ACP User's Guide

ANSYS, Inc. Release 2025 R1

Southpointe January 2025
2600 Ansys Drive
Canonsburg, PA 15317 ANSYS, Inc. and
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Table of Contents
1. Getting Started ....................................................................................................................................... 1
1.1. Overview .......................................................................................................................................... 1
1.1.1. Introduction ............................................................................................................................ 1
1.1.2. Supported Platforms and Functional Add-ons ........................................................................... 3
1.1.3. Known Limitations ................................................................................................................... 3
1.1.4. First Steps ................................................................................................................................ 5
1.2. The Ansys Product Improvement Program ......................................................................................... 5
1.3. Graphical User Interface .................................................................................................................... 9
1.3.1. Menus ................................................................................................................................... 10
1.3.1.1. File ................................................................................................................................ 10
1.3.1.1.1. Workbench ........................................................................................................... 11
1.3.1.1.2. Stand Alone .......................................................................................................... 11
1.3.1.2. View .............................................................................................................................. 12
1.3.1.2.1. Perspectives ......................................................................................................... 12
1.3.1.2.2. View Manager ....................................................................................................... 13
1.3.1.3. Tools ............................................................................................................................. 13
1.3.1.3.1. Extract Materials From Composite CAE H5... ........................................................... 14
1.3.1.3.2. Winding Wizard .................................................................................................... 14
1.3.1.3.3. Migration Helper ................................................................................................... 16
1.3.1.3.4. Preferences ........................................................................................................... 16
1.3.1.3.4.1. Add Ons ....................................................................................................... 17
1.3.1.3.4.2. Ansys Product Improvement Program ........................................................... 17
1.3.1.3.4.3. General ACP Preferences .............................................................................. 17
1.3.1.3.4.4. Logger Settings ............................................................................................ 18
1.3.1.3.4.5. Material Database ........................................................................................ 18
1.3.1.3.4.6. Notifications and Pop-ups ............................................................................ 19
1.3.1.3.4.7. Scene Preferences ........................................................................................ 19
1.3.1.3.4.8. Section Generation ...................................................................................... 20
1.3.1.3.4.9. Units ............................................................................................................ 20
1.3.2. Tree View ............................................................................................................................... 21
1.3.3. Scene ..................................................................................................................................... 23
1.3.3.1. Scene Manipulation ....................................................................................................... 23
1.3.4. Toolbar .................................................................................................................................. 23
1.3.4.1. Updates ........................................................................................................................ 24
1.3.4.2. Edit Entities with Excel ................................................................................................... 24
1.3.4.3. Scene Options ............................................................................................................... 25
1.3.4.4. Mesh Appearance .......................................................................................................... 26
1.3.4.5. Orientation Visualization ................................................................................................ 26
1.3.4.6. Fiber Directions ............................................................................................................. 28
1.3.4.7. Draping ......................................................................................................................... 29
1.3.4.8. Other Features ............................................................................................................... 32
1.3.4.9. Configure Plots .............................................................................................................. 33
1.3.5. View Panes ............................................................................................................................. 34
1.3.5.1. Shell View ...................................................................................................................... 34
1.3.5.2. Keyboard Shortcuts ....................................................................................................... 35
1.3.5.3. Logger .......................................................................................................................... 35
1.3.5.4. History View .................................................................................................................. 36
1.3.6. Keyboard Shortcuts ................................................................................................................ 36
1.3.6.1. General Shortcuts .......................................................................................................... 36

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1.3.6.2. Scene View Shortcuts .................................................................................................... 36

