Constrained Torsional Analysis of Multi Cell

Thin Walled Tapered Composite Beams

Group Members

Muhammad Awais (150509)

Muhammad Bilal (150512)
Atif Masood (150559)

Project Advisor: Dr. Malik Nazir Ahmad

Co-Advisor: Ma’am Muneeza Azmat

1
 Table of contents
• Introduction----------------------------------------------------------------------------------------------------------3
• Objective of the research-----------------------------------------------------------------------------------------4
• Torsional Theory of Multi Cell Thin Walled Composite Beams-------------------------------------------5
• Finite Element Analysis--------------------------------------------------------------------------------------------6
• CAD model------------------------------------------------------------------------------------------------------------8
• Meshing and Results-----------------------------------------------------------------------------------------------9
• Results of Isotropic Material(Aluminum)---------------------------------------------------------------------10
• Comparative analysis using different layups-----------------------------------------------------------------12
• Comparative analysis using different composite materials----------------------------------------------19
• Comparative analysis using different geometric configurations----------------------------------------26
• Comparative analysis using different lengths---------------------------------------------------------------30
• Comparative analysis using different loading intensities-------------------------------------------------37
• Conclusions----------------------------------------------------------------------------------------------------------41

2
Introduction
• Analytical study of multi cell thin walled tapered composite
beams when subjected to constrained torsional loading.
• To analyze the effect of different layups, geometry, lengths,
materials and torque change on torsional behavior of multi cell
tapered beams.
• NX Nastran is used for structural analysis of multi cell tapered
beams.
• Using the software to obtain different results.

3
Objective of the research

• To comparatively analyze the beam using different layups,

composite material , lengths, geometric configuration and
loading intensity

• To validate the published results

4
Finite Element Analysis

• Geometry
• Elements connecting nodes
• Boundary conditions
• Load application
• Analysis
• Results in the form of Graphs

5
Continued…..
• Meshing
CQUAD4 meshing
Mesh topology resulted in 7000, 9000 and 11000 elements for 600 mm, 800 mm
and 1000 mm beam length respectively

• RBE2 Elements (R-Type Elements)

Elements which are used to retain the shape of beam after torsion

• Boundary Conditions
All DOF of all nodes at fixed end were restrained

6
CAD model
Parameters Dimensions

No of cells 3

Height 50 mm

Width of each cell 50 mm

Total width 150 mm

Wall Thickness 1 mm

7
Meshing and Results

8
Isotropic Material(Aluminum)

9
Comparative analysis using different:
 Layups • All [0/45/-45/90]s
• All [(45/-45)2]s
• Flanges All [0/45/-45/90]s
Webs All [(45/-45)2]s

 Composite materials • Carbon Epoxy

• Boron Epoxy
• Glass Epoxy

 Lengths • 600 mm
• 800 mm
• 1000 mm

 Taper ratios • α=β= 0.5 degree

• α=β= 1 degree
• α=β= 1.5 degree
 Loading intensity • 1000 KNmm
• 1500 KNmm
• 2000 KNmm
10
Comparative analysis using different layups
Three different layups have been used
• All[0/45/-45/90]s
• All[(45/-45)2]s
• Flanges[0/45/-45/90]s
Webs[(45/-45)2]s

