HeliusMCT Users Guide Ansys

Users Guide
Helius:MCT Version 4.0 for ANSYS February1, 2011
Abstract This document describes the use of Helius:MCT for ANSYS in performing enhanced finite element analysis of composite structures. For questions, comments or further information, contact Firehole Composites at support@firehole.com.
Legal Notices
Copyright 2011, Firehole Technologies, Inc. Helius:MCT is a trademark of Firehole Technologies, Inc. Any use of the Helius:MCT trademark requires the prior written consent of Firehole Technologies, Inc. ANSYS is a trademark of ANSYS, Inc.
Table of Contents
1 INTRODUCTION TO HELIUS:MCT ................................................................................................... 4 1.1 1.2 1.3 2 A NOTE ON THE HELIUS:MCT- LINEAR VERSION ............................................................................ 4 HELIUS:MCT INTERACTION WITH ANSYS ........................................................................................ 4 HELIUS:MCT SUPPORT DOCUMENTATION ..................................................................................... 7
GENERAL REQUIREMENTS FOR ANSYS INPUT FILES ............................................................... 9 2.1 2.2 2.3 IDENTIFICATION AND DEFINITION OF HELIUS:MCT MATERIALS ......................................................... 9 NONLINEAR SOLUTION CONTROL PARAMETERS FOR HELIUS:MCT .................................................. 9 REQUESTING OUTPUT OF SOLUTION VARIABLES THAT ARE UNIQUE TO HELIUS:MCT ...................... 10
USING THE ANSYS MECHANICAL APDL TO CREATE ANSYS INPUT FILES FOR USE WITH HELIUS:MCT .................................................................................................................................. 11 3.1 3.2 3.3 3.4 CREATING USER-DEFINED MATERIALS WITH THE HELIUS:MCT GUI .............................................. 11 MODELING ISSUES FOR IMPOSING TEMPERATURE CHANGES ......................................................... 17 NONLINEAR SOLUTION CONTROL PARAMETERS ........................................................................... 19 REQUESTING MCT STATE VARIABLE OUTPUT ............................................................................... 22
USING A TEXT EDITOR TO CONVERT PRE-EXISTING ANSYS INPUT FILES FOR USE WITH HELIUS:MCT .................................................................................................................................. 24 4.1 4.2 4.3 4.4 4.5 DEFINING A HELIUS:MCT MATERIAL ............................................................................................ 24 MODELING ISSUES FOR IMPOSING TEMPERATURE CHANGES ......................................................... 33 NONLINEAR SOLUTION CONTROL PARAMETERS FOR HELIUS:MCT ................................................ 33 REQUESTING OUTPUT OF THE MCT STATE VARIABLES ................................................................. 34 MODELING DAMAGE TOLERANCE ................................................................................................ 35
EXAMINING HELIUS:MCT RESULTS WITH ANSYS MECHANICAL APDL ................................ 36 5.1 5.2 USING CONTOUR PLOTS TO VIEW THE MCT STATE VARIABLES ....................................................... 36 DETECTION OF GLOBAL STRUCTURAL FAILURE .............................................................................. 41
RUNNING ANSYS WITH HELIUS:MCT .......................................................................................... 45 6.1 6.2 BATCH MODE............................................................................................................................. 45 GUI MODE ................................................................................................................................ 45 HELIUSMCT COMMAND ARGUMENTS ....................................................................... 48 ARGUMENT #1: MATERIAL REFERENCE NUMBER ........................................................ 50 ARGUMENT #2: NUMBER OF STATE VARIABLES (SVARS) ........................................... 52 ARGUMENT #3: SYSTEM OF UNITS ............................................................................. 53 ARGUMENT #4: PRINCIPAL MATERIAL COORDINATE SYSTEM ........................................ 55 ARGUMENT #5: PROGRESSIVE FAILURE ANALYSIS ...................................................... 57 ARGUMENT #6: PRE-FAILURE NONLINEARITY ................................................................ 59 ARGUMENT #7: POST-FAILURE NONLINEARITY .............................................................. 61 ARGUMENT #8: HYDROSTATIC STRENGTHENING ........................................................... 63 ARGUMENT #9: RESIDUAL STRESSES FROM STRESS-FREE TEMPERATURE ..................... 64 ARGUMENT #14: MATRIX POST-FAILURE STIFFNESS FRACTION ...................................... 66 ARGUMENT #15: FIBER POST-FAILURE STIFFNESS FRACTION ......................................... 67
APPENDIX A
APPENDIX A.1 APPENDIX A.2 APPENDIX A.3 APPENDIX A.4 APPENDIX A.5 APPENDIX A.6 APPENDIX A.7 APPENDIX A.8 APPENDIX A.9 APPENDIX A.10 APPENDIX A.11 APPENDIX B
MCT STATE VARIABLES (SVARS) .............................................................................. 68
Helius:MCT Users Guide - ANSYS
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Table of Figures
FIGURE 1: SCHEMATIC DIAGRAM OF THE INDIVIDUAL COMPONENTS OF THE HELIUS:MCT SOFTWARE AND THEIR INTERACTION WITH THE ANSYS SOFTWARE COMPONENTS.......................................... 6 FIGURE 2: ANSYS CLASSICAL GUI AT START-UP ................................................................................... 11 FIGURE 3: THE HELIUS:MCT GRAPHICAL USER INTERFACE (GUI) ...................................................... 12 FIGURE 4: REFERENCE TEMPERATURE DIALOG BOX ACCESSED FROM WITHIN THE ANSYS GUI. ....... 18 FIGURE 5: UNIFORM TEMPERATURE DIALOG BOX ACCESSED FROM WITHIN THE ANSYS GUI............. 18 FIGURE 6: EXAMPLE OF NROPT COMMAND ENTERED INTO THE ANSYS COMMAND PROMPT. ............ 19 FIGURE 7: ACCESS OF PRED COMMAND VIA ANSYS MECHANICAL APDL. ......................................... 20 FIGURE 8: W HERE TO SPECIFY THE NUMBER OF SUBSTEPS IN THE ANSYS MECHANICAL APDL........ 21 FIGURE 9: ACCESS OF CNVTOL COMMAND VIA THE ANSYS MECHANICAL APDL. ............................. 21 FIGURE 10: ACCESS OF THE NEQIT COMMAND VIA THE ANSYS MECHANICAL APDL. ....................... 22 FIGURE 11: NON-UNIFORM CONTOURS DIALOG BOX............................................................................. 37 FIGURE 12: COMPARISON OF A PLNSOL CONTOUR PLOT AND A PLESOL CONTOUR PLOT USING THREE DISCRETE COLOR CONTOURS TO REPRESENT DISTRIBUTION OF SVAR1=1,2,3 .............. 38 FIGURE 13: OPTIONS FOR OUTPUT DIALOG BOX ................................................................................... 39 FIGURE 14: PLESOL CONTOUR PLOTS OF SVAR1 AT SEVERAL DIFFERENT POINTS IN TIME DURING A PROGRESSIVE FAILURE ANALYSIS ................................................................................................... 40 FIGURE 15: 8-PLY COMPOSITE PLATE UNDER IMPOSED AXIAL DISPLACEMENT .................................... 42 FIGURE 16: THE GLOBAL STRUCTURAL FORCE IS OBTAINED BY SUMMING THE VERTICAL REACTION FORCES AT ALL NODES ALONG THE TOP EDGE OF THE COMPOSITE PLATE ................................... 42 FIGURE 17: GLOBAL STRUCTURAL FORCE VS. GLOBAL STRUCTURAL DEFORMATION .......................... 43 FIGURE 18. HELIUS:MCT FOR ANSYS EXAMPLE BATCH RUN............................................................... 45 FIGURE 19. EXAMPLE OF OPENING THE HELIUS:MCT FOR ANSYS LAUNCHER .................................. 46 FIGURE 20. HELIUS:MCT FOR ANSYS LAUNCHER ............................................................................... 46 FIGURE 21. EXAMPLE OF SELECTING THE CUSTOM ANSYS EXECUTABLE IN THE ANSYS PRODUCT LAUNCHER ....................................................................................................................................... 47 FIGURE A22: HELIUS:MCT SOLUTION FOR FAILURE PROPAGATION IN THE 0 PLIES OF A COMPOSITE LAMINATE LOADED IN TENSION ........................................................................................................ 58 FIGURE A23: COMPARISON OF PREDICTED VS. MEASURED LONGITUDINAL SHEAR RESPONSE FOR A TYPICAL FIBER-REINFORCED COMPOSITE LAMINA .......................................................................... 60 FIGURE A24: HELIUS:MCT STRESS-STRAIN SOLUTIONS FOR THE CENTRAL 90 PLY WITHIN A (0/90/0) LAMINATE UNDER AXIAL TENSION, SHOWING THE EFFECT OF INCLUDING THE POST-FAILURE NONLINEARITY FEATURE .................................................................................................................. 62
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1 Introduction to Helius:MCT
Helius:MCT is composed of a set of two software modules and a composite material database that integrate seamlessly with the Ansys finite element analysis system, providing the user with state-of-theart material modeling capability for fiber-reinforced composite materials. Helius:MCT utilizes a form of multiscale material modeling that is based on Multicontinuum Theory (or MCT) which has been under continuous joint development by the University of Wyoming and Firehole Composites for the past 15 years. The MCT modeling methodology provides an unsurpassed combination of accuracy and efficiency in predicting damage evolution and material failure in composite materials. In sharp contrast to traditional continuum mechanics, where physical quantities of interest (e.g., stress and strain) are averaged over the entire heterogeneous microstructure of the composite material, Multicontinuum Theory retains the identities of the distinct material constituents within the microstructure. Consequently, physical quantities of interest (e.g., stress and strain) are averaged over each individual constituent material. These constituent average quantities provide much deeper insight into the thermo-mechanical behavior of the composite material than the traditional composite average quantities. To briefly summarize, Multicontinuum Theory focuses on two concepts: 1) the development of relationships between the various constituent average quantities of interest, and 2) the development of relationships that link the composite average quantities to the constituent average quantities. For a complete discussion of Multicontinuum Theory and the advantages that it provides in the analysis of composite materials, see the Helius:MCT Theory Manual. 1.1 A Note on the Helius:MCT- Linear Version
Starting with Helius:MCT version 3.0, Firehole Composites began offering a limited-functionality version of Helius:MCT. This version is often referred to as Helius:MCT-Linear. Helius:MCT-Linear provides users access to advanced multi-scale analysis, constituent level stress and strain values and multi-scale failure indices when running linear elastic finite element simulations. Helius:MCT Linear does not provide access to many of the advanced, nonlinear functionality that is available in the full version of Helius:MCT such as progressive failure modeling, material nonlinearity, and many other advanced features. In an effort to communicate the features that are not available in the Linear version of Helius:MCT, the following graphic will be displayed in this document when describing a feature that requires a license to the full featured version of Helius:MCT.
Functionality not available in Helius:MCT Linear
1.2
Helius:MCT Interaction with Ansys
In an Ansys structural-level finite element analysis of a composite structure, Helius:MCT quickly and accurately decomposes the composite average stress/strain field into constituent average stress/strain fields. The constituent average stress states are then used by Helius:MCT to predict damage evolution and material failure for each constituent material (fiber and matrix). Subsequently, Helius:MCT homogenizes the current damaged microstructure in order to provide an accurate assessment of the current composite average stiffness for use in the structural-level finite element analysis. Helius:MCT is designed to provide this enhanced composite modeling capability without significantly increasing the time required to run the
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structural-level finite element analysis. For example, using Helius:MCT in conjunction with a structurallevel finite element analysis usually increases the overall solution time by two to three percent (a very small price to pay for the increased solution accuracy provided by Helius:MCT). Figure 1 shows a schematic diagram of the individual components of the Helius:MCT software and their interaction with the Ansys software components. In Figure 1, bold rectangles indicate the components of the Ansys finite element modeling package, while ovals indicate the individual components of the Helius:MCT software. In Figure 1, the Helius:MCT Graphical User Interface (GUI) is accessed from within the Ansys Mechanical APDL and assists the user in defining the Ansys input file commands that are required during a finite element analysis that employs the use of Helius:MCT. The Helius:MCT User Programmable Feature (see Figure 1) calculates composite constitutive relations and stresses for use within the Ansys finite element code. The Helius:MCT User Programmable Feature contains all of the MCT constitutive relations for the individual constituent materials (fiber and matrix) and the homogenized composite material. In addition, the Helius:MCT User Programmable Feature contains the constituent damage and failure criteria and the algorithms to degrade the stiffnesses of the constituents and the homogenized composite material to reflect the current damaged state of each constituent material. The Ansys finite element code calls the Helius:MCT User Programmable Feature at each Gaussian integration point in the model where constitutive relations or stresses are needed. In Figure 1, the Helius:MCT Composite Material Database is used to store all of the material coefficients that are needed to completely define the MCT multiscale material model for various composite materials. Before a particular composite material can be used in a Helius:MCT-enhanced finite element model, the composite material must undergo MCT characterization, and its coefficients must be entered into the Helius:MCT Composite Material Database. As shown in Figure 1, the Helius:MCT User Programmable Feature opens and reads the Helius:MCT Composite Material Database to extract the necessary material coefficients for any composite materials that are used in the finite element model.
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ANSYS Mechanical APDL

ANSYS input file
Helius:MCT
Graphical User Interface (GUI)
Helius:MCT ANSYS Solver

User Programmable Feature
ANSYS results file
Helius:MCT ANSYS Mechanical APDL

Composite Material Database
Figure 1: Schematic diagram of the individual components of the Helius:MCT software and their interaction with the ANSYS software components.
In addition to the software modules depicted in Figure 1, Helius:MCT contains one additional auxiliary program: Helius Material Manager. Helius:Material Manager is a stand-alone program that allows the user to characterize new composite materials and add them to the Helius:MCT Composite Material Library.
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1.3
Helius:MCT Support Documentation
This Users Guide assumes that the reader is familiar with the basic use of the Ansys finite element modeling system, including the following three processes: 1) Creating input files for the Ansys solver, 2) Running Ansys finite element analyses, 3) Viewing the results from an Ansys finite element analysis. Given this assumption, the purpose of this document is to describe those aspects of creating an Ansys input file that are unique to finite element analyses that utilize Helius:MCT for enhanced multiscale modeling of fiber-reinforced composite structures. In addition, this document discusses appropriate methods for viewing the enhanced results that are available in the output file when Helius:MCT is used in the finite element analysis. The remainder of this document is organized as follows: Section 2 This section identifies the different groups of Ansys commands that should be present in an Ansys input file to achieve compatibility with Helius:MCT and take full advantage of its superior convergence characteristics for nonlinear problems. This section describes the use of the Ansys Mechanical APDL to create Ansys input files that are compatible with Helius:MCT. More specifically, Section 3 describes the use of the Helius:MCT Graphical User Interface (GUI) that is accessed from within the Ansys Mechanical APDL. For users who choose to employ a text editor to manually create their Ansys input files or for users who use a general pre-processor to create an Ansys input file, Section 4 describes the process of manually converting existing Ansys input files to achieve compatibility with Helius:MCT. Finally, this section describes the enhanced solution variables that are computed by Helius:MCT during a finite element simulation, and describes the use of the Ansys Mechanical APDL to view the enhanced MCT results.
Section 3
Section 4
Section 5
The collective documentation for Helius:MCT is divided into several documents. These documents are listed below along with a brief description of each one. Helius:MCT Installation Guide The Installation Guide explains the installation of the Helius:MCT software on your computer. Helius:MCT Users Guide The Users Guide is a general reference for using Helius:MCT to provide enhanced composite modeling capability for Ansys finite element analyses of composite structures.
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Helius:MCT Material Manager Users Guide The Material Manager Users Guide provides step-by-step guidelines for using the Helius Material Manager, a convenient graphical user interface (GUI) for creating a material file required to execute a Helius:MCT analysis. Helius:MCT Tutorials 1 and 2 These two documents are step-by-step tutorials that demonstrate the use of Helius:MCT. The primary emphasis is the creation of Ansys input files that are compatible with Helius:MCT and the viewing of special solution variables that are computed by Tutorials 1 & 2 Helius:MCT. Include progressive Tutorial 1 demonstrates the use of Ansys Mechanical APDL in building an Ansys failure functionality not available in input file. Helius:MCT Linear Tutorial 2 demonstrates the process of manually converting an existing Ansys input file to achieve compatibility with Helius:MCT. Tutorial 3 demonstrates the use of the linear functionality of Helius:MCT and uses Ansys Mechanical APDL to build and analyze an input file. Both tutorials also demonstrate the use of the Ansys Mechanical APDL to view the enhanced solution results computed by Helius:MCT. Helius:MCT Theory Manual The Theory Manual provides an in-depth explanation of MCT theory and discusses the various features that are implemented in the Helius:MCT User Programmable Feature. In addition, the Theory Manual describes the important process of characterizing a particular composite material for use with the MCT decomposition.
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2 General Requirements for Ansys Input Files

