A tool to set up composite material analysis with Ansys LS-DYNA

The J-Composites series consists of ”Form Modeler”, a tool to set up press forming analysis, ”Compression Molding”, a tool to set up compression molding analysis, and “Fiber Mapper”, a tool to map the simulated fiber behavior from a resin flow on to a structural mesh .

Feature Highlights

Simple building of material models for composites
Creating an efficient laminate model
Simulating compression forming

Press forming simulation modeling tool: Form Modeler

J-Composites / Form Modeler provides three major functions: ”Material DB” creates and manages material data, ”Lay-up Modeler” creates a composite model, and “Lay-up Mapper” maps a fiber result to a structural model.

Based on material test results, J-Composites / Form Modeler automatically identifies the material parameters required for press forming simulation and uses them to create material models. The user-friendly interface enhances the efficiency of creating and managing laminate models.

Material DB: Create and manage material data

By using Material DB, material test data can be automatically converted into material property parameters for FEM press simulation. The resulting material model enables accurate estimation of the material behavior. With the help of the provided standard material database, users can start simulation right away.

Lay-up modeler: Define laminates

By using Lay-up modeler, a press simulation model with a complex laminate construction (no. of plies, fiber angle for each ply) can be created in a few simple steps. Lay-up modeler auto-creates the various definitions needed for each ply in the laminate, including the conditions for contact with the tools, eliminating repetitive and cumbersome manual operations.

Lay-up Mapper: Map the resulting fiber direction

With Lay-up Mapper, the result of the press forming simulation can be used when preparing the subsequent structural analysis. Because fiber-direction governs the behavior of a composite material, a change in fiber direction during forming strongly influences the product’s mechanical properties. By mapping the post-forming fiber direction to a structural mesh, Lay-up Mapper enables structural analysis that accounts for the effects of forming.

Compression molding simulation modelling tool: Compression Molding

J-Composites / Compression Molding is a tool to support building an LS-DYNA FRP model for compression molding simulation using the beam-in-solid coupling method. You can create a simulation model by reading a shape model, then setting the tools’ forming conditions, the composite material, and the analysis conditions. There is a material database for creating and managing material model data.

Shape Model Viewer

Compression Molding provides a viewer to display the shape model (template model), consisting of the workpiece and tools, during the setup process. The viewer helps in understanding the details of the workpiece and the tools.

Create and manage materials (Material DB)

Composite materials consist of three types of data: fiber, matrix resin, and fiber-matrix resin interaction. Each data type can be managed in the database and new composite materials created by combining them.

Fiber model (beam elements) generation

A fiber model (beam elements) can be generated by inputting parameters such as fiber composition type (ROS, ROF, UD, CUD), fiber length, strand size, number of layers, and layer pattern, etc. The estimated number of beam elements to be generated can be checked in advance.

Resin flow simulation model mapping tool: Fiber Mapper

J-Composites / Fiber Mapper provides an interface function which connects Ansys LS-DYNA and the forming simulation result. Connecting these enables structural simulation accounting for the forming simulation result for discontinuous fiber reinforced plastic (process chain simulation).

Fiber Mapper can map the forming simulation result on to the structural mesh and create a material model input, making it easy to create process-chain simulation models.

Map the forming simulation result

Fiber Mapper appropriately maps the fiber orientation data obtained from a forming simulation on to a structural mesh. The mapping scope can be limited by part. Parallel processing is taken advantage of when possible to help map large models smoothly.

Ease complex and difficult composite material model creation

The fiber orientation data from a forming simulation can be automatically converted into a material model input. Eliminates time-consuming repetitive operations.