Total no of plies=8
Thickness of one ply= 0.125 mm
Total thickness= 1 mm

11
Warping displacement along the length of beam

layups material Loading Tapered angle At 0 mm At 600 mm

All[0/45/-45/90]s Carbon epoxy 1000 KNmm α=β= 1 degree 0 mm 0.131 mm

All[(45/-45)2]s Carbon epoxy 1000 KNmm α=β= 1 degree 0 mm 0.076 mm

Flanges[0/45/-45/90]s Carbon epoxy 1000 KNmm α=β= 1 degree 0 mm 0.158 mm

Webs[(45/-45)2]s
12
Warping displacement around the beam

Layups Material Loading At 0 mm At 21.5 mm At 86 mm

All[0/45/-45/90]s Carbon epoxy 1000 KNmm 0 mm 0.1 mm 0 mm

All[(45/-45)2]s Carbon epoxy 1000 KNmm 0 mm 0.06 mm 0 mm

Flanges[0/45/-45/90]s Carbon epoxy 1000 KNmm 0 mm 0.12 mm 0 mm

Webs[(45/-45)2]s
13
Force intensity along the length of the beam

Layups Material Loading At 0 mm At 200 mm At 600 mm

All[0/45/-45/90]s Carbon epoxy 1000 KNmm 105 N/mm 9 N/mm 0 N/mm

All[(45/-45)2]s Carbon epoxy 1000 KNmm 70 N/mm 1.115 N/mm 0 N/mm

Flanges[0/45/- Carbon epoxy 1000 KNmm 119 N/mm 11 N/mm 0 N/mm

45/90]s

Webs[(45/-45)2]s 14
Force intensity around the beam cross section

Layups Material Loading At 0 mm At 25 mm At 98 mm

All[0/45/-45/90]s Carbon epoxy 1000 KNmm 0 N/mm 68 N/mm 0 N/mm

All[(45/-45)2]s Carbon epoxy 1000 KNmm 0 N/mm 28 N/mm 0 N/mm

Flanges[0/45/-45/90]s Carbon epoxy 1000 KNmm 0 N/mm 90 N/mm 0 N/mm

Webs[(45/-45)2]s
15
Shear flow along the length of beam

Layups Material Loading At 0 mm At 100 mm At 600 mm

All[0/45/-45/90]s Carbon epoxy 1000 KNmm 90 N/mm 77 N/mm 184 N/mm

All[(45/-45)2]s Carbon epoxy 1000 KNmm 91 N/mm 75 N/mm 181 N/mm

Flanges[0/45/-45/90]s Carbon epoxy 1000 KNmm 101 N/mm 78 N/mm 186 N/mm

Webs[(45/-45)2]s

16
Shear flow around the beam cross section

Layups Material Loading At 0 mm At 69.75 mm At 93 mm

All[0/45/-45/90]s Carbon epoxy 1000 KNmm 75 N/mm 62.7 N/mm 74 N/mm

All[(45/-45)2]s Carbon epoxy 1000 KNmm 70 N/mm 67 N/mm 79.5 N/mm

Flanges[0/45/-45/90]s Carbon epoxy 1000 KNmm 76 N/mm 68 N/mm 73.8 N/mm

Webs[(45/-45)2]s

17
Comparative analysis using different
composite materials
Three different composite materials have Property Carbon
epoxy
Glass epoxy Boron epoxy

been used
• Carbon epoxy E11(N/m^2) 1.4e11 3.86e10 2.09e11

• Boron epoxy
E22(N/m^2) 1e10 8.27e9 1.9e10
• Glass epoxy
G12(N/m^2) 5e9 4.14e9 6.6e9

For this analysis the conditions are:

V12(N/m^2) 0.3 0.26 0.21
• Layup All[(45/-45)2]s
• Length 600 mm Density(kg/m^3) 1600 1900 2000

