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Erik90

Composite laminate with shell to sold conversion

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Hallo everybody,


 


I want to optimize a composite monocoque for a formula student car. For this I want to take a composite sandwich. But I still get errors, when I start the analysis. First I want to create a plate (275mm x 500mm) to look if it works like this. Here is what I have done so far:


 


 


1) load the CAD data in hyperworks


 


 2) mesh the geometry with elementsize 4


 


 3) create 2 materials. One for the cfk (MAT8) and one for the core (MAT9ORT)


               


 4) create 2 properties. One PCOMPP for the laminates and one PSHELL for the core


 


 5) create 5 plys. 2 for the inner layer, 2 for the outer layer and one for the core. Assign material, thickness and elements to the plys


 


 6) create 3 sublaminate. One for the inner layer, one for the outer layer and one for the core


 


 7) create a sublaminate with the 3 sublaminates


 


 8) make a "solid to shell conversion" with laminate "core". Now there is a new component with an SOLID property. Assign material to the solid Property. (MAT9ORT)


 


 9) assign PCOMPP property to the first component


 


 10) create two loadcollectors for the force and for the constraint. Create a force in the middle of the plate and 4 constraints at the corners and then create a loadstep with these two loadcollectors.


This is just a trial if the analysis works without failures


 


 11) make a "GLOBAL_OUTPUT_REQUEST" with CSTRESS and CSRAIN


 


 12) start analysis with Optistruct


 


 


But everytime I start the analysis, I got an error. When I fix one error there comes another. Can you please help me to find my mistake? And can you tell whereon I have to pay attention on, when I want to make a Composite Sandwich with sublaminate and interface Laminate.


 


Thank you for your responses.


 


 


Regards


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HI,Erik90

 

Could you please let us know what the errors are?

 

MAT9ORT is compatible with solid property and not with shell. Please check this. This could be one of the reasons for the errors.

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Thank your for your quick Response.

 

I get the Error:

 

 A fatal error has been detected during input processing:
 
  *** ERROR # 606 ***
  Element 918582 references a PCOMPP card without being referenced
  by any STACK card.

 

When I make the shell to solid conversion hypermesh creates a new solid property. So I delete the shell property and assign the MAT9ORT to the solid property.

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Hi Erik,


 


Looks like your model has shell element (Element ID 918582) which has a PCOMPP property. PCOMPP should go with a STACK and PLY in the deck.


 


If the element is not required, please delete and run the analysis.

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Hi Prakash,


 


I have exactly the same problem as Eric ( *** ERROR # 606 ***  Element 1 references a PCOMPP card without being referenced by any STACK card.).


I have already worked with composites (OptiStruct profile) and PCOMPP property some months ago and it worked. Now I get the error even tough I have done all the steps as shown in several composite tutorials deling with PCOMPP. The plies have PLY card and the laminates STACK card assigned and my component just PCOMPP. The display of the different layer works fine but the simulation does not run due to the error.


I still have old output-files which run, when I open the old model file and just re-export them I get the error mentioned above...even though I changed nothing in the model. What is wrong? I don't have any idea...


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Hi, I have found what is causing the error in my case (see previous post #5), but it's not a problem with my modell but rather maybe with HyperMesh (?)


 


When I export the solver deck with export option 'displayed' enabled I get the error "*** ERROR # 606 ***  Element 1 references a PCOMPP card without being referenced by any STACK card."


When I set the option to export 'all' no error occurs and the simulation runs.


 


Even when I enable all my entities in the model browser and export with option 'displayed' the error occurs. Is this a problem with HyperMesh?


I really need to work with the option 'displayed' because I have a complex model and there are a lot of entities which shall not be exported so I cannot use 'export all'.


Is there any possibility to solve this?


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Refering to my two previous post I have found the problem by comparing the .fem-output files with the help of an editor.


 


When I use the 'export displayed' option neither the bulk data with plies and stacking definition nor the property nor material definition are exported, as you can see in the screenshots below.


On the left side you have the source code with export option 'displayed', and on the right side with option 'all'. The green lines indicate the differences.


 


Is this a bug? The export option 'displayed' works fine with all other non-composite modells...I only have this problem when using PCOMPP property.


post-37320-0-76760000-1438599468_thumb.j

post-37320-0-18769200-1438599476_thumb.j

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It works fine when I use the 'custom' option for export, which is only some additional clicks...one just has to activate/deactivate (the export check box) all entities in the entity state browser the same way the entities are displayed in the model browser. At least a good workaround with not much effort for now.


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