup
Automated Prepreg
Winding
RTM
Geometry
Complex
Complex
Near to rotational
Complex
Holes/Inserts
Possible
Possible
Difficult
Possible
Stiffeners
Possible
Possible
Difficult
Possible
Back Tapering
Possible
Possible
Not possible
Difficult
Moderate Good1
Good1
Moderate1
Good2
Fiber Architecture
Any
Any
Limited
Any
Typ. Fiber Volume

Content
40%
65%
50%
50%
Middle
High
Middle
Middle
Quality
Moderate
Very good
Middle
Good
Reproducability
Moderate
Very good
Good
Good
Low
Very High
High
High
Surface
Mechanical Properties
Tooling Costs
According to Ermanni, ETH Zrich
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only one side

2
both sides
From Fibers to Finished Composite Components
By SGL Group
The Carbon Company
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Draping
The ability to drape describes the formability of textile
preforms and how they adapt themselves to the contour of
3D surfaces
Draping is simulated to avoid wrinkles or other undesired
effects and to consider changes of the fiber orientation
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Draping of a Ply
Inside a Ply
In a Laminate
Trellis-Effect:
change of angle between fiber
directions due to shearing
Fiber Stretching:
curvature of woven fibers
changes due to tensile loading
Fiber Straining:
due to elasticity of fibers
Fiber Translation:
due to slipping, especially at
edges and corners
Translation:
translation of plies with respect
to each other
According to Ermanni, ETH Zrich
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Ability to Drape
High ability to drape and low

deformation resistance allow
draping of complex
geometries
high
Draping
2DKnitted Fabrics
Mats
2D-Wovens
low
3D-Wovens
UD-Clutch
high
low
Deformation Resistance
Plank, Wiesbaden 1992
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Ply Drop Offs
Achieve gradual thickness changes and tapering
in composite laminates
Introduces resin pockets, which may lead to
delamination failure
terminated plies
resin pocket
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Positive Features of Composite Designs
Oriented stiffness and strength properties
Material properties adjustable by engineers (material design)

Parameters to modify e.g. type of fibers and matrix, fiber
volume fraction, fiber orientation, stacking sequence, layer
thickness, fabrication method
Significant reduced weight compared to metals

High stiffness and strength properties with respect to weight
High fatigue resistance
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Positive Features of Composite Designs
Specific material characteristics possible (e.g. thermal
stability due to negative coefficient of thermal expansion of
carbon fibers)
Reduced corrosion tendency
Low moisture absorption
Damping of vibrations
Less sensitive for imperfections (geometrical and physical)
Electrical conductivity or non-conductivity
(depending on the materials used)
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Negative Features of Composite Designs
Low stiffness and strength perpendicular to fiber direction
Large thermal strains perpendicular to fiber direction

Low interlaminar shear stiffness and strength
Long time durability (especially concerning environmental
influence, e.g. heat, moisture, chemical, UV, aging )
Heat resistance (e.g. fire resistance of matrix material)
Undesirable brittle failure behavior (safety concepts)
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Negative Features of Composite Designs
Open questions concerning recycling
Difficulties in damage detection (x-rays, ultra sonic, thermo

graphic, non-destructive methods)
Open questions concerning reparability
Relatively high material costs
Problems with conventional joints (bolts, rivet, adhesive)
Sensitive with respect to the fabrication process (flaws,
bubbles, dust)
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Raw Materials
Composite materials are made of at least
two distinct materials
One component (fiber) is used as a
reinforcing material for the matrix
Carbon Fiber - Epoxy
The matrix holds fibers
The matrix will guarantee a load transfer

in between the fibers as well as external
loadings into the fibers
Matrix takes forces

