1/8 | P a g e MODULAR PROGRAMME- COURSEWORK ASSESSMENT SPECIFICATION Module Details Module Code UFMFWD-30-M Run 15SEP/FR/JUN16/1 Module Title MODELLING AND SIMULATION Module Leader Prof. Yufeng Yao Module Coordinator Yuying Xia Module Tutors Yuying Xia David Fisher Component and Element Number A: CW1 Weighting: (% of the Module's assessment) 30% Element Description COURSEWORK 1 (FEA (composite) coursework) Total Assignment time 30 hours Dates Date Issued to Students 11/10/2016 Date to be Returned to Students Submission Place Blackboard Submission Date 08/12/2016 Submission Time 2.00 pm Deliverables Spread sheet + Report (via blackboard); CD/DVD (Coursework Hub) Module Leader Signature Yuying Xia2/8 | P a g e Task 1- Laminate Analysis 30% A laminate is subjected to three forces and three moments as shown in Figure 1 Figure 1- A laminate subjected to forces and moments Where  Nx = normal force resultant in the x direction (N/m)  Ny = normal force resultant in the y direction (N/m)  Nxy = shear force resultant (N/m)  Mx = Bending moment resultant in the x direction (Nm/m)  My = Bending moment resultant in the y direction (Nm/m)  Mxy = Turning moment resultant (Nm/m) The laminate is made of N plies, where N is variable parameter and N ≤ 20; each ply having a thickness of tk and an angle of θk with the x axis (global coordinate). The material properties of one ply in its principle directions are given in table 1 E1 Longitudinal modulus of elasticity (Pa) E2 Transverse modulus of elasticity (Pa) G12 shear modulus (Pa) ν12 Poisson's ratio ν21 Poisson's ratio α1 Longitudinal Coefficient of thermal expansion ( m/mC) α2 Transverse Coefficient of thermal expansion (m/mC) β1 Longitudinal moisture swelling coefficient (m/m/kg/kg) β2 Transverse moisture swelling coefficient (m/m/kg/kg) The strength of each ply on its principle directions and also the maximum ply's shear strength are given in table 2 Table 2 -Allowable strength S1tensile Pa S1compressive Pa S2tensile Pa3/8 | P a g e S2compressive Pa S(S12 ) Pa This laminate is subjected to forces, moment, change of temperature ΔT and a moisture concentration of Δm. Design an interactive spreadsheets to calculate the 1. Factor of safety of each ply and the whole laminate based on maximum stress criterion 2. Factor of safety of each ply and the whole laminate based on Energy Based Interaction Theory – Tsai-Hill Criterion 3. Factor of safety of each ply and the whole laminate based on Interactive Tensor Polynomial Theory - Tsai-Wu Criterion Deliverables  A spreadsheet for the given task labelled with your name and student number.  Please submit your spreadsheet via Blackboard. Note: You need this spreadsheet for the Task2.4/8 | P a g e Task 2- Design and analysis of a composite pressure vessel 70% Introduction- filament winding Filament winding is used for the manufacture of parts with high fibre volume fractions and controlled fibre orientation. Fibre tows are immersed in a resin bath where they are coated with low or medium molecular weight reactants. The impregnated tows are then literally wound around a mandrel (mould core) in a controlled pattern to form the shape of the part. After winding, the resin is then cured, typically using heat. The mould core may be removed or may be left as an integral component of the part. The filament winding process was originally invented to produce missile casings, nose cones and fuselage structures, but with the passage of time industries other than defence and aerospace have discovered the strength and versatility of filament winding. Examples of products created using the process of filament winding include:  Tubes  Transmission poles  Aircraft fuselages  Gas, water, or tanks  Cement Mixers  Pipes Brief Your task is to design an 8-layers laminate layout (N=8) for a pressure vessel as shown in figure 2. The pressure vessel subjected to three different types of boundary conditions (position of supports) and operates under an internal pressure of 60bar. Your final design must