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Abaqus Version 6.12-1 2008 SIMULIA, Inc.
Users Manual
Table of Contents
1. Background .....................................................................................................................................................4
1.1 Plug-in Overview ......................................................................................................................................5
1.2 Top-Level Icons ........................................................................................................................................5
2. COPV (Tank) Creation....................................................................................................................................7
2.1 Model & Tank Initialization .......................................................................................................................7
2.1.1 Model Creation ..................................................................................................................................7
2.1.2 Tank Creation....................................................................................................................................8
2.2 Liner Geometry Assignment .....................................................................................................................8
2.2.1 Geodesic Dome ................................................................................................................................8
2.2.2 Elliptical, Spherical Domes ...............................................................................................................9
2.2.3 From-Part Instance Dome...............................................................................................................10
2.2.4 Transition Radii ...............................................................................................................................10
2.2.5 Defining the Dome Set Properly .....................................................................................................11
2.2.6 Viewing Dome Geometry in Sketcher .............................................................................................13
2.2.7 Adjusting Spline Refinement ...........................................................................................................14
2.3 Winding Layout .......................................................................................................................................15
2.3.1 Layer Manager Dialog .....................................................................................................................15
2.3.2 Layer Shape Controls .....................................................................................................................16
2.3.2.1 End Fraction Override ..................................................................................................................17
2.3.2.2 Transition Radius Override ..........................................................................................................17
2.3.2.3 Transition Radius Override (Ignoring End Cap) ...........................................................................18
2.3.2.4 Transition Angle ...........................................................................................................................19
2.3.2.5 Overlap Fraction ..........................................................................................................................20
2.3.3 Helical Layers..................................................................................................................................21
2.3.3.1 Controlling the Wind Angle at the Turnaround Radius ................................................................22
2.3.3.2 Varying Wing Angle over Cylinder Section ..................................................................................23
2.3.4 Helical Layer with Friction ...............................................................................................................24
2.3.5 Doily & Hoop Layers .......................................................................................................................25
2.3.6 Layer-Level Mesh Controls .............................................................................................................26
2.4 Mesh Partitioning ....................................................................................................................................26
2.5 Mesh Creation ........................................................................................................................................28
2.6 Properties Creation ................................................................................................................................29
2.6.1 Material Properties ..........................................................................................................................29
2.6.2 Material Orientations .......................................................................................................................30
2.6.3 Uvarm Subroutine ...........................................................................................................................30
3. Running the Analysis ....................................................................................................................................32
4. Output Processing ........................................................................................................................................32
5. Sample Test Cases ......................................................................................................................................35
6. Micromechanics Module ...............................................................................................................................36
6.1 Introduction .............................................................................................................................................36
6.1.1 Plug-in Overview .............................................................................................................................37
6.2 Plug-in Usage .........................................................................................................................................38
6.2.1 Fiber Packing Arrangement ............................................................................................................38
6.2.2 Fiber Volume Fraction .....................................................................................................................39
6.2.3 Fiber Elastic Properties ...................................................................................................................39
6.2.4 Matrix Elastic Properties .................................................................................................................40
6.2.5 Thermal Expansion Properties ........................................................................................................41
6.2.6 Density Properties ...........................................................................................................................41
6.3 Plug-in Output ........................................................................................................................................41
6.4 Micromechanics Theory .........................................................................................................................42
6.4.1 Micromechanics unit cell geometry .................................................................................................42
6.4.2 Unit cell boundary conditions ..........................................................................................................43
6.4.3 Volume-averaged ply properties .....................................................................................................43
7. Installation of WCM Plug-in ..........................................................................................................................45
8. References ...................................................................................................................................................45
WCM References .........................................................................................................................................45
Micromechanics References ........................................................................................................................45
2
Abaqus References ......................................................................................................................................45
3
1. Background
The process of filament winding has become a popular technique in a wide variety of industries for creating
extremely high stiffness-to-weight structures. Aerospace industry applications include rocket propellant tanks
and solid rocket motors casings. Automotive industry applications include high pressure fuel storage tanks
for hydrogen powered automobiles.