in between fibers
Fibers take forces

in fiber direction
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Relative Importance of Fibers and Matrix
Fiber
Matrix
Mechanical Properties
Stiffness
Strength
Fatigue
Damage tolerance
Impact behavior
Thermo-mechanical properties
Fiber-matrix bonding
Ermanni, ETH Zrich
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No Importance
High Importance
Relative Importance of Fibers and Matrix
Fiber
Matrix
Physical Properties
Corrosion Behavior
Thermal Stability
Chemical Stability
Electrical properties
Ermanni, ETH Zrich
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No Importance
High Importance
Glass Fibers
Basically silica(SiO2)
Isotropic properties
E-glass (electrical glass)
Most common fiber
Moderate stiffness, high strength
Relatively heavy
Good chemical, environmental
conditions and fire resistance
inexpensive
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Glass Fiber Roving
Glass Fibers
R-, S-glass (strength glass, other
chemical mixture)
higher stiffness (+20%) and
strength compared to E-glass
expensive
Glass Fiber Roving
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Carbon Fibers
Orthotropic properties
Many different types available
Expensive to extremely expensive
Low density
Low ductility in impact
Coefficient of thermal
expansion nearly zero
Electrically conductive
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Carbon Fiber Sandwich
Carbon Fibers
PAN (polyacrylnitrile)-fiber
Low stiffness
Very high tensile & compressive strength
(HT-, HS-, HM-fibers)
Pitch-fiber
High to ultra high stiffness (HM-, UHM-fiber)
High tensile and low compressive strength
Large scatter in material properties
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Aramid Fibers (also known as Kevlar, Twaron)
Orthotropic properties
Lowest density of all fibers
Higher stiffness compared
to glass fiber
High tensile strength
Low compressive strength
Highly ductile in impact
Woven Aramid
Negative coefficient of thermal expansion
Moisture absorption decreases material properties
Available with low stiffness (life vests, robes, etc.)
Moderately expensive
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Other Fiber Materials
For special application, e.g. embedded in
ceramic or metal matrix
Boron
Silicon Carbide (SiC)
Silicon Oxide (SiO2)
Aluminum Oxide (Al2O3)
others
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Thermosets as Matrix Material
Isotropic properties
Polyester (unsaturated)
Most common resin
Good resistance against chemicals and
UV-light
Catalytic reaction, short curing time,
emits styrene
Large shrinkage during curing
Inexpensive
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Epoxy
Most often used resin for high
quality composite materials
Very good strength properties,
good gluing properties
Curing with hardener through
polyaddition is critical in view
of health
Low shrinkage
Expensive
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Epoxy Resin
and Hardener
Vinyl ester
Properties in between Polyester and Epoxy
Very good chemical resistance
Low shrinkage
Moderate price
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Thermoplastics as Matrix Material
Different production process
necessary (valid for mass production)
Needs heat to be formed
and solidified
Creeps at larger
temperatures
Larger ductility then
thermosetting
Press for Thermoplastics,

University Kaiserslautern
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Thermoplastics as Matrix Material
PP (Polypropylene), PE (Polyethylene),
PA (Polyamide), PEEK (Polyether ether ketone)
High ductile resistance
Good mechanical properties
Temperature resistance (up to max. 250 C)
Expensive
Polyamide
Less thermal resistance but less expensive
PTFE (Teflon)
Temperature resistant
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Non-Polymer Matrix Materials
Metal-Matrix-Composites (MMC)
Aluminum
Titanium
Copper
Magnesium
Ceramics-Matrix-Composites (CMC)
Aluminum oxide
Mullite
Carbon
Silicon carbide
Concrete
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Steel Fiber Reinforced

Concrete
Ceramic Particles in
Aluminum
Bor Fibers in Aluminum
Core Materials
Foam
Polyurethane PU
Polyvinylchloride PVC
Polystyrene PS
Honeycombs
Aluminum
Plastic (Nomex)
Glass / Penol
Nomex
Paper
Honeycomb
Wood
Balsa
Prestressed wooden cores
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Foam
Balsa
Get a feeling for size.
5.000.000 : 1
Scale relation
geometry to fiber
diameter
Rotor Diameter 82m
Hub Height up to 100m
(Figure Coutesy by REpower Systems SE )
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Micro-Scale Approach
Meso-Scale (Laminate Level)

Approach
Macro-Scale Approach
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The most detailed approach describes the micro-structure
of the composite. This includes fiber shape, fiber location
and material properties of reinforcement and matrix.
If only displacements, buckling loads, or vibration
frequencies and modes are required, the laminate can be
analyzed as a homogeneous shell using a macro-scale
approach. In this case the stress distribution can not be
obtained.
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Analyzing strains, stresses and failure criteria of the
composite laminate requires to model the single layers a
composite design is built up by. This method is called
meso-scale approach. It requires material properties and
thicknesses for each layer of the design.
ANSYS Composite PrepPost is mainly used to prepare and

evaluate composite specific results of a design using the
meso-scale approach.
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Single Plies
The Ply Coordinate System
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1-Direction: Parallel to fiber direction

