Modeling Sandwich Composites in Workbench: Non-Penalty Based Contact?

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SUMMARY

This discussion focuses on modeling honeycomb composite materials in ANSYS Workbench, specifically using orthogonal solid tetrahedral elements for the core and isotropic shell elements for aluminum face sheets. The user reports achieving accurate stress results compared to hand calculations but encounters significant discrepancies in deflection values. They seek guidance on improving their modeling approach, particularly regarding contact issues between the face sheets and core material, and consider using non-penalty based contact methods or coupling elements (CP) for better results.

PREREQUISITES
  • Understanding of ANSYS Workbench for composite material modeling
  • Familiarity with solid tetrahedral and isotropic shell elements
  • Knowledge of honeycomb material properties and stiffness calculations
  • Basic proficiency in APDL (ANSYS Parametric Design Language)
NEXT STEPS
  • Research non-penalty based contact methods in ANSYS Workbench
  • Explore the use of coupling elements (CP) for improved modeling accuracy
  • Study the effects of different material properties on composite deflection
  • Learn advanced APDL techniques for composite modeling
USEFUL FOR

Engineers and analysts involved in composite material design, particularly those using ANSYS Workbench for structural analysis and seeking to optimize their modeling techniques for sandwich composites.

BlkHwkEng
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When I model a honeycomb type composite in workbench I tired modeling the core material as an orthogonal material type using solid tet elements and the aluminum face sheets as isotropic shell elements. I base the core material properties off of the honeycomb manufactures data for stiffness. using this approach I am able to get fairly accurate stress results when compared to hand calculations of the same simple problems (i.e. simple beam with distributed loading) but my deflections are completely wrong. I was hoping someone could give me insight on how to go about modeling sandwich composites in workbench...hopefully without paying another 50k for some type of composites modeler. Also I am getting a little better at APDL so if anyone wants to give advice based upon it I would be all ears.

Also I get tons of penetration between the face sheet and core material, should I use a non-penalty based contact or will this mess things up even more.

I hope this post makes sense...it is very late here and I am about to fall asleep on my keyboard.
 
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Rather than using contact elements, perhaps you could try coupling them (CP)?
 


Way better results doing in like that. Thanks again minger
 

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