The difficulty in accurately analyzing the behavior of filament wound structures derives from the varying
orientation of the wound filaments throughout the structure. The standard capabilities of commercial finite
element codes are inadequate to model the variation of fiber orientation in a practical way. Thus, the Wound
Composite plug-in for Abaqus was warranted. This Wound Composite Modeler for Abaqus plug-in was
developed to analyze a wide variety of axisymmetric or three-dimensional, wound composite pressure
vessels. This documentation describes the capabilities and usage of the plug-in.
4
1.1 Plug-in Overview
The Wound Composite Modeler for Abaqus plug-in is a vertical application which is designed to facilitate the
creation of an entire axisymmetric or three-dimensional finite element model of a composite overwrapped
pressure vessel (COPV). The model created is a representation of the full tank. The plug-in automates the
creation of the tank geometry and its corresponding mesh and element-by-element material property and
orientation assignments.
The plugin is brought up by selecting Wound Composite Modeler (Show/Hide) under the Plugins drop down
menu. The WCM plugin follows the same tree structure of the model and output data base trees, therefore,
the model tree must be displayed in order to work in the WCM. To toggle the model tree on and off, click
CTRL-t.
5
The post processing icon, , brings up a dialog that is used to automatically generate path plots of output
quantities such as stress and strain along the length of any given layer.
The micro-mechanics icon, , is used to bring up a separate utility to generate the micro mechanical
material properties of a lamina consisting of fiber and matrix materials. Clicking the Users Manual button as
shown in the dialog below brings up a separate detailed description of the utilitys capabilities.
6
2. COPV (Tank) Creation
7
2.1.2 Tank Creation
Once the WCM model has been created, a tank is initialized by selecting the Tanks repository, right clicking,
and selecting Create. The dialog brought up is shown below. The first item to be chosen is whether to model
a full tank or only a partial tank by defining a symmetry plane. A number of options are provided to assign
default element controls that are assigned to all of the tanks layers to be created. These controls can be
overridden on a layer-by-layer basis as the layers are created.
In the case of a 3D COPV model, an axis must be defined which represent the vessel centerline. A datum
axis may be used or one of the axes of a datum coordinate system. During the tank creation of the 3D
COPV, this axis must be selected.
8
Analytic category, then choosing the dome type as Geodesic. Each end of the tank may be assigned
different dome types.
For example, Figure 2.2.1-2 shows a dome in blue which is constructed from a wind angle of five degrees
and a dome in grey which is constructed from a wind angle of ten degrees.
For the given geodesic wind angle, the helical turns around at a radius equal to the vessel radius at the tan-
gent line times the sine of the wind angle. The underlying geometry follows the geodesic shape up until this
turnaround radius, then is assumed to extend vertically as though the first layer abutted to an imaginary polar
boss. For a radius less than this so called turnaround radius, the layer would simply intersect the extended
assumed polar boss geometry.
9
Figure 2.2.1: Elliptical and Spherical Domes
10
Figure 2.2.4-1: From-Part Dome Input
11
Case 1: Large Fillet Polar Boss & Continuum Model: Set transition radius at the beginning of the fil-
let. Assign all layers abutting polar boss a radius less than the transition radius. Any layers with turn-
around radii less than transition radius will abut to the polar boss, regardless of the end controls.
Case 2: Arbitrarily-shaped Polar Boss & Continuum Model: Use transition radius less than the radius
of any point along the vertical face of the polar boss. Assign all layers abutting polar boss a radius
less than the transition radius. Use the vertical segments of the polar boss.
12
2.2.6 Viewing Dome Geometry in Sketcher
The proper creation of the underlying dome geometry set is critical to building the tank properly. To ensure
this set is being read properly by the WCM, it can be plotted by clicking on the sketch icon . As shown
below, the solid yellow line represents the shape of the underlying geometry based on the set provided. The
dashed vertical lines attached to either end of the solid yellow line represent the extended polar boss geome-
try. The dashed yellow lines slightly offset from the extended polar boss geometry represent the transition
radii.
13
Figure 2.2.6:-1 Liner Geometry Sketch
Number of
Refinement
Points
Coarse 150
Medium 300
Fine 450
14
The first composite layer of the tank is drawn by projecting the points along the base geometry in the normal
direction through a distance equal to the layer thickness at the points being generated. These projected
points are then combined to draw splines representing the exterior of the first layer. The second layer is then
drawn in the same manner by projecting the exterior points of the first layer. Thus, by continuing this pattern,
the points along the liner geometry are propagated up through all of the layers of the entire tank. The amount
of time required to generate the tank part is directly related to the number of points used to draw the splines.
