JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 27

Fig. 1: Laminates strength typically shows variability
in particular due to material and process variability

must be recalculated with each new layup
choice. For each one, engineers must be
able to determine:

Current limitations
The realities of today's aerospace and
automotive design processes demand that
engineers have calculated assurances that

Many of the drawbacks in laboratory tests
stem from their reliance on prototypes.
Building a prototype and instrumenting it
for every possible variation of a composite's layup is impractical from a workflow
standpoint. Even if it were not, it is financially impossible. Prototyping's cost and
time constraints also hinder innovation.
Prototypes are typically built late in the
design process, when the design is all but final. Major changes at the prototyping stage
are prohibitively expensive and can delay a
new design's entry into the market. These
realities essentially limit engineering teams
to one chance to integrate composite parts
or assemblies into a design without causing
a major failure. With that possibility hanging over their heads and lacking adequate
testing resources, many teams add more
mass to their designs than necessary as a
precaution against failure, which defeats
the purpose of using a composite.

"Virtual allowable" approach
e-Xstream engineering, an MSC Software

company, created Digimat-VA (Virtual
Allowables) to enable engineers to take the
results of basic lab tests on composite lamina
and use them to predict the behavior of
virtually any plain or notched laminate.
Digimat-VA combines efficient micromechanical modeling, progressive failure analysis, and non-linear finite element analysis
(FEA) in an integrated tool. With DigimatVA, engineers can compare laminates
stiffness and strength virtually before going
into the extensive and expensive process of
developing physical allowables. They define
their test matrix through Digimat-VA's
point-and-click interface, and the software
generates the virtual allowable based on the
test parameters and the ply data.
Testing in the virtual environment is essentially free. The virtual allowables complement laboratory/prototype testing hence
saving time and money. Engineers can freely
innovate by doing unlimited "what if" analyses about constituents, material architecture,
environmental conditions, etc. They can
save time by starting the component design
phase using virtual allowables. They can
save time and money by optimizing their
choice of physical testing based on virtual allowables results. Of course at the end of the
day, no steps are skipped in the certification
process, but the development is accelerated.
Tools such as Digimat-VA are essential to the
integration of composites into aerospace and
automotive design. Physical testing alone
cannot give engineers the versatility they
need to take full advantage of composites'
potential. It is not simply the newness of
composites that makes them a challenge in
aerospace designs, but their most fundamental difference from traditional materials: their variability and anisotropy. With
current testing tools along, that variability is
a challenge to be overcome. With software
tools that enable virtual testing, variability
becomes the essential attribute that makes
composites the key to lighter, more fuel efficient aircrafts and cars. n

Fig. 2: Open-hole tensile test can be predicted by Digimat-VA. Red zones indicate full fiber damage.

No96 April 2015 / jec

More information:
www.e-xstream.com

Feature Aeronautics

- where damage will occur, its nature, and
how readily it can be detected;
- the extent of damage and how much
residual strength the composite retains
once it is damaged;
- the effects of damage and multiple sights;
- the influence of environmental factors -
heat, humidity, etc.
Current industry testing processes are not
geared to accommodate materials with
the anisotropy and constituent/process
variability of composites, having been
created with isotropic metals and plastics
in mind. However, software tools that
integrate composite material properties
into the design process are emerging to
provide stress analysts as well as material
and process engineers with the speed and
economy they need to freely innovate with
composites.

composite components and assemblies will
withstand reasonable loads without failing
or deforming until damage from fatigue,
flaws, etc., is detected. The testing processes most commonly available to them
today, however, rely heavily on laboratory
testing and prototyping. Laboratory testing
methods enable engineers to document a
new composite's behaviour, but they cannot do it on the scale required to map the
entire design space, or at the speed required
to avoid slowing the design process. It takes
a minimum of 50 repetitions of a test under
varying
environmental conditions to yield a statistically valid allowable strength value for a
composite laminate.

composites magazine 27


http://www.e-xstream.com/

JEC COMPOSITES MAGAZINE - Issue #96 - April 2015

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #96 - April 2015

Cover
Edito
Point of view : composites integration
Contents
COMPANY & BUSINESS
China
In brief
JEC Americas
Agenda of Events
APPLICATIONS
Catamaran
RIB
Trimaran
MARKET
Carbon fibre
FEATURE AERONAUTICS
Simulation
Cost-effectiveness
Low cost manufacturing
Thin-ply
High temperature
LFT
Thermoplastics
Laser projection
Release agent
Manufacturing
RESEARCH & DEVELOPMENT
Health Monitoring
Health monitoring techique for large composite structures
TECHNOLOGY & INNOVATIONS
IOT
Braiding
Resin
Vacuum infusion
Machining center
PBT
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Cover
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 2
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Edito
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Point of view : composites integration
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 5
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Contents
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 7
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - China
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - In brief
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - JEC Americas
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 11
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 12
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 13
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 15
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Catamaran
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 17
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - RIB
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Trimaran
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 20
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Carbon fibre
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 22
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 23
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 24
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 25
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Simulation
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 27
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Cost-effectiveness
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 29
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Low cost manufacturing
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 31
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 32
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Thin-ply
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 34
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 35
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - High temperature
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 37
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - LFT
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 39
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 40
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 42
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 43
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 44
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Laser projection
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 46
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Release agent
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Manufacturing
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 49
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 50
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 51
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Health Monitoring
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 53
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 54
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 55
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Health monitoring techique for large composite structures
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 57
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 58
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 59
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - IOT
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 61
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Braiding
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 63
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 64
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Resin
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 66
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Vacuum infusion
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 68
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Machining center
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 70
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 71
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - PBT
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - Index
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - In the world
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 75
JEC COMPOSITES MAGAZINE - Issue #96 - April 2015 - 76
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