This section identifies the commands that should be present in an Ansys input file to ensure complete compatibility with Helius:MCT and to take full advantage of its superior convergence characteristics for nonlinear, progressive failure problems. More specifically, this section explains the need for these commands in terms of the unique characteristics of Helius:MCT. This section does not discuss the formatting requirements of any individual command, nor does it discuss any of the specific options or data of any individual command; these issues will be covered later in Sections 3 and 4. 2.1 Identification and Definition of Helius:MCT Materials
If Helius:MCT is used to provide the constitutive relations for a particular composite material, then Ansys considers the composite material to be a user-defined material. Consequently, Ansys requires the following command for each Helius:MCT user-defined material that is used in the finite element model: HELIUSMCT, < arguments > The HELIUSMCT command calls the Helius:MCT macro and the arguments provided as part of the HELIUSMCT command are passed to the Helius:MCT macro. The specific values available for the different arguments of the HELIUSMCT command (along with their formatting requirements) will be discussed in Sections 3 and 4. For now, it suffices that the reader is aware that the HELIUSMCT command will be used to identify each of the composite materials that will be processed by Helius:MCT and to identify the specific form of multiscale constitutive relations that will be used for each of the composite materials. 2.2 Nonlinear Solution Control Parameters for Helius:MCT
It is a widely accepted notion that good convergence (or any convergence at all) is difficult to achieve in a progressive failure simulation of a composite structure. In fact, many progressive failure simulations terminate early, not due to global structural failure, but rather due to the inability of the finite element code to obtain a converged solution at a particular load step. Helius:MCT significantly improves the overall convergence rate and Nonlinear solution robustness of finite element simulations of progressive failure of composite control parameters are not required for structures. Experienced users of Ansys are no doubt familiar with the codes simulations using tendency to reduce (or cut-back) the time increment size when the code senses Helius:MCT Linear that convergence is difficult to achieve. However, when Helius:MCT is used in conjunction with Ansys to perform a progressive failure analysis, the increased robustness of the solution greatly diminishes the need for time incrementation reductions (or cut-backs), thus the analysis can be completed much faster than without Helius:MCT. In order to take full advantage of the superior convergence characteristics of Helius:MCT, the user must change some of the default settings that govern the nonlinear solution process used by Ansys. These changes can be enacted using the NROPT, PRED, NSUBST, NEQIT, and CNVTOL commands. The specific data and options that are used with the NROPT, PRED, NSUBST, NEQIT, and CNVTOL commands will be discussed later in Sections 3.3 and 4.3.
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2.3
Requesting Output of Solution Variables that are Unique to Helius:MCT
Helius:MCT calculates a number of specialized state variables that define the constituent average stress and strain fields, in addition to the damage state of the composite material. These state variables are stored by Ansys at each individual integration point within the finite element model. In order that these state variables can be examined in the Ansys Mechanical APDL, the Ansys input file must explicitly specify that SVAR will be written in the Ansys results file. This request is made via the OUTRES command. Specific usage and formatting of the OUTRES command will be discussed in Sections 3.4, 4.4, and 5. Appendix B contains a description of each of the MCT state variables.
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3 Using The Ansys Mechanical APDL To Create Ansys Input Files For Use With Helius:MCT
Section 3 describes the use of the Ansys Mechanical APDL to create an Ansys input file that is compatible with Helius:MCT. It is assumed that the reader is familiar with the process of using the Ansys Mechanical APDL to create an Ansys input file. Consequently, this section focuses primarily on those aspects of model creation that are unique to models that are intended for use with Helius:MCT. In particular, this section explains the use of the Helius:MCT Graphical User Interface (or GUI) that can be accessed from within the Ansys Mechanical APDL. The Helius:MCT GUI provides a simple, intuitive means for the user to create material definitions that are compatible with Helius:MCT. 3.1 Creating User-Defined Materials with the Helius:MCT GUI
Each composite material that will be processed by Helius:MCT is considered by Ansys to be a user-defined material. The Helius:MCT GUI provides a simple means of creating these composite material definitions in the Ansys input file. The Helius:MCT GUI allows the user to select a composite material from the Helius:MCT composite material database and then select a number of different options for the multiscale constitutive relations that will be used for the composite material. The Helius:MCT GUI can only be accessed in the model creation preprocessor (/PREP7). To open the Helius:MCT GUI from within the Ansys Mechanical APDL, go to the Ansys Toolbar and click on the HELIUS button. Figure 2 depicts where this button is located.
Figure 2: Ansys classical GUI at start-up
Once the HELIUS button is clicked, the Helius:MCT GUI will appear as shown in Figure 3.
1 2 4 3
5 6 7 8 9 10
11 12 13
Figure 3: The Helius:MCT Graphical User Interface (GUI)
As shown in Figure 3, there are thirteen possible steps involved in using the Helius:MCT GUI to define a composite material type for Helius:MCT. Each of the thirteen steps is discussed below. 1. Composite Material Selection The user selects a composite material from the Helius:MCT material library. If the material library does not contain a composite material that the user would like to use in an analysis, a material data file must first be created and added to the material library (refer to Helius Material Manager Users Guide). Once a composite material is selected, the homogenized (or composite average) engineering constants for that material will be displayed in the box labeled Engineering Constants for Your Selected Composite. These constants are displayed in Helius:MCTs default system of units (N/m/K). To display these constants in a different coordinate system, the user may select a different system of units (see step 2). 2. System of Units The user selects the system of units that should be used by Helius:MCT to compute constitutive relations and stresses. By default, Helius:MCT expresses constitutive
relations and computes stress in the (N/m/K) system of units. If the finite element model is created using a different system of units, then Helius:MCT must convert its constitutive calculations to the system of units required by the finite element model. For such purposes, Helius:MCT contains conversion factors for four commonly used systems of units: N/m/K, N/mm/K, lb/in/R, and lb/ft/R. If the finite element model uses one of these four systems of units, the user must select the appropriate system from the drop-down list. In the event that the finite element models system of units does not appear in the drop-down list, the user should select the default system of N/m/K and then refer to Appendix A.3 for details on how to manually modify the Ansys input file to utilize a custom system of units. The reader can also refer to Appendix A.3 for more detailed information on systems of units in general. 3. Principal Material Coordinate System Helius:MCT expresses constitutive relations and computes stresses in the principal material coordinate system of the composite material. Here the user selects one of two or three possible orientations for the composites principal material coordinate system. For Unidirectional Microstructures: Helius:MCTs default principal material coordinate system is oriented with the 1 direction aligned with the fiber direction, while the 2 and 3 directions lie in the materials plane of transverse isotropy. This default orientation of the principal material coordinate system corresponds to the selection of "1" from the fiber direction drop down menu. However, in situations where it adds convenience or simplicity to the model creation process, the user may change the orientation of the principal material coordinate system so that the 2 direction is aligned with the fiber direction, while the 1 and 3 directions lie in the composite materials plane of transverse isotropy. This particular orientation of the principal material coordinate system corresponds to the selection of "2" from the fiber direction drop down menu. If the user selects the value 2 from the dropdown list, the Helius:MCT GUI updates the contents of the display box labeled Engineering Constants for Your Selected Composite. For Woven Microstructures: Helius:MCTs default principal material coordinate system is oriented with the 1 direction aligned with the fill tow direction, while the 2 direction corresponds to the warp tow direction, and the 3 direction corresponds with the out-of-plane direction. This default orientation of the principal material coordinate system corresponds to the selection of "1" from the fiber direction drop down menu. However, in situations where it adds convenience or simplicity to the model creation process, the user may change the orientation of the principal material coordinate system so that the 2 direction is aligned with the fill tow direction, while the 1 direction corresponds to the warp tow direction. This particular orientation of the principal material coordinate system corresponds to the selection of "2" from the fiber direction drop down menu. Additionally, the user may change the orientation of the principal material coordinate system so that the 3 direction is aligned with the fill tow direction while the 2 direction corresponds to the warp tow direction. This particular orientation of the principal material coordinate system corresponds to the selection of "3" from the fiber direction drop down menu. For more information on the orientation of principal material coordinate systems, please refer to Appendix A.4. 4. Temperature Dependence (unidirectional composites only) If a list of temperatures is displayed, then the material data file for the selected material contains material properties at multiple temperatures. After selecting a temperature, the properties that are stored for that
temperature are displayed in the Engineering Constants for Your Selected Composite. During a finite element analysis, Helius:MCT linearly interpolates the composite and constituent properties for any given temperature that lies within the bounds of the lowest and highest temperature points stored in the material file. For temperatures below the lowest stored temperature datum, Helius:MCT will use the material properties stored at the lowest temperature datum (Helius will not extrapolate properties beyond the bounding stored temperature data points). The same is true for temperatures above the highest stored temperature datum. For further information on the use of temperature dependent material properties in Helius:MCT, please refer to section 9 of the Helius:MCT Theory Manual. For further information on adding a new temperature dependent material to the Helius:MCT material library, please refer to the Helius:MCT Material Manager Users Guide.
Steps 5, 6, 7, 8, 9, 11 and 12 listed below do not apply to Helius:MCT Linear
5. Progressive Failure - The user chooses whether or not to perform a Progressive Failure Analysis. If the user checks this box, then Helius:MCT will routinely evaluate both the matrix failure criterion and the fiber failure criterion to determine if either constituent has failed. Each constituent failure criterion is based on the corresponding constituent average stress state. In the event that one or both of the constituents fail, the stiffness of the failed constituent(s) and the stiffness of the composite are appropriately reduced instantaneously. It should be emphasized that an instantaneous reduction of the stiffness of a failed constituent effectively results in a discontinuous, piecewise linear stress/strain response for the constituent and the composite. However, when this type of discrete material response is applied independently at each of the integration points in a large finite element model, the net result is a gradual (or progressive) degradation of the overall stiffness of the composite structure (hence the name Progressive Failure Analysis). The progressive failure analysis feature is the foundation component of Helius:MCTs nonlinear multiscale constitutive relations. Other aspects of material nonlinearity can be invoked, however, these additional forms of nonlinearity cannot be activated unless the progressive failure analysis feature is also activated. Consequently, if the user chooses not to check the progressive failure analysis box, then Helius:MCT will use linear elastic constitutive relations. For further information on progressive failure analyses and constituent failure criteria, refer to Appendix A.5 of this User's Guide and Section 4 of the Helius:MCT Theory Manual. 6. Calculate Failed Plain Weave Properties - (plain weave composites only) Selecting this option will force Helius:MCT to calculate the failed plain weave properties using the matrix and fiber degradation levels specified in steps 11 and 12. If this option is not selected, the failed material properties that were calculated when the material data file was created using Helius:Material Manager are used. For example, if the matrix degradation value was 0.7 and the fiber degradation value was 0.015 when the material was created (using Helius:Material Manager) and this option is unselected, the failed material properties corresponding to a matrix degradation of 0.7 and a fiber degradation of 0.015 are used. If, on the other hand, this option is selected and, for example, the user specifies a matrix degradation of 0.8 and a fiber degradation of 0.001 in steps 11 and 12, then the failed material properties corresponding to a matrix degradation of 0.8 and a fiber degradation of 0.001 are used. Note: The matrix degradation for woven laminae is recommended to be not less than 0.7.
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7. Hydrostatic Strengthening of the Composite (unidirectional composite only) The user chooses whether or not to account for the experimentally observed strengthening of the composite in the presence of a hydrostatic compressive stress. If the user checks this box, then Helius:MCT will monitor the hydrostatic compressive stress level in the matrix constituent. If the hydrostatic compressive stress level in the matrix constituent exceeds a threshold value, then the strength of both the matrix constituent and the fiber constituent are scaled upwards commensurate with the level of hydrostatic compressive stress level in the matrix constituent. For further information on Hydrostatic Strengthening of the Composite, refer to Appendix A.8 of this User's Guide and Section 7 of the Helius:MCT Theory Manual. 8. Pre-Failure Nonlinearity (unidirectional composites only) The user chooses whether or not to account for the nonlinear longitudinal shear stress/strain response that is commonly observed in fiber-reinforced composite materials. If the user checks this box, then Helius:MCT will employ a four-segment, piecewise linear representation of the longitudinal shear stress/strain response (i.e., c c c c 12 vs. 12, and 13 vs. 13), while the responses of the other four stress and strain components remain unaffected by this feature. The entire series of three discrete reductions in the longitudinal shear moduli of the composite is conducted in such a way that the piecewise linear longitudinal shear response closely matches experimentally measured longitudinal shear data for the composite. It should be emphasized that this feature is only available for those unidirectional composite materials where a longitudinal shear stress/strain curve was supplied during the MCT material characterization process. If this feature is requested for a composite material that was characterized without a longitudinal shear stress/strain curve, then Helius:MCT will issue an error message at runtime and execution will halt. For further information on the Pre-Failure Nonlinearity feature, refer to Appendix A.6 of this User's Guide, Section 5 of the Helius:MCT Theory Manual, and Example Problem 2. For further information on characterizing new composite materials with Pre-Failure Nonlinearity capability, please refer to the Helius:MCT Material Manager Users Guide. 9. Post-Failure Nonlinearity (unidirectional composites only) The user chooses whether or not to account for the support that is provided to a failed lamina by the surrounding un-failed lamina. When individual matrix cracks appear in a lamina, the surrounding undamaged lamina are able (via interlaminar shear stresses) to divert the load path around the individual matrix cracks and back into the failed lamina. The net result of this process is that matrix failure in a lamina is not a discrete catastrophic event, rather it is a gradual process marked by a gradual increase in the density of matrix cracks. In this case, the matrix failure criterion is assumed to simply identify the onset of matrix crack development. As the deformation of the lamina continues to increase, the stiffness of the matrix constituent is subject to a series of discrete reductions until the stiffness of the matrix constituent finally reaches its minimal level indicating complete matrix failure (i.e., matrix crack saturation). It is of importance to note a consistent set of material properties is enforced between the microscopic and macroscopic scales to allow for the composite material properties to degrade along with the matrix. It should be emphasized that this feature is only available for those unidirectional composite materials where the transverse normal failure strain was supplied during the MCT material characterization process. If this feature is requested for a composite material that was characterized without a transverse normal failure strain, then Helius:MCT will issue an error message at runtime and execution will halt. For further information on the Post-Failure
Nonlinearity feature, refer to Appendix A.7 of this User's Guide and Section 6 of the Helius:MCT Theory Manual. For further information on characterizing new composite materials with PostFailure Nonlinearity capability, please refer to the Helius:MCT Material Manager Users Guide. 10. Residual Stresses (applicable to unidirectional composites only) This option is used to specify whether or not to explicitly account for thermal residual stresses in the response of the composite material. If this option is checked, then Helius:MCT computes the ply-level and constituent-level thermal residual stresses that are caused by the post-cure cool down from the stress-free temperature displayed under Engineering Constants for Your Selected Composite to ambient temperature (defaults to 72.5F = 22.5C = 295.65K). In this case, these ply-level and constituent-level thermal residual stresses will be present prior to the application of any external mechanical and/or thermal loads that are imposed during the simulation. If the user chooses to explicitly account for thermal residual stresses in the analysis, then the user should verify that the stress-free temperature (synonymous with cure temperature) displayed under Engineering Constants for Your Selected Composite is indeed a reasonable value; otherwise, the predicted thermal residual stresses could be quite erroneous. If this option is not checked for a particular composite material, then thermal residual stresses are not included in the response of that particular composite material during the simulation. In this case, the stress free temperature of the composite material defaults to Tsf =0 (regardless of the system of units employed), and the temperature change that is used in the constitutive relations [ = C(T)] is simply computed as T = T Tsf = T. Several points should be emphasized here. First, the stress free temperature Tsf defaults to 0 even if the composite material data file (Mdata file) explicitly defines a non-zero stress free temperature. Second, regardless of the system of units that are employed by the finite element model, the current temperature T completely defines the temperature change T that is used in the constitutive relations. Third, for composite materials that are characterized at multiple temperatures, the current temperature T will be used to interpolate the various material properties that contribute to the constitutive relations; consequently, it is recommended that a singletemperature characterization (i.e., a single-temperature Mdata file) should be used for the composite material in question. In summary, if the user does not request this option, then the current temperature T influences Eqs. 10.1 of the Theory Manual in two different ways: 1) the temperature change used in the constitutive relations simply becomes T=T, and 2) T is used to interpolate the temperature-dependent material properties that contribute to the constitutive relations. Refer to Section 10 of the Helius:MCT Theory Manual for further information on the thermal residual stresses formulation used by Helius:MCT. It should be emphasized that the default temperature in Ansys is 0. This default temperature is completely compatible with the default stress free temperature of 0 that is assumed when the ninth user material constant is specified as 0. In this case, the model can still be subjected to temperature changes by simply imposing a temperature other than 0; however, these thermal stresses develop over the course of the analysis, as opposed to being present at the start of the analysis. 11. Matrix Post-Failure Stiffness This value is a fraction that is used to define the damaged elastic moduli of the matrix constituent after matrix constituent failure occurs. Specifically, the value is the ratio of the failed matrix constituent moduli to the unfailed matrix constituent moduli. A value of 0.1 would mean that after a matrix failure occurs at an integration point, all six of the m m m m m m matrix constituent moduli (E11, E22, E33, G12, G13, G23) are reduced to 10% of the original
undamaged matrix constituent moduli. The matrix post-failure stiffness value must be greater than 0, and less than or equal to 1. By default, the matrix post-failure stiffness value is set to 0.1. If the post-failure nonlinearity feature is turned on, this value will be ignored. 12. Fiber Post-Failure Stiffness This value is a fraction that is used to define the damaged elastic moduli of the fiber constituent after fiber constituent failure occurs. Specifically, the value is the ratio of the failed fiber constituent moduli to the unfailed fiber constituent moduli. A value of 0.01 would mean that after a fiber failure occurs at an integration point, all six of the fiber f f f f f f constituent moduli (E11, E22, E33, G12, G13, G23) are reduced to 1% of the original undamaged fiber constituent moduli. The fiber post-failure stiffness value must be greater than 0, and less than or equal to 1. The default value of the fiber post-failure stiffness is automatically set to 0.01. 13. Output Constituent Average Stress and Strain States The user chooses whether or not to output the fiber average stress and strain fields and the matrix average stress and strain field to the results file. If the user checks this box for a unidirectional composite, then the number of MCT state variables output to the results file increases from 6 to 34. If the user checks this box for a woven composite, then the number of MCT state variables output to the results file increases from 6 to 90. Printing these extra state variables increases the total run time slightly and significantly increases the size of the results file. Thus, this option should only be selected if the constituent average stress and strain states are of interest to the user. After completing steps 1 through 13, the user should click the OK button on the Helius:MCT GUI to create the user-defined composite material. Once the OK button is clicked, the appropriate Ansys command is created and executed for the new user-defined composite material. The newly created Ansys command (HELIUSMCT) can be viewed in the Ansys log file. 3.2 Modeling Issues for Imposing Temperature Changes
The composite materials that are stored in the Helius:MCT Composite Material Database are assumed to have a reference temperature of 0 in the system of units that is specified by the Helius:MCT GUI. Any desired temperature change must be specified relative to the assumed 0 reference temperature. For example, assuming the user requests the pound/inch/R system of units, the composite material is assumed to have a reference temperature of 0 R. In this case, the user can impose a temperature change of +100 R by simply specifying the operating temperature of the model as 100. The Reference Temperature dialog box (Figure 4) is used to specify the reference temperature for applying a uniform temperature to all nodes via the Uniform Temperature dialog box (Figure 5). It should be noted that if the user chooses to specify the reference temperature via the Reference Temperature dialog box, then the reference temperature must be specified as 0 or an error will result. However, a reference temperature is not required since the default reference temperature in Ansys is 0.
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Figure 4: Reference Temperature dialog box accessed from within the Ansys GUI.
Figure 5: Uniform Temperature dialog box accessed from within the Ansys GUI.
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3.3
Nonlinear Solution Control Parameters
Helius:MCT significantly improves the overall convergence rate and robustness of finite element simulations of progressive failure of composite structures. However, in order to take full advantage of the superior convergence characteristics of Nonlinear Solution Control Parameters are only Helius:MCT, the user must change some of applicable to the full version of Helius:MCT as they the default settings that govern the nonlinear pertain to progressive failure simulations. solution process used by Ansys. This section discusses the use of the Ansys Mechanical APDL to make the recommended changes to the parameters that govern the nonlinear solution process used by Ansys. These changes can be enacted using the NROPT, PRED, NSUBST, CNVTOL, and NEQIT commands. Regardless whether the SOLCONTROL command is ON (default) or OFF, the user will need to override these nonlinear solution control parameters. NROPT The NROPT command is used to do two things: a) instruct Ansys to use the Full Newton Raphson algorithm, and b) prevent Ansys from using their Adaptive Descent algorithm to help the solution process. The NROPT command can only be specified via the Ansys command prompt. Figure 6 shows how to type this command into the command prompt.
Figure 6: Example of NROPT command entered into the Ansys command prompt.
In Ansys, the nonlinear solution process is based on the fundamental assumption of the NewtonRaphson algorithm that the nonlinear response of the composite structure is sufficiently smooth at both the global and local levels. However, in a progressive failure simulation of a composite structure, the nonlinear response of the composite structure is not smooth, especially at the local level where material failure results in an instantaneous reduction of material moduli. This nonsmooth material response is one of the primary factors responsible for the difficulty in obtaining convergence in progressive failure simulations. Helius:MCTs method of managing material nonlinearity is specifically designed to handle this localized non-smooth material response; however, the default settings of Ansyss nonlinear solution control parameters must be changed in order to allow Helius:MCT to improve the convergence characteristics of the finite element simulation. PRED The PRED command prevents Ansys from using the converged solution at the last substep to estimate the solution for the current substep. This interferes with Helius:MCTs method of managing material linearity. Figure 7 shows how to access this command via the Ansys
Mechanical APDL. As seen in Figure 7, the DOF solution predictor drop-down menu needs to have Off selected.
Figure 7: Access of PRED command via Ansys Mechanical APDL.
NSUBST The NSUBST command specifies the minimum and maximum allowable number of substeps for the current load step. Firehole Composites does not recommend any minimum or maximum values and engineering judgment should be exercised. However, provided that enough equilibrium iterations are allowed per substep (discussed under NEQIT heading), Helius:MCT will always find a converged solution. This is a deviation from typical nonlinear solution processes where multiple substep size cutbacks may be required. Helius:MCT will converge at each substep, regardless of the size (again provided that enough equilibrium iterations are allowed per substep), so care must be taken when deciding on substep size. Figure 8 displays where to specify the number of substeps in the Ansys Mechanical APDL.
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Figure 8: Where to specify the number of substeps in the Ansys Mechanical APDL.
CNVTOL The CNVTOL command is used to define the convergence tolerance for residual node forces. There are two arguments set in this command that allow Helius:MCT to better handle the nonlinear solution process: a) set forces (F) as the convergence label, and b) set the norm selection to infinite norm (check each DOF separately). Figure 9 displays where to set these arguments in the Ansys Mechanical APDL.
Figure 9: Access of CNVTOL command via the Ansys Mechanical APDL. Helius:MCT Users Guide - ANSYS Page 21 of 75
NEQIT The NEQIT command is used to specify the minimum number of equilibrium iterations that must be performed before Ansys evaluates the need for cutting-back the size of the current substep. Helius:MCT has the unique ability to converge regardless of the substep size or extent of nonlinearity occurring during the substep. In the experience of Firehole Composites, convergence always occurs when the number of equilibrium iterations allowed per substep before a substep cutback occurs is set to 1000. Figure 10 displays how to set this argument via the Ansys Mechanical APDL.
Figure 10: Access of the NEQIT command via the Ansys Mechanical APDL.
3.4
Requesting MCT state variable output
The solution-dependant MCT state variables are used to track constitutive quantities of interest at each integration point in the finite element model. If the user checked the box labeled Output Constitutive Stress/Strain in the Helius:MCT GUI, then 34 SVAR1 tracks MCT state variables are tracked for unidirectional composite materials or 90 damage which is not MCT state variables are tracked for woven composite materials; otherwise, 6 used in Helius:MCT Linear, all of the MCT state variables are tracked. The default naming convention for the other output solution-dependant MCT state variables is SVARi, where i=1,2,3,,6 or 34 (or variables are utilized 90 for woven materials). The most useful of the MCT state variables is SVAR1 in Helius:MCT which is used to track the discrete failure state of the composite material at Linear. each integration point in the finite element model. The exact interpretation of the discrete values of SVAR1 will depend upon the exact set of Helius:MCT material nonlinearity features that are used in the analysis. Appendix B provides a complete description of each of the MCT state variables, including tables that define the interpretation of SVAR1 for various combinations of material nonlinearity features.
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Output of the MCT state variables to the results file is accomplished with the OUTRES command. The command, OUTRES, SVAR, ALL, may be issued to write the state variables to the results file at every substep. For more information on the OUTRES command, refer to the Ansys documentation.
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4 Using A Text Editor To Convert Pre-Existing Ansys Input Files For Use With Helius:MCT
For those users who choose to employ a text editor to manually create an Ansys input file or for users who use a general pre-processor to create an Ansys input file, this section describes the process of manually converting an existing Ansys input file to achieve complete compatibility with Helius:MCT. 4.1 Defining a Helius:MCT Material
In an Ansys input file, there is one different command that collectively defines a Helius:MCT userdefined composite material. This command is HELIUSMCT. Consider the following line from an Ansys input file that completely specifies a Helius:MCT user-defined composite material. HELIUSMCT, MATID, NSTATV, UNITS, PFIB_DIR, PFA, PREFAIL, POSTFAIL, PRESS, TEMPDEPEND, unused, unused, unused, unused, MDEG, FDEG, FCONV (optional), LCONV (optional), TCONV (optional) An example of an HELIUSMCT command looks like: HELIUSMCT, 9007, 6, 1, 1, 1, 0, 0, 0, 0, 0, 0, 0, 0, 0.01, 0.01 The HELIUSMCT command calls the Helius:MCT macro and the arguments provided as part of the HELIUSMCT command are passed to the Helius:MCT macro. For any given Helius:MCT material, the number of arguments must be between 5 and 18. The first five arguments are required for all Helius:MCT materials; the last three arguments (i.e., the 16th, 17th, and 18th arguments) are only required if the finite element model is defined using a custom system of units (discussed further in Appendix A.3). Arguments 10-13 are unused and a value of 0 should be entered for these arguments. Appendix A provides a detailed description of each of the arguments, including the range of allowable values for each argument and the impact that each argument has on the multiscale constitutive relations used to represent the material. Each of the arguments are shown in Table 1 and listed below along with a brief description. For a more detailed description of any particular argument, refer to the appropriate section of Appendix A.
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Table 1: Helius:MCT Command Arguments