Therefore, controlling the number of points used to draw the liner is critical in controlling the amount of time
required to draw the entire tank. The refinement option allows the user to control the number of points along
the liner, and thus the number of points used to draw the tank. Using coarse refinement will build the tank
quickly, but in areas where one layer wraps over another, the geometry created may show inaccuracies.
If the liner part is an orphan-mesh part, then the points used to define the liner geometry are the actual node
points contained in the node set. In this case, the refinement option is ignored.
The entire layup can be defined and verified from with the Layer Manager dialog. Each layer is assigned a
layer type, material, thickness, and wind angle. The inner and outer radius, hoop height and band width are
applicable to specific layer types. A row of buttons is listed below to assist in table manipulation. The first four
buttons are for adding, removing, and moving layers. The Add Rows button adds a row at the end of the
table by copying all of the layer information, including controls, of the layer in which the cursor is placed. The
Move Up and Move Down buttons simply move the entire layer, along with its control information, up or
down. Multiple layers can be moved up and down simultaneously.
15
Figure 2.3.1-2: Layer Manager Dialog
As changes are made to the table, they can immediately be viewed by clicking on the Sketch icon . This
will sketch the layers of the table, as well as the liner. The Sketch All icon , the Sketch Top icon , and
the Sketch Bottom icon, allow the user to control which portions of the tank are being sketched. This allows
the user to focus on viewing parameter changes that are specific to the top, for example, while ignoring
parameters specific to the bottom. This can also speed up sketching in large layups. If changes are made to
the table and in the sketch mode, the Refresh icon must be clicked for the sketch to reflect the changes.
Each layer has a multitude of controls that affect the thickness buildup, the shape at the end of the layer,
how the layer abuts to the polar boss, and more. By clicking the Visible Columns icon , each of the controls
can be displayed and modified in the table. Because there are so many, they are not displayed by default.
The Default Columns icon displays the default columns. The Top Columns icon displays controls
specific to the top of the tank. Likewise, the Bottom Columns icon displays controls that are specific to the
bottom portion of the tank. The All Columns icon displays all controls for all of the layers. The Mesh
Columns icon displays controls related to the mesh. The Symmetric Tank icon allows the bottom
controls to be set identical the top controls in which case only the top controls can be modified. Regardless
of which columns are shown, the information stored in each column is saved upon submission of the Layer
Manager dialog.
The thickness buildup described in the sections below for helicals is very accurate throughout the tank, with
the exception of the regions very near the polar bosses. Because of the many ways in which individual wind-
ing machines affect the polar boss region buildup, some tools in the WCM have been added to allow the user
to control how each of the layers are shaped close to the polar boss. In order to demonstrate how these con-
trols affect the polar boss region, a single layer will be considered which terminates near the polar boss
which has a boss radius of 2.0. Each of the parameters which affect the shape will be modified to demon-
strate the affect. In order to display the controls, the Top Columns icon can be clicked and the table is up-
dated to show all of the layer controls of the top of the tank.
16
Figure 2.3-2-1: Layer Manager Dialog
The End Fraction parameter controls how the end of the layer is terminated. The thickness buildup equation
described in subsequent sections approaches infinity as the radius at which the thickness is calculated ap-
proaches the turnaround radius of the layer. In reality the end of the layer tapers off. The shape of the taper
can be controlled by the winding software used to wind the COPV. As a default, the WCM calculates the
point, referred to as the transition point, at which the thickness buildup equations are no longer used and a
rounded or straight line describes the remainder of the end cap of the layer. The distance from the turna-
round point to a point at the base of the layer corresponding to the transition point is determined as a fraction
of the bandwidth for helical layers and a fraction of the constant layer thickness for hoop layers. This fraction,
referred to as the End Fraction, is determined automatically by the WCM but can be overridden. Below is
displayed plots corresponding to End Fractions of 0.25, 0.5, 1.0, and 2.0.