1.3.6.3. Tree View Shortcuts ....................................................................................................... 37
1.3.6.4. Shell View ...................................................................................................................... 37
1.3.6.5. Properties Windows ....................................................................................................... 38
1.4. Implementation in Workbench ........................................................................................................ 38
1.4.1. Basic Workflow ....................................................................................................................... 39
1.4.1.1. Transfer Types ................................................................................................................ 42
1.4.2. ACP Component Properties .................................................................................................... 42
1.4.3. Supported Analysis Types ....................................................................................................... 44
1.4.3.1. ACP–LS-DYNA ............................................................................................................... 45
1.4.4. Multiple Load Cases and Analyses ........................................................................................... 47
1.4.5. Shared Composite Definition for Different Models .................................................................. 47
1.4.6. Solid Modeling ....................................................................................................................... 48
1.4.7. Assembly ............................................................................................................................... 50
1.4.7.1. Renumbering and Transfer Type ..................................................................................... 51
1.4.7.2. Creating a Mixed Assembly ............................................................................................ 51
1.4.8. Limitations ............................................................................................................................. 52
1.5. Migrating ACP Projects from Previous Versions ................................................................................ 53
1.6. The ACP Python Scripting User Interface .......................................................................................... 56
1.7. Stand Alone Operation ................................................................................................................... 56
1.7.1. Starting ACP in Windows ........................................................................................................ 57
1.7.2. Starting ACP in Linux .............................................................................................................. 57
1.7.3. Command Line Options and Batch Mode ................................................................................ 57
1.7.4. Workflow in Stand Alone Operation ........................................................................................ 58
1.8.Tutorials and Examples .................................................................................................................... 59
2. Usage Reference .................................................................................................................................... 61
2.1. Features ......................................................................................................................................... 61
2.1.1. Model .................................................................................................................................... 62
2.1.1.1. Model Properties - General ............................................................................................ 63
2.1.1.1.1. ACP Model ............................................................................................................ 65
2.1.1.1.2. Reference Surface ................................................................................................. 65
2.1.1.1.3. Lay-Up Computation ............................................................................................. 65
2.1.1.1.4. Model Summary ................................................................................................... 66
2.1.1.2. Solve ............................................................................................................................. 66
2.1.1.3. Import/Export of ACP Composite Definitions File ........................................................... 67
2.1.1.4. Import From/Export to HDF5 Composite CAE File ........................................................... 68
2.1.1.5. Import Section Data from Legacy Model ........................................................................ 68
2.1.1.6. Element- vs. Node-based Thicknesses ............................................................................. 68
2.1.1.7. Winding Wizard ............................................................................................................. 71
2.1.2. Scripts ................................................................................................................................... 71
2.1.2.1. Executing Scripts ........................................................................................................... 72
2.1.2.2. Script Properties ............................................................................................................ 72
2.1.2.3. Limitations .................................................................................................................... 73
2.1.2.4. Tips and Best Practices ................................................................................................... 73
2.1.2.5. Sorting Scripts ............................................................................................................... 74
2.1.3. Material Data ......................................................................................................................... 74
2.1.3.1. Materials ....................................................................................................................... 75
2.1.3.1.1. Materials Context Menu ........................................................................................ 75
2.1.3.1.2. Temperature Dependent and General Variable Material Properties ......................... 75
2.1.3.1.3. Material Properties Dialog ..................................................................................... 76
2.1.3.1.4. Thermal Expansion Coefficients ............................................................................. 78

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2.1.3.1.5. Fabric Fiber Angle ................................................................................................. 78

2.1.3.1.6. Strain Limits .......................................................................................................... 79
2.1.3.1.7. Stress Limits .......................................................................................................... 80
2.1.3.1.8. Puck Constants ..................................................................................................... 81
2.1.3.1.9. Puck for Woven ..................................................................................................... 82
2.1.3.1.10. Tsai-Wu Constants ............................................................................................... 83
2.1.3.1.11. LaRC Constants ................................................................................................... 84
2.1.3.2. Fabric ............................................................................................................................ 84
2.1.3.2.1. General ................................................................................................................. 85
2.1.3.2.2. Polar Properties .................................................................................................... 85
2.1.3.2.3. Fabric Solid Model Options ................................................................................... 86
2.1.3.2.4. Draping ............................................................................................................... 87
2.1.3.3. Stackup ......................................................................................................................... 88
2.1.3.3.1. Top-Down or Bottom-Up Sequence ....................................................................... 89
2.1.3.3.2. Symmetries .......................................................................................................... 89
2.1.3.3.3. Analysis ................................................................................................................ 91
2.1.3.3.4. Stackup Solid Model Options ................................................................................ 93
2.1.3.3.5. Draping Options ................................................................................................... 93
2.1.3.4. Sublaminates ................................................................................................................ 93
2.1.4. Element and Edge Sets ........................................................................................................... 94
2.1.4.1. Element Sets ................................................................................................................. 95
2.1.4.1.1. Context Menu ....................................................................................................... 96
2.1.4.2. Edge Sets ...................................................................................................................... 96
2.1.5. Geometry .............................................................................................................................. 97
2.1.5.1. CAD Geometries ............................................................................................................ 99
2.1.5.1.1. Direct Import ...................................................................................................... 100
2.1.5.1.2. Workbench Geometry Link .................................................................................. 101
2.1.5.2. Virtual Geometries ....................................................................................................... 101
2.1.6. Rosettes ............................................................................................................................... 103
2.1.6.1. Rosette Definition ........................................................................................................ 106
2.1.7. Look-Up Tables ..................................................................................................................... 107
2.1.7.1. 3D Look-Up Table With The Excel Link ........................................................................... 107
2.1.7.2. 1D Look-Up Table with .csv Files ................................................................................... 109
2.1.7.3. Look-Up Table with a Python Script .............................................................................. 111
2.1.7.4. 1-D Look-Up Table ....................................................................................................... 112
2.1.7.5. 3D Look-Up Table ........................................................................................................ 112
2.1.7.6. Look-Up Table Column Properties ................................................................................ 114
2.1.8. Selection Rules ..................................................................................................................... 115
2.1.8.1. Basic Selection Rules .................................................................................................... 116
2.1.8.2. Tube Selection Rule ..................................................................................................... 118
2.1.8.3. Cut-Off Selection Rules ................................................................................................ 120
2.1.8.3.1. Geometry Cut-Off Selection Rule ......................................................................... 121
2.1.8.3.2. Taper Cut-Off Selection Rule ................................................................................ 123
2.1.8.3.3. Example Cut-Off .................................................................................................. 124
2.1.8.4. Geometrical Selection Rule .......................................................................................... 125
2.1.8.5. Variable Offset Selection Rule ....................................................................................... 128
2.1.8.6. Boolean Selection Rules ............................................................................................... 131
2.1.9. Oriented Selection Sets (OSS) ............................................................................................... 132
2.1.9.1. Reference Direction ..................................................................................................... 134
2.1.9.1.1. Use Cases for Rotation Angle ............................................................................... 135
2.1.9.2. Selection Rules ............................................................................................................ 137

