Sec4 Optimization of Composites 021712

SECTION 4
Optimization of Composite Structures
Composites Technology Day, February 2012

Copyright 2012 MSC.Software Corporation
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Time
Agenda: Composites Technology Day with MSC Nastran
9:00-9:15
Welcome
9:15-9:45
Overview of MSCs Composites Solution
9:45-10:30
Introduction to Analysis of Composites Structures

Hands-on Training
Workshop 1: Stress Analysis of a Composite Wing
10:30-10:45
Break
10:45-12:15
Solid Composite Elements

Hands-on Training
Workshop 2: Solid Shell Composites Modeling
12:15-12:45
Lunch
12:45-2:15
Progressive Ply Failure and Delamination Modeling

Hands-on Training
Workshop 3: Open-Hole-Tension Test Coupon
2:15-2:30
Break
2:30-4:00

Hands-on Training
Workshop 4: Minimizing the Weight of a Composite Wing
4:00-4:30
Curing, Draping, and Direct CAD Interface
4:30-4:45
Feedback/Wrap-up
We are here

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What is Optimization?
Time
Agenda: Composites Technology Day with MSC Nastran
9:00-9:15
Welcome
9:15-9:45
Overview of MSCs Composites Solution
9:45-10:30
Introduction to Analysis of Composites Structures

Hands-on Training
Workshop 1: Stress Analysis of a Composite Wing
10:30-10:45
Break
10:45-12:15
Solid Composite Elements

Hands-on Training
Workshop 2: Solid Shell Composites Modeling
Design variables
12:15-12:45
Lunch
Topical lectures and hands-on

workshops
12:45-2:15
Progressive Ply Failure and Delamination Modeling

Hands-on Training
Workshop 3: Open-Hole-Tension Test Coupon
2:15-2:30
Break
2:30-4:00

Hands-on Training
Workshop 4: Minimizing the Weight of a Composite Wing
4:00-4:30
Curing, Draping, and Direct CAD Interface
4:30-4:45
Feedback/Wrap-up
Optimization Problem Statement

Objective
Maximize your understanding
of composites technology
available from MSC Software
Constraints
Limited by the clock and my
own personal understanding

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What is Design Optimization?

Automated modifications of the analysis model parameters to achieve
a desired objective while satisfying specified design requirements
Objective
Minimize weight
Minimize Error Function (test/analysis)
Design Variables
Element properties (I, J, Area, t, etc.)
Grid locations (shape optimization)
Topology (remove structure)
Design Constraints
Direct Response
Stress Limit, Freq, Disp.
Derived Response
Equation
DESVAR range ( .04<t<.25)

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Optimization in MSC Nastran

SOL 200 is the solution sequence that performs optimization
Analysis Types
Statics
Normal modes
Buckling
Direct complex eigenvalue
Modal complex eigenvalue
Direct frequency
Modal frequency
Modal transient
Static aero elasticity
Aeroelastic flutter
Structural
Optimization

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Gradient Based Numerical Optimization

Optimization
Design
Variables
Optimization
Objective
Repeat
And
Refine
Numerical
Optimizer
Structural
Optimization
Constraints
Improved
Design

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So what is gradient based optimization?

In a nutshell go downhill go
downhill fast
Nastran calculates the sensitivity of
each response to changes in the
design variables
The Optimizer uses these gradients
(think slopes) to determine which
design variables to change
b
h
L
A/b = h /b = -6M/b2h2
A/h = b /h = -12M/bh3
Method of Steepest Descent along with

other more efficient methods are used
Dont forget about constraints!

Search direction must be feasible, i.e.,
cant violate constraints
A constraint on the path

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How do I know it is the optimal solution?