The transition radius is the radius at which the slope of the outer line is abruptly overridden and continued on
a straight line until an intersection with the polar boss or underlying layers is found. The sketches below were
generated with the values shown. The polar boss is set to a radius of 2.0, the layer turnaround radius is set
to 2.1, and the end fraction is set to 1.0 with a band width of 0.5. Therefore, the end cap of the layer begins
at a radius of 3.1 - just outside of the values of each of the transition radii shown. The dashed vertical line
represents the transition radius for the layer. By modifying the value of the transition radius, the thickness
buildup can be controlled precisely.
17
Figure 2.3.2.2: Effect of Transition Radius
In the plots above you will notice that the WCM attempted to draw the end cap of the layer until the transition
radius was reached, at which point the slope remained constant until an intersection with the polar boss was
found. Alternatively, if the layer terminates inside of the transition radius, the sketching of the end cap can be
ignored. The thickness buildup is based on the theoretical thickness buildup until the transition radius is
reached. Then the slope remains constant until an intersection with the polar boss is found.
18
Figure 2.3.2.2: Effect of Transition Radius while Ignoring End Cap
The default behavior of the layer thickness buildup is to continue the outer layer slope from at the transition
point until an intersection with the polar boss is found. As an alternative, that slope can be modified by set-
ting the transition angle to a non-zero number. A positive transition angle causes the layer to increase in
thickness, while a negative transition angle causes the layer to decrease in thickness.
19
Figure 2.3.2.4: Effect of Transition Angle
As one layer overlaps the end of another, a void is formed which contains resin, but no composite fibers. The
size of the void region depends on a number of factors such as wind angle, tape tension, and whether a
post-layup treatment is applied to squeeze out excess resin material. The WCM provides an overlap fraction
parameter which controls length of the void region. The curved line drawn begins at a point above the transi-
tion point of the underlying layer (i.e. the point at which the end cap begins). The slope used is that of the
liner if this point were projected onto the liner. The curved line then terminates at
20
Figure 2.3.2.5: Effect of Overlap Fraction
R R0
n
R0
( R) sin
1
R Rtl R0
21
Equation 2.3.3: Wing Angle Definition
Here, R is the radial distance from the center line to a point in the layer, R o is the radial distance from the
centerline to the turnaround point, and Rtl is the radius at the dome-cylinder tangent line, and is the
difference in degrees between the frictionless wind angle (input for the layer) and the wind angle calculated
by the first term of Equation 2.3.3. A frictionless winding pattern is obtained by choosing . If friction is
accounted for, 0, then the wind angle distribution will vary as described in more detail in later sections.
The wind angle distribution of helicals with our without friction are described by the equation above.
22
Figure 2.3.3.2: 90 Wind Angle Shown in Red
23
2.3.4 Helical Layer Thickness Buildup
The thickness specified in the winding layout table is the thickness at the cylinder tangent line. As the layer
traverses the dome to the polar boss, the thickness of the helical layer gradually builds up as described by
the equation below.
r 2 BW
rtl r 0
r r0
n
r0
r (r ) sin
1
r rtl r 0
Equations 2.3.4
24
90
80
70
60
Wind Angle
50
40
30
20
Theta2
10
Theta1
0
R1 R2 Rtl
Dome Radius
Figure 2.3.5-1: Doily Layer in Blue (Only half of the tank is shown)
Modeling a hoop entails specifying the y-coordinates of the termination. The y-coordinates are measured
from the center of the tank, which is determined half way between the two extreme y-coordinates of the liner.
A uniform-thickness layer which begins in the cylinder region and terminates at a position along the tank axis
is shown in Figure 2.3.5-2. A hoop layer is usually orthotropic like a doily with the primary material direction
rotated from the meridional axis of the tank by the value of the wind angle typically 90 degrees.
25
Figure 2.3.5-2: Hoop Layer in Blue (Only half of the tank is shown)
The mesh partitioning options allow for the creation of partitions through the thickness of a layer all along the
length of the layer. The spacing of the partitions can be biased toward the top of the layer, the bottom of the
layer, or evenly spaced throughout the layer.
26
Figure 2.4-1: Geometry/Mesh with and without Partitioning
27
Figure 2.4-2: Geometry/Mesh with and without Partitioning
If a partition passes too close to an existing vertex, the mesh creation may fail as shown in the figure below.
