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Overview

ESAComp is a software for analysis and design of composites. Its scope ranges from conceptual and preliminary design of layered composite structures to advanced analyses that are applicable for the final verification of a design.

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ESAComp Showcase Video Brief introduction video about the capabilities of Altair ESAComp and its placement in the HyperWorks portfolio.





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ESAComp for Automotive Use Case ESAComp is software for analysis and design of composites. Its scope ranges from conceptual and preliminary design of layered composite structures to advanced analyses that are applicable to the final verification of a design. Read More
ESAComp has a vast set of analysis capabilities for solid/sandwich laminates and for micromechanical analyses. It further includes analysis tools for structural elements: flat and curved panels, stiffened panels, beams and columns, cylinders, bonded and mechanical joints. ESAComp is a stand-alone software tool, but thanks to its ability to interface with widely used finite element software packages ESAComp fits seamlessly into design processes.
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"Today the bi-directional interface between HyperWorks and ESAComp is mature enough to be tasked with RUAG's demanding real cases: set up the finite element model, to run the quasi-static and dynamic load cases and to evaluate the results.”
–Ralf Usinger, Product Lead Engineer Satellite Structures
RUAG Space

Benefits

Explore Possibilities

The combinations of composite material systems and structural concepts are limitless. The ESAComp materials database gives a good basis for trying potential materials for a design. The analysis capabilities of ESAComp enable quick and easy trade-off studies, such as between solid, sandwich or stiffened designs.

Be Efficient

Using the right tool at different phases of a project ensures efficiency. The FEA environment is not ideal for laminate level studies or lay-up design. In the early phases of a project, the structural elements of ESAComp provide fast analysis without a full geometric model.

Avoid Pitfalls

Designing with composites is a challenge. Without careful assessment of the structure, a potential failure mode can be easily missed. ESAComp complements the capabilities of FE tools in doing this. Advanced ESAComp features, such as probabilistic analysis, become very useful when verifying the real performance of the design.

Optimize Your Design

Besides the user environment that allows practical hands-on optimization of designs, ESAComp integrates as part of more complex optimization systems.

Learn About Composites

To help users get started, ESAComp's easy-to-follow documentation includes tutorials and reference materials, along with first-class technical support.

Gallery

ESAComp analysis and optimization capabilities were used in the design of the Biofore Concept Car. ESAComp allows quick modeling of stiffened composite panels for preliminary dimensioning. From concept to final composite structure – the marine industry is among those that utilize ESAComp. Biofore Concept Car applies composites in innovative ways – with some help from ESAComp. ESAComp can optimize the lay-up and geometry of structural elements together with HyperStudy. ESAComp enhances the post-processing capabilities of HyperWorks for composite structures. ESAComp interfaces with HyperWorks for both pre- and post-processing. For the analysis of cylindrical structures, ESAComp can be used with a winding simulation tool.
ESAComp analysis and optimization capabilities were used in the design of the Biofore Concept Car. ESAComp allows quick modeling of stiffened composite panels for preliminary dimensioning. From concept to final composite structure – the marine industry is among those that utilize ESAComp. Biofore Concept Car applies composites in innovative ways – with some help from ESAComp. ESAComp can optimize the lay-up and geometry of structural elements together with HyperStudy. ESAComp enhances the post-processing capabilities of HyperWorks for composite structures. ESAComp interfaces with HyperWorks for both pre- and post-processing. For the analysis of cylindrical structures, ESAComp can be used with a winding simulation tool.
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Capabilities

Data Bank and Multi-level Database

The ESAComp Data Bank includes data for a wide selection of composite materials and material systems. User and company specific material libraries can be stored in the database, as well as data related to design studies. Besides materials, the ESAComp database includes ESAComp objects: fibers/matrix materials, plies, laminates, beams, panels, cylinders, bonded and mechanical joints, loads, and boundary conditions.

Design Environment

ESAComp forms an efficient platform for performing design studies of composite structures. The display of graphical results helps in performing trade-off studies between materials and structural alternatives. Users have almost limitless options for selecting and combining the resulting data and to display it as numeric tables, layer, bar, line, and polar charts, carpet plots, failure envelopes and 3D contour plots.

Comprehensive Documentation

ESAComp documentation not only helps structural engineers familiarize themselves with composite engineering, but also provides extensive theoretical reference documents needed by composites experts.

Analysis Capabilities

See the detailed list below.

SI and British/U.S. Units

Units and output formats can be changed at any time during the session.

Python Scripting

Enabling extension of analysis capabilities with user scripts, execution of batch runs, and integration to user's design workflows.

HyperWorks Integration

Pre-processing

Materials and lay-ups can be transferred to HyperMesh while taking advantage of ESAComp's capabilities, such as multiple strength sets, environment-dependent material data (e.g. temperature or moisture), the practical user interface for lay-up definition, and its laminate design capabilities.

Material and laminate data can be exported in the following solver formats: OptiStruct, Nastran, Abaqus, ANSYS, and LS-DYNA.

Post-processing

FE results, material, and lay-up data of related elements can be transferred to ESAComp for additional failure analysis. Failure analysis includes the application of advanced failure criteria such as Puck or LaRC03, which are often not available in solvers. Reserve factors are computed for all layers as well as on laminate level, covering, for example, wrinkling failure and interlaminar shear. This information can be passed to HyperMesh Desktop for visualization along with information on failure modes and critical layers.