Depends on what optimal means
Out of all possible designs, this one is the best - Maybe

Global max/min? - Maybe
Local max/min? - Yes
Improved design? - Yes
MSC Nastran finds local

minimums
Several factors influence

which minimum will be
found
Starting location, step size
both have big effect
And dont forget constraints!
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Optimization Applications
Structural design improvements
Minimize thickness, hence weight
Generation of feasible designs from infeasible

designs
Original model violates stress levels
Preliminary Design
Candidate designs from topology optimization
Model matching to produce similar response

Frequency response, modal test
Sensitivity evaluation
Identify which regions of the model are most
sensitive to design changes or imperfections

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Composites Optimization
using Patran and MSC Nastran

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Set up an Optimization Job

Pre-Processing
Build the optimization model
Logical guided workflow
Post-Processing
Results
XY Plot

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Creating Design Model
Objective
Minimize Weight
Design Variable
Thickness, Area, etc.
Constraint
Allowable deflection, allowable stress, etc.
Response
Deflection, Von Mises Stress, Sxy, etc.
Constraint Set
Collection of active constraints
MinMax
Minimize the max response frequency response
Variable Relation
Linking variables, i.e., think linking ply thicknesses and/or orientations
Design Study
Select which variables, constraints, etc. are active

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FIRST CREATE DESIGN VARIABLES

a
b
a) Tools/Design Study/ Pre-Process
b) Create/Design Variable/ Material
c) Enter Variable Name ply1_0_thick
d) Enter Analysis Model Value
0.0054
e) Category:
Composite
f)
Selected Composites(s)
Select Material Sets
8Ply-symmetric-quasi
g) Select Material Properties
Select ply 1
h) Apply
i)
Repeat steps f-h for each additional

ply
Creates Nastran entries:
g
g
DESVAR entries, design

variables
DVPREL1, DVMREL1, and

DVCREL1 relate DESVAR to
PSHELL, MAT1, CQUAD4, etc.
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NEXT CREATE DESIGN OBJECTIVE
Create/Objective
Solution: Global
Response: Weight
Enter Objective Name

Apply
Creates Nastran entries:
DESOBJ(MIN) case
control
DRESP1 bulk data entry

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NEXT CREATE DESIGN CONSTRAINT AND

CONSTRAINT SET
a
b
c
a)
Create/Constraint
b)
Solution: Linear Static
c)
Response: Comp. Fail
d)
Enter Constraint
Name:
ply_1_fail_constr
j)
Create/Constraint
Set
Select Property Set
k)
Solution: Linear
Static
l)
Constraint Set
Name: Comp Fail
m)
Constraints to be
included: select all
n)
Apply
e)
comp
d
e
f)
Lower Bound: -.1
g)
Upper Bound: 1.0
h)
Apply
i)
Repeat steps e-h for

each ply
l
m
This creates Nastran

entries:
DRESP1
DCONSTR
h
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NEXT CREATE DESIGN STUDY SELECT RESPONSES,

OBJECTIVE, AND CONSTRAINTS
a
a) Select Responses:
Select All
Close
b) Select Objective:
Click on Min_Weight
Close
c) Select Constraints:
a
b
Select All
Close
d) Apply
c
d

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FINALLY SET UP THE OPTIMIZATION JOB

a
b
a) Analysis
b) Action/Optimize
c) Method/Analysis Deck
d) Job Name/ sem9
e) Design Study Select
Select Comp_Strength
f) Global Obj/Constr Select:
Min_Weight
g) OK

g
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SET UP THE OPTIMIZATION JOB (CONT.)
a) Optimization Parameters
Set parameters as desired
This creates the Nastran
DOPTPRM entry

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a) Subcases
b) Solution Type: Linear Static
c) Select Untitled.SC1
d) Select
Constraints/Objective
e) Click on Constraint Sets
f) Select Comp_Failure
g) OK
h) Apply
i) Cancel
j) Apply
g
h
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b
a) Subcase Select
b) Solution Type: Linear Static

c) Make sure it looks something like
this under Subcases Selected
d) OK
e) Apply
d
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a
e
NASTRAN OPTIMIZATION OUTPUT

Review the Design Variable history at the end of the f06 printout.
.f06 file excerpt

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Review the Objective and Constraint history in the f06 file.
A positive constraint value is a failed constraint.

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The convergence condition is also stated.