• Loading 1000 KNmm

• Taper ratio α=β= 1 degree
18
Warping displacement along the length of beam

Materials Layups Loading At 0 mm At 200 mm At 600 mm

Carbon epoxy All[(45/-45)2]s 1000 KNmm 0 mm 0.058 mm 0.071 mm

Glass epoxy All[(45/-45)2]s 1000 KNmm 0 mm 0.178 mm 0.22 mm

Boron epoxy All[(45/-45)2]s 1000 KNmm 0 mm 0.027 mm 0.035 mm

19
Warping displacement around the beam cross section

Materials Layups Loading At 0 mm At 21.5 mm At 86 mm

Carbon epoxy All[(45/-45)2]s 1000 KNmm 0 mm 0.06 mm 0 mm

Glass epoxy All[(45/-45)2]s 1000 KNmm 0 mm 0.16 mm 0 mm

Boron epoxy All[(45/-45)2]s 1000 KNmm 0 mm 0.065 mm 0 mm

20
Force intensity along the length of beam

Materials Layups Loading At 0 mm At 100 mm At 600 mm

Carbon epoxy All[(45/-45)2]s 1000 KNmm 70 N/mm 2.95 N/mm 0 N/mm

Glass epoxy All[(45/-45)2]s 1000 KNmm 75 N/mm 8.43 N/mm 0 N/mm

Boron epoxy All[(45/-45)2]s 1000 KNmm 65 N/mm 3.65 N/mm 0 N/mm

21
Force intensity around the beam cross section

Materials Layups Loading At 0 mm At 24.5 mm At 98 mm

Carbon epoxy All[(45/-45)2]s 1000 KNmm 0 N/mm 32 N/mm 0 N/mm

Glass epoxy All[(45/-45)2]s 1000 KNmm 0 N/mm 35 N/mm 0 N/mm

Boron epoxy All[(45/-45)2]s 1000 KNmm 0 N/mm 30 N/mm 0 N/mm

22
Shear flow along the length of beam

Materials Layups Loading At 0 mm At 100 mm At 600 mm

Carbon epoxy All[(45/-45)2]s 1000 KNmm 81 N/mm 62.63 N/mm 178.7 N/mm

Glass epoxy All[(45/-45)2]s 1000 KNmm 91 N/mm 67 N/mm 181 N/mm

Boron epoxy All[(45/-45)2]s 1000 KNmm 80 N/mm 61.25 N/mm 176.85 N/mm

23
Shear flow around the beam cross section

Materials Layups Loading At 0 mm At 69.75 mm At 93 mm

Carbon epoxy All[(45/-45)2]s 1000 KNmm 70 N/mm 80 N/mm 79.5 N/mm

Glass epoxy All[(45/-45)2]s 1000 KNmm 70 N/mm 82.5 N/mm 81 N/mm

Boron epoxy All[(45/-45)2]s 1000 KNmm 69.73 N/mm 80.1 N/mm 77.61 N/mm

24
Comparative analysis using different
Geometric configurations
Under geometric configuration the beams for analysis are:
Prismatic Beam
Tapered Beams with tapered angle of
• α=β= 0.5 degree
• α=β= 1 degree
• α=β= 1.5 degree

Conditions for analysis are:

• Layup All[(45/-45)2]s
• Material Carbon Epoxy
• Torque 1000 KNmm
• Length 600 mm
25
Warping along the length of beam

Geometric Material Length Torque At 0 mm At 600 mm

configuration
Prismatic Carbon epoxy 600 mm 1000 KNmm 0 mm 0.0444 mm

α=β= 0.5⁰ Carbon epoxy 600 mm 1000 KNmm 0 mm 0.04795mm

α=β= 1⁰ Carbon epoxy 600 mm 1000 KNmm 0 mm 0.0763 mm

α=β= 1.5⁰ Carbon epoxy 600 mm 1000 KNmm 0 mm 0.1185 mm

26
Force intensity along the length of beam

Geometric Material Length Torque At 0 mm At 100 At 600 mm

configuration mm

Prismatic Carbon epoxy 600 mm 1000 KNmm 55 N/mm 2.5 N/mm 0.0444 N/mm

α=β= 0.5⁰ Carbon epoxy 600 mm 1000 KNmm 73 N/mm 3.8 N/mm 0.04795N/mm

α=β= 1⁰ Carbon epoxy 600 mm 1000 KNmm 75 N/mm 4.2 N/mm 0.0763 N/mm

α=β= 1.5⁰ Carbon epoxy 600 mm 1000 KNmm 78.4 N/mm 6.4 N/mm 0.1185 N/mm
27
Shear flow along the length of beam

Geometric Material Length Torque At 0 mm At 100 mm At 600 mm

configuration

Prismatic Carbon 600 mm 1000 KNmm 90 N/mm 53 N/mm 52 N/mm

epoxy

α=β= 0.5⁰ Carbon 600 mm 1000 KNmm 90 N/mm 75 N/mm 85 N/mm

epoxy
α=β= 1⁰ Carbon 600 mm 1000 KNmm 90 N/mm 77 N/mm 153 N/mm
epoxy
α=β= 1.5⁰ Carbon 600 mm 1000 KNmm 90 N/mm 85 N/mm 432.75 N/mm
epoxy 28
Comparative analysis using different
lengths of beam
Lengths which are used for this analysis are
• 600 mm
• 800 mm
• 1000 mm

Conditions for this analysis are:

• Layup All[(45/-45)2]s
• Material Carbon Epoxy
• Torque 1000 KNmm
• Taper ratio α=β= 1 degree
29
Warping along the length of beam

Materials Layups Material At 0 mm At 600 mm At 800 mm At 1000 mm

600 mm All[(45/-45)2]s Carbon Epoxy 0 mm 0.062 mm ------- --------

800 mm All[(45/-45)2]s Carbon Epoxy 0 mm 0.066 mm 0.07 mm --------

1000 mm All[(45/-45)2]s Carbon Epoxy 0 mm 0.067 mm 0.076 mm 0.081 mm

30
Warping displacement around the beam cross section

31
Force intensity along the length of beam

Materials Layups Material At 0 mm At 600 mm At 800 mm At 1000 mm

600 mm All[(45/-45)2]s Carbon Epoxy 70 N/mm 0 N/mm ------- --------

800 mm All[(45/-45)2]s Carbon Epoxy 68 N/mm 6.15 N/mm 0 N/mm --------

1000 mm All[(45/-45)2]s Carbon Epoxy 72 N/mm 6.445 N/mm 7.355 N/mm 0 N/mm
32
Force intensity around the beam cross section

