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RADIOSS Composites
Analysis, Concept, and Optimization

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HyperWorks 9.0
Table of Contents
RADIOSS Composites
Analysis, Concept and Optimization of Composites Structures
Table of Contents.................................................................................................................... II
Chapter 1: Theoretical Introduction........................................................................ 1
1 Composite Material ................................................................................................... 1
1.1 Why Composites .................................................................................................... 1
1.2 - Definitions ............................................................................................................... 2
1.3 - Material Laws (Elastic Linear) ................................................................................. 6
1.3.1 - Adding Thermal Strain........................................................................................ 11
1.4 - Micromechanics of Composite Materials ............................................................... 13
1.5 - Effective Homogenized Stiffness Matrix of a Ply.................................................... 13
2 Macromechanical Behavior of a Laminate (Ply)....................................................... 16
3 Classical Lamination Theory (CLT).......................................................................... 17
3.1 - Laminate Convention ............................................................................................ 17
3.2 Mid-Plane Forces and Moments........................................................................... 18
3.3 The [ABD] Matrix .................................................................................................. 19
3.4 Smear Technology ............................................................................................... 21
3.5 Stacking Sequence Dependence of [ABD] Matrix................................................. 22
3.6 Laminate Examples.............................................................................................. 24
3.7 Composite Failure Theories.................................................................................. 26
Exercise 1.1 - Evaluate the ply and laminate matrices................................................... 27
Chapter 2: Composite Pre-processing - Analysis ............................................... 31

1 - Composite Laminates .............................................................................................. 31
1.1 - Analysis of Composites ......................................................................................... 32
2 - How to Setup a Composite in HyperMesh ................................................................ 34
HyperWorks 9.0
II
2.1 Using Hyper Laminate .......................................................................................... 38

2.1.1 Creating a Laminate .......................................................................................... 39
2.2 PCOMP - Composite Laminate Property .............................................................. 45
2.3 - PCOMPG Global Composite Laminate Property ................................................ 47
2.4 - PCOMPP Composite Laminate Property for Ply-Based...................................... 49
2.4.1 How to define a Laminate using the Ply-Based cards ........................................ 49
Exercise 2.1: Clamped BEAM (PCOMP) ..................................................................... 51
Exercise 2.2: Clamped I BEAM (PCOMPG) ................................................................ 56
Exercise 2.3: Clamped I BEAM (PCOMPP-STACK-PLY) ............................................ 62
Chapter 3: Composite Optimization ..................................................................... 69

1 What is Optimization? ............................................................................................. 70
1.1 Optimization Definitions........................................................................................ 71
1.2 Topologic optimization.......................................................................................... 72
1.2.1 Homogenization method.................................................................................... 72
1.2.2 Density method ................................................................................................. 73
1.2.3 Why Topologic optimization on composites? ..................................................... 73
2 Free-Size Optimization ............................................................................................ 74
2.1 Interpreting Topology and Free-size Results ........................................................ 77
2.2 Free-Size applied to Concept Design Synthesis of Composite Laminates ............ 77
3 Size Optimization .................................................................................................... 78
3.1 Size Optimization applied to Composites.............................................................. 79
4 Ply Stacking Sequence Optimization ....................................................................... 79
5 Phase Transitions in the Optimization of Composite Structures............................... 80
Exercise 3.1: Optimization Driven Design of a Composite plate .................................... 81
Exercise 3.2: Optimization Drive Design of a Composite Wing Design.......................... 97
III
HyperWorks 9.0
Chapter 1: Theoretical Introduction
Chapter 1
Theoretical Introduction
1- Composite Material
The word composite for a structural engineer means that two or more materials are
combined on a macroscopic scale to form a new material. The macroscopic scale is a key
definition, because we intend to look only the global behavior of the component. The advantage
of a composite material is that if the component is well designed, it shows the desired qualities
where it is required, and in almost all cases better than the material alone.
Properties such as strength, fatigue life, wear resistance, thermal insulation, stiffness,
weight, acoustical insulation; etc can be improved by forming a composite material.
The main reason to develop a component built with a composite material is that the
material can have the characteristics needed to optimize the component performance.
There are several different types of composites. The below lists the main ones:
a. Particulate Composites (Particles + Matrix)
b. Laminated Composites (Layers)
c. Fibrous-Matrix Laminated Composites (Layers Long fiber + Matrix)
d. Core Stiffened Laminated Composites
This training will focus on the Fibrous-Matrix Laminated Composites, which are the most
commonly used composites for high performance structural components.
1.1 - Why Composites

Composite materials have great advantages when compared with homogeneous
materials. With this technology it is possible to build the material based on the application
requirements. Some applications like aerospace components where the weight is a decisive
factor, lot of performance gain is achieved with the usage of materials.
HyperWorks 9.0
RADIOSS Composites 1
1.2 Definitions
a. Microscopic: is a term used to describe physical objects smaller than can easily be
seen by the naked eye and which require a lens or microscope to see
clearly.
b. Micromechanics: is the study of composite material behavior wherein the interaction of
the constituent materials is examined in detail as part of the definition
and behavior of the heterogeneous composite material.
c. Macroscopic: is a term used to describe physical objects that are measurable and
observable by the naked eye and do not require a lens or microscope to
see clearly.
d. Macromechanics: is the study of composite material behavior wherein the material is
assumed homogenous and the effects of the constituent materials are
detected only as averaged apparent properties (i.e. effective
properties) of the composite material.
e. Homogeneous: The material has uniform properties in all points (i.e. the properties are
independent of the position)
f. Heterogeneous: The material has nonuniform properties (i.e. the properties are
dependent of the position)
g. Isotropic: The material properties are the same in all directions (i.e. the properties are
independent of the direction)
h. Orthotropic: The material has properties that are different in three mutually
perpendicular directions and it presents 3 symmetric planes.
i. Anisotropic: The material properties is different for all directions, no symmetric plane can
be defined.
j. Stress Cube:
k. Strain Cube:
HyperWorks 9.0
l. Transformation Matrix 3D Tensors:
X
Y
Z
x
l1
l2
l3
y
m1
m2
m3
l1 = cos(x, X ) =
X l12
l 2
Y 2
Z l32
=
XY l1l2
YZ l2l3

XZ l1l3
m12
m22
m32
m1m2
m2 m3
m1m3
n12
n22
2l1m1
2l2 m2
2m1n1
2m2 n2
n32
2l3m3
2m3n3
n1n2 l1m2 + m1l2 m1n2 + n1m2
n2 n3 m2l3 + l2 m3 n2 m3 + m2 n3
n1n3 l1m3 + m1l3 m1n3 + n1m3
z
n1
n2
n3
x X
xX
x

y
2l3n3 z

n1l2 + l1n2 xy
l2 n3 + n2l3 yz

n1l3 + l1n3 xz
2l1n1
2l2 n2
or
X l12
l2
Y 2
Z l32
=
XY l1l2
YZ l2 l3

XZ l1l3
m12
m22
n12
n22
2l1m1
2l 2 m2
2m1n1
2 m2 n 2
m32
m1m2
m2 m3
m1m3
n32
n1n2
n 2 n3
n1n3
2l3m3
l1m2 + m1l2
m2 l3 + l2 m3
l1m3 + m1l3
2m3n3
m1n2 + n1m2
n2 m3 + m2 n3
m1n3 + n1m3
HyperWorks 9.0
x

y
2l3 n3 z

n1l2 + l1n2 xy
l2 n3 + n2 l3 yz

n1l3 + l1n3 xz
2l1n1
2l 2 n 2
m. Transformation Matrix 2D Tensors (Plane Stress)
{ x } = [TS ]1 { 1 }
x cos 2

2
y = sin
cos sin
xy
sin 2
cos 2
cos sin
2 cos sin 1

2 cos sin 2
cos 2 sin 2 12
This is valid for strain too:
{ x } = [TS ]1 { 1 }
[TS ]
[TS ]T
cos 2
= sin 2
cos sin
sin 2
2
cos
cos sin
cos2
=
sin 2
2 cos sin
sin 2
cos2
2 cos sin
2 cos sin
2 cos sin
cos 2 sin 2
cos sin
cos sin
cos2 sin 2
HyperWorks 9.0
n. Kirchhoff Plate Theory
u = u0 z
w0
x
v = v0 z
w0
y
Kirchhoff Plate
o. Linear Elastic 2D Strain-Displacement relationship
x =
u
x
y =
v
y
xy =
u v
+
y x
p. Strain-Displacement for Kirchhoff Plate
u0
2 w0
x =
z
x
x 2
v0
2 w0
y =
z 2
y
y
xy
u0 v0
2 w0
=
+
2z
y x
xy
x x0 k x
0
y = y + z ky
0 k
xy xy xy
{ x } = { x
}+ z{k}
HyperWorks 9.0
1.3 Material Laws (Elastic Linear)

a. Anisotropic:
For an anisotropic material there are 21 independent constants which define the
anisotropic stiffness matrix as follows;
i = Cij j
1 C11
C
2 21
3 C31
=
12 C 41
23 C51

13 C61
C12
C22
C32
C42
C52
C62
i , j = 1,...,6
C13 C14
C 23 C 24
C33 C34
C 43 C 44
C53 C54
C63 C64
The Stiffness matrix is always Symmetric: Cij = Cji.
The inverse is called Compliance Matrix S = C-1.
1 S11
S
2 21
3 S 31
=
12 S 41
23 S 51

13 S 61
C15
C 25
C35
C 45
C55
C65
C16 1
C26 2

C36 3

C46 12
C56 23

C66 13
S16 1
S 26 2

S 36 3

S 46 12
S 56 23

S 66 13
S12
S13
S14
S15
S 22
S 32
S 42
S 52
S 62
S 23
S 33
S 43
S 53
S 63
S 24
S 34
S 44
S 54
S 64
S 25
S 35
S 45
S 55
S 65
HyperWorks 9.0
b. Isotropic:
Isotropic materials have an infinite number of planes of material property symmetry and
thus material properties are the same in all directions at a point within a body.
1 C11
C
2 12
3 C12
=
12 0
23 0

13 0
C12
C12
C11
C12
C12
C11
0
0
0
0
0
0
0
0
(C11 C12 )
(C11 C12 )
1

2
3

0 12
0 23
(C11 C12 )
2
13
0
0
0
or
1 S11
S
2 12
3 S12
=
12 0
23 0

13 0
S12
S11
S12
S12
0
0
0
0
S12
0
S11
0
0
2(S11 S12 )
0
0
2(S11 S12 )
1

2
0
3

0
12
23
0

2(S11 S12 ) 13
0
0
with these two equations is possible to isolate the stiffness matrix:

C11 =
S112 S122
S113 3S11 S122 + 2 S123
C12 =
S122 S12 S11

S113 3S11 S122 + 2 S123
Isotropic linear elastic materials have two independent engineering constants, any two of E, G,
or which are related by equation:
1 E1

2 E

Rewriting the Strain-Stress relationship: 3 = E
12 0
23 0

13 0
G=
E
2(1 + )
1
E
0
0
0
0
1
E
1
G
0
0
0
0
0
0
1
G
0 1
0 2

0 3

0 12
0 23

1
G 13
Plane Stress: 3 = 13 = 23 = 0
1 E1
( ) : 2 = E
0
12
1 Q11

( ) : 2 = Q12
0
12
E
1
E
0
Q12
Q22
0
0 1

0 2
1
G
12
with: 3 =
0 1

0 2
Q44 12
( 1 2 )
E
Q11 =
S22
S11S22 S122
Q22 =
S11
S11 S 22 S122
where:
Q12 =
S12
S11S 22 S122
Q44 =
1
S44
* There are some restrictions to the engineering constants for linear isotropic materials:
E>0
G>0
-1 < <
HyperWorks 9.0
c. Transverse Isotropic:
Transversely isotropic materials have one plane of material property symmetry in which
the material properties are the same within that single plane at a point within a body.
Transversely isotropic materials have 5 independent engineering constants, E1, E2, 12, 23, and
G12. In the case of unidirectional fiber-matrix composites the 23 plane is the single plane of
material property symmetry as shown in
Transversely Isotropic Composite
1 C11
C
2 12
3 C12
=
12 0
23 0

13 0
C12
C22
C12
C23
0
0
0
0
C23
0
C22
0
0
C44
0
0
(C22 C23 )
1 S11
S
2 12
3 S12
=
12 0
23 0

13 0
S12
S 22
S12
S 23
0
0
0
0
S 23
0
S 22
0
0
S 44
0
0
0
0
0
0
0
0
( S22 S23 )
0 1
0 2

0 3

0 12
0 23

C44 13
0 1
0 2

0 3

0 12
0 23

S 44 13
Combining these equations we can isolate the stiffness matrix terms as function of the
compliance terms:
C11 =
where:
2
2
S 22
S 23
S
C12 =
S12 S 23 S12 S 22
S
C 22 =
S11 S 22 S122
S
C 23 =
S122 S 23 S11
S
2
2
2
S = S11 S 22
S11 S 23
2 S 22 S122 + 2 S12 S 23
In terms of engineering constants we can rewrite the Strain-Stress relation as:

12
12
0
0
0 1
1 E11
E1
E1
23
12
1
0
0
0 2
E2
2 E1 E2

E1
E2
3 E112 E223 E12
0
0
0 3 where: G =
G23 =
12
2(1 + 12 )
2(1 + 23 )
0
0 G112 0
0 12
12 0
23 0
0
0
0 G123 0 23

0
0
0
0 G112 13
13 0
HyperWorks 9.0
3 = 13 = 23 = 0
Plane Stress:
1 E11
12
2 = E1
0
12
12
E1
1
E2
0 1 S11

0 2 = S12
1
0
G12 12
S12
S 22
0
0 1

0 2
S 44 12
with: 3 = 12 1 + 23 2
E2
E1
1 Q11 Q12 0 1

2 = Q12 Q22 0 2
0
0 Q44 12
12
where: Q11 =
S 22
S11 S 22 S122
Q12 =
S12
S11 S 22 S122
Q22 =
S11
S11 S 22 S122
Q44 =
1
S44
* There are some restrictions to the engineering constants for linear transversely isotropic
materials:
12 <
E1 , E1 , G12 > 0
1 2122
E1
E2
23 < 1
E2
E
2
23
2122 23 2 > 0
E1
E1
HyperWorks 9.0
d. Orthotropic:
Orthotropic materials have three orthogonal planes of material property symmetry in
which the material properties are the same within these three mutually orthogonal planes at a
point within a body. Orthotropic materials have 9 independent engineering constants, E1, E2, E3,
12, 23, 13, G12, G23, and G13.
1 C11
C
2 12
3 C12
=
12 0
23 0

13 0
1

2
3
=
12
23

13
S11
S
12
S12
0
0
C12
C22
C23
0
0
0
C12
C23
C22
0
0
0
0
0
0
C44
0
0
0
0
0
0
C55
0
0 1
0 2

0 3

0 12
0 23

C66 13
S12
S12
S 22
S 23
S 23
0
S 22
0
0
S 44
0
0
S 55
0 1
0 2

0 3

0 12
0 23

S 66 13
Stiffness and Compliance Matrix for an Orthotropic Material
In terms of engineering constants, the orthotropic compliance matrix is defined as follows:

1
1 E1
12
2 E1
3 E113
=
12 0
23 0

13 0
31
E3
32
E3
1
E3
1
G12
0
0
0
0
0
0
0
0
21
E2
1
E2
23
E2
1
G 23
0 1
0 2

0 3

0 12
0 23

1
G13
13
HyperWorks 9.0
3 = 13 = 23 = 0
Plane Stress:
S is symmetric:
1 E11
12
2 = E1
0
12
12
E1
1
E2
ij
Ej
ji
i, j = 1,2,3.
Ej
0 1 S11

0 2 = S12
1
0
G12 12
S12
S 22
0
i j
0 1

0 2
S 44 12
with: 3 = 12 1 + 23 2
E2
E1
1 Q11 Q12 0 1

2 = Q12 Q22 0 2
0
0 Q44 12
12
where: Q11 =
S 22
S11 S 22 S122
Q12 =
S12
S11 S 22 S122
Q22 =
S11
S11 S 22 S122
Q44 =
1
S44
* There are some restrictions to the engineering constants for linear orthotropic materials:
12 <
E1
E2
23 <
1 122
E2
E3
13 <
E1
E3
E
E
E2
2 E2
23
132 3 212 2313 3 > 0
E1
E3
E1
E1
1.3.1 Adding Thermal Strain

Generalized Hooks Law = C , doesnt include the thermal strain however this
equation needs to be modified to account for free thermal strains. Consider a bar placed freely
on a table in a room currently at room temperature. Now, turn on the heat in the room, the bar
will expand an amount ()(T) due to the temperature change. However, this expansion, while
causing thermal strains, does not cause the bar to be stressed as it is unconstrained on the
table. Therefore, Stress-Strain needs to be modified to account for such a condition by defining
different types of strains which contribute to the overall strain of the body.
There are three types of strains which need to be defined in a thermal environment; the total,
free thermal, and mechanical strains.
Total strains are the summation of both the free thermal and mechanical strains.
= T +M
Free thermal strains are the strains caused by free thermal expansion or contraction.
HyperWorks 9.0
Mechanical strains are the strains which cause stress.
Typically the mechanical strains are the strains of interest in engineering calculations.
Note, however, that most commercial FEA codes output the total strains by default and
therefore the user must set an option to output the needed mechanical strains if thermal
boundary conditions are present.
Then the Stress-strain relation becomes:
i = Cij ( j j T )
i, j = 1 6
where:
j is the total strain, the sum of free thermal and mechanical strains;
j T is the free thermal strain
M = T is the mechanical strain which causes stress
HyperWorks 9.0
1.4 Micromechanics of Composite Materials