have a factor of safety of 1.2. You are required to use your laminate design spreadsheets and the Abaqus® finite element analysis software package.5/8 | P a g e Figure 2- General layout of a composite pressure vessel subjected to internal pressure The pressure vessel is supported by two concrete supports as shown in figure 2. The concrete supports are assumed to be rigid compared to the pressure vessel. The environmental effects of temperature and moisture may be assumed to be negligible. There are two inlets on each spherical end cap of the pressure vessel and there are two outlets on the top and bottom of cylindrical part as presented in figures 2 and 3. Diameters of inlets and outlets are given to be 60mm. Dimensions of the pressure vessel are given in Figure 3 and Table 36/8 | P a g e Figure 3- All Dimensions in mm Table 3- Dimensions for the outer radius and position of supports First Initial R ( mm) D( mm) A 300 1600 1500 1400 B 320 1600 1500 1400 C 340 1600 1500 1400 D 360 1600 1500 1400 E 380 1600 1500 1400 F 400 1600 1500 1400 G 420 1600 1500 1400 H 440 1600 1500 1400 I 420 1600 1500 1400 J 400 1600 1500 1400 K 380 1600 1500 1400 L 360 1600 1500 1400 M 340 1600 1500 1400 N 320 1600 1500 1400 0 340 1600 1500 1400 P or Q 360 1600 1500 1400 R 380 1600 1500 1400 S 400 1600 1500 1400 T 410 1600 1500 1400 U or V 420 1600 1500 14007/8 | P a g e W 430 1600 1500 1400 X or Y or Z 440 1600 1500 1400 Material properties for the lamina in the principal directions are given in Tables 4 and 5. Table 4- Lamina's properties long. modulus E1 120000 N/mm2 trans. modulus E2 8000 N/mm2 shear modulus G12 6000 N/mm2 Poisson's ratio n12 0.3 - Density 1450 kg/ m3 Longitudinal Coefficient of thermal expansion -4 µ/Cº Transverse Coefficient of thermal expansion 57 µ/Cº Table 5- Lamina's strength Allowable stresses: long. tension Xt = 1800 N/mm2 long. comp. Xc = 1200 N/mm2 trans.tension Yt = 80 N/mm2 trans. comp. Yc = 200 N/mm2 shear S = 150 N/mm2 Procedure 1. Research on filament winding method (to determine the limitation of this method and preferable angles of fibres) 2. Use the theory of pressure vessels (without consideration of the vessel's weight) to determine the applied longitudinal and hoop forces per unit length ( Nx, Ny, Nxy, …) 3. Use your spreadsheet to determine the best layout for the applied forces- using Solver will help you significantly in this section 4. Use your theoretical laminate layout from step 3 to analyse the pressure vessel using Abaqus® 5. Perform a mesh study to determine the optimum size of mesh 6. If your FOS is within limit go to step 7 otherwise change the thickness or angle of fibres to achieve the given FOS8/8 | P a g e 7. Try different given boundary conditions (different values of D) to investigate if your laminate layout is suitable for different dimension of D. 8. Investigation on how to connect tubes to the inlet and outlets and how this effect the strength of the pressure vessel 9. Investigation of the effect on your design with the consideration of the weight of the vessel 10. Investigation of the effect on your design with the consideration of environmental temperature change ΔT=20 Note: You need to document every step of your work. Remember that ONLY your report will be marked. Marking scheme  Research 5%  Theory of pressure vessels and calculations 5%  Use of your spreadsheet 5%  Analysis of the pressure vessel in Abaqus® 20%  Design Iterations 5%  Application of different boundary conditions (different values of D ) 5%  Mesh study 5%  Investigation with consideration the weight of the vessel 10%  Investigation with consideration the temperature change 10% Deliverables  A detail report for task 2 (PDF file) + Abaqus® files (CD/DVD)  Please submit report with PDF version via Blackboard before the deadline.  Report length is maximum 20 pages of A4, minimum font size of 11. Please note the mark will be reduced if the page limit is exceeded.  Please burn all your original Abaqus® files into CD/DVD and submit to Coursework Hub.