(also II-direction, L-direction or x-direction)
2-Direction: Perpendicular to fiber direction

(also direction, T-direction or y-direction)
3-Direction: Normal to ply

(also out of plane or z-direction)
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Unidirectional Plies
Fiber Volume Fraction
Fiber Volume
F Total Volume V F
V tot
Fibers
AF AM
Fiber Weight Fraction
Fiber Weight G F
Total Weight Gtot
A
A A
F
Matrix Weight Fraction
Matrix Weight G M
Total Weight
Gtot
Conversion
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A
A A
M
1
1 1
1 F
M M
Matrix
Unidirectional Plies
Fiber volume fraction, fiber mass and the ply thickness
are dependent values
Wovens and Fabrics:
Fiber volume fraction for
M
t
specific ply thickness
Ply thickness for a specific
t M
fiber volume fraction
F
t arg et
t arg et
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kg
2
m
Rules of Mixture
Rules of mixture are used to estimate material properties
(Young's modulus in the 1 and 2 direction) of a composite
based on the fiber and matrix material properties
Multiple different rules of mixture exist in literature, all of
them are an estimation
Using the rules of mixture we simplify the mechanics of
the composites layers
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Rules of Mixture, Halpin-Tsai Equations
Semi-empirical model
Contiguity factor usually defined empirical by curve
fitting. See recommended values on next slide.
E1
1
EM 1
1
EF 1
1
E
M1
EF 1
1
EM 1
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E2
1
EM 2
1
EF 2
1
E
M2
EF 2
1
EM 2
G12
1
GM 12
1
GF 12
1
G
M 12
GF 12
1
GM 12
Rules of Mixture, Halpin-Tsai Equations
Contiguity factor
E1 for perfectly aligned continuous fibers
E1 for imperfectly (or wavy) aligned

continuous fibers
<
(often in range of 100-1000)
E1 for aligned discontinuous fibers
= 2 fiber aspect ratio
E2 for aligned continuous or

discontinuous fibers
=2
G12 for aligned continuous or

discontinuous fibers
=1
(Source: Fire properties of polymer composite materials by A. P. Mouritz,A. G. Gibson)

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Rules of Mixture, Jones
E1 EF1 (1 ) EM
G12
GM GF 12
GM (1 ) GF12
12 F12 (1 ) M
21 12
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E2
E1
February 7, 2013
E2
EM E F 2
EM (1 ) EF 2
Rules of Mixture, Puck
Empirical modification with respect to experimental
values using a nonlinear approach according to Puck
E1 EF1 (1 ) EM
EM (1 0.85 2 )
E2
*
EM
(1 )1.25
EF 2
*
EM
*
EM
1 M2
GM (1 0.6 0.5)
G12
G
M (1 )1.25
GF 12
12 F12 (1 ) M
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21 12
E2
E1
Homogeneous and Heterogeneous Materials
Heterogeneous materials have varying properties at
different locations within the material
In contrast, properties for homogeneous materials (e.g
steel) are the same at every location within the material
Composite laminate material is considered
predominantly as a homogenous material for simulations
on a laminate level.
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Anisotropic Material
Isotropic material (e.g. steel) has the same properties in any
direction.
Anisotropic material has properties (mechanical, etc.) that
vary with the orientation.
The stiffness of an isotropic material is described by two
properties, the modulus of elasticity E and Poissons ratio ,
whereas anisotropic material requires up to 21 properties
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Anisotropic Material
Material definition requires the full 66 elastic coefficient
matrix [D]
xx D11
D
yy 21
zz D31

xy D41
yz D51

xz D61
D22
D32
D42
D52
D62
D33
D43
D53
D63
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xx
symmetry
yy
zz

D44
xy
yz
D54 D55

D64 D65 D66 xz
Orthotropic Material
An orthotropic material has three planes of material symmetry
A unidirectional fiber-reinforced composite may be
considered to be orthotropic
One plane of symmetry is perpendicular to the fiber direction,
and the other two can be any pair of plane orthogonal to the
fiber direction
Z
Fibers
Matrix
Y
X
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Fibers
Matrix
Nine constants are required to describe an orthotropic material