The goal of micromechanics, as applied to fiber-matrix laminated composites, is to
either:
a. Calculate the effective engineering constants of the combined homogenized
material given the engineering constants for each individual constituent or,
b. Calculate the homogenized mechanical stress or strain tensors in each
constituent (fiber and matrix in the case of fiber-matrix laminated composites)
given the homogenized mechanical strain tensor of the ply and the engineering
constants for each individual constituent.
1.5 - Effective Homogenized Stiffness Matrix of a Ply

There are several methods available which can be used to calculate the effective
homogenized stiffness matrix of a ply, [C], most of which fall under two categories; strength of
material approaches and elasticity approaches.
Cij = Cij (E f , f , V f , E m , m , Vm )
The rule of mixtures is the simplest of the strength of materials approaches and makes
the following broad assumptions:
o
The ply is linear elastic, macroscopically homogeneous, and orthotropic
The fibers are linear elastic, macroscopically homogeneous, isotropic,

regularly spaced, perfectly aligned, and perfectly bonded to the matrix
The matrix is linear elastic, macroscopically homogenous, isotropic, and void

free.
Hypothesis Representation
HyperWorks 9.0
Determination of Ply E1
P = 1 A = f A f + m Am
1 = E1 1
f = Ef f
m = E m m
1 = f = m
as:
E1 = E f V f + EmVm
Unidirectional Stress (1)
Determination of Ply E2
W = 2W = f V f W + mVmW
2 =
2
E2
f =
m =
Ef
m
Em
1 = f = m
as:
E2 =
E f Em
E f V f + EmVm
Determination of Ply 12
12 =
W = 2W = 121W
W = f 1V f W + m1VmW
12 = f V f + mVm
HyperWorks 9.0
Determination of Ply G12
= 12W = f V f W + mVmW
12 =
12
G12
f =
f
Gf
m =
m
Gm
12 = f = m
G12 =
G f Gm
G f V f + GmVm
Pure Shear Stress (12)
HyperWorks 9.0
2 Macromechanical Behavior of a Laminate (Ply)

The constitutive stress/strain relationships we have developed so far are all written in
the principal material 1-, 2-, 3- coordinate system as given by this equation:
1 Q11

2 = Q12
0
12
Q12
Q22
0
1 1
+ T
2 2
Q44 12 3
0
0
However, in order to determine the global behavior of a ply we need to write this
relationship in the global x-, y-, z- coordinate system. This is accomplished by using the 2D
plane stress transformations, with the addition of free thermal strain considerations, as shown
below:
{ x } = [TS ]1 [Q ][TS ]T ({ x } { x }T )
{ x } = [Q ]({ x } { x }T )
On global coordinate the stiffness matrix is:
[Q ] = [TS ]
[Q ][TS ]T
Q 11 = Q11 cos 2 + 2(Q12 + 2Q44 ) sin 2 cos 2 + Q22 sin 4

Q 12 = (Q11 + Q22 4Q44 ) sin 2 cos 2 + Q12 (sin 4 + cos 4 )
Q 14 = (Q11 Q12 2Q44 ) sin cos 3 + (Q12 Q22 + 2Q44 ) sin 3 cos
Q 22 = Q11 sin 2 + 2(Q12 + 2Q44 ) sin 2 cos 2 + Q22 cos 4
Q 24 = (Q11 Q12 2Q44 ) sin 3 cos + (Q12 Q22 + 2Q44 ) sin cos 3
Q 44 = (Q11 + Q22 2Q12 2Q44 ) sin 2 cos 2 + Q44 (sin 4 + cos 4 )
HyperWorks 9.0
3 Classical Lamination Theory (CLT)

3.1 - Laminate Convention
RADIOSS uses the laminate stacking sequence and ply z-coordinate conventions
showed on the image below:
Laminate Stacking Sequence and Z-coordinate Conventions
Note that the xy plane defined by the global coordinate system goes through the middle surface
of the plate with z-axis defined using right hand rule, which in this case is down.
Taking a plane section through the plate, Plane A, the details of the laminate stacking sequence
and ply z-coordinate conventions can be investigated.
Plies are given a number 1 thru n:

o
1st ply always defined as the most negative z ply
nth ply as the most positive z ply.
z-coordinate value for the kth ply is always defined as the most positive zcoordinate interface for that ply.
Laminates are typically specified in the engineering community using the notation shown below:
[ply1/ply2/(ply3/ply4)n /.../plyn]s/as/n
n: Define the number of repeating units;
s: Symmetric Laminate
as: Anti-symmetric Laminate
For symmetric and anti-symmetric laminates only the most positive half, of the plies are
specified.
HyperWorks 9.0
3.2 Mid-Plane Forces and Moments

The positive sign convention for homogeneous or laminated plate mid-plane forces is
given in Figure below. For a homogenous single ply plate of constant thickness the midplane
forces can be written in terms of stress variation through the thickness of the plate as:
N x t / 2 x

N y = y dz
N t / 2
xy
xy
Positive Mid-Plane Forces
For a laminated plate made up of n constant thickness plies the mid-plane forces can
be written in terms of the sum of the stress variation through the thickness of each ply as:
Nx
x
n zk

N y = y dz
N k =1 z k 1
xy
xy
The positive sign convention for homogeneous or laminated plate mid-plane moments is
given in Figure below. For a homogenous single ply plate of constant thickness the midplane
moments can be written in terms of stress variation through the thickness of the plate as:
M x t / 2 x

M y = z y dz
M t / 2
xy
xy
Positive Mid-Plane Moments
Mx
x
zk
n

M y = z y dz
M k =1 z k 1
xy
xy
HyperWorks 9.0
3.3 The [ABD] Matrix

Using the relationship between Stress-Strain:
{ x } = [Q ]({ x } { x }T )
We can by adding the subscript k designate the equation on the laminated coordinates for
each ply:
{ x }k
[ ] ({ } { } T )
= Q
x k
x k
Now we can rewrite the mid-plane forces as:

n
zk
{N x } = ([Q ]k ({ x
} + z {k } { } T ))dz
}+ [B]{k } {N }
k =1 z k 1
x k
This can be rewrite as:
{N x } = [A]{ x
T
x
Where:
n
[A] = ([Q ]k (zk zk 1 ))

k =1
n
[B ] = 1 ([Q ] k (zk2 zk21 ))

2
k =1
{N }= 12 ([Q ] { } (z
T
x
x k
zk 1 )
k =1
Doing the same for the mid-plane moments:

n
zk
{M x } = ([Q ]k ({ x
k =1
} + z {k } { } T ))zdz
k
x k
z k 1
This can be rewrite as:
HyperWorks 9.0
{M x } = [B]{ x
}+ [D]{k } {M }
x
T
x
Where:
n
[B] = 1 ([Q ]k (zk2 zk21 ))

2 k =1
n
[D] = 1 ([Q ]k (zk3 zk31 ))

3 k =1
{M }= 12 ([Q ] { } (z
T
x
x k
2
k
zk21 )
k =1
With it we finally can define the relationship between the mid-plane generalized forces and
strain:
N A B 0 N T
=
k T
M
B
D

M
[A]
o
Mid-plane forces mid-plane extension (Tentsion and compression)
The [A] matrix is stacking sequence independent
A14 and A24 these terms represent extensional shear coupling between the
mid-plane forces and midplane shear strain.
Mid-plane forces coupling between plate curvature strain (bending and twist)
Mid-plane moments coupling between mid-plane extension (Traction and

compression)
The [B] matrix is zero for symmetric laminates
Mid-plane Moments plate curvature strain (bending and twist)
D14 and D24 These terms represent bending - twist coupling between the midplane moments and plate curvatures.
[B]
[D]
HyperWorks 9.0
3.4 Smear Technology

Smear technology is use to calculate a laminated plate [ABD] matrix with an
indeterminate stacking sequence. The intention of using SMEAR technology with composite
design is to ultimately make the design optimization phase, or concept design optimization
phase, stacking sequence independent as in these phases a laminate is being defined in the
first place (i.e. a stacking sequence does not exist we are trying to define one).
It can be shown that the average [D] matrix of all possible combinations of stacking
sequences for a given laminate is equal to the smeared [D] matrix for that laminate, [D]smear.
Therefore, using [D]smear is an appropriate action when you have a laminate with an
indeterminate stacking sequence as youll calculate the average [D] matrix for all possible
stacking sequences.
Homogeneous plate stacking and Z-coordinate Definitions

LAMINATED
[A]
([Q ] (z
k
HOMOGENEOUS
[Q ]t
zk 1 )
k =1
[B]
[D]
1 n
Q k (zk2 zk21 )
2 k =1
1 n
Q k (zk3 zk31 )
3 k =1
([ ]
([ ]
1
1
Q t 3 = [A]t 2
12
12
[]
1. No extensional bending or shear twist coupling in a homogeneous plate

2. Only [A] needs to be evaluated.
HyperWorks 9.0
3.5 Stacking Sequence Dependence of [ABD] Matrix

On the Figure below we see a plot of the [Q] matrix terms, the plane stress stiffness
matrix in global coordinates for the kth ply, versus the angle the kth ply makes with the global xaxis.
Looking at the plot the following statements can be made about the various components
of the [Q] matrix for the kth ply:
1. Q 11 and Q 22 are ninety degrees out of phase (i.e. a 90-deg ply is a 0-deg ply in the yaxis) and are always positive for any positive or negative theta angle.
2. The Q 12 and Q 44 terms are in phase with each other and are always positive for any
positive or negative theta angle.
3. The Q 14 and Q 24 components are thirty degrees out of phase and change sign with
theta angle. Both are positive for positive angles and negative for negative angles. In
addition, Q 14 and Q 24 components are zero for theta angle values of zero and ninety.
HyperWorks 9.0
We will assume that each ply is made of the same material; however each ply can have
its own unique theta angle. As shows bellow the values for the (zkn-zk-1n) terms for each ply.
-3
Ply a, t=1
-2
Ply b, t=1
-1
Ply c, t=1
0
Ply d, t=1
1
Ply e, t=1
2
Ply f, t=1
3
Z coordinate
Ply a
Ply b
Ply c
Ply d
Ply e
Ply f
[A]
zk
z k z k 1
-3
-2
-1
0
1
2
3
(-2)-(-3)=1
(-1)-(-2)=1
(0)-(-1)=1
(1)-(0)=1
(2)-(1)=1
(3)-(2)=1
[B]
2
k
z z
[D]
2
k 1
3
k
z z k31
(-2)2-(-3)2=-5
(-1)2-(-2)2=-3
(0)2-(-1)2=-1
(1)2-(0)2=1
(2)2-(1)2=3
(3)2-(2)2=5
(-2)3-(-3)3=19
(-1)3-(-2)3=7
(0)3-(-1)3=1
(1)3-(0)3=1
(2)3-(1)3=7
(3)3-(2)3=19
[A] Characteristics
o
z k z k 1 is always positive and equal to ply thickness, then [A] is stacking
o
o
independent.
[A] is equal for any stack sequence with the same number of plies.
A14 and A24 are zero for any balanced Laminated. Because Q 14 and Q 24 are on
domain (odd function).
[B] Characteristics
o
[B] is zero for any symmetric laminate. (Odd function on thickness domain)
[D] Characteristics
o
o
o
o
[D] is sequence dependent because z k3 z k31 is always positive and increase

significantly with the distance from the mid-plane.
Q 11 are higher for 0o, the location of these plies in the stacking sequence of a given
laminate influence the bending behavior of it on X-direction.
The same happen for bending on transverse direction with the 90o plies (Y-direction).
Balanced and Anti-Symmetric D14 and D24 are equal to zero, then no coupling on
bending-twisting.
HyperWorks 9.0
D14 and D24 terms become insignificant for laminates with grater than 16 plies.
3.6 Laminate Examples

a. Symmetric Laminates
A symmetric laminate is defined as a laminate which is composed of plies such that both
geometric (theta and thickness) and material properties are symmetrical about the middle
surface of the plate.
o
The [B] = 0 no extensional bending or shear twisting coupling.
i - [0 / 45 / 90 / 45 / 0] [0 / 45 / 90]s
ii - [0 / 45 / 90 / 90 / 45 / 0] [0 / 45 / 90]s
b. Anti-Symmetric Laminates
An anti-symmetric laminate is defined as a laminate for which every + and - ply on one
half of the middle surface there exist a - and + ply respectively of the same thickness and
material property at the same location on the other half of the middle surface. In addition, 0 plies
and 90 plies must be symmetric about the middle surface.
iii - [0 / 45 / 90 / 45 / 0] [0 / 45 / 90]as
iv - [0 / 45 / 90 / 90 / 45 / 0] [0 / 45 / 90]as
v - [0 / 90 / 45 / 45 / 90 / 0] [0 / 90 / 45]as
Anti-Symmetric laminates must have an even number of layers if adjacent laminas also have
alternating signs of the principal material property direction with respect to the laminate axes (iv
and v). If the adjacent laminas do not have alternating signs, then the number of layers not need
be even (iii).
c. Balanced laminates
A balanced laminate is defined as a laminate for which every + ply there exists a - ply
of the same thickness and material property.
o
A balanced laminate does not define where in the laminate stacking sequence
the plies need to exist, just that there are same number of + and - plies.
A14 and A24 components for balanced laminates will always be zero and thus
exhibit no extensional shear coupling.
In addition, if a balanced laminate is also anti-symmetric, then D14 and D24

components will be zero and thus will also not exhibit bending twisting
coupling.
HyperWorks 9.0
vi - [0 / 45 / 45 / 0] [0 / 45]as
vii - [0 / 45 / 22.5 / 22.5 / 45 / 0] [0 / 45 / 22.5]as
viii - [0 / 45 / 45 / 45 / 45 / 0] [0 / 45 / 45]s
xi - [0 / 22.5 / 22.5 / 30 / 30]
d. Cross-Ply Laminates
A cross-ply laminate is defined as a laminate composed of only 0 and 90 plies.
o
A14, A24, D14, and D24 components for cross-ply laminates will always be zero and
thus exhibit no extensional shear or bending -twisting coupling.
xii - [0 / 90 / 90 / 0] [0 / 90]s
xiii - [90 / 0 / 90 / 0 / 90 / 0]
e. Angle-Ply Laminates
An angle-ply laminate is defined as a laminate composed of only + and - plies.
xiv - [ 30 / 30 / 45 / 45 / 30 / 30] [ 30 / 30 / 45]as

xv - [30 / 0 / 30 / 0 / 30 / 0]
f.
General Laminates
A general laminate is defined as a laminate which does not fall into any of the previous
categories of laminate definitions. General laminates can exhibit fully populated [ABD] matrices
and thus all types of coupling can exist including;
o
Extension shear coupling (A14 and A24 terms)
Extension bending coupling ([B] matrix terms)
Shear twisting coupling ([B] matrix terms)
Bending twisting coupling (D14 and D24 terms
xiv - [ 30 / 30 / 22.5 / 90 / 0 / 30]

xv - [30 / 60 / 30 / 25 / 30 / 15]
HyperWorks 9.0
3.7 Composite Failure Theories

There are several challenges facing engineering when it comes to using analytical
methods to predict or even capture trends by assessing the failure of a material, structure, or
system. The first challenge is defining, what is failure?.
In the most general terms, failure refers to any action leading to an inability on the part of the
structure (or system) to function in the manner intended.A. Ugural and S. Fenster Advanced
Strength and Applied Elasticity
Typical failure modes for metallic structures include:
o
Excessive linear elastic deflection
Permanent deformation or Yielding
Instability or Buckling
Creep and Fatigue
Fracture or the creation of new surfaces
In a similar manner, typical failure modes for composite structures include:

o
Excessive linear elastic deflection
Matrix Crazing and Matrix Shear Yielding (See SIFT failure theory)
Fiber Fracture
Instability or Buckling
Creep and Fatigue
Transverse Matrix Fracture or the creation of new surfaces within a ply
Delamination or the creation of new surfaces between plies
HyperWorks 9.0
Exercise 1.1: Evaluate the ply and laminate matrices.