Further, ESAComp offers through-the-thickness plots, which illustrate the stresses, strains or reserve factors (margins of safety and inverse reserve factors, respectively), Loads and laminates can be derived from the imported load case to benefit from ESAComp's whole set of tools for design improvement.

Currently supported solver profiles are OptiStruct and Nastran.

Analysis tools

  • Fiber/matrix micromechanics

    • ply engineering constants and thermal/moisture expansion coefficients based on the mechanics of materials approach, Halpin-Tsai, or user specified micromechanics models
    • ply properties as a function of volume/weight fraction or ply directionality of bi-directional plies

  • Plies

    • analyses for constitutive and thermal/moisture expansion behavior of plies
    • ply carpet plots for (0/90/±θ)s laminates; notched laminate carpet plots

  • Laminates

    • 2.5D behavior - classical lamination theory (CLT) based analyses for constitutive and thermal/moisture expansion behavior of solid and sandwich laminates
    • parameterized "theta-laminates" - orientation of ±θ-layers as a variable
    • parameterized "p-laminates" - proportional amount of selected layers as a variable
    • laminate strength in principal loading conditions
    • load response - laminate and layer level response including out-of-plane shear stresses, effects due to thermal/moisture loads
    • failure

      • first ply failure (FPF) and degraded laminate failure (DLF)
      • several commonly used failure criteria (e.g. max stress/strain, Tsai-Hill, Tsai-Wu, Puck 2D/3D, LaRC03) and a possibility to add user specified criteria
      • interlaminar shear failure
      • core shear failure and face sheet wrinkling of sandwich laminates
      • constant and variable load approach in determining margins of safety
      • prediction of failure modes and critical layers

    • failure and design envelopes

      • FPF and DLF analyses combined with wrinkling
      • stress or strain space, any combination of principal loads
      • layer envelopes of a single laminate, laminate envelopes for multiple laminates and multiple failure criteria, thermal/moisture or mechanical load as parameter

    • laminate thermal conductivity
    • probabilistic 2.5D behavior, strength and load response/failure - Monte Carlo simulation, input as statistical distributions of ply properties and loads, and given layer angle variations
    • sensitivity studies for 2.5D behavior and FPF analyses - tolerances for a ply property or layer orientations
    • notched laminate analysis of circular and elliptic holes - load response, FPF, and stress concentration factors
    • layer drop-off - exterior or embedded drop-off in a solid laminate or a face sheet of a sandwich
    • free edge analysis based on quasi-3D FE analysis
    • laminate through-the-thickness temperature distribution
    • laminate through-the-thickness moisture distribution and moisture content as a function of time
    • laminate through-the-width delamination/debonding - onset of damage propagation and load-deformation path, along with buckling modes

  • Panels

    • flat and curved panels with or without stiffeners
    • Mindlin plate analysis using FEA
    • rectangular plates with any combination of clamped, simply supported, and free edges
    • beam type stiffeners with I, C, Z, or T cross section in x and/or y directions, beam or shell modelling
    • hat (omega) stiffeners (bonded or integral) with shell modelling
    • load response, failure and stability under applied loads (combinations of point loads, line loads, pressure load and edge forces/moments)
    • natural frequencies

  • Cylinders

    • cylinders and tubes with constant diameter or conical shape
    • lay-up may vary in the axial direction
    • beam type stiffeners in the axial and/or circumferential directions with beam modelling
    • boundary conditions and applied forces and moments at the ends of the structure
    • pressure load or inertial loads due to linear acceleration or rotation
    • static load response and failure, buckling and natural frequency analyses based on linear eigenvalue approach

  • Nonlinear panel and cylinder analysis

    • geometrically nonlinear analysis with Riks’ method
    • possibility to identify post-buckling behavior, stress stiffening, stress softening, snap-through, collapse
    • geometric imperfections based on mode shapes or analytical formulations

  • Composite pressure vessels

    • geometry and lay-up definitions imported from ComposicaD filament winding simulation software
    • shell and solid element based analysis
    • load response and failure due to internal pressure

  • Beams and columns

    • cross section properties for laminate/sandwich, circular, elliptic, rectangular, and I cross sections
    • beam analysis based on Timoshenko beam theory
    • combinations of clamped, simply supported, and free end supports
    • load response and failure due to transverse loads (combinations of a point load, distributed load and end moments), stability and failure under axial loads, natural frequencies

  • Bonded joints

    • joint types: single lap, single strap, double lap, double strap, single sided scarfed lap joint, double sided scarfed lap joint, bonded doubler
    • beam and plate models for adherends, linear and nonlinear adhesive models
    • combinations of axial, bending, and in-plane/out-of-plane shear loads
    • joint deflections, forces and moments in adherends, adhesive stresses, margins of safety for cohesive failure of adhesive and laminate failure due to in-plane and bending loads

  • Mechanical joints

    • single and double lap joints under axial loads
    • fastener and by-pass loads, laminate stresses and strains on fastener holes, margins of safety for failure, prediction of failure mode

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