33
Shear flow along the length of beam

Materials Layups Material At 0 mm At 600 mm At 800 mm At 1000 mm

600 mm All[(45/-45)2]s Carbon 70 N/mm 191 N/mm ------- --------

Epoxy

800 mm All[(45/-45)2]s Carbon 68 N/mm 192 N/mm 295 N/mm --------

Epoxy

1000 mm All[(45/-45)2]s Carbon 72 N/mm 190 N/mm 300 N/mm 515 N/mm
Epoxy
34
Shear flow around the beam cross section

35
Comparative analysis using different
loading conditions
For different loading conditions we use torque of:
• 1000 KNmm
• 1500 KNmm
• 2000 KNmm

Conditions for this analysis are:

• Layup All[(45/-45)2]s
• Material Carbon Epoxy
• Length 600 mm
• Tapered ratio α=β= 1 degree 36
Warping displacement along the length of the beam

Loading Material Tapered angle Length At 0 mm At 600 mm

conditions

1000 KNmm Carbon Epoxy α=β= 1⁰ 600 mm 0 mm 0.071 mm

1500 KNmm Carbon Epoxy α=β= 1⁰ 600 mm 0 mm 0.1172 mm

2000 KNmm Carbon Epoxy α=β= 1⁰ 600 mm 0 mm 0.1512 mm

37
Force intensity along the length of beam

Loading Material Tapered Length At 0 mm At 150 mm At 600 mm

conditions angle

1000 KNmm Carbon α=β= 1⁰ 600 mm 70 N/mm 0.5 N/mm 0 N/mm

Epoxy
1500 KNmm Carbon α=β= 1⁰ 600 mm 118 N/mm 1.614 N/mm 0 N/mm
Epoxy
2000 KNmm Carbon α=β= 1⁰ 600 mm 153 N/mm 2.745 N/mm 0 N/mm
38
Epoxy
Shear flow along the length of beam

Loading Material Tapered Length At 0 mm At 50 mm At 600 mm

conditions angle

1000 KNmm Carbon α=β= 1⁰ 600 mm 87 N/mm 71 N/mm 185 N/mm

Epoxy

1500 KNmm Carbon α=β= 1⁰ 600 mm 140 N/mm 110 N/mm 283 N/mm
Epoxy

2000 KNmm Carbon α=β= 1⁰ 600 mm 180 N/mm 150 N/mm 367 N/mm
Epoxy 39
Conclusions

• Among different layups, the beam having angle ply layup both in
webs and flanges undergoes minimum stresses and deformations.
Beams with angle ply layup in webs and quasi isotropic layup in
flanges undergoes maximum stresses and deformations.

• Among different materials, beams made of glass epoxy composite

materials undergoes maximum stresses and deformations and beam
made of boron epoxy composite material undergoes minimum
deformation and stresses.

40
Continued……

• Among different taper angles, beams with minimum taper angle

experience minimum stresses and deformations and beams with
maximum taper angle experience maximum stresses and
deformations.
• By increasing the length of beams, deformation and stresses also
increases and vice versa.
• Increasing the load intensity on the beams, increases the deformation
and stresses. The ratio of deformation and stresses increment is the
same as the ratio of load increment.

41
Thank You So Much
Any Question?

42
 Free torsion Restrained torsion

• Beam is not restrained • Beam is restrained

at one end. axially at one end
• The only stress that • Along with shear stress,
exist in free torsion is axial stress are also
shear stress. produced.
• The rate of twist • The rate of twist does
remains constant no longer remain
constant

43
Meshing types
• Different kind of meshing
• Different scale factors
• C Quad 4 meshing

44
Boundary Conditions
• In both type of beams, prismatic and tapered, one end is constrained
and other is free
• Free end is loaded with different magnitude of torques
• Different values of torques are used such as 100, 1000, 10000 kNmm
in different cases