This exercise will be used to fix some basic fundamentals about composites that will be
important on the practical exercises later.
a. Given the following unidirectional fiber-matrix ply material properties, calculate the
orthotropic compliance [S], stiffness [C], plane stress compliance [S], and plane
stress stiffness [Q] matrices.
b. Using the same properties, build the A, B and D matrices for this laminates:
i - [0,0,45,45,-45,-45]S
ii - [0,45,-45,0,45,-45]S
Model Information
Orthotropic Material Data:

o E1 = 18.7e6
psi
o E2 = E3 = 1.40e6
psi
o 12 = 13 = 0.3
o 23 = 0.6
o G12 = G13 = 0.5e6 psi
o G23 = 0.45e6 psi
o 1 = 1.0e-7
o 2 = 3 = 18.0e-6
Problem Setup: Copy the file matrix.xls
HyperWorks 9.0
PART a
Step 1: Build the S matrix for Plane Stress/3D for an orthotropic material:
Plane Stress
E11
[S ] = E112
0
3D
0
1
G12
12
E1
1
E2
E11
12
E1
E12
[S ] = 1
0
0
12
E1
12
E1
23
E2
1
E2
1
G12
0
0
1
G23
1
E2
23
E2
0
0
0
0
1
G12
Step 2: Calculate Q and C matrix:

Plane Stress
[Q ] = [S ]
3D
[C ] = [S ]1
HyperWorks 9.0
PART b
Step 1: Calculate [TS ] for all angles (0, 45, -45):
1
cos2
[TS ] 1 = sin2
cos sin
Step 2: Calculate
2 cos sin
2 cos sin
cos2 sin 2
sin 2
2
cos
cos sin
[Q] for all angles: [Q] = [TS ] [Q][TS ]

1
Q 11 = Q11 cos 2 + 2(Q12 + 2Q44 ) sin 2 cos 2 + Q22 sin 4

Q 12 = (Q11 + Q22 4Q44 ) sin 2 cos 2 + Q12 (sin 4 + cos 4 )
Q 14 = (Q11 Q12 2Q44 ) sin cos 3 + (Q12 Q22 + 2Q44 ) sin 3 cos
Q 22 = Q11 sin 2 + 2(Q12 + 2Q44 ) sin 2 cos 2 + Q22 cos 4
Q 24 = (Q11 Q12 2Q44 ) sin 3 cos + (Q12 Q22 + 2Q44 ) sin cos 3
Q 44 = (Q11 + Q22 2Q12 2Q44 ) sin 2 cos 2 + Q44 (sin 4 + cos 4 )
2.50E+07
2.00E+07
1.50E+07
Q_11
Q_12
Q_14
Q_22
Q_24
Q_44
1.00E+07
5.00E+06
0.00E+00
-100
-50
50
100
-5.00E+06
-1.00E+07
HyperWorks 9.0
Step 3: Calculate
[A], [B] and [D] for all layers, where it needs the appropriate
[Q] matrix:
n
[A] = ([Q ]k (zk zk 1 ))

k =1
[B] = 1 ([Q ]k (zk2 zk21 ))

2 k =1
n
[D] = 1 ([Q ]k (zk3 zk31 ))

3 k =1
HyperWorks 9.0
Chapter 2: Composite Pre-processing - Analysis
Chapter 2
Composite Pre-processing Analysis

1 - Composite Laminates
Plates and shells can be made of layered composites in which several layers of different
materials (plies) are bonded together to form a cohesive structure. Typically, the plies are made
of unidirectional fibers or of woven fabrics and are joined together by a bonding medium
(matrix). In OptiStruct/RADIOSS composite shells, the plies are assumed to be laid in layers
parallel to the middle plane of the shell. Each layer may have a different thickness and different
orientation of fiber directions.
Four-layer composite with ply angle shown.
Classical lamination theory is used to calculate effective stiffness and mass density of
the composite shell. This is done automatically within the code using the properties of individual
plies. The homogenized shell properties are then used in the analysis.
After the analysis, the stresses and strains in the individual layers and between the
layers can be calculated from the overall shell stresses and strains. These results may then be
used to assess the failure indices of individual plies and of the bonding matrix.
HyperWorks 9.0
Chapter 2: Composite Pre-processing
1.1 - Analysis of Composites

Analysis of composite shells is very similar to the solution of standard shell elements.
The primary difference is the use of the PCOMP or PCOMPG property card, instead of
PSHELL, to specify shell element properties. From the ply information specified on the PCOMP
entry, OptiStruct automatically calculates the effective properties of the shell element.
After the analysis, the available results include shell-type stresses as well as stresses,
strains, and failure indices for individual plies and their bonding. These results are controlled by
the results flags on the PCOMP or PCOMPG entry and the usual I/O control cards.
PCOMP and PCOMPG define the composite lay-up in two different ways.
o
PCOMP defines the structure and properties of a composite lay-up which is then
assigned to an element. The ply is only defined for that particular property and there is
no relationship of a ply that reaches across several properties.
PCOMPG defines the structure and properties of a composite lay-up allowing for global
ply identification which is then assigned to an element. Plies of different PCOMPG
definitions can have a relationship because of the use of global ply IDs.
HyperWorks 9.0
Some remarks are in place regarding the specifics of composite analysis:

1. The most typical material type used for composite plies is MAT8, which is planar
orthotropic material. The use of isotropic MAT1 or general anisotropic MAT2 for ply
properties is also supported.
2. While it is possible to specify ply angles relative to the element coordinate system, the
results become strongly dependent upon the node numbering in individual elements.
Thus, it is advisable to prescribe a material coordinate system for composite elements
and specify ply angles relative to this system.
3. Depending on the specific lay-up structure, the composite may be offset from the
reference plane of the shell element, i.e. has more material below than above the
reference plane (or vice versa).
4. Stress results for composites include both shell-type stresses and individual ply
stresses. Importantly, shell-type stresses are calculated using homogenized properties
and thus only represent the overall stress-state in the shell. To assess the actual stressstate in the composite, individual ply results need to be examined.
HyperWorks 9.0
2 - How to Setup a Composite in HyperMesh

1. Import or create the 2D geometry that will represent your component.
2. Organize your model in components
3. Generate the Mesh.
4. Align the elements according to the laminate main direction.
TETA (Angle that the element needs to be rotate from definition)
MCID (Local coordinate system)
Both are defined as the (7th field for CQUAD or 6th field for CTRIA)
HyperWorks 9.0
5. Define the composite materials.

E1 = 1.3e5
12 = 13 = 0.3
G12 = G13 = 3450
1 = 1.0e-7
Mpa
Mpa
mm/mm o
/C
E2 = E3 = 9650
23 = 0.6
G23 = 3100
2 = 3 = 18.0e-6
Mpa
MPa
mm/mm o
/C
6. Define the PCOMP or PCOMPG properties:

PCOMP (1 mm) [45, 90, -45]S
PCOMPG (1 mm) [45, 90, -45]S
7. Assign the properties to the components.
HyperWorks 9.0
8. Apply the boundary conditions for a simple tension problem. (SPC)
9. Apply the loads. (Load)
10. Create the load step with the constraints and loads.
11. Run the analysis
HyperWorks 9.0
12. Pos-processing
?????
Results Representation: (Global x Analysis System)
o
Analysis System is the element definition system:

o
BLANK : X (G1 G2) / Z = Element Normal
THETA: X (G1 G2) Rotated by THETA. / Z = Element Normal
MCID: X is defined by the local coordinate system.
HyperWorks 9.0
2.1 Using Hyper Laminate

Menus
Toolbar
Laminate
Browser
Define/Edit
Pane
Review/Results
Pane
Menus
The HyperLaminate menu bar contains five menus that allow you to manage files, edit
materials, laminates, HLS loadcases and design variables, change views, and access on-line
help.
Toolbar
The HyperLaminate toolbar contains five tools that allow you to generate new materials,
laminates, HLS loadcases or design variables, and to cut, copy, paste, and delete entries in text
boxes.
Laminate Browser
This browser, located on the left side of the HyperLaminate window, provides a vertical tree
view of materials, laminates, HLS loadcases and size design variables in your model.
Left-clicking on an entity populates the Define/Edit and Review panes with details of that
branch.
Right-clicking on a branch offers context-sensitive operations for that branch.
Define/Edit Pane
This is the central pane of the HyperLaminate module. Here users may enter or change data
related to a material, laminate, HLS loadcase or design variable definition (depending on the
selected branch in the laminate browser).
Review Pane
This is the right-hand pane of the HyperLaminate module. The Review/Results pane has a
number of tabs that display the current state of the selected branch.
HyperWorks 9.0
2.1.1 Creating a Laminate

HyperLaminate is a very efficient interactive tool, to better understand how it works we will
show how to create the material and the properties for this laminate: [-45,90,45,0]S where ply
thickness equal to 1mm and material properties as below:
Mpa
E2 = E3 = 9650
Mpa
E1 = 1.3e5
12 = 13 = 0.3
23 = 0.6
G12 = G13 = 3450
Mpa
G23 = 3100
MPa
-7
mm/mm o
-6
mm/mm o
/C
2 = 3 = 18.0e
/C
1 = 1.0e
1.
Create a orthotropic material (Mat 8)
HyperWorks 9.0
2. Create a PCOMP property or a PCOMPG
HyperWorks 9.0
3. Create a load case
HyperWorks 9.0
4. Using HyperLaminate to Calculate the Laminate properties
HyperWorks 9.0
HyperWorks 9.0
HyperWorks 9.0
2.2 PCOMP - Composite Laminate Property

Defines the structure and properties of an n-ply composite laminate material.
Format
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
PCOMP
PID
Z0
NSM
SB
FT
TREF
GE
LAM
MID1
T1
THETA1 SOUT1 MID2
MID3
T3
THETA3 SOUT3
T2
(10)
THETA2 SOUT2
etc.
DS
MOST USED FIELDS

PID Property Number (Unique)
Z0 Distance from reference Mid-plane to the bottom. (Default = 0.5 Thk.)
FT Failure Theory code (Default = No)
o HILL for Hill theory,
o HOFF for Hoffman theory,
o TSAI for Tsai-Wu theory,
o STRN for Maximum Strain Theory.
LAM Laminate Option
Blank (Default) All plies must be specified.
SYM Only plies on the Bottom half of the composite lay-up need to be
specified.
MEM All plies must be specified, but only membrane terms are developed.
BEND All plies must be specified, but only Bending terms are developed.
SMEAR All plies must be specified, stacking sequence is ignored, and MID1 is
set equal to MID2 on the derived equivalent PSHELL, while MID3, MID4, TS/T,
and 12I/T**3 are set to zero.
SMCORE All plies must be specified. The last ply specifies core properties
and the previous plies specify face sheet properties. The face sheet properties
are calculated without regard for stacking sequence; half of the total face sheet
thickness is then placed on top of the core, and half is placed on the bottom, to
produce a symmetric laminate. Stiffness of the core is ignored while its density is
included in inertia calculations.
SYMEM Membrane Symmetric.
SYBEND Bending Symmetric.
SYSMEAR SMEAR Symmetric.
MIDi Material IDs of the individual plies. (Default is the last defined MID)
Ti Thickness of the individual ply. (Default is the last defined Ti)
Thetai Orientation angle, in degrees, of the longitudinal direction of each ply relative to the xaxis of the material coordinate system associated with a given element.
* The description for the other fields can be found on the online documentation.
HyperWorks 9.0
Plies are listed from the bottom surface upwards, in respect to the elements normal direction.
(a) shows the stacking sequence for a non-symmetrical laminate;

(b) shows the stacking sequence for a symmetrical laminate.
Example
(1)
(2)
(3)
PCOMP
-0.5
0.2
0.2
(4)
(5)
(6)
(7)
1.E5
STRN
100.
0.0
YES
0.6
0.0
YES
(8)
(9)
90.0
NO
(10)
HyperWorks 9.0
2.3 - PCOMPG Global Composite Laminate Property

Defines the structure and properties of a composite laminate material, allowing for
global ply identification.
Format
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
PCOMPG
PID
Z0
NSM
SB
FT
TREF
GE
LAM
GPLYID1
MID1
T1
THETA1 SOUT1
GPLYID2
MID2
T2
THETA2 SOUT2
(10)
DS
MOST USED FIELDS

Z0 Similar to PCOMP
FT Similar to PCOMP
LAM Laminate Option
Blank (Default) All plies must be specified.
MEM All plies must be specified, but only membrane terms are developed.
BEND All plies must be specified, but only Bending terms are developed.
SMEAR All plies must be specified, stacking sequence is ignored, and MID1 is
set equal to MID2 on the derived equivalent PSHELL, while MID3, MID4, TS/T,
and 12I/T**3 are set to zero.
SMCORE All plies must be specified. The last ply specifies core properties
and the previous plies specify face sheet properties. The face sheet properties
are calculated without regard for stacking sequence; half of the total face sheet
thickness is then placed on top of the core, and half is placed on the bottom, to
produce a symmetric laminate. Stiffness of the core is ignored while its density is
included in inertia calculations.
GPLYID Global Ply Identification number.
MIDi Similar to PCOMP
Ti Similar to PCOMP
Thetai Similar to PCOMP
* The description for the other fields can be found on the online documentation.
HyperWorks 9.0
Plies are listed from the bottom surface upwards, in respect to the elements normal direction.
The image below, shows the stacking sequence for a non-symmetrical laminate.
Example
(1)
PCOMP
(2)
(3)
-0.5
101
2
103
(4)
(5)
(6)
(7)
1.E5
STRN
100.
0.2
0.0
YES
0.6
90.0
NO
0.2
0.0
YES
(8)
(9)
(10)
HyperWorks 9.0
2.4 - PCOMPP Composite Laminate Property for Ply-Based

Defines the properties of a composite laminate material used in ply-based composite
definition.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
PCOMPP
PID
Z0
NSM
SB
FT
TREF
GE
(9) (10)
MOST USED FIELDS

Z0 Similar to PCOMP
FT Similar to PCOMP
1. The PCOMPP card is used in combination with the STACK and PLY cards to create
composite properties through the ply-based definition.
2.4.1 How to define a Laminate using the Ply-Based cards

Suppose this laminate with 4 layers [0, 90, 0, 45]
With these plies:
FIRST
SECOND
THIRD
HyperWorks 9.0
FOURTH
This process is similar to the process defined at section 2 of this chapter (2 How to Setup a
Composite in HyperMesh) that covers the setup using PCOMP or PCOMPG.
1. Follow the steps 1 thru 5 from the section 2.
2. Define the element sets that define each ply
3. Define PLIES (Angle, Elements Sets, Thickness, etc)
4. Define the PCOMPP property
5. Define the Stack sequence (Ply sequency)
6. Now just follow the steps 9 thru 12 defined on the section 2.
HyperWorks 9.0
Exercise 2.1: Clamped BEAM (PCOMP)

This exercise runs a static analysis on a laminate clamped beam [0, -45, 45, 90] with uniform
thickness equal 1 mm for all plies. The problem intends to describe all the details involved in a
composite analysis using the PCOMP card.
Ply(1) 0o
Ply(2) -45o
Ply(4) 90o
Ply(3) 45o
Problem description
Model Information
Geometry:
o
One load case:

o
(L = 300, h = 150, b = 4 mm)
Force = 1N
Material:
E1 = 1.3e5
Mpa
12 = 13 = 0.3
G12 = G13 = 3450 Mpa
E2 = E3 = 9650
23 = 0.6
G23 = 3100
Mpa
MPa
Problem Setup
You should copy these Files: BEAM_COMPOSITE.hm;
HyperWorks 9.0
Step 1: Open the model on HyperMesh.

1. Launch HyperMesh with User Profile > RADIOSS > BulkData.
2. Open the HyperMesh database
BEAM_COMPOSITE.hm.
Step 2: Model Setup

1. Create a Orthotropic material (MAT8) with the values below:
2. Create the PCOMP properties.

Using PCOMP we need to determine all the layer sets that this model has, this can be done if
we find the common elements between the plies as showed below.
o
1,2,3,4
NULL
1,3,4
HyperWorks 9.0
1,2,4
2,3,4; 1,2,3 NULL
1,2; 2,3; 1,3; 1,4 NULL
2,4
3,4
o 1; 2; 3; 4 NULL.
It is a good procedure, if using PCOMP; isolate the elements in different components for
pos-processing.
HyperWorks 9.0
3. Assign the appropriate properties created above to the element of the beam components.
134
124
24
34
Step 3: Run and study the results

1. Save this model BEAM_COMPOSITE_PCOMP.HM.
2. Run this model and call BEAM_COMPOSITE_PCOMP.FEM
Global Results
1. Which result it would be important to plot in addition to these?

_________________________________________________________________________
_________________________________________________________________________
2. What is the mainly difficult with PCOMP?
_________________________________________________________________________
_________________________________________________________________________
HyperWorks 9.0
Step 4: Rerun the model and request now the CSTRESS and the CSTRAIN and
study the results for each ply
1. Save this model BEAM_PCOMP_CS.HM.
2. Run this model and call BEAM_PCOMP_CS.FEM
CSSTRAIN FOR EACH LAYER (On the PCOMP order)
PCOMP (1) [ 0 , 45, 90]
PCOMP (2) [ 0 , -45, 90]
PCOMP (3) [ -45, 90]
PCOMP (4) [ 45, 90]
RESPONSE:
The individual ply results as showed above.
2. What is the mainly difficult with PCOMP?
Pos-processing with different properties, mainly when the component has multiple
planes or regions, where there is no link between the common plies (GLOBAL PLY), with
PCOMPG this can be addressed.
HyperWorks 9.0
Exercise 2.2: Clamped I BEAM (PCOMPG)

This exercise runs a static analysis on a laminate clamped I beam with uniform thickness equal 1
mm for all plies and layout as showed below. The problem intends to describe all the details
involved in a composite analysis using the PCOMPG card.
Ply (1)
0
N (0,1,0)
N (-1,0,0)
N (0,-1,0)
Problem description
Ply (2)
45
Ply (3)
Ply (4)
-45
Ply (5)
90
Ply (6)
Ply (7)
45
Ply (8)
Ply (9)
-45
Ply (10)
90
Ply (11)
Ply (12)
45
Ply (13)
Ply (14)
-45
Ply (15)
90
Ply (16)
Ply (17)
45
Ply (18)
Ply (19)
-45
Ply (20)
90
Model Information
Geometry:
o
(L = 100, h = 40, b = 40 mm, Total Thickness = 5mm, Uniform layers = 1mm)
* Z is the main ply direction (Local 1) for all plies on this component
One load case:

o
Force = (0, -100, 0) N on Y=100 mm.
Clamped on Y=0.
Material:
E1 = 1.3e5
Mpa
E2 = E3 = 9650
Mpa
12 = 13 = 0.3
23 = 0.6
G12 = G13 = 3450 Mpa
G23 = 3100
MPa
Problem Setup: You should copy these Files: I_BEAM_COMPOSITE.hm;
HyperWorks 9.0

I_BEAM_COMPOSITE.hm.
Step 2: Model Setup

1. Create the PCOMPG properties.
This model is very simple and can be easily defined using PCOMPG or PCOMP, it could
became a hard to setup if the layers had different shapes that is the most common case on
real components.
TOP RIGHT
[15, 14, 13, 12, 11,
5, 4, 3,
2,
1]
TOP LEFT
[20, 19, 18, 17, 16,
5, 4, 3,
2,
1]
WEB
[20, 19, 18, 17, 16, 11, 12, 13, 14, 15]
BOTTOM RIGHT [15, 14, 13, 12, 11, 10, 9, 8,
7,
6]
BOTTOM LEFT
7,
6]
[20, 19, 18, 17, 16, 10, 9, 8,
Use HyperLaminate to create these properties, hint:

USE THE DUPLICATE FUNCTION.
HyperWorks 9.0
2. Assign the appropriate properties created above to the element of the I beam component.
HyperWorks 9.0

1. Save this model I_BEAM_COMPOSITE_PCOMPG.HM.
2. Run this model and call I_BEAM_COMPOSITE_PCOMPG.FEM
Global Results

_________________________________________________________________________
_________________________________________________________________________
2. What is the mainly difficult with PCOMPG?
_________________________________________________________________________
_________________________________________________________________________
HyperWorks 9.0
Step 4: CSTRESS and the CSTRAIN and study the results for each ply
CSTRAIN FOR EACH LAYER
HyperWorks 9.0
CSTRESS FOR EACH LAYER
CSTRESS VS. CSTRAIN FOR PLY 1 AND PLY 6

Individual ply results as we discussed on exercise 2.1.
2. What is the mainly difficult with PCOMPG?
With PCOMPG we can set the global layer, but it is not appropriate to optimization
because the global layer is not linked during the solution for a different PCOMPG.
HyperWorks 9.0
Exercise 2.3: Clamped I BEAM (PLY-STACK APPROACH)

This exercise runs a static analysis on a laminate clamped I beam with uniform thickness equal 1
mm for all plies and layout as showed below. The problem intends to describe all the details
involved in a composite analysis using the PLY-STACK approach.
N (0,1,0)
N (-1,0,0)
N (0,-1,0)
Problem description1.3E5
Model Information
Geometry:
o
(L = 100, h = 40, b = 40 mm, Total Thickness = 5mm, Uniform layers = 1mm)
* Z is the main ply direction (Local 1) for all plies on this component
One load case:

o
Force = (0, -100, 0) N on Y=100 mm.
Clamped on Y=0.
Material:
Mpa
E2 = E3 = 9650
Mpa
E1 = 1.3e5
12 = 13 = 0.3
23 = 0.6
G12 = G13 = 3450 Mpa
G23 = 3100
MPa
Problem Setup: You should copy these Files: I_BEAM_COMPOSITE_PCOMPP.hm;
HyperWorks 9.0

I_BEAM_COMPOSITE_PCOMPP.hm.
Step 2: Model Setup

1. Create the element sets for each region.
TOP RIGHT (101)
TOP LEFT (102)
WEB (103)
BOTTOM RIGHT (104)
BOTTOM LEFT (105)
2. Create the properties PCOMPP for each region.