Argument 1 2 Constitutive Issue Controlled by the User Material Constant Material Reference Number Number of State Variables (SVARs) Allowable Values Integer greater than zero Unidirectional ~ 6 or 34 Woven ~ 6 or 90 1 N/m/K 2 N/mm/K 3 Lb/in/R 4 Lb/in/R 5 Custom Unidirectional: 1 (1 = fiber, 2/3 = plane of transverse isotropy) 2 (2 = fiber, 1/3 = plane of transverse isotropy Woven: 4 Principal Material Coordinate System 1 (1 = fill tow, 2 = warp tow, 3 = out of plane) 2 (2=fill tow, 1=warp tow, 3=out of plane) 3 (3 = fill tow, 2 = warp tow, 1 = out of plane) Uni: 0 (off), 1 (on) Woven: 0 (off), 1 or 2 (on) 0 is default For unidirectional composites only. Must have Progressive Failure Analysis activated 1 is default Notes
System of Units
1 is default
Progressive Failure Analysis
Pre-Failure Nonlinearity
0 (off), 1 (on)
0 is default For unidirectional composites only. Must have Progressive Failure Analysis activated
Post-Failure Nonlinearity
0 (off), 1 (on)
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0 is default For unidirectional composites only. Must have Progressive Failure Analysis activated 0 is default For unidirectional composites only.
Hydrostatic Strengthening
0 (off), 1 (on)
9 10 11 12 13 14
Stress Free Temperature (Thermal Residual Stress) Not used Not used Not used Not used Matrix Post Failure Stiffness
0 (0) 1 (temperature read from material file) 0 or blank 0 or blank 0 or blank 0 or blank
0.1 (10%) is default 0 < value 1 For unidirectional composites only. 0.01 (1%) is default For unidirectional composites only.
15
Fiber Post Failure Stiffness Force Conversion for Custom Units Length Conversion for Custom Units Temperature Difference Conversion for Custom Units
0 < value 1 Must be greater than zero Must be greater than zero Must be greater than zero
16 17 18
1. MATID The first argument allows the user to specify a material reference number to be associated with a Helius:MCT material. When Helius:MCT is installed for Ansys, a HeliusMCT_MatDB.xml file is created in the < Helius Root Directory > \ Materials folder (by default this is defined as C:\Firehole\Materials). The purpose of this file is to link the material reference number (MATID) with the name of a material stored in the < Helius Root Directory > \ Materials folder. The material reference numbers for the composite materials that come with the Helius:MCT install are already included in this file. If a new material file is created using the Helius Material Manager, the HeliusMCT_MatDB.xml file is automatically updated to include the new material and is assigned a material ID number. However, if the material files are manually copied and edited, the HeliusMCT_MatDB.xml file must be updated to include the new link between the material reference number (MATID) and the name of the newly created composite material. If the HeliusMCT_MatDM.xml file is opened using a text editor or internet browser, the contents will look similar to the following (if opened with a text editor): <?xml version="1.0"?> <HeliusMCT_MatDB> <Material id="9001" name="AS4-3501-6"/>
<Material id="9002" name="AS4_3502"/> <Material id="9003" name="AS4_8552"/> <Material id="9004" name="AS_Epoxy1"/> <Material id="9005" name="Eglass21xK43Gevetex-LY556"/> <Material id="9006" name="HTS150_TC250"/> <Material id="9007" name="IM7-977-2"/> <Material id="9008" name="IM7_5250-4"/> <Material id="9009" name="IM7_8551"/> <Material id="9010" name="IM7_8552"/> <Material id="9011" name="IM7_977-3"/> <Material id="9012" name="S2_Glass_Epoxy2"/> <Material id="9013" name="SilEglass1200tex-MY750"/> <Material id="9014" name="T300-BSL914C"/> <Material id="9015" name="T300_976"/> <Material id="9016" name="T300_PR319"/> <Material id="9017" name="T800H_3900-2"/> </HeliusMCT_MatDB> To add a link between a newly created material file and an Ansys material reference number (MATID), copy the format of the existing file to add an additional line that links the two items. For example, if the newly created material file was saved as example_composite_material, the file would be modified as: <?xml version="1.0"?> <HeliusMCT_MatDB> <Material id="9001" name="AS4-3501-6"/> <Material id="9002" name="AS4_3502"/> <Material id="9003" name="AS4_8552"/> <Material id="9004" name="AS_Epoxy1"/> <Material id="9005" name="Eglass21xK43Gevetex-LY556"/> <Material id="9006" name="HTS150_TC250"/> <Material id="9007" name="IM7-977-2"/> <Material id="9008" name="IM7_5250-4"/> <Material id="9009" name="IM7_8551"/> <Material id="9010" name="IM7_8552"/> <Material id="9011" name="IM7_977-3"/> <Material id="9012" name="S2_Glass_Epoxy2"/> <Material id="9013" name="SilEglass1200tex-MY750"/> <Material id="9014" name="T300-BSL914C"/> <Material id="9015" name="T300_976"/> <Material id="9016" name="T300_PR319"/> <Material id="9017" name="T800H_3900-2"/> <Material id="9018" name="example_composite_material"/> </HeliusMCT_MatDB> The value 9018 would be used as the first argument in the HELIUSMCT command and tells Helius:MCT to use the material example_composite_material.
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2. NSTATV The second argument is used to identify the number of solution-dependent MCT state variables (SVARS) that must be tracked at each integration point in the finite element model. The number of solution-dependent MCT state variables is dependent upon whether or not the user desires access to constituent average stresses and strains and the microstructure of the composite (unidirectional or woven). Allowable values for this argument are 6 or 34 for unidirectional materials and 6 or 90 for woven materials. 6 state variables should be requested unless the user desires access to the constituent average stresses and strains. In this case, 34 state variables should be requested for unidirectional materials and 90 state variables should be requested for woven materials. 3. UNITS The third argument specifies the system of units that should be used by Helius:MCT in computing the constitutive relations and stresses. In the example provided above, the third argument has a value of 1, indicating that Helius:MCT should compute the constitutive relations and stresses in its default system of units (N/m/K). There are three other systems of units (N/mm/K - 2, lb/in/R - 3, and lb/ft/R - 4) that can be requested via specific values of the first user material constant, in addition to a custom (or user-defined) system of units which would be specified using the value of 5. For more information, refer to Appendix A.3 which provides a detailed discussion of the third argument. 4. PFIB_DIR Helius:MCT expresses constitutive relations and computes stress in the principal material coordinate system of the composite material. The fourth user material constant specifies the specific orientation of the principal material coordinate system that will be used by Helius:MCT. For Unidirectional Microstructures: Helius:MCTs default principal material coordinate system is oriented with the 1 direction aligned with the fiber direction, while the 2 and 3 directions lie in the materials plane of transverse isotropy. However, in situations where it adds convenience or simplicity to the model creation process, the user may change the orientation of the principal material coordinate system so that the 2 direction is aligned with the fiber direction, while the 1 and 3 directions lie in the composite materials plane of transverse isotropy. The numerical value (1 or 2) of the fourth user material constant specifies which of the principal material coordinate axes will be aligned with the fiber direction. For more information, refer to Appendix A.4 which provides a detailed discussion of the fourth argument. For Woven Microstructures: Helius:MCTs default principal material coordinate system is oriented with the 1 direction aligned with the fill tow direction, while the 2 direction corresponds to the warp tow direction and the 3 direction corresponds with the out-of-plane direction. However, in situations where it adds convenience or simplicity to the model creation process, the user may change the orientation of the principal material coordinate system so that the 2 direction is aligned with the fill tow direction, while the 1 direction corresponds to the warp tow direction. Additionally, the user may change the orientation of the principal material coordinate system so that the 3 direction is aligned with the fill tow direction while the 2 direction corresponds to the warp tow direction. For more information, refer to Appendix A.4 which provides a detailed discussion of the fourth argument.
5. PFA The fifth user material constant activates or deactivates Helius:MCTs progressive failure analysis feature. If the progressive failure feature is activated, then Helius:MCT will routinely evaluate both the matrix and fiber failure criterion to determine if either constituent material has
failed. Each constituent failure criterion is based on the corresponding constituent average stress state. In the Progressive Failure Analysis is not available in Helius:MCT Linear, event that one or both of the constituents fail, the its default value is zero and a stiffnesses of the failed constituent(s) and the stiffnesses nonzero entry will be adjusted back of the composite are appropriately reduced to the to zero by Helius:MCT Linear at respective post-failure stiffnesses. It should be runtime. All other nonlinear emphasized that the progressive failure analysis feature is material constants will also default to zero. the foundation component of Helius:MCTs nonlinear multiscale constitutive relations. Other aspects of material nonlinearity can be invoked via the 6th, 7th, and 8th user material constants; however, these additional forms of nonlinearity cannot be activated unless the progressive failure analysis feature is also activated. For more information on the progressive failure analysis feature, refer to Appendix A.5 of this document and Section 4 of the Helius:MCT Theory Manual. Unidirectional Microstructures: A value of 1 activates the progressive failure analysis feature, while a value of 0 deactivates the progressive failure analysis feature. Woven Microstructures: A value of 0 deactivates the progressive failure feature, a value of 1 activates the progressive failure feature and uses the matrix and fiber degradation levels from the material data file to calculate the failed material properties, and a value of 2 activates the progressive failure feature and uses the matrix and fiber degradations levels specified by the fourteenth and fifteenth user material constants to calculate the failed material properties. Selecting a value of 2 for plain weaves will add approximately 45-60 seconds to the pre-processing time per woven material. A value of 1 will not add run-time during pre-processing because the failed material properties (at the matrix and fiber degradation levels specified during material creation in Helius:Material Manager) are already stored in the material file.
6. PREFAIL (optional, for unidirectional composites only) The sixth user material constant activates or deactivates Helius:MCTs Pre-Failure Nonlinearity feature. A value of 1 activates the pre-failure nonlinearity feature, while the default value of 0 deactivates the pre-failure nonlinearity feature. If the pre-failure nonlinearity feature is activated, then Helius:MCT will explicitly account for the Pre-Failure Nonlinearity is not available in Helius:MCT Linear, nonlinear longitudinal shear stress/strain response that is its default value is zero. typically observed in unidirectional fiber-reinforced composite materials. The Pre-Failure Nonlinearity feature imposes a series of discrete reductions in the longitudinal shear stiffness of the matrix constituent material, causing the composite materials nonlinear longitudinal shear response to closely match experimentally measured data. It should be emphasized that the Pre-Failure Nonlinearity feature only affects the longitudinal shear moduli of the composite (i.e., c12 vs. c12, and c13 vs. c13), while the responses of the other four composite stress and strain components remain unaffected by this feature. Also, the Pre-Failure Nonlinearity feature will not alter the shear stress level at which the composite fails; however, it will result in an overall increase in longitudinal shear deformation of the composite prior to failure. For further information on the Pre-Failure Nonlinearity feature, refer to Appendix A.6 of this document and Section 5 of the Helius:MCT Theory Manual. Note: The Pre-Failure Nonlinearity feature is only available for unidirectional composite materials. This feature is ignored by woven composites.
Note: The Pre-Failure Nonlinearity feature is only available for those unidirectional composite materials where a longitudinal shear stress/strain curve was supplied during the MCT material characterization process. If this feature is requested for a composite material that was characterized without a longitudinal shear stress/strain curve, then Helius:MCT will issue an error message at runtime and execution will halt. For more information on using measured longitudinal shear data during the material characterization process, please refer to the Helius Material Manager Users Guide. 7. POSTFAIL (optional, for unidirectional composites only) The seventh user material constant activates or deactivates Helius:MCTs Post-Failure Nonlinearity feature. A value of 1 activates the Post-Failure Nonlinearity feature, while the default value of 0 deactivates the Post-Failure Nonlinearity feature. If the Post-Failure Nonlinearity feature is activated, then Helius:MCT will gradually Post-Failure Nonlinearity is not available in Helius:MCT Linear, its default value reduce the stiffness of the matrix constituent moduli is zero. to their minimum values. When the Post-Failure Nonlinearity feature is activated, the matrix failure criterion simply identifies the initiation of the matrix failure process (or the initiation of matrix cracking). After the matrix failure criterion is triggered, the matrix constituent stiffness is gradually reduced via a series of discrete stiffness reductions that are applied as the matrix average strain state continues to increase beyond the level present at failure initiation. For further information on Post-Failure Nonlinearity, refer to Appendix A.7 of this document and Section 6 of the Helius:MCT Theory Manual. Note: The Post-Failure Nonlinearity feature is only available for unidirectional composite materials. This constant is ignored by woven composites. Note: The Post-Failure Nonlinearity feature is only available for those unidirectional composite materials where the transverse tensile failure strain (22ult) was supplied during the MCT material characterization process. If this feature is requested for a composite material that was characterized without a transverse tensile failure strain, then Helius:MCT will issue an error message at runtime and execution will halt. For more information on the MCT material characterization process, please refer to the Helius Material Manager Users Guide. Note: If the Post-Failure Nonlinearity feature is turned on, then the matrix post-failure stiffness value is ignored. 8. PRESS (optional, for unidirectional composites only) The eighth argument activates or deactivates Helius:MCTs hydrostatic strengthening feature. A value of 1 activates the hydrostatic strengthening feature, while a value of 0 deactivates the hydrostatic strengthening feature. If the hydrostatic strengthening feature is activated, then Helius:MCT explicitly accounts for the experimentally observed strengthening of the composite in the presence of a hydrostatic compressive stress. If the hydrostatic compressive stress in the matrix constituent exceeds a threshold value, then the strength of both the matrix constituent and the fiber constituent are scaled upwards commensurate with the level of hydrostatic compressive stress level in the matrix constituent. For further information on the hydrostatic strengthening feature, refer to Appendix A.8 of this document and Section 7 of the Helius:MCT Technical Manual. Note: The Hydrostatic Strengthening feature is only available for unidirectional composite materials. This feature is ignored by woven composites.
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9. TEMPDEPEND (optional, for unidirectional composites only) - The ninth argument (0 or 1) is used to specify whether or not to explicitly account for thermal residual stresses in the response of the unidirectional composite material. If the ninth argument is specified as 1, then Helius:MCT computes the ply-level and constituent-level thermal residual stresses that are caused by the postcure cool down from the stress-free temperature (i.e. cure temperature) to ambient temperature. In this case, the stress free temperature is read from the material data file (mdata file) and ambient temperature corresponds to 72.5F, 22.5C or 295.65K. If the ninth argument is specified as 1, ply-level and constituent-level thermal residual stresses will be present in the composite material prior to the application of any external mechanical and/or thermal loads that are imposed during the actual simulation. If the user chooses to explicitly account for thermal residual stresses in the analysis, then the user should verify the material data file (mdata file) actually contains a defined stress free temperature; otherwise, the stress free temperature will default to 0 and the predicted thermal residual stresses will be quite erroneous. If the ninth argument is specified as the default value of 0, then thermal residual stresses are not included in the response of that particular composite material during the simulation. In this case, the stress free temperature of the composite material defaults to Tsf =0 (regardless of the system of units employed), and the temperature change that is used in the constitutive relations [ = C(T)] is simply computed as T = T Tsf = T. Several points should be emphasized here. First, the stress free temperature Tsf defaults to 0 even if the composite material data file (mdata file) explicitly defines a non-zero stress free temperature. Second, regardless of the system of units that are employed by the finite element model, the current temperature T completely defines the temperature change T that is used in the constitutive relations. Third, for composite materials that are characterized at multiple temperatures, the current temperature T will be used to interpolate the various material properties that contribute to the constitutive relations; consequently, it is recommended that a singletemperature characterization (i.e., a single-temperature mdata file) should be used for the composite material in question. In summary, if the user does not request this option, then the current temperature T influences the constitutive relations in two different ways: 1) the temperature change used in the constitutive relations simply becomes T=T, and 2) T is used to interpolate the temperature-dependent material properties that contribute to the constitutive relations. It should be emphasized that the default reference temperature in Ansys is 0. This default temperature is completely compatible with the default stress free temperature of 0 that is assumed when the ninth argument is specified as 0. In this case, the model can still be subjected to temperature changes by simply imposing a temperature other than 0; however, these thermal stresses develop over the course of the analysis, as opposed to being present at the start of the analysis. ARGUMENTS 10-13 ARE NOT USED AND SHOULD BE SET TO 0.
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14. MDEG (optional, for unidirectional composites only) The fourteenth user material constant is a fraction that is used to define the damaged elastic moduli of the matrix constituent after matrix constituent failure occurs. Specifically, the Matrix Post-Failure Stiffness is part of value is the ratio of the failed matrix constituent progressive failure analysis and is not available moduli to the unfailed matrix constituent in Helius:MCT Linear, its default value is zero. moduli. A value of 0.1 would specify that after a matrix failure occurs at an integration point, all six of the matrix constituent moduli (Em11, Em22, Em33, Gm12, Gm13, Gm23) are reduced to 10% of the original undamaged matrix constituent moduli. The matrix post-failure stiffness value must be greater than 0, and less than or equal to 1. In the event that the fourteenth user material constant is not specified, the default value of 0.10 is assumed. For more information on the matrix postfailure stiffness, please refer to Appendix A.9 of this documentation. Note: If the Post-Failure Nonlinearity feature is turned on, then the fourteenth user material constant will be ignored since the matrix post-failure stiffness is determined by the Post-Failure Nonlinearity feature. Note: The matrix post-failure stiffness (fourteenth user material constant) can only be specified for unidirectional composites; the fourteenth user material constant is ignored by woven composites. 15. FDEG (optional, for unidirectional composites only) The fifteenth user material constant is a fraction that is used to define the damaged elastic moduli of the fiber constituent after fiber constituent failure occurs. Specifically, the value is the ratio of the failed fiber Fiber Post-Failure Stiffness is part of progressive failure analysis and is not available in Helius:MCT Linear, its constituent moduli to the unfailed fiber default value is zero. constituent moduli. A value of 0.01 would specify that after a fiber failure occurs at an integration point, all six of the fiber constituent moduli (Ef11, Ef22, Ef33, Gf12, Gf13, Gf23) are reduced to 1% of the original undamaged fiber constituent moduli. The fiber post-failure stiffness value must be greater than 0, and less than or equal to 1. In the event that the fifteenth user material constant is not specified, the default value of 0.01 is assumed. For more information on the fiber post-failure stiffness, please refer to Appendix A.10 of this User's Guide. Note: The fiber post-failure stiffness (fifteenth user material constant) can only be specified for unidirectional composites; the fifteenth user material constant is ignored by woven composites. The last three user material constants (i.e., the 16th, 17th and 18th constants) are only required if the finite element model is defined using a custom system of units. If using a custom set of units, please refer to Appendix A.3 for formatting details. Ansys 11 Note: A longitudinal elastic modulus (EX) must be defined for each Helius:MCT material. Ansys simply uses this parameter as a place holder and its value has no effect on the analysis. This is only required for Ansys 11 and is not required for Ansys 12 and later. In order to specify EX, add the following line after each HELIUSMCT command: MP,EX,matID,value
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Where matID is the ANSYS material ID that corresponds to the Helius:MCT material and value is the value of EX for that material. Again, the particular value of EX does not influence the results. 4.2 Modeling Issues for Imposing Temperature Changes
The composite materials that are stored in the Helius:MCT Composite Material Database are defaulted to have a stress-free temperature of zero in the system of units that is specified by the value of the 3rd argument unless it is specified by the 9th argument that the stress-free temperature stored in the material file should be used. Any initial temperature specified via the TREF command (including the default value of 0) will be used to calculate the residual stresses present in each of the constituents and the composite due to the unmatched coefficients of thermal expansion between the fiber and matrix. For details on how the temperature changes imposed in a model affect how Helius:MCT calculates residual stresses, please refer to Section 10 in the Helius Theory Manual. 4.3 Nonlinear Solution Control Parameters for Helius:MCT
It is a widely accepted notion that good convergence (or any convergence at all) is difficult to achieve in a progressive failure simulation of a composite structure. In fact, many progressive failure simulations terminate early, not due to global structural failure, but simply due to the inability of the finite element code to obtain a Nonlinear Solution Control Parameters are not used in converged solution at a particular load step. In light of this Helius:MCT Linear. problem, one of the major advantages of Helius:MCT is that it has been optimized to significantly improve the overall convergence rate and robustness of finite element simulations of progressive failure of composite structures. However, in order to take full advantage of the superior convergence characteristics of Helius:MCT, the user must change some of the default settings that govern the nonlinear solution process used by Ansys. These changes can be enacted using the NROPT, PRED, NSUBST, CNVTOL, and NEQIT commands. Regardless whether the SOLCONTROL command is ON (default) or OFF, the user will need to override these nonlinear solution control parameters. NROPT The NROPT command is used to do two things: a) instruct Ansys to use the Full Newton Raphson algorithm, and b) prevent Ansys from using their Adaptive Descent algorithm to help the solution process. An example of the NROPT command fulfilling these two requirements is shown below. NROPT, FULL, , OFF In Ansys, the nonlinear solution process is based on the fundamental assumption of the NewtonRaphson algorithm that the nonlinear response of the composite structure is sufficiently smooth at both the global and local levels. However, in a progressive failure simulation of a composite structure, the nonlinear response of the composite structure is not smooth, especially at the local level where material failure results in an instantaneous reduction of material moduli. This nonsmooth material response is one of the primary factors responsible for the difficulty in obtaining convergence in progressive failure simulations. Helius:MCTs method of managing material nonlinearity is specifically designed to handle this localized non-smooth material response; however, the default settings of Ansyss nonlinear solution control parameters must be changed in
order to allow Helius:MCT to improve the convergence characteristics of the finite element simulation. PRED The PRED command prevents Ansys from using the converged solution at the last substep to estimate the solution for the current substep. This interferes with Helius:MCTs method of managing material linearity. An example of the PRED command that fulfills this is shown below. PRED, OFF, , OFF NSUBST The NSUBST command specifies the minimum and maximum allowable number of substeps for the current load step. Firehole Composites does not recommend any minimum or maximum values and engineering judgment should be exercised. However, provided that enough equilibrium iterations are allowed per substep (discussed under NEQIT heading), Helius:MCT will always find a converged solution. This is a deviation from typical nonlinear solution processes where multiple substep size cutbacks may be required. Helius:MCT will converge at each substep, regardless of the size (again provided that enough equilibrium iterations are allowed per substep), so care must be taken when deciding on substep size. CNVTOL The CNVTOL command is used to define the convergence tolerance for residual node forces. There are two arguments set in this command that allow Helius:MCT to better handle the nonlinear solution process: a) set forces (F) as the convergence label, and b) set the norm selection to infinite norm (check each DOF separately). An example of the CNVTOL command that fulfills these two items is shown below. CNVTOL, F, , , 0 NEQIT The NEQIT command is used to specify the minimum number of equilibrium iterations that must be performed before Ansys evaluates the need for cutting-back the size of the current substep. Helius:MCT has the unique ability to converge regardless of the substep size or extent of nonlinearity occurring during the substep. In the experience of Firehole Composites, convergence always occurs when the number of equilibrium iterations allowed per substep before a substep cutback occurs is set to 1000. An example of what this command looks like is shown below. NEQIT, 1000
4.4
Requesting Output of the MCT State Variables
The solution-dependant Helius:MCT state variables are used to track constitutive quantities of interest at each integration point in the finite element model. The number of solution-dependent Helius:MCT state variables is defined via the second argument of the HELIUSMCT command in the input file (see Section 4.1). The default naming convention for the solution-dependant MCT state
variables is SVARi, where i=1,2,3,,6 or 34 (or 90). The most useful of the MCT state variables is SVAR1, which is used to track the discrete failure state of the composite material at each integration point in the finite element model. The exact interpretation of the discrete values of SVAR1 will depend upon the exact set of Helius:MCT material nonlinearity features that are used in the analysis. Appendix B provides a complete description of each of the MCT state variables, including tables that define the interpretation of SDV1 for various combinations of material nonlinearity features. Solution-dependant Helius:MCT state variables are used to track the history of certain quantities that are computed in the Helius:MCT user programmable feature. Appendix B describes each of the MCT state variables. These MCT state variables are not written to the database unless explicitly requested in the Ansys input file. Listed below is a method for requesting SVAR output to the results file: OUTRES,SVAR,ALL. This command will write only SVAR to the results file and is useful for limiting the size of the results file. For more information on the OUTRES command, refer to the Ansys documentation. 4.5 Modeling Damage Tolerance
Damage tolerance is the ability of a structure to retain required structural strength or stiffness after it has sustained damaged. When a composite part is damaged, there are numerous failure modes that can exist. These failure modes are constituent-level defects (i.e. fiber and matrix level defects) so it is appropriate to model damage at this level. Helius:MCT is well-suited for modeling damage tolerance because it allows the user to specify constituent-level damage in elements at the start of the analysis. For example, if a plate was impacted by a mass and there is diffuse matrix damage in impacted region, the user can designate a region that represents the damaged region and assign matrix failure to that region prior to the start of the analysis. At the start of the analysis, this region will have an SVAR1 value of 2 (matrix failure) and as the simulation progresses, the region can undergo fiber failure which will result in an SVAR1 value of 3. The initial value of SVAR1 that is assigned to the damaged region is not fixed and can change if either the matrix or fiber failure criterion is satisfied. The initial value of SVAR1 must be an integer value equal to 1, 2, or 3. For unidirectional materials, 1 corresponds to no failure, 2 corresponds to matrix failure, and 3 corresponds to fiber and matrix failure. For woven materials, 1 corresponds to no failure, 2 corresponds to matrix failure in all tows and the matrix pocket, and 3 corresponds to fiber failure in all tows plus matrix failure in all tows and the matrix pocket. The Ansys commands listed below are used to activate damage tolerance: HELIUSMCT, TB, STATE, < MATID >, , < NSTATV > TBDATA, 1, < initial value of SVAR1 (2 or 3) > Note: The TB and TBDATA commands required to specify that a material is using degraded material properties must immediately follow the HELIUSMCT command that defines the undamaged material. Note: The MATID and NSTATV arguments in the TB command above must exactly match the MATID and NSTATV arguments supplied during the HELIUSMCT command (see section 4.1).
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Examining Helius:MCT Results with Ansys Mechanical APDL

