Composite Optimization

Oguzhan Coban
Oguzhan Coban New Altair Community Member
edited October 2020 in Community Q&A

Hello everyone, I'm trying to optimize a composite component (which is freezed together with some aluminum components) that has already been modeled and analyzed in Hypermesh using a plybook with 86 plies.

Some Information to my setup:
Plies:    0° : unidirectional carbon fiber 0.1mm     -----       45°, 90°: carbon fiber fabric 0.2mm
I have created two material cards and defined a property card as PCOMPP and entered the data of those that they have been laminated together (Z0 Option: Z0=0, Laminate option: total).  After some research, I found out that I should change the laminate setting to smear before optimizing it and I changed it.

Goals:
I want to keep the mass as low as possible and at the same time reduce the displacement at a desired point so that the component no longer fails (TSAI WU failure criteria) in a load case. I tried a few things but I was not happy with the results of the FreeSize optimization and I received many error messages during these attempts.

My questions & doubts:
1. I am using the same laminate which I created for the linear static analysis: Should I create a simple layer structure and do the optimizations for it?
2. I have not assigned any material for the composite component because the two materials are defined in the laminate anyway. Am I right?
3. I would like to keep the thickness of the layers the same (0 ° = 0.1mm, 45 ° / 90 ° = 0.2mm) because I only have these materials available. : I've defined 3 Plyman parameters for this... Does anyone have a different opinion?
4. Response: res_mass, res_displacement --> cont_displacement: upper bound has been defined --> objective: min - mass
5. Mindim: Min Member Size > 4 x mesh size but I still get very strange shapes
6. My next steps are size and shuffling optimizations. I also tried to finish the size optimization and before that I updated the TMANUK of all plies and the upper / lower bounds of the design variables... the thicknesses of plies are changing to the desired values but I can not improve the mass or the displacement or the shapes of plies.
7. What would you have done differently than I did? or can anyone identify my mistakes?


I would be very happy for your help or tips.

Best regards

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Answers

  • Adriano A. Koga
    Adriano A. Koga
    Altair Employee
    edited July 2020
    Altair Forum User said:

    Hello everyone, I'm trying to optimize a composite component (which is freezed together with some aluminum components) that has already been modeled and analyzed in Hypermesh using a plybook with 86 plies.

    Some Information to my setup:
    Plies:    0° : unidirectional carbon fiber 0.1mm     -----       45°, 90°: carbon fiber fabric 0.2mm
    I have created two material cards and defined a property card as PCOMPP and entered the data of those that they have been laminated together (Z0 Option: Z0=0, Laminate option: total).  After some research, I found out that I should change the laminate setting to smear before optimizing it and I changed it.

    Goals:
    I want to keep the mass as low as possible and at the same time reduce the displacement at a desired point so that the component no longer fails (TSAI WU failure criteria) in a load case. I tried a few things but I was not happy with the results of the FreeSize optimization and I received many error messages during these attempts.

    My questions & doubts:
    1. I am using the same laminate which I created for the linear static analysis: Should I create a simple layer structure and do the optimizations for it?
    2. I have not assigned any material for the composite component because the two materials are defined in the laminate anyway. Am I right?
    3. I would like to keep the thickness of the layers the same (0 ° = 0.1mm, 45 ° / 90 ° = 0.2mm) because I only have these materials available. : I've defined 3 Plyman parameters for this... Does anyone have a different opinion?
    4. Response: res_mass, res_displacement --> cont_displacement: upper bound has been defined --> objective: min - mass
    5. Mindim: Min Member Size > 4 x mesh size but I still get very strange shapes
    6. My next steps are size and shuffling optimizations. I also tried to finish the size optimization and before that I updated the TMANUK of all plies and the upper / lower bounds of the design variables... the thicknesses of plies are changing to the desired values but I can not improve the mass or the displacement or the shapes of plies.
    7. What would you have done differently than I did? or can anyone identify my mistakes?


    I would be very happy for your help or tips.

    Best regards

     

    1. Same as analysis

    2. Only need material in the ply

    3. Plyman, correct.

  • Oguzhan Coban
    Oguzhan Coban New Altair Community Member
    edited August 2020
    Altair Forum User said:

     

    1. Same as analysis

    2. Only need material in the ply

    3. Plyman, correct.


    Hello Adriano, I have received many error messages so far and all the errors have been resolved by doing some research in the forum, but now I am getting the error message: 'INTERNAL PROGRAMMING ERROR # 8011' and I cannot find any information for this. 

    Can you tell me how I can fix this error?

    I have two different versions of hyperworks and I tried both of them: 2019.1 and 2020

    Thanks in advance.
    Best regards,
    Oguzhan

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