PCOMPP_TOP (1)
PCOMPP_BOTTOM (2)
PCOMPP_WEB (3)
HyperWorks 9.0
3. Assign the property to the appropriate elements.

4. Create the appropriate ply SETS.
TOP
or 11
or 12
or 13
or 14
or 15
TOP_1
90
[1]
TOP_2
-45
[2]
TOP_3
[3]
TOP_4
45
[4]
TOP_5
[5]
TOP_6
90
[6]
TOP_7
-45
[7]
TOP_8
[8]
TOP_9
45
[9]
TOP_10
[10]
BOTTOM
20 or 15
19 or 14
18 or 13
17 or 12
16 or 11
10
9
8
7
6
BOTTOM_1
90
[11]
BOTTOM_2
-45
[12]
BOTTOM_3
[13]
BOTTOM_4
45
[14]
BOTTOM_5
[15]
BOTTOM_6
90
[16]
BOTTOM_7
-45
[17]
BOTTOM_8
[18]
BOTTOM_9
45
[19]
BOTTOM_10
[20]
WEB
WEB_1
20
19
18
17
16
11
12
13
14
15
90
[21]
WEB_2
-45
[22]
WEB_3
[23]
WEB_4
45
[24]
WEB_5
[25]
WEB_6
[26]
WEB_7
45
[27]
WEB_8
[28]
WEB_9
-45
[29]
WEB_10
90
[30]
HyperWorks 9.0
5. Create the stack sequences

3 sequences:
o
(1) TOP
[1, 2, 3, 4, 5, 6, 7, 8, 9, 10]
= [90, -45, 0, 45, 0, 90,-45,0,45,0]
(2) BOTTOM
[11,12,13,14,15,16,17,18,19,20]
= [90, -45, 0, 45, 0, 90,-45,0,45,0]
(3) WEB
[21,22,23,24,25,26,27,28,29,30]
= [90, -45, 0, 45, 0, 0,45,0,-45,90]

1. Save this model I_BEAM_COMPOSITE_PCOMPP.HM.
2. Run this model and call I_BEAM_COMPOSITE_PCOMPP.FEM
Global Results
HyperWorks 9.0
Step 4: CSTRESS and the CSTRAIN and study the results for each ply
CSTRAIN FOR EACH LAYER (TOP)
CSTRAIN FOR EACH LAYER (BOTTOM)
CSTRAIN FOR EACH LAYER (WEB)
HyperWorks 9.0
CSTRESS VS. CSTRAIN FOR GPLY 20
HyperWorks 9.0
HyperWorks 9.0
Chapter 3: Composite Optimization
Chapter 3
Composite Optimization
OptiStruct offers a comprehensive optimization package aimed at simplifying the design
of composite structures. This package includes the following optimization phases and
associated techniques:
o
Phase I Concept.
Free-sizing optimization is used to generate design concepts, while only considering
global responses and optional manufacturing constraints.
Phase II Dimension.
Sizing optimization with ply-based modeling is performed to control the thickness of
each ply bundle, while considering all design responses and optional manufacturing
constraints.
Phase III Sequence.

Ply-stacking optimization is applied to determine the detailed stacking sequence, again
while considering all behavior responses and manufacturing constraints.
Even though these techniques can be used independently, it is recommended to use

them together as a three-phase integrated process guiding the design from concept to finish.
This is particularly important when manufacturing constraints are involved. In order to satisfy
such constraints at the finishing stage, they should be incorporated at the beginning so that the
design concept can be carried forward. Automated tools are provided to facilitate the transition
between the design optimization phases.
HyperWorks 9.0
1 What is Optimization?
Optimization on CAE can be described as the automatic search process for a min or a
max of a response. It can be formally defined as:
min f (x ) = f (x1 , x1 ,..., xn )

Subject to:
g j (x ) 0
xiL xi xiU
j = 1, L , m
i = 1, L , n
The objective function f(x) and the constraint functions gj(x) are structural responses
obtained from a finite element analysis. On OptiStruct the selection of the design variables x is
what define the type of optimization:
o
Topology optimization, the design variables are element densities.
Size optimization (including free-size), the design variables are properties of structural
elements.
In topography and shape (including free-shape) optimization, the design variables are
the factors in a linear combination of shape perturbations.
HyperWorks 9.0
1.1 Optimization Definitions

Objective Function f(x)
The objective function is defined using a DESOBJ entry in the subcase information
section. DESOBJ references a response defined by either the DRESP1, DRESP2, or DRESP3
bulk data entry. Depending on the type of response, DESOBJ is located inside or outside of a
SUBCASE.
Constraints Functions gj(x)

The constraints are defined using a DESSUB or DESGLB entry in the subcase
information section, depending on if the type of response is subcase related or global,
respectively. DESSUB and DESGLB refer to DCONSTR or DCONADD bulk data entries.
DCONSTR relates the constraint value or bound to a response defined by DRESP1, DRESP2,
or DRESP3.
A constraint is considered:
o active if it is satisfied exactly gj = 0;
o inactive if gj < 0;
o violated if gj > 0.
Design Variables
They are the parameters that can be varied to optimize system performance.
Design Space
It is the region where the responses are defined, for example in a topologic optimization
it is the volume where the material can be removed.
Response
It is any measure on the system performance that depend on the design variables
values. For example mass, volume, stress, displacement, etc
Feasible Design
It is a point or set of design variable values that satisfies all the constraints.
Infeasible Design
It is a point or set of design variable values that violates one or more constraint
functions.
Optimum Design
Set of design variables values that minimize (or maximize) the objective function and
that satisfy all the constraints.
HyperWorks 9.0
1.2 Topologic optimization

Topology Optimization is a mathematical technique that produces an optimized
shape and material distribution for a structure within a given package space. By
discretizing the domain into a finite element mesh, OptiStruct calculates material
properties for each element. The OptiStruct algorithm alters the material distribution to
optimize the user-defined objective under given constraints.
Example of a topologic optimization
OptiStruct solves topological optimization problems using either the homogenization or

density method. Under topology optimization, the material density of each element should take
a value of either 0 or 1, defining the element as being either void or solid, respectively.
Unfortunately, optimization of a large number of discrete variables is computationally
prohibitive. Therefore, representation of the material distribution problem in terms of continuous
variables has to be used.
1.2.1 - Homogenization method

For the homogenization method, the material of the structure is represented as a porous
continuum with certain periodic microstructure or layered composites of different ranks of
densities. The homogenization method implemented in OptiStruct uses a material
microstructure that contains periodic rectangular voids (hexahedral voids in 3-D). The design
variables for each element are the breadth and depth of these rectangular voids and their
orientations. These define the elasticity properties and the density of the material.
Using a normalized formulation, the density of an element may be determined by:
= 1.0 (1.0 a )(1.0 b )
HyperWorks 9.0
where (1.0 a)(1.0 b) represents the total volume of void in an element. It is easy to see that
a=b=0 represents the state of void for this element, and a=1 or b=1 implies that the element is
solid, i.e. filled with the 'real' material. Intermediate values of a and b represent fictitious
material.
The void size variables are considered to be continuous variables varying between 0
and 1. The void orientation of each element is also a continuous variable, which is determined
by the orientation of the principle strain. Note that while the real material is isotropic, the
fictitious material of intermediate density is anisotropic.
1.2.2 - Density method

With the density method, the material density of each element is directly used as the
design variable, and varies continuously between 0 and 1; these represent the state of void and
solid, respectively. As with the homogenization method, intermediate values of density
represent fictitious material.
With this method, the stiffness of the material is assumed to be linearly dependent on
the density. This material formulation is consistent with our understanding of common
materials. For example, steel, which is denser than aluminum, is stronger than aluminum.
Following this logic, the representation of fictitious material at intermediate densities is more
realistic under the density approach. An anisotropic representation of the semi-dense material
is not consistent with the behavior of the real isotropic material, although it is more 'efficient' due
to optimal material orientation.
In general, the optimal solution of problems, using both formulations (Homogenization
and Density), involves large gray areas of intermediate densities in the structural domain. Such
solutions are not meaningful when we are looking for the topology of a given material, and not
meaningful when considering the use of different materials within the design space. Therefore,
techniques need to be introduced to penalize intermediate densities and to force the final design
to be represented by densities of 0 or 1 for each element. The penalization technique used for
the density approach is the "power law representation of elasticity properties," which can be
expressed for any solid 3-D or 2-D element as follows:
K ( ) = p K
where K and K represent the penalized and the real stiffness matrix of an element, respectively,
is the density and p the penalization factor which is always greater than 1.
1.2.3 Why Topologic optimization on composites?

Topologic optimization is the best tool to define the optimized load path in a design
space, with this result it is possible to identify the geometry (position and thickness for example)
of an optimized component. This is a conceptual tool that should be always used in the
beginning of any development and then refine the model with other optimizations techniques as
we will describe on the next sections.
HyperWorks 9.0
2 Free-Size Optimization - Concept

The purpose of composite free-sizing optimization is to create design concepts that
utilize all the potentials of a composite structure where both structure and material can be
designed simultaneously. By varying the thickness of each ply with a particular fiber orientation
for every element, the total laminate thickness can change continuously throughout the
structure, and at the same time, the optimal composition of the composite laminate at every
point (element) is achieved simultaneously. At this stage, a super-ply concept should be
adopted, in which each available fiber orientation is assigned a super-ply whose thickness is
free-sized.
For a shell cross-section (shown below), free-size optimization allows thickness to vary
freely between T and T0 for each element; this is in contrast to topology optimization which
targets a discrete thickness of either T or T0.
Free size definition
In addition, in order to neutralize the effect of stacking sequence, the SMEAR option is
usually a good choice for this design phase unless the user intended to follow through with the
stacking preference of the super-ply laminate model.
Coupling between total Thickness and Laminate Families (%0 %45)
To determine the optimum laminate OptiStruct uses the SMEAR technology that
captures the stacking sequence effects:
o
A = Stacking Sequence independent
B = 0 (Symmetric)
D = At2/12 - Stacking Sequence Independent
In OptiStruct, additional manufacturing constraints are available for free-sizing

optimization. As a composite laminate is typically manufactured through a stacking and curing
process, certain manufacturing requirements are necessary in order to limit undesired side
effects emerging during this curing process. For example, one typical such constraint for
carbon fiber reinforced composite is that plies of a given orientation cannot be stacked
successively for more than 3 or 4 plies. This implies that a design concept that contains areas
of predominantly a single fiber orientation would never satisfy this requirement. Therefore, to
achieve a manufacturable design concept, manufacturing requirements for the final product
need to be reflected during the concept design stage. For the particular constraint mentioned
HyperWorks 9.0
above, for instance, the design concept would offer enough alternative ply orientations to break
the succession of plies of the same orientation if the percentage of each fiber orientation is
controlled (e.g. no ply orientation should drop below 15%). In addition, balancing of a pair of ply
orientations could be useful for practical reasons. For example, balancing 45 and -45 plies
would eliminate twisting of a plate bended along the 0 axis. In order to address these needs,
the following manufacturing constraints are made available for composite free-sizing:
Lower and upper bounds on the total thickness of the laminate.
Lower and upper bounds on the thickness of individual orientations.
Lower and upper bounds on the thickness percentage of individual orientations.
Thickness balancing between two given orientations.
Constant thickness of individual orientations.
HyperWorks 9.0
Example: Cantilever plate

The cantilever plate is shown in the following figure. Base-plate thickness T0 is zero.
The optimization problem is stated as:
Minimize Compliance
Subject to Volume fraction < 0.3
Cantilever Plate
The next figure shows the final results of topology and free-size optimization as
performed on this plate, side by side. As expected, the topology result created a design with
70% cavity, while the free-size optimization arrived at a result with a zone of variable thickness
panel.
Topology result
Free-size result
Compliance of both designs
It is not surprising to see that the free-size design outperforms the topology design in
terms of compliance since continuous variation of thickness offers more design freedom.
It should be emphasized that free-size offers a concept design tool alternative to
topology optimization for structures modeled with 2-D elements. It does not replace a detailed
size optimization that would fine tune the size parameters of an FEA model of the final product.
To illustrate the close relationship between free-size and topology formulation, consider
a 3-D model of the same cantilever plate shown previously. The thickness of the plate is
modeled in 10 layers of 3-D elements.
Cantilever plate 3-D model
3-D topology result
The topology design of the 3-D model shown above looks similar to the free-size results
shown previously. This should not be surprising because when the plate is modeled in 3-D, a
variable thickness distribution becomes possible under the topology formulation that seeks a
discrete density value of either 0 or 1 for each element. If infinitely fine 3-D elements are used,
HyperWorks 9.0
a continuous variable thickness of the plate can be achieved via topology optimization. The
motivation for the introduction of free-size is based on the conviction that limitations due to 2-D
modeling should not become a barrier for optimization formulation. In regards to the 3-D
modeling of shell, topology optimization is equivalent to the application of extrusion constraint(s)
in the thickness direction of a 3-D modeled shell.
It is important to point out that while free-size often creates variable thickness shells
without extensive cavity, it does not prevent cavity if the optimizer demands it. For the example
already shown, we can see cavity in the free-size result in the 45 degree region, adjacent to the
support, and in the upper and lower corners of the free end.
Free-size optimization is defined through the DSIZE bulk data entry that is supported in
the HyperMesh optimization panel. Features available for free-size include: minimum member
size control, symmetry, pattern grouping and pattern repetition, and stress constraints applied to
von Mises stresses of the entire structure.
Involving both topology and free-size in the same optimization problem is not
recommended since penalization on topology components creates a bias that could lead to suboptimal solutions.
2.1 - Interpreting Topology and Free-size Results

Interpretation of topology results is rather straight-forward. For free-size, the change in
thickness of individual plies provides insight for ply dropping/adding zones. The thickness of
each ply in each individual zone can then be defined as a design variable in a detailed size
optimization. At this stage, discrete variables can be used to reflect the discrete nature of ply
thickness change. Overlapping all zones of individual plies can than help to generate PCOMP
zones, where a ply traveling through different zones can be defined using PCOMPG.
2.2 Free-Size applied to Concept Design Synthesis of Composite

Laminates
For composite structures, topology and free-size optimization are defined through the
DTPL and DSIZE bulk data entries, respectively. Both are supported in the HyperMesh
optimization panel. Features available include: minimum member size control, symmetry,
pattern grouping and pattern repetition. Stress or failure constraints are not supported at this
stage.
Prior to OptiStruct 8.0, composite topology optimization was based on the notion that the
homogenized properties of an element remain unchanged. This construct does not allow the
freedom for material redefinition. However, if this is indeed a preferred assumption, the HOMO
option can be set on the MAT line of the DTPL card. Otherwise, an individual ply-based
formulation (discussed below) will be the default option.
Topology and free-size methods target a system level composite design where laminate
family definition is the objective. Therefore, the PCOMP model should not reflect a detailed
stacking of plies of the same orientation. For example, even though 10 layers of 0 degree
graphite cloth might be separated in the stacking of the final structure, the modeling for a
concept study using topology and free-size should group them together in one ply in the
PCOMP so that the optimal total thickness distribution of a 0 degree ply is optimized throughout
the structure.
HyperWorks 9.0
Problem Formulation
For a composite shell element (shown in the figure below), the thickness it of each ply is
a variable between 0 and Ti defined on the PCOMP card.
Composite element
The only difference between topology and free-size here is that the former targets a
discrete final solution of 0 (or Ti) for it, while free-size allows it to vary freely between 0 and Ti.
The discrete solution is achieved by penalizing intermediate thickness. Most general
characteristics of regular shell topology and free-size optimization also apply to composite.
3 Size Optimization
In finite elements, the behavior of structural elements (as opposed to continuum
elements), such as shells, beams, rods, springs, and concentrated masses, are defined by input
parameters, such as shell thickness, cross-sectional properties, and stiffness. Those
parameters are modified in a size optimization. Some structural elements have several
parameters depending on each other; like beams in which the area, moments of inertia, and
torsional constants depend on the geometry of the cross-section.
The property itself is not the design variable in size optimization, but the property is
defined as a function of design variables. The simplest definition, as defined by the designvariable-to-property relationship DVPREL1, is a linear combination of design variables defined
on a DESVAR statement such that
p = C0 + DVi Ci
where p is the property to be optimized, and Ci are linear factors associated to the design
variable DVi.
Using the equation utility DEQATN, more complicated functional dependencies using
even trigonometric functions can be established. Such design-variable-to-property relations are
then defined using the DVPREL2 statement.
For a simple gage optimization of a shell structure, the design-variable-to-property relationship
turns into
t = DVi
where the gage thickness t is identical to the design variable DVi.
HyperWorks 9.0
3.1 Size Optimization applied to Composites - Dimension