E x , E y , E z , xy , yz , xz , Gxy , G yz , Gxz
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xx D11
D
yy 21
zz D31

xy
yz

xz
D12
D22
D32
D13
D23
D33
D44
D55
xx

yy
zz

xy
yz

D66 xz
Fibers
Matrix
The compliance matrix S S D1 is defined as
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E1
xx x
Exy
yy x
zz Exzx

xy
yz

xz
yx
Ey
1
Ey
yz
Ey
Ezxz
zy
Ez
1
Ez
1
G xy
1
G yz
1
G xz
xx

yy
zz

xy
yz

xz
Transversal Isotropic Material
Transversal isotropic materials are orthotropic materials
characterized by isotropic material behavior in one material
symmetry plane
A unidirectional layer has transversal isotropic material behavior
with the fiber direction as symmetry axis
A woven fabric has transversal isotropic material behavior with
the out of plane normal direction as symmetry axis
The number of constants to define is reduced to 5
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Transversal Isotropic Material
Unidirectional Layer
E y Ez
Gxy Gxz
xy xz
G yz
Ey
2 1 yz
Unidirectional
Woven Fabrics
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Ex E y
yz xz
G yz Gxz
Ex
Gxy
2 1 xy
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Woven
Isotropic Material
Most common materials of industrial use are isotropic
(aluminum, steel, etc.)
Isotropic materials have an infinite number of planes of
symmetry, meaning that the properties are independent of the
orientation
Two constants (Young modulus and Poissons Ratio) are
necessary to represent the elastic properties of isotropic
material
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From Three Dimensional to Plane Stress State
Composite materials are often used in form of plates and
shells, which have two dimensions (length and width) much
larger than the third dimension (thickness). When the
thickness of a plate is small compared to the other dimension,
it is reasonable to assume that the transverse stress is zero
(Z=3=0).
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From Three Dimensional to
Plane Stress State
z 0, yz 0, xz 0
xx S11
S
yy 21
zz S31

xy
yz

xz
S12
S 22
S32
Compliance Matrix S
x S11

y S12

xy
S11
S13
S 23
S33
S 44
S55
xx

yy
zz

xy
yz

S 66 xz
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February 7, 2013
x

y
S 66 xy
1
1
1
, S 22
, S 66
E1
E2
G12
S12 S 21
12
E1
Stiffness Matrix D
x D11

y D12

xy
D12
D22
x

y
D66 xy
E1
E
, D22 2 , D66 G12
E
S12 S 21 12 2
E
2
1 2 12
E1
D11
83
S12
S 22
Transformation to the Global Coordinate System
Layers are defined with different specific fiber angles
In order to build a stiffness matrix for the complete layup the
stiffness matrixes for each layer are transformed from the
layers x,y,z or 1,2,3 coordinate system into the global
coordinate system using a transformation matrix
cos 2
T sin 2
sin cos
cos 2
T 1 sin 2
sin cos
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sin 2
cos 2
sin cos
sin 2
cos 2
sin cos
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2 sin cos
2 sin cos
cos 2 sin 2
2 sin cos
2 sin cos
cos 2 sin 2
x
y
z
Y
Transformation to the Global Coordinate System
x
X
1
Y T y

XY
xy
x
X

y T Y

XY
xy
x
X

y T Y

XY
xy
x
y
x
X

1
Y T y

XY
xy
Compliance Matrix
X S11

Y S12

XY
S12
S 22
Y
S 66 XY
Stiffness Matrix
X
X D11 D12

Y D12 D22
Y

D66 XY
XY
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T 1 S T
T 1 D T
Layered Shell-Elements in ANSYS
4-Node Structural Shell
8-Node Structural Shell
Structural shell elements require the definition of the