In order to insure that the partitions do not terminate too close to an existing vertex, the sketcher mode may
be entered by clicking on the sketch icon while the partition properties are being edited. For example, in a
particular layup, one partition terminates very near the vertex. This may result not only in a poorly formed
mesh in this region, but may also prevent the mesher from generating a mesh altogether. To eliminate this
particular partition line, click the Remove Individual Partitions icon , thick pick on the line to be removed
and hit the Done button. This process will ensure a nicely formed mesh will be created throughout the tank.
28
Very poorly shaped elements: This is usually caused by an inadequate number of elements along
the length of the tank. Increase the number of elements along the length of the tank so that the as-
pect ratios of the elements in the cylindrical section of the tank do not exceed 2 to 1.
No mesh on a face: This often occurs because a partition passes too closely to an existing vertex for
the mesher to honor the mesh seeds. Edit the partitions and remove any lines passing very near a
vertex.
No mesh at all on a 3D tank: This can occur if too few elements were chosen in the hoop direction.
Very slow creation for 3D models. Reduce the number of segments in the hoop direction and the
number of lines used for mesh partitioning. In the cylinder region of the tank, only use mesh parti-
tions near the transitions from cylinder to dome. Mesh seeding, setting the sweep direction, and
meshing all are slowed down by the number of cells in the tank.
If after trouble shooting a mesh you are still not able to generate a mesh on a tank, attempt to generate the
mesh directly within the Abaqus/CAE mesh module. For example, on some 3D models the mesher may fail
to generate a mesh, but if sections are meshed individually in sequence the mesher is able to generate a
mesh. If you are able to use the tools in the mesh module to generate an adequate mesh, you can then right
click on the mesh icon in the WCM tree and select Set as Completed. This will indicate to the WCM that an
adequate mesh has been created and will allow the final step of the property generation to be completed.
29
range of a given wind angle bin is assigned a single material property based on the wind angle of the bin. No
materials are created for bins which have no elements associated with them.
The orthotropic materials for each wind angle bin are calculated as angle-ply laminate () materials, where
the angle is the bin wind angle. The orthotropic material properties input by the user are for the composite
lamina (single-ply) with 1=fiber direction, 2=transverse and 3=normal. The plug-in transforms these material
properties to the following global directions for axisymmetric-continuum and axisymmetric-shell geometry: 1-
meridional, 2=radial, and 3=hoop, and the following global directions for three-dimensional geometry:
1=meridional, 2=hoop, and 3=radial. These transformed material properties, along with a section definition,
are assigned to each wind angle bin and a unique material definition is created. Material properties other
than orthotropic *ELASTIC, *CONDUCTIVITY, and *EXPANSION are assigned directly to the wind angle bin material
without being altered and are also written to the include file. Anisotropic *ELASTIC and *EXPANSION are not
supported.
30
By default, the plug-in creates five UVARM output variables for axisymmetric shell and continuum
geometries are as follows:
UVARM1: wind angle in degrees
UVARM2: logarithmic strain along the fiber direction
UVARM3: logarithmic strain transverse to the fiber direction
UVARM4: logarithmic shear strain
UVARM5: stress in the fiber direction
UVARM6: stress transverse to the fiber direction
UVARM7: shear stress
Because we have the logarithmic strain in the pressure vessel coordinate reference frame and we know the
wind angle at each point along the dome, we are able to rotate these strains into a fiber direction coordinate
reference frame. For three-dimensional analyses, additional terms are added for fibers at the negative of the
wind angles. Specifically, the output variables are as follows:
UVARM1: wind angle in degrees
UVARM2: logarithmic strain along the fiber direction (positive angle)
UVARM3: logarithmic strain along the fiber direction (negative angle)
UVARM4: logarithmic strain transverse to the fiber direction (positive angle)
UVARM5: logarithmic strain transverse to the fiber direction (negative angle)
UVARM6: logarithmic shear strain (positive angle)
UVARM7: logarithmic shear strain (negative angle)
UVARM8: stress along the fiber direction (positive angle)
UVARM9: stress along the fiber direction (negative angle)
UVARM10: stress transverse to the fiber direction (positive angle)
UVARM11: stress transverse to the fiber direction (negative angle)
UVARM12: shear stress (positive angle)
UVARM13: shear stress (negative angle)
For Heat Transfer analyses, UVARM2 and UVARM3 are filled with the heat flux along and fibers and
transverse to the fibers.