Complimentary to the conventional property-based composite definition, a new plybased modeling technique was introduced in OptiStruct 9.0. In this format, laminates are
defined in terms of ply entities and stacking sequences, which reflect the native language of
ply-book standard to composite laminate modeling and manufacturing. The PLY card specifies
the thickness, orientation and material data for each ply, as well as its layout in the structure.
The STACK card glues the PLYs together to produce the laminate structure.
Properties of every zone of unique laminate lay-ups are uniquely, albeit implicitly,
defined. This allows the user to simply focus on the physical buildup of the composite structure
and eliminates the burden associated with identifying patches (PCOMPs) of unique lay-ups,
which can be especially complicated for a free-sizing generated design.
3.1.1 - Ply-based Optimization

In property-based sizing optimization, the designable entities are the ply thicknesses
associated with the PCOMP(G) properties. In ply-based sizing optimization, the PLY
thicknesses are directly selected as designable entities. This approach greatly simplifies the
design variables definition, since ply continuity across patches is automatically taken into
account.
As with free-sizing optimization, several composite manufacturing constraints are available to
control the thickness of the laminate or the thicknesses of specific orientations. These
constraints are defined on the DCOMP card and should generally be inherited from the concept
phase.
In addition, discrete optimization is automatically activated when TMANUF, the thickness
of the basic manufacturable ply, is specified for the PLY associated with a given design
variable. This feature forces ply bundles to reach thicknesses reflecting a discrete number of
physical plies.
4 Ply Stacking Sequence Optimization

Composite plies are shuffled to determine the optimal stacking sequence for the given
design optimization problem while also satisfying additional manufacturing constraints, defined
on the DSHUFFLE card, such as:
o
The stacking sequence should not contain any section with more than a given number of
successive plies of same orientation.
The 45 and -45 orientations should be paired together.
The cover and/or core sections should follow a predefined stacking sequence.
An efficient proprietary technique is developed to allow the process to evaluate a huge

number of stacking combinations from both performance and manufacturability perspectives.
HyperWorks 9.0
5 - Phase Transitions in the Optimization of

Composite Structures
In order to simplify the transition between the three design phases, OptiStruct is able to
automatically generate input decks after the free-sizing optimization or the sizing optimization
stages have converged.
OUTPUT, FSTOSZ (free-sizing to sizing) is an output request that can be used during the freesizing optimization phase to write a ply-based sizing optimization input deck. For each
orientation, the composite interpreter identifies regions of similar thickness and creates PLYs for
these regions. The resulting deck contains PCOMPP, STACK, PLY, and SET cards describing
the ply-based composite model, as well as DCOMP, DESVAR, and DVPREL cards defining the
optimization data. Manufacturing constraints are transferred from the DSIZE card to the
DCOMP card. Typically, additional design responses such as stress/failure constraints would
be introduced at this optimization stage.
OUTPUT, SZTOSH (sizing to shuffling) is an output request that can be used during the plybased sizing optimization stage to write a ply stacking optimization input deck. Each PLY
bundle is divided into multiple PLYs whose thickness is equal to the manufacturable thickness
TMANUF, and the STACK card is updated accordingly. The DESVAR and DVPREL cards
from the previous stage are removed, and a bare DSHUFFLE card is introduced.
HyperWorks 9.0
Exercise 3.1: Optimization Driven Design of a Composite plate

For this example we need to design a cantilever beam made with composites plies that
can have angles 0, 45, -45 & 90 degrees. It needs to support an in-plane force at
middle of the unconstrained end (see figure below).
This is a design of simplified plane wing, where:

o
The objective is to determine the minimum mass!
Max Disp. < 3.00e-04.
Parameters (PLATE) laminate definition
Min of each family (ANGLE) 10% (PPMIN)
Manufacturable thickness (in) 0.05 (PTMAN)
BALANCED 45 AND -45 FAMILIES.
To achieve this optimum design we will introduce you the process called Optimization
Driven Design for Composite. It is divided in 3 phases:
o
PHASE I - Free Size Optimization, (Ply topology)
PHASE II - Size Optimization (Thickness and number of plies)
PHASE III Shuffle Optimization (Stacking Sequence).
Model Information:
PCOMP with 4 plies 0, 45, -45 & 90
Orthotropic Material MAT8_1 (1)

o
E1 = 18.7e6 psi
N12 = 0.321
E2 = 1.40e6 psi
G12 = 0.5e6 psi
rho = 1.6e-06 lb/in3
Problem Setup: Copy PCOMP_PLATE.hm to your working directory
HyperWorks 9.0
Phase 0: Model Analysis.

Step 1: Model Checking
1. Launch HyperMesh and set the User Profile > OptiStruct
2. Open the HyperMesh data base
PCOMP_PLATE.hm.
Plate FEA model

3. Verify the normal of the elements.
4. Verify the element orientation.
HyperWorks 9.0
5. Verify the PCOMP_1 property.

The property card is presented below:
Note that there are only 4 plies that are 1 inch thick each for a total thickness of
4 inches.
These are super-plies, each with a unique fiber direction.
For this model the plies are all the same thickness and composite material.
Each ply can have different materials and thicknesses.
Step 2: Run the Super ply model analysis.

6. Create a subdirectory called 00_ANALYSIS
7. Run the analysis on this subdirectory
Displacement contour (Disp. Node (1211) = 1.7e-4)
HyperWorks 9.0
Phase I: Free size optimization

Step 1: Create design variable for free sizing optimization
1. Create a subdirectory called 01_FREE_SIZE
2. Save the HyperMesh database as PCOMP_PLATE.hm on this directory.
3. From the Analysis page, select the optimization panel.

4. Select the free size panel.
5. Choose the create subpanel using the radio button on the left.
6. Click the field next to desvar= and enter DSIZE.
7. Verify that type: is set to PCOMP(G).
8. Click the yellow props button, to enter the property selection panel.
9. Check the box next to PCOMP_1.
10. Click select.
11. Click the create button.
Design Model Browse Tree
Step 2: Add manufacturing constraints to the optimization.

1. Select the composites radio button
2. Select the maximum laminate thickness toggle and type in 3.2.
Recall that the initial design has four 1.0 thick plies with a total thickness of 4, it will
force the laminate thickness to be lower then 3.2.
3. Leave the laminate minimum thickness off.
4. Select the green edit button to edit the design variable DSIZE.
5. Check the PLYPCT and BALANCE boxes.
6. Enter a PPMIN (minimum ply percentage) value of 0.1 (10%).
This make the existence of each family as minimum as 10%.
7. Leave PPMAX (maximum ply percentage) off
8. Enter a PTMAN (manufacturable ply thickness) value of 0.05.
This define that all plies will be a multiple of this value.
9. Enter 45.0 in the BANGLE1 filed and hit the tab key to jump to the BANGLE2 field
and enter -45.0.
HyperWorks 9.0
It makes that each plies of 45 or -45 will be in a pair with one off the other one.
10. This constraint requires that the 45.0 degree plies be in balance with the -45.0
degree plies.
11. Return to the free size composite page.
12. Click update to apply changes.
13. Click return to exit the panel.
Step 3: Create the 2 responses (mass and disp1211) for the optimization.
1. Enter the response panel.
2. Enter disp1211 in the response= field.
3. Select static displacement for the response type.
4. Select the node where the load is applied or by ID node # 1211.
5. Select total disp
6. Click create
7. Create a second response called volume.
8. Select volume for the response type.
9. Click create
10. Return to the optimization page.
Response Model Browse Tree
Step 4: Create a displacement constraint (disp1211 < 3e-4)

1. Enter the dconstraints panel
2. Enter Cdisp1211 in the constraint= field.
3. Click response= and select disp1211 as the design response.
4. Check the box next to upper bound and enter a value of 3.00e-04.
5. Click loadstep and select SUBCASE1.
6. Click select.
7. Click create.
8. Click return.
HyperWorks 9.0
Constraint Model Browse Tree
Step 5: Create the objective function as minimize volume

1. Enter the objective panel.
2. Click the response= field and select volume.
3. Click create.
4. Click return twice.
Objective Model Browse Tree
Step 6: Add required OUTPUT cards

1. Enter the control cards panel on the Analysis page.
2. Click Next until you see OUTPUT
3. Click OUTPUT
4. Change the number_of_outputs = to 2.
5. Set the first row as H3D and the FREQ to ALL.
6. And the second as FSTOSZ for the keyword and YES for the FREQ.
7. Click return.
Note that second request will create a FILENAME_sizing.fem file that will have
incorporated ply and element set information that includes ply patch configurations
for each ply type.
a. The default is to repeat the super ply 4 times for each ply defined on the
PCOMP(G) property that will give a total of 16 plies.
b. This is the default value and can be changed to adding the number of
desired ply sequence repetitions at the end of the line in *.fem file. For
example: OUTPUT,FSTOSZ,YES,5 This request would result in the
PCOMP ply sequence being repeated 5 times for a total of 20 plies.
HyperWorks 9.0
Step 7: Run the optimization

1. Go to the OptiStruct panel
2. Set export options, run options & memory options to all, optimization &
memory default
3. Click OptiStruct.
Step 8: Review the Free Size results

1. When the job is complete click HyperView and load results into HyperView.
2. First it is interesting to look at the optimization history to understand the design
evolution, it can be done opening the file .hgdata:
Optimization History
It shows that the model had converged for a feasible solution with an
optimum volume.
Now we need to verify the plies shapes to understand if this can be

manufactured.
3. One important result is the total element thickness using HyperView select the
last iteration on the file, it should be understood as the topography of the
laminate.
The total element thickness contour plot is presented below:

HyperWorks 9.0
4. Now it is important to see the individual angle plies thickness, it will be used per
OptiStruct to define the shape of the individual ply, this plot can be saw again
as a topographic plot of the stack for each angle ply:
Element thicknesses contour for the individual angle plies
HyperWorks 9.0
Phase II: Sizing optimization

Step 1: Import the fem generated from the OS run and review
1. Create a subdirectory called 02_SIZE
2. Import the HyperMesh FEA model
PCOMP_PLATE_sizing.fem
3. Save the HyperMesh database as PCOMP_PLATE.hm on this new subdirectory.

4. Review the model PLY, STACK, SET, DESVAR and DVPREL1 cards.
ELEM SET cards will list what elements will be used for each ply,
Element sets for 0 degree angle plies (1, 2, 3 and 4)
Element sets for -45 degree angle plies (5, 6, 7 and 8)
HyperWorks 9.0
Note that the PLY cards have the individual ply description
STACK card will show how the plies are stacked
DESVAR cards will provide the initial, minimum and maximum thickness for
each ply.
HyperWorks 9.0
DVPREL1 cards relate design variables to analysis model properties.
Step 2: Set up the Sizing Optimization

1. Go to the Analysis page and enter the control cards panel.
2. Click Next until you see OUTPUT and click it.
3. Change FSTOSZ to SZTOSH and select the option ALL.
The second request in output will make OptiStruct export the input file
PCOMP_PLATE_shuffling.fem prepared to perform the PHASE 3 Shuffle.
4. Click return.
5. Click next until you see STACK and click it.
6. Change SMEAR to blank
7. Click return twice.

HyperWorks 9.0
8. From the Analysis page enter the optimization panel then the size subpanel.
9. Double click the desvar= button
Edit the upper bound for each design variables to give more Design Space to the
upper bound predefined per OptiStruct:
DV
ID
NAME
X0
Xmin
Xmax
DESVAR
1010100
autoply
0.12
0.00
0.30
DESVAR
1010200
autoply.1
0.34
0.00
0.80
DESVAR
1010300
autoply.2
0.48
0.00
1.00
DESVAR
1010400
autoply.3
0.06
0.00
0.20
DESVAR
1020100
autoply.4
0.17
0.00
0.40
DESVAR
1020200
autoply.5
0.12
0.00
0.30
DESVAR
1020300
autoply.6
0.13
0.00
0.30
DESVAR
1020400
autoply.7
0.58
0.00
0.80
DESVAR
1030100
autoply.8
0.17
0.00
0.40
DESVAR
1030200
autoply.9
0.12
0.00
0.30
DESVAR
1030300
autoply.10
0.13
0.00
0.30
DESVAR
1030400
autoply.11
0.58
0.00
0.80
DESVAR
1040100
autoply.12
0.08
0.00
0.20
DESVAR
1040200
autoply.13
0.05
0.00
0.20
DESVAR
1040300
autoply.14
0.07
0.00
0.20
DESVAR
1040400
autoply.15
0.80
0.00
1.00
ANGLE(o)
-45
45
90
10. Click Return twice to exit the panel.

11. Export the PCOMP_PLATE_SIZE.fem model.
12. Open the PCOMP_PLATE_SIZE.fem model with a text editor and include the
stress response as showed bellow
13. Include the stress constrain and edit the DCONADD as on the image bellow:
14. Save this input deck as PCOMP_PLATE_SIZE_FINAL.fem.
HyperWorks 9.0
15. Run OptiStruct directly using the RADIOSS manager or load the model into
HyperMesh and run OptiStruct from it.
16. First it is interesting to look at the optimization history to understand the design
evolution, it can be done opening the file .hgdata to plot the displacement:
Optimization History
It shows that the model had converged for a feasible solution with an
optimum volume.
The Composite stress response is not available on the history on 9.0, but
can be reviewed for example on the .out file:
Last iteration stress constrain results
HyperWorks 9.0
17. Now it is important to review the thickness of each plies:

DV
ID
NAME
X0
Xmin
Xmax
OPTIM
DESVAR
1010100
autoply
0.12
0.00
0.30
0.10
DESVAR
1010200
autoply.1
0.34
0.00
0.80
0.40
DESVAR
1010300
autoply.2
0.48
0.00
1.00
1.00
DESVAR
1010400
autoply.3
0.06
0.00
0.20
0.05
DESVAR
1020100
autoply.4
0.17
0.00
0.40
0.15
DESVAR
1020200
autoply.5
0.12
0.00
0.30
0.10
DESVAR
1020300
autoply.6
0.13
0.00
0.30
0.10
DESVAR
1020400
autoply.7
0.58
0.00
0.80
0.15
DESVAR
1030100
autoply.8
0.17
0.00
0.40
0.15
DESVAR
1030200
autoply.9
0.12
0.00
0.30
0.10
DESVAR
1030300
autoply.10
0.13
0.00
0.30
0.10
DESVAR
1030400
autoply.11
0.58
0.00
0.80
0.15
DESVAR
1040100
autoply.12
0.08
0.00
0.20
0.20
DESVAR
1040200
autoply.13
0.05
0.00
0.20
0.20
DESVAR
1040300
autoply.14
0.07
0.00
0.20
0.05
DESVAR
1040400
autoply.15
0.80
0.00
1.00
0.05
ANGLE(o)
-45
45
90
HyperWorks 9.0
Phase III: Shuffling optimization

In this phase, the sequence in the stacking patterns of the patches created in phase 2 will be
optimized with additional design constraints.
1. Create a folder called 03_Shuffle.

2. Import the file PCOMP_PLATE_SIZE_FINAL_shuffling.fem on a new HM
database.
3. Select the analysis page, control card: OUTPUT
4. Change FSTOSZ,YES to PROPERTY,LAST.
5. Click Return to exit the panel
6. Select control card: DEBUG
7. Enter 2 for number_of_debugs
8. Define the DEBUG card to help on understand the shuffle steps:
DEBUG,SHUFHTML,1
This will generate a file in a HTML format with a table with the shuffle iterations:
Wing_example_suffle_shuf.hist.html
DEBUG,SHUFTEXT,1
This will generate a text file with the stack sequences during the shuffle iterations:
Wing_example_suffle.shuf
9. Right click on the Card: BULK_UNSUPPORTED_CARDS and edit it as showed

bellow:
MAXSUCC: limits the number of plies of the same type (orientation) that are
adjacent to each other.
The second shuffling constraint, PAIR, constrains each 45.0 degree ply to be
adjacent to a -45.0 degree ply.
10. Save file, import into HyperMesh and run Optistruct.