following mechanical material properties per layer
Young's Modulus in X, Y and Z direction
Shear Modulus in the XY, YZ and XZ plane
Poisson's Ratio in the XY, YZ and XZ plane
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Element Technology in ANSYS
A layup can also be defined for solid elements (SOLID185,
SOLID186) and solid like shell elements (SOLSH190) in ANSYS
Furthermore discrete reinforcements (REINF264) are possible
for shell and solid elements
Please see the ANSYS Theory Reference in the ANSYS Help
(// Theory Reference) for more information on element
technology in ANSYS
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Measuring Ply Properties
Mechanical properties of composite materials depend on the production
process and the specific material properties of the basic materials used as
well as on the manufacturing process of the composite design
General material databases are available (ESAComp has a comprehensive
material database) but the data provided are standard material data
For individual material data ask your material manufacturer about data,
recommended tests and/or recommended test laboratories
Contact test laboratories offering standard test (ISO or ASTM) and non
standard tests
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International Organization for Standardization
The International Organization for Standardization is an international

standard-setting body composed of representatives from various national
standards organizations.
Examples:
ISO 14125:1998 fiber-reinforced plastic composites -- Determination of
flexural properties
ISO 527-5:2009 Plastics -- Determination of tensile properties -- Part 5:
Test conditions for unidirectional fiber-reinforced plastic composites
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American Society for Testing and Materials (ASTM)
ASTM International is an international standards organization that develops

and publishes voluntary consensus technical standards for a wide range of
materials, products, systems, and services.
Examples:
Committee D30 on Composite Materials
ASTM D7205 / D7205M - 06 Standard Test Method for Tensile Properties
of Fiber Reinforced Polymer Matrix Composite Bars
ASTM D7617 / D7617M - 11 Standard Test Method for Transverse Shear
Strength of Fiber-reinforced Polymer Matrix Composite Bars
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Tension Tests and Failure Mode
Unidirectional
Composite Tensile Test
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Compression Tests and Failure Mode
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In-Plane Shear Tests and Failure Modes
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Failure Indicator
FPF First-Ply-Failure Indicator
Mathematical equations indicating first failure of any ply
Indicates the occurring failure mode: fiber tension, fiber
compression, matrix tension, matrix compression
Determines reserve factor, inverse reserve factor, margin of
safety
Typical criteria: Max. Stress, Max. Strain, Tsai-Wu, Tsai-Hill,
Hashin, Puck2D, Puck3D, Cuntze
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Failure Indicator
LPF Last-Ply-Failure (Progressive Damage)
Further loading beyond FPF until ultimate failure of laminate.
Post-failure formulations needed (ply-discount method)
May also include energy dissipating methods
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Delamination
Interface failure between two plies in normal direction
Interlaminar Failure
Driven by normal stress in thickness direction
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Debonding
Interface failure between face sheet and core
of sandwich structures.
Only predictable when core and sheet are
separately modeled.
Compression Test
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Wrinkling
Local buckling of a face sheet under
compression
Failure indicator available using shell
modeling of sandwich
Core Failure
Local failure of core in shear or tensile
loading
Failure indicator available using shell
modeling of sandwich
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ANSYS Composite PrepPost

Modeling Composites the Simple Way

2011 ANSYS, Inc.

General Introduction Composites

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Composite materials are made of multiple

They are light weight and high in strength.

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2011 ANSYS, Inc.

Matrix- A homogeneous base

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Laminate- A stack of lamina joined

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2011 ANSYS, Inc.

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Carbon Fiber - Epoxy

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Glass Fiber - Epoxy

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Long Fiber Reinforced

Random and oriented

Random and oriented

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2011 ANSYS, Inc.

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Composite layer are placed manually on a mold

Hand Laying Carbon

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Fibers or fabrics with a pre-catalysed resin

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Curing of thermoset composites uses

Chopped fiber reinforcements and catalyzed resin is placed onto a

2011 ANSYS, Inc.

2011 ANSYS, Inc.

Filament winding of a subsea

Resin impregnated fibers or laminates are

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Improves mechanical properties of open mold processes

How-To Use a Vacuum Bag

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2011 ANSYS, Inc.

A mechanical or hydraulic press with heated molds forms

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Continuous method to manufacture composite parts having a

2011 ANSYS, Inc.

combines the braiding performing technique and composite

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2011 ANSYS, Inc.

Reinforcement material (can be continuous fibers, mats, preforms,

Reinforcement material and resin are mixed and injected into a

Structural Reaction Injection Molding (SRIM)

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2011 ANSYS, Inc.

Used for making cylindrical, hollow shapes such as tanks, pipes

2011 ANSYS, Inc.