This section mainly deals with progressive failure, which is not available in Helius:MCT Linear. Helius:MCT Linear users may however find the portion on the selection of section points helpful.
This section discusses the use of Ansys to examine the finite element results that are generated by Helius:MCT. It is assumed that the reader is familiar with using Ansys to view finite element results and perform any necessary post-processing of finite element results. Therefore this section focuses on issues that are unique to the processes of examining and interpreting the progressive failure results generated by Helius:MCT. This section is divided into two parts. The first part focuses on the generation of contour plots for the MCT state variables. The second part deals with the issue of correlating damage distribution with overall changes in structural stiffness, including the detection of global structural failure. 5.1 Using contour plots to view the MCT state variables
The MCT state variables (SVARs) are element output variables stored at each integration point within each element; consequently, the same methods are used to view the MCT state variables as the familiar stress and strain variables. However, in order to view any of the MCT state variables in Ansys, the Ansys input file must first request that they be written to the Ansys results file (see Sections 3.4 and 4.5). For a complete description of each of the MCT state variables, refer to Appendix B. Contour plots are usually the most appropriate means of examining the distribution of the MCT state variables. To generate a contour plot of the MCT state variables within Ansys, first open the results file by clicking Main Menu General Postproc Data & File Opts and selecting the results file. Data from a set must be read, which is accomplished via the SET command or by clicking Main Menu General Postproc Read Results. To view the MCT state variables that are computed by Helius:MCT, use the PLESOL or PLNSOL commands. As an example, to create a contour plot of state variable 1, enter PLESOL,SVAR,1 into the command prompt. The number of SVARs that are available to plot depends entirely on the number of SVARs requested for output by the Ansys input file. Note, that in order to view SVARs greater than 11, power graphics must be turned off by issuing the /GRAPHICS, FULL command. The fundamental MCT state variable is SVAR1 which indicates the discrete damage state of the composite material. SVAR1 is an integer variable. The range of integer values that can be assumed by SVAR1 depends entirely upon the specific set of material nonlinearity features that were used by Helius:MCT during the finite element solution (see Appendix B). As a specific example, Appendix B states that if Helius:MCT is used with its progressive failure feature activated and its pre-failure and postfailure nonlinearity features de-activated, then SVAR1 can only assume the integer values 1, 2, or 3 as shown in the table below.
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Progressive Failure Analysis (activated) Pre-Failure Nonlinearity (de-activated) Post-Failure Nonlinearity (de-activated)
Range of Integer Values for SVAR1 1 2 3
Discrete Composite Damage State No Failure or Degradation Matrix Failure only Matrix & Fiber Failure
Because SVAR1 is an integer variable that can only assume a finite number of values (e.g., 1,2,3), it is important for the user to change the settings of Ansys so that a unique color contour is associated with each integer value of SVAR1. In the case where SVAR1 can assume values of 1, 2, or 3, the user should set the number of color contours to 3. The number of contour intervals used in a contour plot can be specified from the Non-uniform Contours dialog box, which is accessed by clicking Utility Menu PlotCtrls Style Contours Non-uniform Contours. The Non-uniform Contours dialog box is shown in Figure 11. In the case where SVAR1 can assume values of 1, 2, or, 3, the user should set V1=1, V2=2, and V3=3 in the dialog box. Alternatively, the /CONTOUR command may be used to specify the number of contours and range of contour values.
Figure 11: Non-uniform Contours dialog box.
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Figure 12 shows two different 3-color contour plots of the integer variable SVAR1 for an axially loaded composite plate with a central hole. In Figure 12, the use of three discrete colors makes it easy to identify the regions where each of the three discrete composite damage states occur. The blue elements (SVAR1=1) are completely undamaged; the green elements (SVAR1=2) have failed matrix constituents and undamaged fibers; the red elements (SVAR1=3) have failed matrix constituents and failed fiber constituents. Note that the PLNSOL contour plot shows contours that are continuous across element boundaries, while the PLESOL contour plot shows contours that are discontinuous at element boundaries. In other words, a PLNSOL plot will average values across element boundaries, while a PLESOL plot simply uses the values of SVAR1 at the individual integration points to establish the color contours independent of the element boundaries.
Figure 12: Comparison of a PLNSOL contour plot and a PLESOL contour plot using three discrete color contours to represent distribution of SVAR1=1,2,3
The remaining MCT state variables (SVAR2, SVAR3, SVAR4,,SVAR34 or 90) are continuous real variables. Therefore, in generating contour plots of these variables, it is not critical to manage the number of color contours. Furthermore, the standard practices used in viewing stress and strain distributions are also appropriate for viewing SVAR2, SVAR3, SVAR4,, etc.. In order to view SVARs greater than 11, power graphics must be turned off using the /GRAPHICS, FULL command.
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Selection of Section Points When viewing finite element solution results for laminated composite structures, the user must be acutely aware of the numbering of the section points through the thickness of multilayer elements. A contour plot will only use the values of the variable stored at a particular section point. To view a contour plot of a particular layer in Ansys, use the LAYER command. The default in Ansys is to display results from the bottom section point of the bottom layer and the top section point of the top layer. To choose a specific section point within a layer of a shell element, use the SHELL command. As an alternative to using the command prompt, the LAYER and SHELL commands can be accessed from the Options for Output dialog box (shown in Figure 13) by clicking Main Menu General Postproc Options for Outp.
Figure 13: Options for Output dialog box As an example of the above discussion consider
Figure 14 which shows PLESOL contour plots of SVAR1=1,2,3 at several points in time during a progressive failure analysis. The composite plate has eight material plies and is loaded in tension. For simplicity, only the third ply of the laminate is shown. In these plots, the color blue represents integration points that have no failure, the color green represents integration points that have matrix failure, and the color red is used to represent integration points that have fiber failure.
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Figure 14: PLESOL contour plots of SVAR1 at several different points in time during a progressive failure analysis
Several important observations can be made regarding the sequence of contour plots shown in Figure 14: At time = 0.4, every element is blue, which means that no points in ply 3 have experienced any type of failure. At time = 0.5 there are elements at the edges of the hole that are partly, or fully green, indicating matrix failure.
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Comparing the plots at times 0.5 and 0.7 indicates the progression of matrix constituent failure as the load increases. At time = 0.8, the matrix failure has spread further, and there are several elements with fiber failure at one or more integration points, as indicated by the red coloring. At time = 0.9, there is significant matrix failure, and the fiber failure has spread out towards the plate edges. At time = 1.0, there is additional fiber failure.
5.2
Detection of global structural failure
In Section 5.1, we used color contour plots to examine the distribution of the discrete composite failure state (SVAR1) within a composite structure. In viewing these contour plots, it is easily appreciated that each of the damaged regions represents material whose stiffness has been significantly degraded. Furthermore, by examining the changes that occur in these contour plots over time, we can see clearly see the cascade of localized material failure that occurs during a progressive failure analysis. However, viewing the distribution of material failure does not provide any indication of the overall impact of the material failure on the global stiffness of the structure. Moreover, it is impossible to detect global structural failure by simply examining the distribution of material failure over the structure. In order to detect global structural failure or to associate a particular distribution of damage with a decrease in overall structural stiffness, we must first examine the relationship between global structural force and global structural deformation. This type of relationship is best examined using a simple 2-D plot of force vs. deformation; however, the key issue is to select an appropriate measure of global structural force and an appropriate measure of global structural deformation. As an example, let us consider an 8-ply composite plate shown in Figure 15. Note that this is the same composite plate problem examined earlier. As seen earlier in Figure 14, the distribution of damage within layer 3 of the composite plate is shown at several different points in time over the course of the analysis. However, simply viewing the contour plots shown in Figure 14 does not provide us with an understanding of how each of the damage distributions affects the global structural stiffness of the composite plate. To understand the degradation of global structural stiffness as localized failures spread throughout the composite plate, let us examine a simple 2-D plot of global structural force vs. global structural deformation. Since this composite plate is subjected to a uniform axial displacement that is imposed along the top edge of the plate, the imposed axial displacement will serve as an appropriate measure of the overall structural deformation in the plate. Similarly, the total axial reaction force along the top edge of the plate will serve as an appropriate measure of global structural force in the plate. This total reaction force is obtained by summing the nodal reaction forces for all of the nodes on the top edge of the plate (see Figure 16). Figure 17 shows a plot of global structural force vs. global structural deformation for the composite plate.
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Figure 15: 8-ply composite plate under imposed axial displacement
Figure 16: The global structural force is obtained by summing the vertical reaction forces at all nodes along the top edge of the composite plate
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18000 16000 14000 12000 Force 10000 8000 6000 4000 2000 0 0 0.02
Major failure event
0.04
0.06 Displacement
0.08
0.1
0.12
Figure 17: Global structural force vs. global structural deformation
Beginning at an imposed displacement of 0.0912, the overall secant stiffness of the structure starts to deteriorate rapidly. Beyond this point, as the imposed axial displacement is further increased, the structure is unable to resist with additional structural force. Examination of Figure 17 reveals that the global force/displacement response of the composite structure appears to remain linear until the imposed displacement reaches a value of approximately 0.0912. If we examine Figure 14, we see that by the time the imposed axial displacement has reached the value of 0.084, the composite plate has accumulated a significant amount of matrix constituent failure along the vertical edges of the circular hole. However, this amount of matrix constituent failure is insufficient to make a visually detectable impact on the global stiffness of the composite plate. As the imposed displacement is increased from 0.084 to approximately 0.096, the global stiffness of the composite plate undergoes a drastic reduction in Figure 17 indicting a significant cascading of localized fiber constituent failures (i.e., a major failure event has occurred). In examining Figure 14, we see that at an imposed displacement of 0.096, the composite plate has experienced a significant amount of fiber constituent failure along the vertical edges of the circular hole. As the imposed displacement is increased beyond 0.096, the composite plate no longer responds to increasing displacement with increasing structural force. Instead, the overall structural force in the composite plate remains relatively constant, indicating that the spread of localized failures is too rapid to build any additional structural force. However, as seen by the two dotted lines in Figure 17, the overall secant stiffness of the composite plate continues to decrease despite the fact that the overall structural force remains relatively constant. There are many possible ways to define global structural failure. The exact point that signals global structural failure depends upon the intended use of the composite plate. The point that should be
emphasized here is that the detection of global structural failure requires an examination of the global structural force vs. global structural deformation. In summary, contour plots of the MCT state variables (especially SVAR1) provide the analyst with a clear picture of the extent of localized failures at any particular point in time. In order to correlate any of the damage distributions with decreased overall stiffness of the composite structural, one must examine plots of global structural force vs. global structural deformation. In this way, the analyst can associate observed changes in the global stiffness of the structure with specific damage distributions.
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6 Running ANSYS with Helius:MCT