11. Review the file: Case1_Plate _freesizing_sizing_shuffling.hist.html.
HyperWorks 9.0
0o Plies
-45o Plies
1010101
1010102
1020101
1020102
1020103
1030101
1030102
1030103
1040101
1040102
1040103
1040104
1010201
1010202
1010203
1010204
1010205
1010206
1010207
1010208
1020201
1020202
1030201
1030202
1040201
1040202
1040203
1040204
1010301
1010302
1010303
1010304
1010305
1010306
1010307
1010308
1010309
1010310
1010311
1010312
1010313
1010314
1010315
1010316
1010317
1010318
1010319
1010320
1020301
1020302
1030301
1030302
1040301
1010401
1020401
1020402
1020403
1030401
1030402
1030403
1040401
1030101
1020101
1010101
1010102
1010201
1040101
1010202
1030102
1020102
1010203
1010204
1040102
1010205
1030103
1020103
1010206
1010207
1040103
1010208
1030201
1020201
1010301
1010302
1040104
1010303
1030202
1020202
1010304
1010305
1040201
1010306
1030301
1020301
1010307
1010308
1040202
1010309
1030302
1020302
1010310
1010311
1040203
1010312
1030401
1020401
1010313
1010314
1040204
1010315
1030402
1020402
1010316
1010317
1040301
1010318
1030403
1020403
1010319
1010320
1040401
1010401
1040401
1040201
1040102
1040101
1030201
1020201
1010101
1010102
1010201
1010202
1030102
1020102
1010306
1010203
1010204
1010205
1030103
1020103
1010307
1010206
1010207
1010208
1030302
1020302
1040203
1040103
1030403
1020403
1010308
1010301
1010302
1010303
1040104
1030401
1020401
1010310
1010309
1010304
1010305
1030101
1020101
1030202
1020202
1010311
1010312
1010313
1010314
1040204
1010401
1010315
1010316
1010317
1040202
1040301
1030301
1020301
1010318
1010319
1010320
1030402
1020402
45o Plies
1040401
1040201
1040102
1040101
1030201
1020201
1010101
1010102
1010201
1010202
1030102
1020102
1010306
1010203
1010204
1010205
1030103
1020103
1010307
1010206
1010207
1010208
1030302
1020302
1040203
1040103
1030403
1020403
1010308
1010301
1010302
1010303
1040104
1030202
1020202
1030401
1020401
1010310
1010309
1010304
1010305
1030101
1020101
1010311
1010312
1010313
1010314
1040204
1030402
1020402
1010401
1010315
1010316
1010317
1040202
1040301
1030301
1020301
1010318
1010319
1010320
1040401
1040201
1040102
1040101
1030201
1020201
1010101
1010102
1010201
1010202
1030102
1020102
1010306
1010203
1010204
1010205
1030103
1020103
1010307
1010206
1010207
1010208
1030302
1020302
1040203
1040103
1030403
1020403
1010308
1010301
1010302
1010303
1030401
1020401
1040104
1030202
1020202
1010310
1010309
1010304
1010305
1030101
1020101
1010311
1010312
1010313
1010314
1040204
1030402
1020402
1010401
1010315
1010316
1010317
1040202
1040301
1030301
1020301
1010318
1010319
1010320
90o Plie
1040401
1040201
1040102
1040101
1030201
1020201
1010101
1010102
1010201
1010202
1030102
1020102
1010306
1010203
1010204
1010205
1030103
1020103
1010307
1010206
1010207
1010208
1030302
1020302
1040203
1040103
1030403
1020403
1010308
1010301
1010302
1010303
1030401
1020401
1040104
1030202
1020202
1010310
1010309
1010304
1010305
1030101
1020101
1010311
1010312
1010313
1010314
1040204
1030402
1020402
1010401
1010315
1010316
1010317
1040202
1040301
1030301
1020301
1010318
1010319
1010320
The table shows the shuffling iterations from beginning to the last.
DSHUFFLE constrains to limit the number of like adjacent plies to a maximum
of four;
It guarantee that on the last iteration we have for every 45.0 degree (103xxxx,
green highlight) ply a -45.0 degree ply (102xxxx, yellow highlight).
SUMMARY
Composite optimization is a three phase task:
1. Begins with Free Size optimization that determines composite patch size, shape, and
location. On this phase OS output the input deck that is then used in the second phase,
2. Size optimization (ply bundle optimization), to determine optimum ply bundle thickness
and required number of plies per patch.
3. Shuffling optimization is the last phase used to optimize stacking sequence and meet
ply book rules, improve performance, and improve manufacturability.
HyperWorks 9.0
Exercise 3.2: Optimization Drive Design of a Composite Wing Design

This exercise have a more complex structure then a simple plate and it is used to show
the extra difficult that the engineer will meet on real problems. The scope of the design is
reduced to just 2 components (TopSkin and BottomSkin) to make it affordable to do it during the
class. The steps and approach describe on it can be easily applied to any structure made with
composites.
This is a design of simplified plane wing, where:
o
Max Disp. < 50mm.
Parameters (TopSkin and BottomSkin) laminate definition
Max of each family (ANGLE) 60% (PPMAX)
Min manufacturable thickness (mm) 1.27 (PTMAN)
Model Information
Aluminum MAT1 (1)

o
E = 76000 MPa
Nu=0.33
rho = 2.7e-9 ton/mm3
CompC MAT8 (2)

o
E1 = 150000 MPa
E2 = 9650 MPa
N12 = 0.321
G12 = 5930 MPa
CompT MAT8 (3)

o
E1 = 150000 MPa
E2 = 9650 MPa
N12 = 0.321
G12 = 5930 MPa
Problem Setup: Copy the file Wing_example.hm to your working directory.
HyperWorks 9.0
Phase 0: Model Analysis.

Step 1 Model Checking.
1. Launch HyperMesh with User Profile > OptiStruct
2. Open the HyperMesh data base
Wing_example.hm.
3. Display only the TopSkin and BottomSkin components
4. Verify the components orientation
TopSkin
Normal
BottomSkin
Normal
Material Orientation (Skin components)
TopSkin
Normal (Skin components)
BottomSkin
Note that there are only 4 plies that are 0.4 thick each for a total thickness of 1.6.
These are super-plies, each with a unique fiber direction.
For this model the plies are all the same thickness and composite material.
HyperWorks 9.0
Each ply can have different materials and thicknesses.
The TopSkin differs only by a different material ID. Both materials for the TopSkin and
BottomSkin are identical for this exercise.
On the other components the material is oriented as (0,0,-1). It is a good exercise to do

verification of it too.
Step 2 Run the Super ply model analysis.

1. Run the analysis on a subdirectory called 00_ANALYSIS.
The analysis is already setup on this model with 2 load cases.
2. Pos-processing the results
Total Displacement (mm) MAX at node 339
Total Mass = 2.95405E-01 ton
HyperWorks 9.0
Phase I: Free size optimization.

Step 1 Defining the Design Variables
1. Save the HM database as Wing_example_FREE_SIZE.hm on a directory called
01_FREE_SIZE.
2. Define 2 Free size DVs one for the TopSkin and other for the BottomSkin:
o
Min Laminate Thickness = 5.08 mm
Min % All = 10%
Balance on 45 and -45 families.
Max % All = 60%
Man. Thickness = 1.27 mm
1 2
3
4
The numbers provided in this example are for training purposes only. Actual
manufacturing and design constraints are very dependent on the manufacturing
process and application.
The same setting on the input deck:
HyperWorks 9.0
Step 2 Setup the Optimization.

1. Create the responses that will be used on the optimization process:
o
MASS Total Model mass.
MAX DISP Total Displacement (node 339)
2. Create the design constrain on the displacement response (MAXDISP < 50 mm)
3. Create the objective function, Min Mass.
4. Define the Free Size to Size output on the OUTPUT card:
With this card OptiStruct will generate the input for the next phase:
Wing_example_FREE_SIZE_freesizing.fem
Alternatively, the following line can be added to the *freesizing.fem file with the other output
lines located just above the case control section at the top of the file.
It will create a *_freesizing_sizing.fem file
Ply and element set information that includes ply patch configurations for each
ply family.
It will also repeat the PCOMP ply sequence 4 times to give a total of 16 plies
each for the TopSkin and BottomSkin.
This is the default value and can be changed to adding the number of desired ply sequence
repetitions at the end of the line.
This request would result in the PCOMP ply sequence being repeated 5 times for
a total of 20 plies.
HyperWorks 9.0

Step 3 Optimization and Pos-processing.

1. Save the HM database and run the FREE SIZE OPTIMIZATION.
2. Pos-processing the results using HyperView.
Optimization history
Summary:
Min Mass = 0.11 ton = 110 kg.
Max Disp. (Max Torque) = 49.97 mm
TopSkin
BottomSkin
Laminate Total thickness (mm)
HyperWorks 9.0
Thickness contour for each ply angle on the TopSkin.
Thickness contour for each ply angle on the BottomSkin.
HyperWorks 9.0

Phase II: Sizing optimization.

Step 1 Setup the Optimization.
3. Create a folder called 02_SIZE.
4. Import the file Wing_example_FREE_SIZE_sizing.fem on a new HM database.
This model is setup using the PCOMPP-STACK-PLY approach.
5. Save this model as Wing_example_SIZE.hm.
6. Hide the all load entities and the components except the TopSkin.
TopSkin component
7. Review the model looking first the STACK card:

You have two stacks:
TopSkin
BottomSkin
These plies were created based on the PCOM or PCOMPG sequence we had, to better
understand it lets explain the number that identify them:
HyperWorks 9.0
Ply 1010100
DV Seq.
Ply
Family
1
1 First DV defined on the FREE SIZE phase
01 First Ply defined on the PCOMP(G)
0100 First shape of the bundle.
* This other example below is not present on the model, it just to show what happen if the
number of DV and plies is superior to 9.
Ply 10130400
DV Seq.
1
Ply
Family
3
8. Review the element Set that are used for representing each ply:
DV SEQ.
Definition
PLY
FREE SIZE
Definition DV SEQ.
01
01
1
01
01
01
01
2
01
01
01
01
3
01
01
01
01
4
01
01
02
02
1
02
02
02
02
2
02
02
02
02
3
02
02
02
02
4
02
02
HyperWorks 9.0
Ply
01
01
01
01
02
02
02
02
03
03
03
03
04
04
04
04
01
01
01
01
02
02
02
02
03
03
03
03
04
04
04
04
Bundle
(FSTOSZ)
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
0100
0200
0300
0400
ESET
ID
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
1010100
1010200
1010300
1010400
1020100
1020200
1020300
1020400
1030100
1030200
1030300
1030400
1040100
1040200
1040300
1040400
2010100
2010200
2010300
2010400
2020100
2020200
2020300
2020400
2030100
2030200
2030300
2030400
2040100
2040200
2040300
2040400

Remember each set is a shape that will be manufactured then it needs to have a clear
topology, we will now show how to improve the shape we got from the FREE SIZE
optimization:
Ply 1010100
o
o
o
o
FROM PCOMP (15)

Theta = 0
Shape OK.
ESET(2)
Ply 1010200
o
o
o
o
FROM PCOMP (15)

Theta = 0
Shape Not OK
ESET(3)
Ply 1010300
o
o
o
o
FROM PCOMP (15)

Theta = 0
Shape Not OK
ESET(4)
o
o
o
o
FROM PCOMP (15)

Theta = 0
Shape Not OK
ESET(4)
Ply 1010400
This should be done for every shape (TopSkin and BottomSkin) that has ill-defined shapes.
HyperWorks 9.0
9. Modify the output card from FSTOSZ to SZTOSH as showed below:
This command will make OS generate the input for the Phase III (Shuffle).
10. Change on the stack cards the third field LAM from SMEAR to blank.
11. Update the maximum value on the Design variables, this will give a little more room for OS
search a optimum design:
Update the size DV on HM

DV
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
HyperWorks 9.0
ID
1010100
1010200
1010300
1010400
1020100
1020200
1020300
1020400
1030100
1030200
1030300
1030400
1040100
1040200
1040300
1040400
2010100
2010200
2010300
2010400
2020100
2020200
2020300
2020400
2030100
2030200
2030300
2030400
2040100
2040200
2040300
2040400
NAME
autoply
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
X0
3.22
3.00
3.54
0.40
0.98
1.89
3.20
4.10
0.98
1.89
3.20
4.10
0.79
0.89
1.49
6.99
3.23
2.98
3.54
0.42
1.00
1.88
3.31
3.97
1.00
1.88
3.31
3.97
0.80
0.92
1.60
6.84
Xmin
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Xmax
4.00
4.00
5.00
1.00
2.00
3.00
4.00
5.00
2.00
3.00
4.00
5.00
1.00
1.00
2.00
9.00
4.00
4.00
5.00
1.00
2.00
3.00
4.00
5.00
2.00
3.00
4.00
5.00
1.00
2.00
2.00
9.00

12. Save this model as Wing_example_SIZE.hm.

13. Run the optimization with the default parameters.
After 2 iterations OptiStruct should stop saying that it had converged to an unfeasible point,
looking on the responses plot, we see that the first change had modified too much the
design, it had improved the objective but at the same time had create an unfeasible solution.
Optimization convergence for default optimization parameters.
14. Run the optimization again with the DELSIZE =0.1 run as Wing_example_Size_0.1.fem.
We have a feasible solution on the initial Design (X0), then what we want is to give a smaller
step to see if around this point we can find a better solution. It can be done using the Opti
Control panel:
DOPTPRM, DELSIZ, 0.1
Mass = 132.7 Kg
Max Disp. = 46.95 mm
Optimization convergence for a initial step = 0.1.
HyperWorks 9.0
The user can modify this initial step to see how it affects the solution, on this example any
step higher than 0.15 tends to drive the solution to an unfeasible point. For values small
than 0.01 the number of iterations can be to high, and the optimum it will be always around
132 Kg.
Other test that the user can do on this case is changing the initial values for some plies and
measures the effects.
The solution for each shape is:
DV
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
DESVAR
HyperWorks 9.0
ID
1010100
1010200
1010300
1010400
1020100
1020200
1020300
1020400
1030100
1030200
1030300
1030400
1040100
1040200
1040300
1040400
2010100
2010200
2010300
2010400
2020100
2020200
2020300
2020400
2030100
2030200
2030300
2030400
2040100
2040200
2040300
2040400
NAME
autoply
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
autoply.
X0
3.22
3.00
3.54
0.40
0.98
1.89
3.20
4.10
0.98
1.89
3.20
4.10
0.79
0.89
1.49
6.99
3.23
2.98
3.54
0.42
1.00
1.88
3.31
3.97
1.00
1.88
3.31
3.97
0.80
0.92
1.60
6.84
Xmin
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Xmax
4.00
4.00
5.00
1.00
2.00
3.00
4.00
5.00
2.00
3.00
4.00
5.00
1.00
1.00
2.00
9.00
4.00
4.00
5.00
1.00
2.00
3.00
4.00
5.00
2.00
3.00
4.00
5.00
1.00
2.00
2.00
9.00
OPTIM
2.54E+00
2.54E+00
3.81E+00
0.00E+00
1.27E+00
1.27E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
1.27E+00
5.08E+00
2.54E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
1.27E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
2.54E+00
3.81E+00
1.27E+00
1.27E+00
1.27E+00
5.08E+00
ANGLE(o)
0
45
-45
90
45
-45
90

TOPSKIN
Ply thickness Angle 0
Ply thickness Angle -45
HyperWorks 9.0
BOTTOMSKIN
Ply thickness Angle -45
HyperWorks 9.0

Phase III: Shuffling optimization.

1. Create a folder called 03_Shuffle.
2. Import the file Wing_example_Size_0.1_shuffling.fem on a new HM database.
This model is setup using the PCOMPP-STACK-PLY approach.
3. Save this model as Wing_example_Shuffle.hm.
4. Modify the output card from SZTOSH to PROPERTY as showed below:
This command will make OS export the property settings for the last iteration on
file_name.prop.
5. Define the DEBUG card to help on understand the shuffle steps:
DEBUG,SHUFHTML,1
This will generate a file in a HTML format with a table with the shuffle iterations:
Wing_example_suffle_shuf.hist.html
DEBUG,SHUFTEXT,1
This will generate a text file with the stack sequences during the shuffle iterations:
Wing_example_suffle.shuf
6. Right click on the Card: BULK_UNSUPPORTED_CARDS and edit it as showed bellow:
HyperWorks 9.0
The first shuffling constraint, MAXSUCC, limits the number of plies of the same
type (orientation) that are adjacent to each other.
The second shuffling constraint, PAIR, constrains each 45.0 degree ply to be
adjacent to a -45.0 degree ply.
7. Run the final optimization to determine the optimum stack sequence for the two skin.
8. Open the HTML to analyze the shuffle process.
The table below shows the shuffling iterations from beginning to the last. Note how the
DSHUFFLE constraints to limit the number of like adjacent plies to a maximum of four and how
the 45.0 degree (103xxxx, yellow highlight) and -45.0 degree (102xxxx, green highlight) plies
are paired together in the last iteration in the far right column.
0o Plies
TopSkin
- 45o Plies
45o Plies
90o Plies
BottomSkin
SUMMARY
Composite optimization is a three phase task:

1. Begins with Free Size optimization that determines composite patch size, shape, and
location. On this phase OS output the input deck that is then used in the second phase,
2. Size optimization (ply bundle optimization), to determine optimum ply bundle thickness and
required number of plies per patch.
3. Shuffling optimization is the last phase used to optimize stacking sequence and meet ply
book rules, improve performance, and improve manufacturability.
HyperWorks 9.0

RADIOSS COMPOSITES ANALYSIS
Instructor Name
Revised Nov. 2008
Altair Proprietary and Confidential Information
Copyright 2008 Altair Engineering, Inc. All rights reserved.
Agenda
Theoretical introduction
Composite Pre-processing Analysis
Composite Optimization
Composite Material
Particulate Composites (Particles + Matrix)
Laminated Composites (Layers)
Fibrous-Matrix Laminated Composites (Layers Long fiber + Matrix)
Core Stiffened Laminated Composites
The training will focus on the Fibrous-Matrix Laminated

Composites, which are the most commons used for high
performance structural components.