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PATRAN OPTIMIZATION OUTPUT

If the op2 result file is used (param,post,-1) for optimization post
processing in Patran, then the following plots are available:
Design variable value versus design cycle XY plot
Objective value versus design cycle XY plot
Constraint value versus design cycle XY plot

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PATRAN OPTIMIZATION OUTPUT (Cont.)
XY Plot
Post/XY Window
Post/Unpost XY Windows
Design Variable History

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Repeat for Maximum Constraint History and Objective Function History

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Results:
Create/ Fringe
Select Result Case

StaticSubcaseD9
Select Fringe
Result
MaximumIndices
Apply

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Topometry Optimization of Composites

Topometry Optimization is element-by-element sizing optimization
Shell thickness
Rod area
Bushings, fasteners, etc.
Because each element is a design variable, it often finds a better

design than conventional property set based optimization
Why? More design variables
Applied to composite laminates allows ply-by-ply element thickness

variation/optimization
Material distribution is optimized across all elements
0 degree Ply
90 degree Ply
+45 degree Ply

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-45 degree Ply
Example: composite plate with in-plane shear load

Objective
Minimize Compliance, aka
maximize Stiffness
(0/90/45/-45)s
Constraint
Fractional mass, i.e., final mass
should be of the initial mass
Effectively this allows for the
selection of a target weight
Design Variables
Ply-by-ply element thickness
640 elements x 4 plies
2560 variables
Final combined thickness distribution

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Composite plate topometry optimization results

Optimal ply placement/distribution
0 degree Ply
90 degree Ply
+45 degree Ply
-45 degree Ply
For this loading and from the perspective of maximizing

stiffness
0o plies arent necessary
General placement and coverage of individual plies
If adding a reinforcing ply
Choose +/- 45s or 90s
General location and coverage
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Topometry optimization post-processing

Optimization results (ply thicknesses) are accessed via
Design Study: Post-Process
The thickness of each ply is output in files named

<jobname>.ply*

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Visualize ply thickness
Design Study: Post-Process
Standard Results Fringe plots

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Optionally, optimized ply coverage may be smoothed to remove
jagged boundaries
Can be used to
guide general
placement and
coverage of
individual plies
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END OF SECTION 4

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SECTION 4

Optimization of Composite Structures

Composites Technology Day, February 2012

Optimization of Composite Structures

Agenda: Composites Technology Day with MSC Nastran

Overview of MSCs Composites Solution

Introduction to Analysis of Composites Structures

Solid Composite Elements

Progressive Ply Failure and Delamination Modeling

Optimization of Composite Structures

Curing, Draping, and Direct CAD Interface

Composites Technology Day, February 2012

Agenda: Composites Technology Day with MSC Nastran

Overview of MSCs Composites Solution

Introduction to Analysis of Composites Structures

Solid Composite Elements

Topical lectures and hands-on

Progressive Ply Failure and Delamination Modeling

Optimization of Composite Structures

Curing, Draping, and Direct CAD Interface

Optimization Problem Statement

Composites Technology Day, February 2012

What is Design Optimization?

DESVAR range ( .04<t<.25)

Composites Technology Day, February 2012

Optimization in MSC Nastran

Composites Technology Day, February 2012

Gradient Based Numerical Optimization

Composites Technology Day, February 2012

So what is gradient based optimization?

Method of Steepest Descent along with

Dont forget about constraints!

A constraint on the path

How do I know it is the optimal solution?

Out of all possible designs, this one is the best - Maybe

MSC Nastran finds local

Several factors influence

Generation of feasible designs from infeasible

Model matching to produce similar response

Composites Technology Day, February 2012

Composites Technology Day, February 2012

Set up an Optimization Job

Composites Technology Day, February 2012

Creating Design Model

Composites Technology Day, February 2012

FIRST CREATE DESIGN VARIABLES

g) Select Material Properties

Repeat steps f-h for each additional

Creates Nastran entries:

DESVAR entries, design

DVPREL1, DVMREL1, and

NEXT CREATE DESIGN OBJECTIVE

Enter Objective Name

Composites Technology Day, February 2012

NEXT CREATE DESIGN CONSTRAINT AND

Solution: Linear Static

Response: Comp. Fail

Select Property Set

Lower Bound: -.1

Upper Bound: 1.0

Repeat steps e-h for

This creates Nastran

NEXT CREATE DESIGN STUDY SELECT RESPONSES,

Composites Technology Day, February 2012