For Coupled Temp-Displacement analyses two additional variables are added as the heat flux along the fiber
direction and transverse to the fiber direction. For the axisymmetric case these are:
UVARM8: heat flux along the fiber direction
UVARM9: heat flux transverse to fiber direction
For the three-dimensional case, the additional variables are:
UVARM14: heat flux along the fiber direction
UVARM15: heat flux transverse to fiber direction
An option is provided for allocating more memory for user-output variables. This is useful if the UVARM
subroutine is to be expanded to include more user-defined output variables. The plug-in then sets the *USER
OUTPUT VARIABLES keyword option in every material definition automatically. A source file, wcUvarmUtils.py,
is provided to allow automatic merging of user-defined UVARM coding with that created by the plug-in. Two
functions are provided: writeDeclarations and addExtra. The first inserts declarations statements immediately
following the generic declaration statements of the UVARM subroutine described in the Abaqus Users
Manual. The second inserts coding immediately following the plug-ins coding for filling its default UVARM
variables. The uvarm argument passed into both routines is the file object to be written to. The nextUvarm
argument is the first available UVARM (an integer) for user-definition. For example, referring to the lists
31
above, for an axisymmetric stress analysis the nextUvarm variable would be set to 8. The UVARM
subroutine is not available in Abaqus/Explicit so the UVARM toggle is stippled for the procedures related to
Abaqus/Explicit.
def writeDeclarations(uvarm):
uvarm.write(" C User-Defined Declaration Statements \n")
uvarm.write(" REAL pi\n")
....
A queuing system on a cluster usually runs a job on any number of nodes (servers) and the particular nodes
may vary from one job to another. In order to ensure that the proper files are available during a run, the clus-
ter queuing software is configured to copy certain types of files to whichever node the job ends up being run
on. Typically user subroutines and include files are properly copied to the node by the queuing software.
However, the UVARM subroutine written by the Wound Composite Modeler references a file with the exten-
sion .ang. This file contains wind angle information read by the UVARM routine. By default, the Wound Com-
posite Modeler hardwires the path of this file assuming it to be that of the current working directory detected
during the UVARM generation. When running on a queuing system, this path needs to be modified to a path
which will remain valid regardless of the node on which the job is run. In order to do this, the function is made
available in wcUvarmUtils.py. This function is called in order to set the path of the .ang file. The fullPath-
Name name variable is set in the first line of the function using the current working directory.
def getWindAngleFilePath(tankName):
fullPathName = '%s%s%s.ang' % (os.getcwd(), os.sep, tankName)
#fullPathName = "/your_directory/%s.ang" % tankName
return fullPathName
Uncomment the line in blue (remove the # sign) and insert a directory which will contain the .ang file and will
be accessible from any node on the cluster. This will allow the Uvarm subroutine to properly read the wind
angle information.
4. Output Processing
When the plug-in generates the COPV model, it automatically generates node sets named Layern along the
bottom of each layer where n is the layer number. The dialog accessed from by clicking on the post
processing icon, , automates the process of creating path plots along the interface between layers using
32
these node sets. The dialog is shown in the figure below. For each layer selected from the table, the script
first details the elements only in that particular layer, then sorts the nodes in the Layern node set from one
end to another, and creates an x-y curve of the chosen field variable along the list of nodes. Finally, all of the
x-y curves are combined into a single path plot as shown in Figure 4-2.
The field output variable, step number, and frame number must be selected prior to opening up the dialog.
An option to smooth out the curves is provided. The path plots can often contains significant spikes in
regions where on layer overlaps another. The Smoothing Factor option simply smoothes out these spikes as
shown in Figure 4-3 using a smoothing factor of 10.0.
33
Figure 4-2: Plot of Wind Angles
34
Figure 4-4: Wind Angle Contour Plot
A number of QA problems have been included with the plug-in. Since these tests are fairly small but test all
of the plug-in functionality, it is recommended that these be run and experimented with in order to familiarize
oneself with the workings of the plug-in. Multiple tests may be selected to be run at one time. Three test
modes are provided:
Generate Model: Generates geometry, mesh, and material properties.