6.1 Batch Mode Helius:MCT installs a Windows batch file which makes it simple to run ANSYS with Helius:MCT using an ANSYS input file from the command line. Note that ANSYS 12.0 requires Helius:MCT to be linked to ANSYS prior to running this batch file. ANSYS 12.1 and ANSYS 13.0 do not require this step. See the Helius:MCT Installation Guide for more information on linking Helius:MCT to ANSYS. This file is located at %FIREHOLEDIR%\ansys-mct.bat and can be modified using a text editor to meet the user's specific needs. To run this file follow these steps (see Figure 18 for an example): 1. 2. 3. 4. Save the ANSYS input file with a .ans extension Open a command prompt Change the directory to the directory which holds the file saved in step 1 Run the job using the following command %FIREHOLEDIR%\ansys-mct.bat VERSION FILE where VERSION is one of 120, 121, or 130 depending on the target ANSYS version and FILE is the name of the input file saved in step 1 (do not include the .ans extension)
Figure 18. Helius:MCT for ANSYS example batch run
6.2
GUI Mode
Helius:MCT installs with a launcher utility which makes it simple to run the ANSYS Classic graphical user interface (GUI) with access to Helius:MCT. Note that ANSYS 12.0 and 12.1 require Helius:MCT to be linked to ANSYS prior to running this launcher application. ANSYS 13.0 does not require this step. See the Helius:MCT Installation Guide for more information on linking Helius:MCT to ANSYS. To run the launcher select the "HeliusMCT for ANSYS Launcher" shortcut installed to the "Firehole Composites" folder under the Start Menu Programs list. Or the application can be opened directly by opening a Windows explorer ( + e) and browse to the Firehole installation directory
(%FIREHOLEDIR%). This is C:\Firehole by default. Then, double click the ansys-mct-launcher.exe file (see Figure 19 for an example).
Figure 19. Example of opening the Helius:MCT for ANSYS Launcher
This will search for installed versions of ANSYS via the ANSYS environment variables: ANSYS 12.0 - %ANSYS120_DIR% ANSYS 12.1 - %ANSYS121_DIR% ANSYS 13.0 - %ANSYS130_DIR%
If these variables are not set the launcher application will not run. Once the launcher finds the installed versions of ANSYS it opens a small window which allows the user to select their target version of ANSYS as depicted in Figure 20.
Figure 20. Helius:MCT for ANSYS Launcher
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The user then selects their target version of ANSYS and clicks OK. This will start up the default ANSYS Product Launcher with the appropriate environment variables set for Helius:MCT to work correctly. ANSYS 13.0 users can then continue to use the ANSYS Product Launcher as normal. ANSYS 12.0 and 12.1 users must select the custom ANSYS executable that is linked to Helius:MCT. See the Helius:MCT Installation Guide for more information on the linking step. This is done under the Customization/Preferences tab as shown in Figure 21.
Figure 21. Example of selecting the custom ANSYS executable in the ANSYS Product Launcher
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Appendix A
HELIUSMCT Command Arguments
A set of arguments are required as part of the HELIUSMCT command. The Helius:MCT user programmable feature uses these arguments to determine the precise form of multiscale constitutive relations that should be used for that particular composite Arguments 5-9 and 14-15 are not used material. For any given Helius:MCT material, the number of in Helius:MCT Linear, their default arguments must either be 15 or 18. The first fifteen values are zero. arguments are required for all Helius:MCT materials; the last th th th three arguments (i.e., the 16 , 17 , and 18 constants) are only required if the finite element model is defined using a custom system of units (see Appendix A.3). Table A1 provides a short description of the constitutive modeling issue that is controlled by each of the 18 possible arguments along with the allowable range of values for each constant. A detailed description of the arguments is found in A.1 through A.10.
Table A1. HELIUSMCT command arguments
Argument 1 2
Constitutive Issue Controlled by the User Material Constant Material Reference Number Number of State Variables (SVARs)
Allowable Values Integer greater than zero Unidirectional ~ 6 or 34 Woven ~ 6 or 90 1 N/m/K 2 N/mm/K 3 Lb/in/R 6 Lb/in/R 7 Custom Unidirectional: 1 (1 = fiber, 2/3 = plane of transverse isotropy) 2 (2 = fiber, 1/3 = plane of transverse isotropy Woven:
Notes
System of Units
1 is default
Principal Material Coordinate System
1 is default 1 (1 = fill tow, 2 = warp tow, 3 = out of plane) 2 (2=fill tow, 1=warp tow, 3=out of plane) 3 (3 = fill tow, 2 = warp tow, 1 = out of plane) 0 (off), 1 (on) 0 (off), 1 (on)
5 6
Progressive Failure Analysis Pre-Failure Nonlinearity
0 is default
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For unidirectional composites only. Must have Progressive Failure Analysis activated 0 is default For unidirectional composites only. Must have Progressive Failure Analysis activated 0 is default For unidirectional composites only. Must have Progressive Failure Analysis activated 0 is default For unidirectional composites only.
Post-Failure Nonlinearity
0 (off), 1 (on)
Hydrostatic Strengthening
0 (off), 1 (on)
9 10 11 12 13 14
Stress Free Temperature (Thermal Residual Stress) Not used Not used Not used Not used Matrix Post Failure Stiffness
0 (0) 1 (temperature read from material file) 0 or blank 0 or blank 0 or blank 0 or blank
0.2 (10%) is default 0 < value 1 For unidirectional composites only. 0.02 (1%) is default For unidirectional composites only.
15
Fiber Post Failure Stiffness Force Conversion for Custom Units Length Conversion for Custom Units Temperature Difference Conversion for Custom Units
0 < value 1 Must be greater than zero Must be greater than zero Must be greater than zero
16 17 18
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Appendix A.1
Argument #1:
Material Reference Number
Ansys requires all material property definitions to have a material reference number assigned to it. This number is used to associate a particular material with the finite elements representing that material. A material reference number must be a positive integer (non-zero). The Helius:MCT GUI can be used to view each material and its corresponding material reference number (MATID). When Helius:MCT is installed for Ansys, a HeliusMCT_MatDB.xml file is created in the < Helius Root Directory > \ Materials folder (by default this is defined as C:\Firehole\Materials). The purpose of this file is to link the material reference number (MATID) with the name of a material stored in the < Helius Root Directory > \ Materials folder. The material reference numbers for the composite materials that come with the Helius:MCT install are already included in this file. If a new material file is created using the Helius Material Manager, the HeliusMCT_MatDB.xml file is automatically updated to include the new material and is assigned a material ID number. However, if the material files are manually copied and edited, the HeliusMCT_MatDB.xml file must be updated to include the new link between the material reference number (MATID) and the name of the newly created composite material. If the HeliusMCT_MatDM.xml file is opened using a text editor or internet browser, the contents will look similar to the following (if opened with a text editor): <?xml version="1.0"?> <HeliusMCT_MatDB> <Material id="9001" name="AS4-3501-6"/> <Material id="9002" name="AS4_3502"/> <Material id="9003" name="AS4_8552"/> <Material id="9004" name="AS_Epoxy1"/> <Material id="9005" name="Eglass21xK43Gevetex-LY556"/> <Material id="9006" name="HTS150_TC250"/> <Material id="9007" name="IM7-977-2"/> <Material id="9008" name="IM7_5250-4"/> <Material id="9009" name="IM7_8551"/> <Material id="9010" name="IM7_8552"/> <Material id="9011" name="IM7_977-3"/> <Material id="9012" name="S2_Glass_Epoxy2"/> <Material id="9013" name="SilEglass1200tex-MY750"/> <Material id="9014" name="T300-BSL914C"/> <Material id="9015" name="T300_976"/> <Material id="9016" name="T300_PR319"/> <Material id="9017" name="T800H_3900-2"/> </HeliusMCT_MatDB> To add a link between a newly created material file and an Ansys material reference number (MATID), copy the format of the existing file to add an additional line that links the two items. For example, if the newly created material file was saved as example_composite_material, the file would be modified as: <?xml version="1.0"?> <HeliusMCT_MatDB> <Material id="9001" name="AS4-3501-6"/> <Material id="9002" name="AS4_3502"/>
<Material id="9003" name="AS4_8552"/> <Material id="9004" name="AS_Epoxy1"/> <Material id="9005" name="Eglass21xK43Gevetex-LY556"/> <Material id="9006" name="HTS150_TC250"/> <Material id="9007" name="IM7-977-2"/> <Material id="9008" name="IM7_5250-4"/> <Material id="9009" name="IM7_8551"/> <Material id="9010" name="IM7_8552"/> <Material id="9011" name="IM7_977-3"/> <Material id="9012" name="S2_Glass_Epoxy2"/> <Material id="9013" name="SilEglass1200tex-MY750"/> <Material id="9014" name="T300-BSL914C"/> <Material id="9015" name="T300_976"/> <Material id="9016" name="T300_PR319"/> <Material id="9017" name="T800H_3900-2"/> <Material id="9018" name="example_composite_material"/> </HeliusMCT_MatDB> The value 9018 would be used as the first argument in the HELIUSMCT command and tells Helius:MCT to use the material example_composite_material.
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Appendix A.2
Argument #2:
Number of State Variables (SVARS)
The number of solution-dependent MCT state variables is dependent upon whether or not the user desires access to constituent average stresses and strains. Allowable values for this argument are 6 and 34 for unidirectional materials and 6 or 90 for woven materials. 6 state variables should be requested unless the user desires post-processing access to the constituent average stresses and strains, in that case 34 (or 90) MCT state variables should be requested. A detailed description of all 34 (or 90) MCT state variables is available in Appendix B.
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Appendix A.3
Argument #3:
System of Units
All numerical quantities in a finite element method input file must be expressed in a consistent set of units. For example, if the geometry of the model is specified in centimeters and the force is specified in Newtons, then the material moduli must be expressed in units of N/cm2. All material properties in the Helius:MCT composite material database are stored using the N,m,K system of units (i.e., force is expressed in Newtons; length is expressed in meters, and temperature is expressed in degrees Kelvin). Therefore, if a model is built using a different system of units, then the user must identify the appropriate system of units that Helius:MCT should use in providing constitutive information to the Ansys finite element code. Helius:MCT has pre-programmed conversion factors that can be used to express constitutive information in several commonly used systems of units. In addition, Helius:MCT has the capability to provide constitutive information in a user-defined (or custom) system of units. The system of units that will be used by the Helius:MCT user programmable feature is defined by the third argument listed as part of the HELIUSMCT command. Table A2 shows the allowable range of integer values for the third argument and lists the system of units specified by each value.
Table A2. Systems of Units Specified by Argument #3
Argument #3 1 2 3 4 5
System of Units N, m, K N, mm, K lb, in, R lb, ft, R Custom
If the third argument is assigned a value of 1, 2, 3, or 4, then Helius:MCT will automatically perform the appropriate unit conversions and provide the constitutive relations in the system of units shown in Table A2. However, if the model is defined using a system of units that is not represented in Table A2, then the user must set the value of the third argument to 5, indicating that a 'custom' system of units will be used. In this case, the user must specify the three conversion factors that are needed by Helius:MCT to convert from the default units of Newtons, meters, and degrees Kelvin to the custom system of units. These three conversion factors for force, length and temperature will be listed as the 16th, 17th, and 18th arguments respectively in HELIUSMCT command. Note that the 16th, 17th, and 18th arguments are required only if the value of the 3rd argument is 5; otherwise, only 15 arguments are required. As an example of a custom system of units, lets say that a finite element model is created using units of kiloNewtons, centimeters, and degrees Fahrenheit. Since this particular system of units is not included in Table A2, it will be considered a custom system of units. Consequently the third argument for any Helius:MCT materials should be assigned a value of 5. Now we must compute the conversion factors for force, length, and temperature that will be listed as the 16th, 17th, and 18th arguments respectively. The force conversion factor that is required to convert from the default units of Newtons, to the desired units of kiloNewtons is computed as
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Fconv =
kN 1kN . = 0.001 N 1000 N
The length conversion factor that is required to convert from the default units of meters, to the desired units of centimeters is computed as
Lconv =
100cm cm . = 100 1m m
The conversion factor for temperature changes (T) that is required to convert temperature change from the default units of K to the desired units of F is computed as Tconv =
9 / 5 F F . = 1.8 1 K K
The 16th, 17th, and 18th arguments should be assigned values of 0.001, 100, and 1.8 respectively. In this case, the HELIUSMCT command would have 18 arguments as shown below. The third argument (value=5) indicates that a custom system of units will be used. The 16th, 17th, and 18th arguments specify the factors needed to convert from the default units of Newtons, meters and Kelvin to the desired units of kiloNewtons, centimeters, and degrees Fahrenheit respectively. An example of the HELIUSMCT command is shown below. HELIUSMCT, 9, 6, 5, 1, 1, 0, 0, 0, 0, 0, 0, 0, 0, 0.1, 0.01, 0.001, 100, 1.8 Two additional points should be emphasized regarding the choice of values for the 3rd argument. First, all stress results printed in the Ansys results files will be expressed in the units specified by the user via the third argument. For example, if the third argument has a value of 3 (specifying the pound, inch, R system of units), then Ansys will output all stresses in units of lb/in2 (psi). Second, custom units are not supported by the Helius:MCT GUI and must be specified manually by the user by either defining a Helius:MCT material via the HELIUSMCT command or by directly editing the input file with a text editor (Notepad).
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Appendix A.4
Argument #4: Principal Material Coordinate System
Helius:MCT expresses constitutive relations and computes stress in the principal material coordinate system of the composite material. For unidirectional microstructures, Helius:MCTs default principal material coordinate system is oriented with the 1 direction aligned with the fiber direction, while the 2 and 3 directions lie in the composite materials plane of transverse isotropy. However, in situations where it adds convenience or simplicity to the model creation process, the user may change the orientation of Helius:MCTs principal material coordinate system so that the 2 direction is aligned with the fiber direction, while the 1 and 3 directions lie in the composite materials plane of transverse isotropy. For woven microstructures, Helius:MCTs default principal material coordinate system is oriented with the 1 direction aligned with the fill tow direction, while the 2 direction corresponds to the warp tow direction and the 3 direction corresponds with the out-of-plane direction. However, in situations where it adds convenience or simplicity to the model creation process, the user may change the orientation of the principal material coordinate system so that the 2 direction is aligned with the fill tow direction, while the 1 direction corresponds to the warp tow direction. Additionally, the user may change the orientation of the principal material coordinate system so that the 3 direction is aligned with the fill tow direction while the 2 direction corresponds to the warp tow direction. The fourth argument is used to specify the orientation of the principal material coordinate system that will be used by Helius:MCT. The numerical value (1 or 2 for unidirectional materials and 1, 2, or 3 for woven materials) of the fourth argument specifies which of the principal material coordinate axes will be aligned with the fiber direction (for unidirectional composites) or fill tow direction (for woven composites). The availability of two different alternatives for the orientation of the principal material coordinate system for unidirectional microstructures and three different alternatives for woven microstructures provides the user with more flexibility in specifying the orientation of the material plies within a section definition. The user should be aware that Ansys outputs the composite average state of stress and strain in the coordinate system that is specified by the second user material constant; however, the constituent average states of stress and strain (stored in SVAR7, SVAR8, ..., SVAR90) are always output in Helius:MCT's default principal material coordinate system. As an example, if the second user material constant is specified as 2, all composite average stress and strain states will be output in the local system defined by the user, with the local 2 direction corresponding to either the longitudinal axis of the fibers for unidirectional materials, or the fill axis for woven materials. However, all constituent average stress and strain states will be reported in the default principal coordinate system of the unidirectional or woven composite material. For unidirectional microstructures, Helius:MCTs default principal material coordinate system is oriented with the 1 direction aligned with the fiber direction, while the 2 and 3 directions lie in the composite materials plane of transverse isotropy. For woven microstructures, Helius:MCTs default principal material coordinate system is oriented with the 1 direction aligned with the fill tow direction, while the 2 direction corresponds to the warp tow direction and the 3 direction corresponds with the out-of-plane direction.
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Consider the following HELIUSMCT command that appears in an Ansys input file representing a unidirectional microstructure: HELIUSMCT, 9, 6, 5, 2, 1, 0, 0, 0, 0, 0, 0, 0, 0, 0.1, 0.01 Note that the forth argument is assigned a value of 2. Therefore, this particular material will use a principal material coordinate system where the 2 axis is aligned with the reinforcing fibers, and the 1 and 3 axes lie in the composite materials plane of transverse isotropy.
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Appendix A.5
Argument #5:
Progressive Failure Analysis
Progressive Failure Analysis is not available in Helius:MCT Linear.
The fifth argument is used to activate or deactivate Helius:MCTs progressive failure analysis feature. A value of 1 activates the progressive failure analysis feature, while a value of 0 deactivates the progressive failure analysis feature. If the progressive failure feature is activated, then Helius:MCT will routinely evaluate both the matrix failure criterion and the fiber failure criterion to determine if either constituent material has failed. Each constituent failure criterion is based on the corresponding constituent average stress state. In the event that one or both of the constituents fail, then the stiffness of the failed constituent(s) are appropriately reduced to minimal values. Helius:MCT then calculates the current composite average stiffness based on the current state (failed, or not failed) of each constituent material. The value of the fifth user material constant has different implications depending on the microstructure of the material. Unidirectional Microstructures: A value of 1 activates the progressive failure analysis feature, while a value of 0 deactivates the progressive failure analysis feature. Woven Microstructures: A value of 0 deactivates the progressive failure feature, a value of 1 activates the progressive failure feature and uses the matrix and fiber degradation levels from the material data file to calculate the failed material properties, and a value of 2 activates the progressive failure feature and uses the matrix and fiber degradations levels specified by the fourteenth and fifteenth user material constants to calculate the failed material properties. Selecting a value of 2 for plain weaves will add approximately 45-60 seconds to the preprocessing time per woven material. A value of 1 will not add run-time during pre-processing because the failed material properties (at the matrix and fiber degradation levels specified during material creation in Helius:Material Manager) are already stored in the material file. The progressive failure analysis feature is the foundation component of Helius:MCTs nonlinear multiscale constitutive relations. Other aspects of material nonlinearity can be invoked (via the 6th and 7th arguments) however, these additional forms of nonlinearity cannot be activated unless the progressive failure analysis feature is also activated. The values of SVAR1 differ depending on the microstructure of the underlying composite and additional forms of material nonlinearity invoked. A comprehensive listing of the possible values for SVAR1 is provided in Appendix B. Additionally, a description of each discrete composite damage state is written in the mct (*.mct) file during the preprocessing phase of the analysis. Figure A18 shows a [0/ 45]s unidirectional composite plate that was analyzed using Helius:MCTs progressive failure feature with both pre-failure nonlinearity and post-failure nonlinearity turned off. Figure A18 shows a contour plot of the MCT state variable SVAR1, representing the composite damage state in the 0 plies. The blue areas represent composite material with unfailed constituents (SVAR1=1); the green areas represent composite material with a failed matrix constituent (SVAR1=2), and the red areas represent composite material with matrix and fiber constituents that have failed (SVAR1=3).
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Failure Key No failure Matrix failure Matrix & Fiber Failure
Figure A22: Helius:MCT solution for failure propagation in the 0 plies of a composite laminate loaded in tension
Note: If any of the other forms of material nonlinearity are activated via the 6th and 7th arguments, the damage states can assume fractional values between 1 and 2 for prefail nonlinearity, and between 2 and 3 for postfail nonlinearity. A description of each discrete composite damage state is written in the MCT (*.mct) file during the first time increment of the analysis. For further information on the Helius:MCTs progressive failure analysis feature, refer to Section 4 of the Helius:MCT Technical Manual.
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Appendix A.6
Argument #6: Pre-Failure Nonlinearity
(Unidirectional composites only, not available for woven composites)