Why Composites ?
The material property of the composites can be engineered

according to the application requirements.
The ability to impart the required material property gives them

great advantage when compared with traditional homogeneous
materials like Steel or Aluminum.
Composites have one the best strength to weight ratio.
Applications like aerospace components, where the weight is a

decisive factor, can benefit tremendously with the usage of
composite materials.
Designable Material property
A simple square steel plate in tension needs to have displacement of

0.1 in x-direction.
Designing for above requirement is a simple task.
How does the displacement look like for the same load in y-direction?
What if the displacement in y-direction needs to be no more

than 0.025 units?
Designable Material property
Steel being an isotropic material, we can not change its properties in

different directions. Hence different behavior in different directions
needs to be achieved through changing the geometry.
In case of composites, achieving the above is as simple as

determining the correct number of plies in x and y directions.
Ability to design the material property gives lot of freedom to the

designers.
However, it greatly increases the complexity of the design task.
Un-desirable behaviors like extensionalshear coupling,

bending-twist coupling, etc, are encountered with composite
materials.
Understanding the material property
We all are familiar with Strain-Stress relationship for Isotropic

linear elastic materials:
1 E1

2 E
3 E
=
12 0
23 0

13 0
E
1
E
1
E
1
G
1
G
0 1
0 2

0 3

0 12
0 23

1
G
13
Isotropic linear elastic materials have only two independent

engineering constants. Any two of E, G, or
which
are related by equation:
G=
E
2(1 + )
Composite material properties in general are

modeled as orthotropic materials
Strain-Stress relationship for orthotropic linear elastic materials:
1 E11
12
2 E1
3 E13
= 1
12 0
23 0

13 0
21
E2
31
E3
32
E3
0
0
1
E3
1
G12
0
0
0
0
0
0
1
G 23
1
E2
23
E2
0 1
0 2

0 3

0 12
0 23

1
G13
13
where:
G12 =
E1
2(1 + 12 )
G23 =
E2
2(1 + 23 )
G13 =
E3
2(1+ 13 )
Strain-Stress relationship for orthotropic Plane Stress

problems:
3 = 13 = 23 = 0
1 E11
12
2 = E1
0
12
with:
ij ji
Ej
12
E1
1
E2
i, j =1,2,3.
Ej
i j
0 1

0 2
1
G12 12
3 = 12 1 + 23 2
E2
E1
Thermal effects on material property
Generalized Hooks Law, = C , doesnt include the thermal

strains caused by thermal effects and hence needs modification.
A bar placed freely on a table will expand due to the temperature

change.
However, this expansion, while causing thermal strains, does not

cause the bar to be stressed as it is unconstrained on the table.
Therefore, the modified Stress-Strain relation is:

1 Q11 Q12 0 1 1

2 = Q12 Q22 0 2 + 2 T
0
0 Q44 12 3
12
OR
i = Cij ( j j T )
i, j = 1 6
Thermal effects on material property
There are three types of strains which need to be defined in a thermal

environment.
Total strains are the summation of both the free thermal and
mechanical strains.
T
M
= +
T
Free thermal
, strains are the strains caused by free thermal
expansion or contraction.
t , j = j T
Mechanical strains are the strains which cause stress
M = T
Macromechanical Behavior of a Ply
The constitutive stress/strain relationship is written in the principal

material 1-, 2-, 3- coordinate system
i = Cij ( j j T )
In order to determine the global behavior of a ply, this relationship

is transformed to the global x-, y-, z- coordinate system, using the
2D plane stress transformations :
{ x } = [TS ]1 [Q ][TS ]T ({ x } { x }T )
OR
{ x } = [Q ]({ x } { x }T )
Where
[Q ] = [TS ]
[Q ][TS ]T
is stiffness matrix in global coordinate
Laminate Convention in RADIOSS
The xy-plane defined by the global coordinate system goes

through the middle surface of the plate with z-axis defined using
right hand rule.
1st ply always defined as the most negative z ply.
Classical Lamination Theory

Mid-Plane Forces
For a homogenous single ply plate of constant thickness the

mid-plane forces can be written in terms of stress variation through
the thickness of the plate as:
N x t / 2 x

N y = y dz
N t / 2
xy
xy
For a laminated plate made up of n constant thickness plies the

mid-plane forces can be written in terms of the sum of the stress
variation through the thickness of each ply as:
Nx
z k x
n

N y = y dz
N k =1 z k 1
xy
xy

Mid-Plane Moments
For a homogenous single ply plate of constant thickness the midplane moments can be written in terms of stress variation through
the thickness of the plate as:
M x t / 2 x

M y = z y dz
M t / 2
xy
xy
For a laminated plate made up of n constant thickness plies the

mid-plane moments can be written in terms of the sum of the stress
variation through the thickness of each ply as:
Mx
x
zk
n

M y = z y dz
M k =1 z k 1
xy
xy
Stress-Strain relationship:
By adding the subscript k to designate the equation on the

laminated coordinates for each ply:
[ ] ({ } { } T )
{ x }k
{ x } = [Q ]({ x } { x }T )
=Q
x k
x k
Using the above in the equation for mid-plane forces:

n
zk
{N x } = ([Q ]k ({ x
k =1 z k 1
} + z {k } { } T ))dz
k
x k
OR
{N x } = [A]{ x
}+ [B]{k } {N }
T
x
Similarly for mid-plane moments:

n
zk
{M x } = ([Q ]k ({ x
} + z {k } { } T ))zdz
k
k =1 z k 1
x k
OR
{M x } = [B]{ x
}+ [D]{k } {M }
T
x
Where:
n
[A] = ([Q ]k (zk zk 1 ))

k =1
[B] = 1 ([Q ] k (zk2 zk21 ))

2 k =1
[D] = 1 ([Q ]k (zk3 zk31 ))

3 k =1
The [A] [B] [D] Matrix

We finally define the relationship between the mid-plane generalized forces
and strain:
N A B 0 N T
=
k T
M
B
D

M
Add the full equation

The [A], [B] and [D] matrices in the above relation have lot of significance in
designing the laminates.
By looking at these matrices the designer can determine,
Various behavior like if the laminate is balanced
If it has coupling between extension, shear, bending, twisting etc.
N A B 0 N T
=
k T
M
B
D

M
The [A] matrix relates mid-plane forces to mid-plane strains defining
the extensional behavior of the laminate.
A14 and A24 terms represent extensional shear coupling
between the mid-plane forces and midplane shear strain.
The [A] matrix is stacking sequence independent
N A B 0 N T
=
k T
M
B
D

M
The [B] matrix relates mid-plane forces to plate curvatures and midplane moments to mid-plane strains.
Both above relations represents extensional bending and
shear - twist coupling.
The [B] matrix is zero for symmetric laminates
N A B 0 N T
=
k T
M
B
D

M
The [D] matrix relates mid-plane moments to plate curvatures
defining the extensional behavior of the laminate
D14 and D24 terms represent bending twist coupling between
the mid-plane moments and plate curvatures.
The [D] matrix is stacking sequence dependent and is most affected
by the location of zero degree plies in the stacking sequence.
Exercise 1.1 - Evaluate the ply and laminate matrices.

2.50E+07
Material Data:
E1 = 18.7e6psi
E2 = E3 = 1.40e6psi
12 = 13 = 0.3
23 = 0.6
G12 = G13 = 0.5e6psi
G23 = 0.45e6 psi
2.00E+07
1.50E+07
Q_11
Q_12
Q_14
Q_22
Q_24
Q_44
1.00E+07
E11
[S ] = E121
0
12
E1
1
E2
0
1
G12
5.00E+06
0.00E+00
-100
-50
50
100
-5.00E+06
[Q ] = [S ]1
-1.00E+07
[Q]
= [TS ] [Q ][TS ]
1
N A B 0 N T
=
T
M B D k M

[0,0,45,45,-45,-45]S
Laminate Matrices.
3
[A] = ([Q ] k (zk zk 1 ))

k =1
n
[B] = 1 ([Q] k (zk2 zk21 ))

2 k =1
n
[D ] = 1 ([Q ]k (zk3 zk31 ))

3 k =1

[0,0,45,45,-45,-45]S
Laminate Matrices.
Specific PrePre-processing
Composites can be modeled using both shells and solids.
In case of solids, each ply needs to be modeled with at least one

solid element. This requires a huge number of solid elements to
model a simple plate.
Majority of the real life parts are modeled with shell elements.
Analysis of composite shells is very similar to the solution of

standard shell elements.
An element is modeled as composite by assigning a composite

property (e.g. PCOMP, PCOMPG or PCOMPP) to it.
Composite material properties in general are modeled with an

orthotropic material model (e.g. MAT8).
Composite Analysis process
Element
Property
(PCOMP)
Ply 1
Ply 2
.
.
.
Ply n
Classical lamination theory

( derive homogenized shell
properties)
Analysis
Ply results
(Stress & strain
for individual ply)
Shell results
(Stress and strain)
Ply Failure
(Ply failure or
matrix failure)
How to Setup a Composite in HyperMesh

1. Import or create the 2D geometry that will represent your
component.
2. Organize your model in components
3. Generate the Mesh.

4. Align the elements according to the laminate main direction
Dont forget
about the
normals!!!
TETA (Angle that the element needs to be rotate from definition)
MCID (Local coordinate system)
Both are defined as the (7th field for CQUAD or 6th field for CTRIA)
5. Define the composite materials.

6. Define the PCOMP or PCOMPG properties
PCOMP (1 mm) [45, 90, -45]S
PCOMPG (1 mm) [45, 90, -45]S

7. Assign the properties to the components.
8. Apply the boundary conditions. (SPC)

Loads applied to
geometry to
simply the display
9. Apply the loads. (Load)

10. Create the load step with the constraints and loads.
11. Run the analysis
12. Pos-processing
Parameters for modeling composites
Define material properties (MAT8)
Ply, matrix and core (HOMOGENIZATION)
Define the material coordinate system to establish the reference for

defining the ply angle
Define the element normal to establish the reference for defining ply
stacking
Define the individual laminate property (PCOMP)
Ply material, Ply thickness (number of plies), Ply angle, Order of stacking
Modeling Flow
Material Property
(MAT8)
Element Property
(PCOMP)
Material
Orientation
Element Normal
Element
(CQUAD4 )
Material Property
(MAT8)
The typical material model used for composites is MAT8, which is

planar orthotropic material.
Each ply is associated with a material property.
Example of typical material property for a ply is
E1 = 18.7e6 psi
12 = 13= 0.3
G12 = G13 = 0.5e6psi
a1 = 1.0e-7
in/in/oC
E2 = E3 = 1.4e6 psi
23 = 0.6
G23 = 0.45e6 psi
a2 = a3 = 18.0e-6
in/in/oC
The use of isotropic MAT1 or general anisotropic MAT2 for ply

properties is also supported.
Material Property
(MAT8)
Definition of material property, MAT8 in Hypermesh

E1 = 18.7e6 psi
12 = 13= 0.3
G12 = G13 = 0.5e6psi
a1 = 1.0e-7
in/in/oC
E2 = E3 = 1.4e6 psi
23 = 0.6
G23 = 0.45e6 psi
a2 = a3 = 18.0e-6
in/in/oC

Element Property
(PCOMP)
Different properties can be used to define composite properties
PCOMP, PCOMPG, PCOMPP
Example of a typical composite property is,

PCOMP Property
Failure Theory
Ply 2
Ply 1
Ply 4
Ply 3
Element Normal
Elements normal direction defines the stacking order.
Plies are listed from the bottom surface upwards, with respect to
the elements normal direction
Material Orientation
The material orientation is important to establish the reference for

ply angle.
Ply angles can be specified relative to the element coordinate

system or its material coordinate system.
Since element coordinate system is strongly dependent upon the

node numbering in individual elements, it is advisable to prescribe a
material coordinate system for composite elements and specify ply
angles relative to this system.
HyperMesh provides an easy way of defining the material

coordinate system.

Material Orientation
2D -> composites panel, allows the user to define, review or modify

the material orientation for elements.
Individual ply orientation can also be reviewed by selecting ply

number.
Material Orientation by default

(based on element node numbering)
Material Orientation by specifying

Material orientation angle

Why is Material orientation is very important?
Sample material property is defined as

E1 = 1.3e5 Mpa
E2 = E3 = 9650 Mpa
12 = 13 = 0.3
23 = 0.6
G12 = G13 = 3450 Mpa
G23 = 3100 MPa
a1 = 1.0e-7mm/mm/oC
a2 = a3 = 18.0e-6 mm/mm/oC
E1 is much stronger than E2 . But, in which directions are E1 and E2

measured?
Material orientation is very important because it defines the

direction for E1 and E2. It also establishes the reference for the
definition of ply angle.

Understanding different coordinate systems
There are many coordinate systems like, global coordinate system,

local coordinate systems, element coordinate systems, material
coordinate systems, etc.
There is always only one global coordinate system which is the

reference for all other coordinate systems.
Direction for E1 is the x-axis of the elements material coordinate

system and direction for E2 corresponds to its y-axis.
How to determine elements material coordinate system?

Understanding the element coordinate system
For anisotropic elements by default the material coordinate system

is aligned with the element coordinate system.
The x-axis of the element coordinate is aligned with side 1-2 (or
direction from G1 G2) of the shell element and z-axis is aligned
with the normal of the shell element.

Material co-ordinate system
Material orientation by default (based
on element node numbering) may not
be aligned properly.
Material coordinate system should be
defined to align the E1 and E2 to the
desired direction.
Material coordinate system can be
defined by defining an angle or a
co-ordinate system.

Material coordinate system
Material orientation can be defined as an angle Rotated by THETA
from the x-axis of the element coordinate system.
THETA = 90 degree
X (G1 G2) Rotated by THETA
Z = Element Normal
MCID: X is defined by the local coordinate system.
HyperLaminate
HyperLaminate is an interactive
tool for pre-processing of
composites.
HyperLaminate allows the user

to create the materials,
properties (ply, orientation,
thickness, stacking sequence)
and provides a graphical
representation to visualize the
laminate.
HyperLaminate also helps the

user to setup optimization of ply
properties.
LIVE DEMO
Different choice for Property definitions

PCOMP
PCOMP defines all the laminate properties like ply material, thickness and
orientation and also the stacking sequence.
PCOMP definition contains no information on plies that are also part of

other regions (PCOMPs). During post-processing, this requires lot of book
keeping to track ply and stacking information for each PCOMP.
Exercise 2.1 - Clamped BEAM (PCOMP)

[0, -45, 45, 90]
Different choice for Property definitions

PCOMPG
PCOMPG is similar to PCOMP and additionally it stores global ply

identification number.
Through the global ply identification number, plies that are part of
many regions can be tracked across the regions, reducing the effort
for keeping track of the ply properties and stacking information.
Exercise 2.2 - Clamped I BEAM (PCOMP)
Exercise 2.2 - Clamped I BEAM (PCOMP)
PCOMPP - PlyPly-Based FEA Modeling

PCOMPP adopts ply based composite definition which is similar to
existing Laminate tools and to the Ply-Book used in typical
manufacturing set up.
Ply definition, stacking and the property are defined separtely through
independent cards (PLY, STACK and PCOMPP).
PLY defines fiber orientation and layout (element sets)

STACK glues PLYs into laminate
Element properties implicit through STACK and PLYs
PCOMP for explicit laminate definition)
(replacing
Ply
ID
MID
THETA
SOUT
TMANUF
ESID1
ESID2
ESID3
ESID4
ESID5
ESID6
ESID7
ESID8
ESID9
PLYID1
PLYID2
PLYID3
PLYID4
PLYID5
PLYID6
STACK
ID
LAM
PLYID7
+
Defining PCOMPP
Define all the ply definitions separately using PLY cards (Angle,
Elements Sets, Thickness, etc)
Define the PCOMPP property

Define the Stack sequence (Ply sequence)
Exercise 2.3 - Clamped I BEAM (PCOMPP)

CSTRAIN FOR EACH LAYER (TOP)

CSTRAIN FOR EACH LAYER (BOTTOM)

CSTRAIN FOR EACH LAYER (WEB)
Difference between different Properties

PCOMP
PCOMPG
PCOMPP
1.
1.
MID-Plane (Z0)
1.
MID-Plane (Z0)
FT (Hill, TSAI,...)
MID-Plane (Z0)
2.
FT (Hill, TSAI,...)
2.
FT (Hill, TSAI,...)
2.
3.
LAM (SMEAR, SYM,...)
3.
LAM (SMEAR, SYM,...)
PLY
4.
MIDi (Ply material)
4.
MIDi (Ply material)
5.
Ti (Ply thickness)
5.
Ti (Ply thickness)
6.
Thetai (Ply Angle)
6.
Thetai (Ply Angle)
1.
2.
3.
7. GPLYID
MIDi (Ply Material)

Ti (Ply thickness)
Thetai (Ply Angle)
STACK
1. LAM (SMEAR, SYM,...)
What is Optimization?
min f (x ) = f (x1 , x1 ,..., x n )
xiL xi xiU
j = 1, L , m
active
g j (x ) 0
inactive
i = 1, L , n
violated
Feasible
Design
Optimum
Design
Design Space (0 - 1)
Infeasible
Design
Topologic optimization
Homogenization method
= 1.0 (1.0 a )(1.0 b )

Density method
K ( ) = p K
Why Topologic optimization on composites?

Topologic optimization is the best tool to define the optimized load path in a
design space, with this result it is possible to identify the geometry (position
and thickness for example) of an optimized component.
FreeFree-Size Optimization - Concept
To determine the optimum laminate OptiStruct uses the SMEAR technology

that captures the stacking sequence effects:
A = Stacking Sequence independent
B = 0 (Symmetric)
D = At2/12 - Stacking Sequence Independent

Phase 2
Size Optimization
Number of Plies?
t = DVi
Ply Bundle Sizing!
p = C 0 + DVi Ci
Sizing
optimization

Characteristics
VS
Challenges
Design Complexity: how to optimally
Enhanced material properties
define geometry, materials, patches,

plies, angles, stacking sequence?
Freedom and flexibility:

material
Properties can be locally
tailored
Complex manufacturing processes
Manufacturing costs
Development phase compression

How to reduce design time?
How to mitigate re-design risk?