Run Full Analysis: Generates and runs model. The displacements in the y-direction at the ends of
tank are extracted and compared to archived results.
An Abaqus/CAE model named WcmTestModel_1-1 is created, for example, when test 1.1 is run. Thus if a
particular feature is of interest, you can scan through the test descriptions and run the test that best
describes the feature of interest. The resulting model will be created and readily available for editing and
testing.
35
Figure 5-1 QA Test Manager Dialog
6. Micromechanics Module
6.1 Introduction
Analysis of laminated composite structures using the Finite Element Method in Abaqus includes a composite
laminate as a homogeneous material with anisotropic properties. This typically requires the input of through-
the-thickness composite lay-up, defined by the individual ply angles, thickness of the plies, and the material
properties of the plies. The individual plies are assumed homogeneous and exhibit transverse isotropy
which require the use of directionally dependent ply properties. However, a ply typically constitutes of two
constituents; the reinforcing fibers arranged in a continuous supporting matrix. Therefore, the properties of
the composite ply are governed by the properties of the fiber, the properties of the matrix, and the fiber
volume fraction. The following Figure 6.1 is a schematic illustration of the influence of the fiber and matrix
properties on the global response of a finite element structural model.
Traditionally, the composite ply properties are estimated based on Rule-of-mixtures formulae [1]. Although
these closed-form solutions provide reasonable estimates of the composite ply properties, they do not
account for the micro-structural arrangement of the fibers in the matrix. A micromechanics model that
incorporates the lamina microstructure in calculating the anisotropic ply properties has been developed. This
documentation discusses its usage and provides some insight into the underlying theory for obtaining the
volume-averaged ply properties.
36
Figure 6.2: Schematic of the relationship between a composite structure and the constituents.
37
Figure6.1.1: The composite micromechanics plug-in dialog box.
38
Figure 6.2.1: Schematic of the model for the two fiber packing options.
39
Estimateoption is provided. Upon clicking this button, a dialog box as depicted in Figure 6.2.3 is displayed
with an estimate of G12 , based on E 22 and 12 , and the formula used. Note that upon the execution of the
plug-in a fiber material with the provided name and material properties will be created in a model named
HexPackModel or SqPackModel depending on the selection of the microstructural arrangement option.
40
6.2.5 Thermal Expansion Properties
In addition to calculating the elastic properties of the ply, the thermal expansion coefficients of the ply can be
requested to be calculated by selecting Include Thermal Expansion Properties option (see Figure 6.2.5 below) and
then providing the coefficients of thermal expansion for the fiber and the matrix materials. Note that the
fibers are assumed transversely isotropic and therefore only require two coefficients of thermal expansion
11 (provided through Alpha 11 - Fiber) and 22 (provided through Alpha 22 - Fiber) whereas the matrix is
isotropic and only require (provided through Alpha - Matrix). The coefficients of thermal expansion for the
composite are calculated by simulating a load case where the finite element model is subjected to a uniform
temperature change.
In addition to calculating the thermo-elastic properties of the ply, the composite ply density can also be calcu-
lated based on rule-of-mixtures formula. Although this property does not require the use of a finite element
model for calculation, it is included here as density is one of most frequently used composite properties. This
calculation can be requested by selecting the Include Densities option as depicted in Figure 6.2.6 and providing
the Fiber Density and Matrix Density for the fiber and the matrix materials respectively. The calculated ply densi-
ty is listed next to Composite Density: label. Note that this sub-option uses the volume fraction supplied
through input box depicted in Figure 6.2.2.
41
Figure 6.3: Composite properties message box.
42
Typically, it is assumed that the packing arrangement of the fibers in the matrix is either hexagonal packing
or square packing. The highlighted regions in the following figures schematically depict the unit cell
geometries representing the two packing arrangements.
Figure 6.4.1-1: Hexagonal packing unit cell and the corresponding finite element model.
Figure 6.4.1-2: Square packing unit cell and the corresponding finite element model.
Extending the above definition to the constituents and expanding over the volume of the domain, the
following relationships are obtained where , f , and m are the volume-averaged stress tensor
components in the composite, fiber, and the matrix whereas , f , and m are the volume-averaged strain
43
tensor components and V f is the fiber volume fraction. Further discussion on volume-averaging can be
found in Nemat-Nasser and Hori [4].