Pre-Failure Nonlinearity is not available in Helius:MCT Linear.
The sixth argument activates or deactivates Helius:MCTs pre-failure nonlinearity feature. A value of 1 activates the pre-failure nonlinearity feature, while a value of 0 deactivates the pre-failure nonlinearity feature. The pre-failure nonlinearity feature is intended to account for the nonlinear longitudinal shear (softening) response that is commonly observed in fiber-reinforced composite materials prior to ultimate failure. This additional form of nonlinearity involves imposing a series of three discrete reductions in the m m longitudinal shear stiffness of the matrix constituent material (G12 and G13) which directly results in a corresponding series of three discrete reductions in the longitudinal shear stiffness of the composite c c material (G12 and G13) . Imposition of these three discrete reductions in the longitudinal shear moduli are completed prior to matrix constituent failure, thus providing a longitudinal shear softening effect prior to matrix constituent failure. Figure A23 shows a typical measured longitudinal stress/strain curve for a unidirectional carbon/epoxy lamina. Helius:MCTs pre-failure nonlinearity feature approximates this type of nonlinear longitudinal shear response with a four-segment, piecewise linear representation of the longitudinal shear response. For further information on the pre-failure nonlinearity feature, refer to Section 5 of the Helius:MCT Technical Manual.
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80
Longitudinal Shear Strength