How to evaluate manufacturing
costs vs. design performances?
Manufacturing
Costs
Integrated ribs
Ply drop-offs
Complex stacking
Manufacturing
Complexity
Plate design
Ply drop-offs
Complex stacking
Plate design
One laminate
Complex stacking
Plate design
One laminate
Quasi isotropic
[0, 90, +-45]nS
Mechanical
efficiency
Design
complexity
OptimizationOptimization-Assisted Composite Design

Proposed solutions
CAE upfront
Optimization
Process automation
Integration of design
and performance
evaluation
OptiStruct 9.0
Solution for concept and pre-design of complex composite structures
Stream-lined process based on structural optimization and process automation
Optimization Driven Design Process
Geometry
definition
Virtual
verification
Design
(CAD)
Design
(CAD)
Verification
(CAE)
Verification
(CAE)
Structural
optimization
(CAE)
Optimization
(CAE)
Physical
verification
Physical Test
(a)
Physical Test
Design
(CAD)
Integrated design
and analysis
Verification
(CAE)
Physical Test
(c)
(b)
(a) Traditional design process

(b) Optimization to improve existing design
(c) Optimization driven design process
Optimization Driven Design Process

Phase I - Concept:
Free-Size or Topology Optimization
Free-Size and Topology design formulation
Manufacturing constraints
Phase II Dimension:
Ply-Bundle Sizing with ply-based FEA modeling
All behavior constraints
Phase III Sequence:

Ply Stacking Sequence Optimization
Stacking manufacturing constraints
Manufacturing Constraints for Composite Optimization

Application Example
nP
e s ig
m
roble
Phase 1
Tailoring?
Phase 2
Number of Plies?
Phase 3
y
x
Laminate Stacking?
Free Sizing!
0
Rule based
Ply Bundle Sizing!
Automation
Automation
45
-45
ply shuffling
90
Patch Interpretation
Automation
Automation
45
-45
0
0
45
-45
90
90
-45
45
0
0
-45
45
Optimized Stacking
Sequence!
Discrete Ply Thickness

Terminology
Tailoring
Cutting the ply patch shapes
Super Ply
Total designable thickness of a particular ply orientation

(SMEAR option is often used to neutralize the stacking effect.)
Ply Bundle
Multiple plies of the same layout in a continuous stack.
Stacking Sequence Order of ply layup in the laminate
Shuffling
Rearranging the stacking sequence of plies
Terminology
0
0Super Ply
90
45
-45
Super Ply Total designable thickness of a particular ply

orientation
Z
Ply Bundle 4
Free Sizing
Ply Bundle 3
Initial Laminate Definition
consisting 4 Super-Plies
OUTPUT,FSTOSZ,YES,4
Ply Bundle 2
Ply Bundle Multiple plies of the same layout in a

continuous stack.
Basically each bundle consists of several plies so that the thickness (number of
plies) can be sized. The bundles do not have to be resulted from free-size, though
it would be the recommended approach.
Ply Bundle 1
Terminology
Ply Bundle 4
Ply Bundle 3
Ply Bundle Multiple plies of the same layout in a

continuous stack.
Ply Bundle 2
Z
Ply Bundle 1
0Plies
90Plies
+45Plies
Linked with
Manufacturing
Constraint
-45Plies
Terminology
Tailoring Cutting the ply patch shapes
Stacking Sequence Order of ply layup in the laminate
Shuffling Rearranging the stacking sequence of

plies
New Composite Optimization Methods

Free Size Optimization
Determine composite patch size, shape & location
Ply Bundle Optimization

Update ply patches in HM if necessary
Determine optimum ply bundle thicknesses
Determine required number of plies per patch
Optimize Stacking Sequence

Meet ply book rules
Improve performance
Improve manufacturability
PHASE I - Concept
Concept: Free-Size or Topology Optimization
Determine composite patch size, shape & location
Incorporate manufacturing constraints

SMEAR-PARAMETER SET
Free Size Optimization
Optimization Setup
Min (Mass)
Maximum Displacement (u) on Tip u 0.6
Manufacturing Constraints
+45
-45
90
Superply Level
Balanced 45Plies
Smeared Superply
Level
Design Variables Ply Thickness Ti for each Element
Ti varies continuously between 0 and Ti-initial
If no stiffness is needed for 90Ply in Element X, the variable T90will reduce or become zero.
Additional plies with different angels can also be used.
T0
F
0
123
90
45
-45
3
T-45
PCOMP
Variable: Ti of each Super-Ply-Element
90
Altair Proprietary
and Confidential Information
0
Material Definition
Property Definition

Finite Element Model
Design Variable Definition

With Manufacturing Constraints
DSIZE
Free Size Design Variable Definition

Optimization Responses Definition
Total Mass
Static Displacement
Total Disp
Node ID 2669

Optimization Setup
Design Constraints
Objective Function
Free Size Optimization Results

Total Element Thickness Distribution

Free Size Optimization Results
Ply Thickness Distribution
90
Balance Constraint
0
Free Size Optimization Design Proposal

Element Thickness
Ply1 (0)
90
Element Thickness
Ply2 (90)
Element Thickness
Ply3 (+45)
LINKED by Constraint
Element Thickness
Ply4 (-45)
Composite FreeFree-Size: Manufacturing Constraints
Min. and max. total laminate thickness

Min. and max. ply thickness
Min. and max. percentage of a fibre
orientation
Linkage of thicknesses of plies
Constant thickness for a particular ply
orientation

Composite Manufacturing Constraints
Min/Max Total Laminate Thickness (LAMTHK)
Min/Max Individual Ply Thickness (i.e. Min/Max 0-Deg Thickness) (PLYTHK)
Min/Max Individual Ply Angle Percentage (i.e. %90...) (PLYPCT)
Balanced Ply Angles (i.e. Balance +/- 45s) (BALANCE)
Constant Individual Ply Thickness (CONST)
45
T = Ply4 (nom)
90
T = Ply3 (nom)
-45
T = Ply2 (nom)
T = Ply1 (nom)
T = Ply1 (nom)
-45
T = Ply2 (nom)
90
T = Ply3 (nom)
45
T = Ply4 (nom)
T_45Ply (1)
T_90Ply (1)
Ply90%
=
Min/Max =
Sum(T_0Ply)
T_0Ply Constant
T_Laminate
T_Laminate Min/Max
Balance_45Ply,
T_45Ply (1) = T_45Ply (2)
Sum(T_90Ply)/T_Laminate
PCOMP
T_90Ply (2)
T_45Ply (1)
Automatic Generation of Plies for Sizing
Automatic extraction of plies

from free-sizing optimization
User defined number of ply

bundles per ply orientation
Tune manufacturing complexity
E.g. 4 Ply Bundles for 0
0 DEG
90 DEG
45 DEG
- 45 DEG

Automatic Generation of Plies for Sizing
90
0 DEG
90 DEG
45 DEG
- 45 DEG
45
-45
Free Size Optimization Output Parameter
0
90
45
OUTPUT,FSTOSZ,YES,VALUE
FreeSize to Size
Creates a new *.sizing.fem deck
Level setting Ply-Bundles: 0plies
Bundle1
Bundle3
Activate output
Number of ply bundles

(Default = 4)
Bundle2
Bundle1
Bundle4
Bundle3
-45
Bundle2
Bundle4
Bundle1
Bundle3
Bundle2
Bundle4
Free Size to Size Output

Example 0Plies
*
Ply1010100 (0-Bundle1)
*
*
*
*
*
*
*
Fig. Set Browser
Result trade off: Cost driven vs. Weight driven

OUTPUT,FSTOSZ,YES,4
0Ply
90Ply
OUTPUT,FSTOSZ,YES,8
45Ply
0Ply
90Ply
45Ply
PHASE II Dimension
System: Ply-Bundle Sizing with ply-based FEA modeling
Determine required number of plies per patch
Phase II Dimension
Ply-Bundle Concept
Free-Size interpretation through level-setting thickness field
Ply-Based FEA modeling
PLY
STACK
Element properties
Ply-Bundle Sizing Optimization
Discrete optimization of Ply-Bundle thickness
All Behavior constraints (failure, displacement, buckling etc.)
Design and manufacturing constraints
Phase II Dimension
Phase II Dimension
Level setting Ply-Bundles: +/- 45plies
Phase II Dimension
PlyPly-Based FEA Modeling

PLY fiber orientation and layout (element sets)
STACK glues PLYs into laminate
Element properties implicit through STACK and PLYs
laminate definition)
(replacing PCOMP for explicit
Ply
ID
MID
THETA
SOUT
TMANUF
ESID1
ESID2
ESID3
ESID4
ESID5
ESID6
ESID7
ESID8
ESID9
PLYID1
PLYID2
PLYID3
PLYID4
PLYID5
PLYID6
STACK
ID
LAM
PLYID7
Native language for
Laminate tools (Fibersim, Anaglyph )
Manufacturing Ply-Book
Optimization definition
PLY and STACK Cards
PLY 4
PLY 3
PLY 2
PLY 1
PLY 4
PLY 3
STACK1
PLY 2
PLY 1
Design Variable Definition

With Manufacturing Constraints
DCOMP
Ply based sizing design variable definition
Manufacturing Constraints are carried over from the Free Sizing

Phase automatically with OUTPUT,FSTOSZ,YES
Output Request from Sizing Optimization
OUTPUT,SZTOSH,YES
Size to Shuffle
Creates a new *.shuffling.fem deck
Activate output
Size Optimization Results Per Fiber Orientation
0 DEG
45 DEG
90 DEG
- 45 DEG
Optimized Ply Bundle Thicknesses: 0 Deg
Optimized Ply Bundle Thicknesses: 90 Deg
Optimized Ply Bundle Thicknesses: +45 Deg
Optimized Ply Bundle Thicknesses: - 45 Deg
Phase II System: PlyPly-Bundle Sizing

Final number of plies in all Ply-Bundles
PHASE III
Detail: Stacking Sequence Optimization
Meet ply book rules
Stacking manufacturing constraints

0
45
-45
90
45
-45
0
0
45
-45
90
90
-45
45
0
0
-45
45

Cantilever Plate
Ply Shuffling
Phase III Sequence:: Ply Stacking Sequence Optimization

Design and Manufacturing Rules
-45
+45
-45
+45
Validate the shuffling optimization through: OUTPUT, PCOMP, YES
-45
Ply Pairing
+45
Core / Cover definition
-45
The lay-up sequence should contain no sections with more than a given
number of successive plies with the same angle (typically 3 or 4)
+45
Ply Shuffling Input Data Definition
DSHUFFLE
Design Variable Definition for Composite Ply Shuffling Optimization
Formulation from Sizing Optimization phase is maintained
Automatically created after the Sizing Optimization phase with
OUTPUT,SZTOSH,YES
Stacking Sequence Optimization Rules
MAXSUCC, MANGLE, MSUCC, VSUCC
PAIR, PANGLE1, PANGLE2, POPT
CORE, CREP, CANG#
COVER, VREP, VANG#


Stacking Sequence before Optimization
Stacking Sequence after Optimization
Optimized stacking sequence written to *.prop file
Ply Rules in Stacking Sequence Optimization
Optimized Stacking Sequence with Different Ply Rules
Initial
No rules
Successive
ply limit = 3
Successive
ply limit = 2
Pairing
constraint 45 -45
Reversed Pairing
constraint 45 -45
Core 0
45 -45 90
90
90
45
90
-45
-45
90
-45
45
90
45
45
45
45
-45
45
-45
45
45
-45
-45
45
45
45
45
45
45
-45
-45
45
-45
45
90
-45
45
45
45
-45
-45
90
45
45
45
-45
-45
-45
45
45
45
-45
-45
90
-45
-45
45
-45
-45
45
-45
90
45
-45
-45
-45
-45
-45
45
90
-45
90
90
90
90
90
90
45
90
90
90
90
90
-45
90
90
90
-45
90
90
45
90
90
-45
90
90
90
90
Cover 0
45 -45 90

Why Optimization for Stacking Sequence Determination
For any ply layup, total number of sequences = (n1+n2 .. ni )!/(n1!n2!.. ni !)
where:
n1 is the number of plies in patch 1
n2 is the number of plies in patch 2
ni is the number of plies in patch i
For this example, Stacking Sequence Combinations:
(43!)/(2!4!10!9!9!3!) = 4.39E+32
If each run takes 6 seconds, testing all available combinations would take:
8.35E+25 years!
OptiStruct found the optimum in:

12 iterations
2 minutes 12 seconds
Composites Optimization Process Summary
STACK
OUTPUT,FSTOSZ
OUTPUT,SZTOSH
PCOMP
Free-sizing
optimization
Sizing optimization
Ply stacking optimization

Max Disp. < 3.00e-04.
Parameters (PLATE) laminate definition
Manufacturable thickness (in) 0.05 (PTMAN)

FREE SIZE

SIZE
DV
ID
NAME
X0
Xmin
Xmax
DESVAR
1010100
autoply
0.12
0.00
0.30
DESVAR
1010200
autoply.1
0.34
0.00
0.80
DESVAR
1010300
autoply.2
0.48
0.00
1.00
DESVAR
1010400
autoply.3
0.06
0.00
0.20
DESVAR
1020100
autoply.4
0.17
0.00
0.40
DESVAR
1020200
autoply.5
0.12
0.00
0.30
DESVAR
1020300
autoply.6
0.13
0.00
0.30
DESVAR
1020400
autoply.7
0.58
0.00
0.80
DESVAR
1030100
autoply.8
0.17
0.00
0.40
DESVAR
1030200
autoply.9
0.12
0.00
0.30
DESVAR
1030300
autoply.10
0.13
0.00
0.30
DESVAR
1030400
autoply.11
0.58
0.00
0.80
DESVAR
1040100
autoply.12
0.08
0.00
0.20
DESVAR
1040200
autoply.13
0.05
0.00
0.20
DESVAR
1040300
autoply.14
0.07
0.00
0.20
DESVAR
1040400
autoply.15
0.80
0.00
1.00
ANGLE(o)
-45
45
90

SIZE

SHUFFLING

Exercise 3.2: Optimization Drive Design of a Composite Wing Design
Design

Max Disp. < 50mm.
Parameters (TopSkin and BottomSkin) laminate definition
Max of each family (ANGLE) 60% (PPMAX)
Min manufacturable thickness (mm) 1.27 (PTMAN)
Conclusions
In OptiStruct 9.0, the composite optimization capabilities were significantly

enhanced. A comprehensive package comprising of three optimization phases was
developed to guide the design process from concept all the way to detailed finish.
The new process is realistic and applicable to practical composite design.
The benefits of this process are even more significant for applications with
Multiple load cases

Multiple Performance requirements such as Failure Index, Strain Targets, Buckling,
Stiffness, Stress Limits etc.
Successful application of this process at various OEMs and suppliers for different
commercial aero projects.
Responsiveness to implement new rules into the algorithm for stacking sequence
optimization.

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A Platform for Innovation

Analysis, Concept, and Optimization

Altair Engineering Contact Information

Address: ftp.altair.com or ftp2.altair.com or http://ftp.altair.com/ftp

Trademark and Registered Trademark Acknowledgments

HyperMesh 1990-2008; HyperCrash 2001-2008; OptiStruct 1996-2008; RADIOSS 1999-2008;

2008; HyperGraph 1995-2008; HyperGraph 3D 2005-2008; MotionView 1993-2008; MotionSolve 2002

Proprietary Information of Altair Engineering, Inc.

Chapter 2: Composite Pre-processing - Analysis ............................................... 31

2.1 Using Hyper Laminate .......................................................................................... 38

Chapter 3: Composite Optimization ..................................................................... 69

Chapter 1: Theoretical Introduction

1.1 - Why Composites

Chapter 1: Theoretical Introduction

Chapter 1: Theoretical Introduction

l. Transformation Matrix 3D Tensors:

Chapter 1: Theoretical Introduction

m. Transformation Matrix 2D Tensors (Plane Stress)

This is valid for strain too:

Chapter 1: Theoretical Introduction

n. Kirchhoff Plate Theory

o. Linear Elastic 2D Strain-Displacement relationship

p. Strain-Displacement for Kirchhoff Plate

Chapter 1: Theoretical Introduction

1.3 Material Laws (Elastic Linear)

The Stiffness matrix is always Symmetric: Cij = Cji.

The inverse is called Compliance Matrix S = C-1.

Chapter 1: Theoretical Introduction

with these two equations is possible to isolate the stiffness matrix:

S122 S12 S11

Chapter 1: Theoretical Introduction

Transversely Isotropic Composite

In terms of engineering constants we can rewrite the Strain-Stress relation as:

Chapter 1: Theoretical Introduction

Chapter 1: Theoretical Introduction

Stiffness and Compliance Matrix for an Orthotropic Material

In terms of engineering constants, the orthotropic compliance matrix is defined as follows:

Chapter 1: Theoretical Introduction

1.3.1 Adding Thermal Strain

Chapter 1: Theoretical Introduction

Mechanical strains are the strains which cause stress.

Chapter 1: Theoretical Introduction

1.4 Micromechanics of Composite Materials

1.5 - Effective Homogenized Stiffness Matrix of a Ply

The ply is linear elastic, macroscopically homogeneous, and orthotropic

The fibers are linear elastic, macroscopically homogeneous, isotropic,

The matrix is linear elastic, macroscopically homogenous, isotropic, and void

Chapter 1: Theoretical Introduction

Unidirectional Stress (2)

Chapter 1: Theoretical Introduction

Determination of Ply G12

Pure Shear Stress (12)

Chapter 1: Theoretical Introduction

2 Macromechanical Behavior of a Laminate (Ply)

Q 11 = Q11 cos 2 + 2(Q12 + 2Q44 ) sin 2 cos 2 + Q22 sin 4

Chapter 1: Theoretical Introduction

3 Classical Lamination Theory (CLT)

Laminate Stacking Sequence and Z-coordinate Conventions

Plies are given a number 1 thru n:

1st ply always defined as the most negative z ply

nth ply as the most positive z ply.

n: Define the number of repeating units;

as: Anti-symmetric Laminate

Chapter 1: Theoretical Introduction