45
Validation
• Composite beams would be made
• Results will be compared against published results

46
RBE (Rigid Body Element)
• There are different kinds of elements such as RBE-2 and RBE-3
• RBE-2 is used so there won’t be any distortion in beam
• One is master node (at mid point), other are slave nodes
• Independent or dependent nodes
• Master node is constrained in all 5 directions ux, uy, uz, ROTx, ROTy
• Slave nodes are constrained in ux, uy. ROTz

47
Convergence of FEM
• FEM divides the body into smaller pieces, enforcing continuity of
displacements along these element boundaries
• For those using finite element analysis, the term “convergence” is
often used
• The meshing scale factor where results don’t show a big change and
appear similar
• Mesh Convergence refers to the smallness of the elements required
in a model to ensure that the results of an analysis are not affected by
changing the size of the mesh.
• Like iterations in MATLAB

48
 Composite Beams
• High Strength and Stiffness to weight ratio
• High fatigue resistance
• Capability to create smooth aerodynamic surfaces
• Mechanical properties can be tailored
• Glass Epoxy, Carbon Epoxy, Boron Epoxy
Material Layups Geometry

Glass epoxy All[0/45-45/90]s Prismatic

Flanges[0/45-/-45/90]s, webs[(45/-45)2]s Tapered: α=β= 0.5 deg
All[(45/-45)2]s Tapered: α=β= 1 deg

Carbon epoxy All[0/45-45/90]s Prismatic

Flanges[0/45-/-45/90]s, webs[(45/-45)2]s Tapered: α=β= 0.5 deg
All[(45/-45)2]s Tapered: α=β= 1 deg

Boron epoxy All[0/45-45/90]s Prismatic

Flanges[0/45-/-45/90]s, webs[(45/-45)2]s Tapered: α=β= 0.5 deg
All[(45/-45)2]s Tapered: α=β= 1 deg
49
FEM (Finite Element Method)
FEA (Finite Element Analysis)
• FEM
• The finite element method, is a numerical method for solving problems of
engineering and mathematical physics
• Typical problem areas of interest include structural analysis, heat transfer,
fluid flow, mass transport, and electromagnetic potential
• FEA
• Finite element analysis (FEA) is a computerized method for predicting how
a product reacts to real-world forces, vibration, heat, fluid flow, and other
physical effects
• Finite element analysis shows whether a product will break, wear out, or
work the way it was designed

50
Force Intensity
• Force intensity develops due to constrained end in a beam
• There won’t be any force intensity if there is no fixed end in a beam
• Force intensity is higher at the beginning (where the beam is fixed)
and then reduces
• Around the beam, it starts from zero, increases to some specific point
and then comes down to zero again

51
Shear Flow
• The term shear flow is used in solid mechanics as well as in fluid dynamics
• Shear stress over a distance in a thin-walled structure
• Shear stress often denoted by τ
• Shear stress arises from the force vector component parallel to the cross
section of the material
• Normal stress, on the other hand, arises from the force vector
component perpendicular to the material cross-section on which it acts.
• Shear stress arises from shear forces, which are pairs of equal and
opposing forces acting on opposite sides of an object.

52
Warping
• Out of plane displacement
• Primary warping is the warping of midplane of cross-section which is
constant through the wall thickness
• Secondary warping is the warping of sections across its wall thickness

53
Bending moment
• Bend that occurs in a beam due to moment
• Perpendicular force multiplied by the distance from
the point
• Deflection of beam occurs which can be calculated
as:
δC = (F a3 / (3 E I)) (1 + 3 b / 2 a)
Where:
E= modulus of Elasticity
I= moment of inertia

54
55
St Venant’s theory
• Difference between the effects of two different but
statically equivalent loads become very small at
sufficiently large distance from load
According to St Venants theory:
In case of:

• free torsion:
The only stress that could exist in thin walled members is
the shear stress
• Restrained torsion:
Along with shear stresses, axial stresses are also
produced in restrained torsion
56
Moment of inertia
Also known as :
• Area moment of inertia, Second moment of area,
Moment of inertia for an area
• Property of a beam that is used to find the
 Deflection
 Bending
 Stresses in a beam
• It measures the beam ability to resist bending
• Larger the moment of inertia the less the beam will
bend

57
Polar moment of inertia

• Also known as second polar moment of area

• Measure the beams ability to resist torsion
• In other words, resistance to torsional deformation
• Larger the polar moment of inertia the less the
beam will twist
• Denoted as Iz

58