70
Experimental Data Helius:MCT Pre Fail NL Off Helius:MCT Pre Fail NL On
measured data progressive failure without pre-failure nonlinearity
Composite Average Longitudinal Shear Shear Stress (MPa)Stress (MPa)
60
progressive failure with pre-failure nonlinearity

50 Threshold
matrix constituent failure
40
30
20
Interval 1
Interval 2
Interval 3
10
0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8
Composite Average Longitudinal Shear Strain (%)
Shear Strain (%)
Figure A23: Comparison of predicted vs. measured longitudinal shear response for a typical fiber-reinforced composite lamina
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Appendix A.7
Argument #7: Post-Failure Nonlinearity

Post-Failure Nonlinearity is not available in Helius:MCT Linear.
The seventh argument activates or deactivates Helius:MCTs post-failure nonlinearity feature. A value of 1 activates the post-failure nonlinearity feature, while a value of 0 deactivates the post-failure nonlinearity feature. Helius:MCTs post-failure nonlinearity feature is intended to account for the residual load carrying capability of a failed composite lamina that is embedded in a composite laminate. If the post-failure nonlinearity feature is activated, then Helius:MCT will gradually reduce the stiffness of the matrix constituent material after the matrix failure criterion is triggered, instead of instantaneously reducing the matrix stiffness to its minimum value. In this case, the matrix failure criterion simply identifies the initiation of the matrix failure process (or the initiation of matrix cracking). After the matrix failure criterion is triggered, the matrix constituent stiffness is gradually reduced to the minimum value via a series four discrete stiffness reductions that are applied as the strain state continues to increase beyond the level present at matrix failure initiation. In using this feature, the MCT state variable SVAR1 can be used to identify the condition of matrix crack saturation which is useful in determining leakage of a pressurized fluid through a composite laminate. For further information on the post-failure nonlinearity feature, refer to Section 6 of the Helius:MCT Technical Manual.
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Progressive Failure Analysis without Post-failure nonlinearity Progressive Failure Analysis with Post-Failure Nonlinearity Continuous degradation of matrix stiffness
Figure A24: Helius:MCT stress-strain solutions for the central 90 ply within a (0/90/0) laminate under axial tension, showing the effect of including the post-failure nonlinearity feature
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Appendix A.8
Argument #8: Hydrostatic Strengthening
(Unidirectional composites only, not available for woven composites) The eighth argument activates or deactivates Helius:MCTs hydrostatic strengthening feature. A value of 1 activates the hydrostatic strengthening feature, while a value of 0 deactivates the hydrostatic strengthening feature. If the hydrostatic strengthening feature is activated, then Helius:MCT explicitly accounts for the experimentally observed strengthening of the composite in the presence of a hydrostatic compressive stress. If the hydrostatic compressive stress in the matrix constituent exceeds a threshold value, then the strength of both the matrix constituent and the fiber constituent are scaled upwards commensurate with the level of hydrostatic compressive stress level in the matrix constituent. The threshold value of the matrix average hydrostatic compressive stress is an experimentally m* m* determined quantity denoted by kk where kk <0. Provided that the matrix average hydrostatic compressive stress (kk = 11 + 22 + 33) is negative and kk<kk , then the longitudinal shear strength of the matrix constituent is increased to S12 = S11 0.04(kk kk )
m m0 m m0 m m* m m m m m m*
(A5)
where S12 is the new matrix average longitudinal shear strength and S12 is the original matrix average longitudinal shear strength. A hydrostatic strengthening ratio Sratio is computed as Sratio = (S12) /(S12 ) . This ratio is then used to increase all of the coefficients of the matrix and fiber constituent failure criteria via the following equations Ai = Ai Sratio Ai = Ai Sratio
m0 f0 f f0 m m0 m 2 m0 2
i=1,2,3,4,5 i=1,2
(A6a) (A6b)
where Ai and Ai denote the original strength coefficients that appear in the failure criteria for the matrix and fiber constituents respectively.
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Appendix A.9
Argument #9: Residual Stresses from Stress-Free Temperature
(Unidirectional composites only, not available for woven composites) At room temperature, an unloaded laminated composite structure already has non-zero self equilibrating stresses at both the composite ply level and the constituent material level caused by the initial cooling of the structure from its elevated cure temperature to room temperature. At the composite ply level, these thermal residual stresses are caused entirely by differences in the thermal expansion characteristics of adjacent plies. At the constituent material level (fiber/matrix), the thermal residual stresses are caused in part by the previously mentioned ply level thermal residual stresses and in part by differences in the thermal expansion characteristics of the fiber and matrix materials. Helius:MCT can explicitly account for these ply-level and constituent-level thermal residual stresses that exist prior to any externally applied loads or temperature changes. In this case, the thermal residual stresses contribute to the total stress state of the composite material and thus influence the mechanical load level at which the material fails. The ninth argument (0 or 1) serves as a flag to turn this feature on or off. If the ninth argument is specified as 1, then Helius:MCT computes the ply-level and constituentlevel thermal residual stresses that are caused by the post-cure cool down from the stress-free temperature (i.e. cure temperature) to ambient temperature. In this case, the stress free temperature is read from the material data file (mdata file) and ambient temperature corresponds to 72.5F, 22.5C or 295.65K. If the ninth argument is specified as 1, ply-level and constituent-level thermal residual stresses will be present in the composite material prior to the application of any external mechanical and/or thermal loads that are imposed during the actual simulation. If the user chooses to explicitly account for thermal residual stresses in the analysis, then the user should verify the material data file (mdata file) actually contains a defined stress free temperature; otherwise, the stress free temperature will default to 0 and the predicted thermal residual stresses will be quite erroneous. If the ninth argument is specified as the default value of 0, then thermal residual stresses are not included in the response of that particular composite material during the simulation. In this case, the stress free temperature of the composite material defaults to Tsf =0 (regardless of the system of units employed), and the temperature change that is used in the constitutive relations [ = C(T)] is simply computed as T = T Tsf = T. Several points should be emphasized here. First, the stress free temperature Tsf defaults to 0 even if the composite material data file (mdata file) explicitly defines a non-zero stress free temperature. Second, regardless of the system of units that are employed by the finite element model, the current temperature T completely defines the temperature change T that is used in the constitutive relations. Third, for composite materials that are characterized at multiple temperatures, the current temperature T will be used to interpolate the various material properties that contribute to the constitutive relations; consequently, it is recommended that a single-temperature characterization (i.e., a single-temperature mdata file) should be used for the composite material in question. In summary, if the user does not request this option, then the current temperature T influences the constitutive relations in two different ways: 1) the temperature change used in the constitutive relations simply becomes T=T, and 2) T is used to interpolate the temperature-dependent material properties that contribute to the constitutive relations.
It should be emphasized that the default reference temperature in Ansys is 0. This default temperature is completely compatible with the default stress free temperature of 0 that is assumed when the ninth argument is specified as 0. In this case, the model can still be subjected to temperature changes by simply imposing a temperature other than 0; however, these thermal stresses develop over the course of the analysis, as opposed to being present at the start of the analysis. For more information on thermal residual stresses, please refer to Section 10 of the Helius:MCT Theory Manual.
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Appendix A.10
Argument #14: Matrix Post-Failure Stiffness Fraction

