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Composite Forming Simulation (double action, multilayered)

Hello everybody,

i want to create a simple forming simulation with composite material. I want to form 2 plies, 0° and 90° fiber orientation. After the simulation, i want to see the fiber orientation etc., as shown here: http://www.altairhyperworks.com/hwhelp/Altair/hw14.0/help/mfs/mfs.htm?tutorial_post_processing_composite_forming_results.htm

Is there any tutorial i can use? http://www.altairhyperworks.com/hwhelp/Altair/hw14.0/help/mfs/mfs.htm?tutorial_setting_up_composite_forming_sim.htm This doesnt help, since its for sandwiches only.

If there is no tutorial:

- Where can i create the laminate? Do i just do this in the User-Process Tree or do i have to create a laminate in the Model-Tree and somehow apply it to my blank?

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Altair Forum User

hi tsombnik,

I understand your requirement and it is possible to create.

Please find the attached similar files below and let me know if it can be used for your references.

regards

santu

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Altair Forum User

Dear Santu,

thank you very very much for your input! This is exactly what i want. Can you please show me how to set up a model like this? This would be the solution to my project, you would help me so so so much.

The perfect scenario in the end is to simulate a thermoforming process. So i somehow have to input heat into the organic sheet (all the layers together). Also the layers somehow need to have a friction contact between them, since in reality they are contacting each other by the plastified thermoplastic matrix.

But first i want to build a model that looks like yours, where i can see the fibers moving in every layer, see possible wrinkles and stress inside of the layers.

Thanks a lot and have a nice day,

Nik

Altair Forum User

Dear Santu,

can you help me? Maybe you forgot this thread.

All the best,

Nik

Altair Forum User

Hi Nik,

It is very easy to setup using HyperForm. Please share some data files, so that I can help you further.

regards

san

Altair Forum User

Hi san,

i attached the .hf file.

I want to simulate a process like the one shown in this video:

I would like to have e.g. 4 plies with different fiber orientation. I guess the influence of the temperature is too complex to add, but it would be nice to at least see where the organic sheet starts to wrinkle or developes high stresses due to the forming process.

Also it would be great if i could view the single plies like in the model you gave to me.

Again, thank you so much!

Nik

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Altair Forum User

Hi nik,

Please find the attached file. I have assumed certain parameters such as blank holding force and the material.

Below is the forming results. Also, attached the deck files with it.

regards

san

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Altair Forum User

Hi Nik,

Also for post-processing for composite forming, please refer the below-mentioned tutorial file from Altair Help(F1).

HF-3100: Post-Processing Composite Forming Results in HyperView

Regards

san

Altair Forum User

Hi san,

Thanks a lot for your help! The .rad files are only the result files, correct? Is it possible to send me the session file (.hf), so that i can understand how the process is configured inside of the program?

Best regards,

Nik

Altair Forum User

Hi Nik,

If I correct you, *.rad file is the input files for RADIOSS to run. So, please run the above-shared *.rad files in RADIOSS for getting results and save the same session file as *.hf.

Regards

san

Altair Forum User

Hi san,

thank you sooo much. It worked like a charm. I dont want to steal your time, but im afraid that i have got another three questions.

1) Does it make sense to include resin into the simulation model as an extra ply to get additional information such as: 'Do i have enough resin at this or that spot', 'where do i have too much resin', etc.?

In the tutorial http://www.altairhyperworks.com/hwhelp/Altair/hw14.0/help/mfs/mfs.htm?tutorial_post_processing_composite_forming_results.htm they also seem to have plies that are called 'resin 1' and 'resin 2'. How do i include them properly? Just add additional layers with different material properties? What material card do i use?

Or is it enough to just use 'friction: 0.125' between the blanks to simulate the resin?

2) In the process that you sent me, you are using binders. In the youtube video they are using this frame with springs attached to it, to hold the organic sheet in place. What would be the best way to simulate that kind of holding force of such a frame?

3) Is it possible to use woven material or is only UD possible? And can i also add thermal effect to simulate hot stamping (as shown in the youtube video)? Or is this not really useful.

Best regards,

Nik

Altair Forum User

Hi Nik,

1. To add extra layer just right click over the blanks and click on the new blank. To decide over the resin distribution in the blank you need to take a call.

2. To predict using spring action force for Binder, use the option in Force, Right click, Type, Spring.

3. Regarding composite hot forming, i have less knowledge.

Regards

san

Altair Forum User

Hi san,

thank you so much. You really helped me out a lot. I am sure this thread will also help many other people, since there are almost no hyperform composite tutorials out there.

Best regards,

Nik

Altair Forum User

I'm working on the same problem

I failed to extract the '.hf' file from the '.rad' file. how can I do it ?

Altair Forum User

Dear Amine !!

You can only save the rad files to HF file. There is no need to convert it. Please download the rad files and recreate the process. To look at the results, just run the Rad files in Radioss solver.

regards

san