V f f (1 V f ) m , V f f (1 V f ) m
Equation 6.4.3.2: Relationship between different volume-averaged tensor components.
Using these volume-averaged stress and strain tensor components, the volume-averaged composite ply
properties are calculated. However, several different load cases are needed for estimating the different ply
properties and the discussion of the same follows.
Load Case 1:
In the first load case, 11 0 and 22 33 12 13 23 0 for the composite. Note that although a
uniaxial state of stress exists in the composite, the constituents can still be subjected to multi-axial states of
stresses. Using this stress state, the lamina properties E11 , 12 , and 13 are calculated.
Load Case 2:
In the second load case, 22 0 and 11 33 12 13 23 0 for the composite. Using this stress
state, the lamina properties E 22 , 21 , and 23 are calculated.
Load Case 3:
In the third load case, 33 0 and 11 22 12 13 23 0 for the composite. Using this stress
state, the lamina properties E33 , 31 , and 32 are calculated.
Load Case 4:
In this load case, 12 0 and 11 22 32 13 23 0 for the composite. Using this stress state,
the lamina property G12 is calculated.
Load Case 5:
In this load case, 13 0 and 11 22 32 12 23 0 for the composite. Using this stress state,
the lamina property G13 is calculated.
Load Case 6:
In this load case, 23 0 and 11 22 32 12 13 0 for the composite. Using this stress state,
the lamina property G23 is calculated.
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7. Installation of WCM Plug-in
The Wound Composites Modeler for Abaqus installation disc contains a single folder named WCM which
contains all the files necessary to run the plug-in. This entire folder and all its subfolders should be installed
under an abaqus_plugins folder as described below and should only be run in Version 6.12 of Abaqus.
When you start Abaqus/CAE, it searches for plug-in files in the following directories and all their subdirecto-
ries:
Abaqus/CAE will import any files in these directories that match the naming convention *_plugin.py. The
abaqus_dir directory for Windows is usually C:\Abaqus\6.12-1 for Abaqus Version 6.12-1.
Thus, if it is preferred that any user in question who has access to the Abaqus installation be allowed access
to the plug-in, then the WCM folder should be copied to the abaqus_dir\cae\abaqus_plugins folder. If the
plug-in should be made available only on a user-by-user basis, then the WCM folder should be copied to a
folder named home_dir\abaqus_plugins in the users home directory.
8. References
WCM References
1 Willardson, R., Gray, D., DeLay, T., "Improvements in FEA of Composite Overwrapped Pressure
Vessels", CPV Symposium 2011, Belgium.
nd
2 Peters, S.T., Humphrey, W.D, and Foral, R.F., Filament Winding Composite Structure Fabrication, 2
Edition.
3 Gray, D.L., and Moser, D.J., Finite Element Analysis of a Composite Overwrapped Pressure Vessel,
American Institute of Aeronautics and Astronautics.
4 Skinner, Michael, Trends, advances and innovations in filament winding, Reinforced Plastics,
February 2006.
5 T. Gll, R. Immel, T. Schtz, V. Schultheis, M. Shubert, CAE Process Chain for Strength and Crash-
Worthiness Prediction of Wet Wound High Pressure Composite Vessels. NAFEMS Proceedings,
November 6-7, 2007 Bad Kissingen, Germany.
Micromechanics References
1 Jones RM. Mechanics of Composite Materials. Second Edition, Taylor and Francis, 1999.
2 Whitcomb JD, Chapman CD, Tang X. Derivation of boundary Conditions for Micromechanics
Analyses of Plain and Satin Weave Composites, J Compos Mater, 2000;34(9):724-747.
3 Venkata Akula. Constitutive Modeling of Damaged Unidirectional Composite Laminae. PhD
Dissertation, University of Wyoming, 2008.
4 Nemat-Nasser S, Hori M. Micromechanics: Overall Properties of Heterogeneous Materials, Elsevier,
Asterdam (1993).
Abaqus References
For additional information on the Abaqus capabilities referred to in this brief please see the following Abaqus
Version 6.12 documentation references:
Analysis Users Manual
Abaqus GUI Toolkit User's Manual
Abaqus User's Manual
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