Matrix Post-Failure Stiffness is not available in Helius:MCT Linear.
The fourteenth user material constant is a fraction that is used to define the damaged elastic moduli of the matrix constituent after matrix constituent failure occurs. Specifically, the value is the ratio of the failed matrix constituent moduli to the unfailed matrix constituent moduli. A value of 0.10 would specify that after a matrix failure occurs at an integration point, all six of the matrix constituent moduli (Em11, Em22, Em33, Gm12, Gm13, Gm23) are reduced to 10% of the original undamaged matrix constituent moduli. The matrix post-failure stiffness value must be greater than 0.0, and less than or equal to 1.0. In the event that the fourteenth user material constant is not specified, the default value of 0.10 is assumed. Experimental data indicates that 10% is an acceptable value for matrix degradation in a multidirectional composite laminate laminate comprised of unidirectional laminae; 70% is an acceptable degradation for laminates comprised of woven laminae. Note: If the Post-Failure Nonlinearity feature is turned on, then the fourteenth user material constant is ignored since the matrix post-failure stiffness is determined by the Post-Failure Nonlinearity feature. Note: For woven composites, it is recommended that the matrix post-failure stiffness should not be less than 0.7. Note: The matrix post-failure stiffness can only be specified for unidirectional composites; the fourteenth user material constant is ignored by woven composites. The value of the fourteenth user material constant can have a pronounced effect on the postfailure response of a multilayer composite structure since this constant is largely responsible for the rate at which local loads are redistributed after a localized matrix constituent failure occurs.
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Appendix A.11
Argument #15: Fiber Post-Failure Stiffness Fraction

Fiber Post-Failure Stiffness is not available in Helius:MCT Linear.
The fifteenth user material constant is a fraction that is used to define the damaged elastic moduli of the fiber constituent after fiber constituent failure occurs. Specifically, the value is the ratio of the failed fiber constituent moduli to the unfailed fiber constituent moduli. For example, a value of 0.01 would specify that after a fiber failure occurs at a particular integration point, all six of the fiber constituent moduli (Ef11, Ef22, Ef33, Gf12, Gf13, Gf23) are reduced to 1% of the original undamaged fiber constituent moduli at the integration point in question. The fiber post-failure stiffness value must be greater than 0, and less than or equal to 1. In the event that the fifteenth user material constant is not specified, the default value of 0.01 is assumed. Note: The fiber post-failure stiffness (fifteenth user material constant) can only be specified for unidirectional composites; the fifteenth user material constant is ignored by woven composites. Note: In response to a fiber constituent failure, the current implementation of Helius:MCT imposes an isotropic degradation of the fiber properties, i.e., all six fiber constituent moduli are reduced by the same percentage, while the fiber constituent Poisson ratios remain unchanged. The value of the fifteenth user material constant can have a pronounced effect on the predicted progressive failure response of a multilayer composite structure since this constant is largely responsible for the rate at which local loads are redistributed after a localized fiber constituent failure occurs. Consequently, as the value of the fifteenth user material constant is reduced from 1.0 toward 0.0, a local fiber failure is more likely to precipitate a cascade of localized fiber failures. Depending upon the magnitude of the fiber failure cascade, the result may be discernable as a noticeable softening of the overall structural response, or it may cascade without arresting and result in a global structural failure.
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Appendix B
MCT State Variables (SVARs)
This appendix provides a description of all 34 of the solution-dependent MCT state variables used with unidirectional composites and all 90 used with woven composites. These solution-dependent state variables are computed or updated by the Helius:MCT user programmable feature at each integration point within each finite element. Ansys will store the converged values of solution-dependent MCT state variables for each substep using the appropriate Ansys OUTRES command (see Sections 3.3 and 4.4). By default, the naming convention adopted by Ansys for solution-dependent state variables is SVARi, where i=1, 2, 3 # of state variables. In order to view SVARs greater than 11, power graphics must be turned off using the /GRAPHICS, FULL command. The following list describes each of the MCT state variables.
SVAR1 is not utilized in Helius:MCT Linear.
SVAR1: SVAR1 is an integer variable that represents the discrete damage state of the composite material. The range and interpretation of integer values that can be assumed by SVAR1 depend upon the specific set of material nonlinearity features that are used by Helius:MCT in the finite element analysis. The following tables provide the interpretation for each allowable integer value of SVAR1 for each possible combination of material nonlinearity features employed by Helius:MCT.
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Unidirectional Composites
For unidirectional composite materials, state variables SVAR2, SVAR3, ..., SVAR34 have the following interpretations: SVAR2: SVAR2 is a continuous real variable that ranges from 0.0 to 1.0 and is used to indicate the fraction of the matrix failure criterion that that has been satisfied. For example, SVAR2 = 0.0 implies that the matrix stress level is zero, while SVAR2 = 1.0 implies that the matrix stress has reached failure level. Numerically, SVAR2 is computed as SVAR2 = A1 (I1 ) A2 (I2 ) + A3 I3 + A4 I4 A5 I1 I2
m m 2 m m 2 m m m m m m m
which is recognized simply as the left hand side of the matrix failure criterion (see Section 4 of the Helius:MCT Theory Manual). SVAR3: SVAR3 is a continuous real variable that ranges from 0.0 to 1.0 and is used to indicate the fraction of the fiber failure criterion that that has been satisfied. For example, SVAR3 = 0.0 implies that the fiber stress level is zero, while SVAR3 = 1.0 implies that the fiber stress has reached failure level. Numerically, SVAR3 is computed as SVAR3 = A1 (I1
f f
+ A4 I4
which is recognized simply as the left hand side of the fiber failure criterion (see Section 4 of the Helius:MCT Theory Manual). SVAR4: SVAR4 is the fourth term in the matrix failure criterion and is used in the pre-failure nonlinearity feature (see Section 4 of the Helius:MCT Theory Manual). SVAR5: SVAR5 is defined as (SVAR2 SVAR4)/SVAR2 and is used in the post-failure nonlinearity feature to determine if matrix cracking is present. SVAR6: SVAR6 is the composite average effective strain at the moment when the matrix failure criterion is triggered. SVAR7: SVAR7 is not applicable to ANSYS analyses SVAR8: SVAR8 is not applicable to ANSYS analyses SVAR9: SVAR9 is not applicable to ANSYS analyses SVAR10: SVAR10 is not applicable to ANSYS analyses For the case of unidirectional composites, the remaining MCT state variables are used to store the individual components of the matrix average stress and strain states and the fiber average stress and strain states.
Page 71 of 75
SVAR11: 11 SVAR12: 22 SVAR13: 33 SVAR14: 12 SVAR15: 13 SVAR16: 23 SVAR17: 11 SVAR18: 22 SVAR19: 33 SVAR20: 12 SVAR21: 13 SVAR22: 23 SVAR23: 11 SVAR24: 22 SVAR25: 33 SVAR26: 12 SVAR27: 13 SVAR28: 23 SVAR29: 11 SVAR30: 22 SVAR31: 33 SVAR32: 12 SVAR33: 13 SVAR34: 23
f f f f f f m m m m m m f f f f f f m m m m m
Woven Composites
For woven composite materials, state variables SVAR2, SVAR3, ..., SVAR90 have the following interpretations: SVAR1: See previous description of SVAR1. SVAR2: SVAR2 is a continuous real variable that ranges from 0.0 to 1.0 and is used to indicate the fraction of the matrix failure criterion that that has been satisfied for the matrix constituent within the fill tows. SVAR3: SVAR3 is a continuous real variable that ranges from 0.0 to 1.0 and is used to indicate the fraction of the fiber failure criterion that that has been satisfied for the fiber constituent within the fill tows.
Page 72 of 75
SVAR4: SVAR4 is a continuous real variable that ranges from 0.0 to 1.0 and is used to indicate the fraction of the matrix failure criterion that that has been satisfied for the matrix constituent within the warp tows. SVAR5: SVAR5 is a continuous real variable that ranges from 0.0 to 1.0 and is used to indicate the fraction of the fiber failure criterion that that has been satisfied for the fiber constituent within the warp tows. SVAR6: Not Used For the case of woven composites, the remaining MCT state variables are used to store the individual components of the average stress and strain states in the various superconstituents and constituents (e.g., fill = fill tow superconstituent, warp = warp tow superconstituent, matrix-pocket = matrix constituent of the intertow matrix pockets, fill-matrix = the matrix constituent of the fill tow, warpmatrix = the matrix constituent of the warp tow, fill-fiber = the fiber constituent of the fill tow, warp-fiber = the fiber constituent of the warp tow.) SVAR7: 11 SVAR8: 22 SVAR9: 33
fill fill fill fill fill fill warp warp warp warp warp warp matrix-pocket matrix-pocket matrix-pocket matrix-pocket matrix-pocket matrix-pocket fill-fiber fill-fiber fill-fiber fill-fiber fill-fiber fill-fiber fill-matrix
SVAR10: 12 SVAR11: 13 SVAR12: 23
SVAR13: 11 SVAR14: 22 SVAR15: 33 SVAR16: 12 SVAR17: 13 SVAR18: 23 SVAR19: 11 SVAR20: 22 SVAR21: 33 SVAR22: 12 SVAR23: 13 SVAR24: 23
SVAR25: 11 SVAR26: 22 SVAR27: 33 SVAR28: 12 SVAR29: 13 SVAR30: 23 SVAR31: 11
Page 73 of 75
SVAR32: 22 SVAR33: 33 SVAR34: 12 SVAR35: 13 SVAR36: 23 SVAR37: 11 SVAR38: 22 SVAR40: 12 SVAR41: 13 SVAR42: 23
fill-matrix fill-matrix fill-matrix fill-matrix fill-matrix warp-fiber warp-fiber warp-fiber
SVARV39: 33
warp-fiber warp-fiber warp-fiber warp-matrix warp-matrix warp-matrix warp-matrix warp-matirx warp-matrix
SVAR43: 11 SVAR44: 22 SVAR45: 33 SVAR46: 12 SVAR47: 13 SVAR48: 23 SVAR49: 11 SVAR50: 22 SVAR51: 33 SVAR52: 12 SVAR53: 13 SVAR54: 23 SVAR55: 11 SVAR56: 22 SVAR57: 33 SVAR58: 12 SVAR59: 13 SVAR60: 23 SVAR61: 11 SVAR62: 22 SVAR63: 33 SVAR64: 12 SVAR65: 13 SVAR66: 23
fill fill fill fill fill fill
warp warp warp warp warp warp matrix-pocket matrix-pocket matrix-pocket matrix-pocket matrix-pocket matrix-pocket fill-fiber fill-fiber fill-fiber
SVAR67: 11 SVAR68: 22 SVAR69: 33
Page 74 of 75
SVAR70: 12 SVAR71: 13 SVAR72: 23 SVAR73: 11 SVAR74: 22 SVAR75: 33 SVAR76: 12 SVAR77: 13 SVAR78: 23 SVAR79: 11 SVAR80: 22 SVAR81: 33 SVAR82: 12 SVAR83: 13 SVAR84: 23 SVAR85: 11 SVAR86: 22 SVAR87: 33 SVAR88: 12 SVAR89: 13 SVAR90: 23
fill-fiber fill-fiber fill-fiber fill-matrix fill-matrix fill-matrix fill-matrix fill-matrix fill-matrix warp-fiber warp-fiber warp-fiber warp-fiber warp-fiber warp-fiber warp-matrix warp-matrix warp-matrix warp-matrix warp-matirx warp-matrix
In order to view SVARs greater than 11, power graphics must be turned off using the /GRAPHICS, FULL command.
Page 75 of 75

HeliusMCT Users Guide Ansys

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HeliusMCT Users Guide Ansys

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Users Guide

Helius:MCT Version 4.0 for ANSYS February1, 2011

MCT STATE VARIABLES (SVARS) .............................................................................. 68

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Helius:MCT Interaction with Ansys

Helius:MCT Users Guide - ANSYS

ANSYS Mechanical APDL

Helius:MCT ANSYS Solver

ANSYS results file

Helius:MCT ANSYS Mechanical APDL

Helius:MCT Users Guide - ANSYS

Helius:MCT Support Documentation

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

2 General Requirements for Ansys Input Files

Helius:MCT Users Guide - ANSYS

Requesting Output of Solution Variables that are Unique to Helius:MCT

Helius:MCT Users Guide - ANSYS

Figure 2: Ansys classical GUI at start-up

Figure 3: The Helius:MCT Graphical User Interface (GUI)

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Nonlinear Solution Control Parameters

Figure 7: Access of PRED command via Ansys Mechanical APDL.

Helius:MCT Users Guide - ANSYS

Requesting MCT state variable output

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Table 1: Helius:MCT Command Arguments

Progressive Failure Analysis

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Requesting Output of the MCT State Variables

Helius:MCT Users Guide - ANSYS

Examining Helius:MCT Results with Ansys Mechanical APDL

Helius:MCT Users Guide - ANSYS

Range of Integer Values for SVAR1 1 2 3

Figure 11: Non-uniform Contours dialog box.

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

Detection of global structural failure

Helius:MCT Users Guide - ANSYS

Figure 15: 8-ply composite plate under imposed axial displacement

Helius:MCT Users Guide - ANSYS

Major failure event

Figure 17: Global structural force vs. global structural deformation

Helius:MCT Users Guide - ANSYS

6 Running ANSYS with Helius:MCT

Figure 18. Helius:MCT for ANSYS example batch run

Figure 19. Example of opening the Helius:MCT for ANSYS Launcher

Figure 20. Helius:MCT for ANSYS Launcher

Helius:MCT Users Guide - ANSYS

Helius:MCT Users Guide - ANSYS

HELIUSMCT Command Arguments

Principal Material Coordinate System