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2.1.9.3. Draping ....................................................................................................................... 137

2.1.10. Modeling Groups ............................................................................................................... 139
2.1.10.1. Modeling Group Structure ......................................................................................... 139
2.1.10.2. Modeling Group Tree Object Context Menu ................................................................ 140
2.1.10.3. Individual Modeling Group Context Menu .................................................................. 140
2.1.10.4. Modeling Ply Properties ............................................................................................. 142
2.1.10.4.1. Draping ............................................................................................................ 142
2.1.10.4.2. Selection Rules .................................................................................................. 145
2.1.10.4.3. Thickness .......................................................................................................... 146
2.1.10.4.4. Modeling Ply Context Menu .............................................................................. 149
2.1.10.5. Interface Layer Properties .......................................................................................... 151
2.1.10.6. Butt Joint Sequence ................................................................................................... 153
2.1.10.6.1. Butt Joint Sequence Notes and Limitations ........................................................ 155
2.1.10.7. Reordering Modeling Plies, Interface Layers, and Butt Joint Sequences ........................ 155
2.1.10.8. Production Ply ........................................................................................................... 156
2.1.10.9. Analysis Ply ................................................................................................................ 156
2.1.10.10. Import from / Export to CSV File ............................................................................... 157
2.1.10.10.1. Export ............................................................................................................. 157
2.1.10.10.2. Import ............................................................................................................ 157
2.1.10.11. Export Ply Geometry ................................................................................................ 158
2.1.11. Imported Modeling Group .................................................................................................. 159
2.1.11.1. Tree Object Context Menu ......................................................................................... 159
2.1.11.2. Imported Modeling Ply .............................................................................................. 160
2.1.11.2.1. Imported Modeling Ply Properties ..................................................................... 161
2.1.11.3. Imported Production Ply ............................................................................................ 164
2.1.11.4. Imported Analysis Ply ................................................................................................ 164
2.1.12. Field Definitions ................................................................................................................. 165
2.1.13. Sampling Points ................................................................................................................. 168
2.1.14. Section Cuts ....................................................................................................................... 170
2.1.14.1. Types of Extrusion ...................................................................................................... 173
2.1.14.2. Section Cut Notes ...................................................................................................... 175
2.1.14.3. Section Cut Export ..................................................................................................... 175
2.1.14.4. Computation of Equivalent Sectional Properties ......................................................... 176
2.1.14.4.1. Theory .............................................................................................................. 178
2.1.14.4.2. Results .............................................................................................................. 179
2.1.14.4.3. Best Practices .................................................................................................... 180
2.1.14.4.4. Limitations ........................................................................................................ 181
2.1.14.4.5. References ........................................................................................................ 181
2.1.15. Sensors .............................................................................................................................. 181
2.1.16. Solid Models ...................................................................................................................... 183
2.1.16.1. Solid Model ............................................................................................................... 184
2.1.16.1.1. Properties ......................................................................................................... 185
2.1.16.1.1.1. General .................................................................................................... 185
2.1.16.1.1.2. Drop-Offs ................................................................................................. 189
2.1.16.1.1.3. Export ...................................................................................................... 191
2.1.16.1.2. Export Solid Model ............................................................................................ 194
2.1.16.1.3. Extrusion Guides ............................................................................................... 195
2.1.16.1.3.1. Mesh Morphing ........................................................................................ 197
2.1.16.1.3.2. Extrusion Guide Examples ........................................................................ 198
2.1.16.1.4. Snap-To Geometry ............................................................................................ 200
2.1.16.1.5. Cut-Off Geometry ............................................................................................. 202

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2.1.16.1.5.1. Defining Cut-Off Geometry ....................................................................... 203

2.1.16.1.5.2. Decomposition of Degenerated Elements ................................................. 205
2.1.16.1.5.3. Limitations ............................................................................................... 205
2.1.16.1.6. Mesh Components ............................................................................................ 206
2.1.16.1.7. Material Handling for Different Extrusion Methods ............................................. 207
2.1.16.1.8. Save & Reload Solid Models ............................................................................... 207
2.1.16.1.9. Node-based Thicknesses ................................................................................... 207
2.1.16.2. Imported Solid Model ................................................................................................ 208
2.1.16.2.1. Imported Solid Model Properties ....................................................................... 209
2.1.16.2.1.1. General Tab .............................................................................................. 210
2.1.16.2.1.2. Export Tab ................................................................................................ 211
2.1.16.2.1.3. Mapping Statistics .................................................................................... 211
2.1.16.2.2. Mesh Components ............................................................................................ 211
2.1.16.2.3. Lay-up Mapping Objects ................................................................................... 212
2.1.16.2.3.1. General Tab .............................................................................................. 212
2.1.16.2.3.2. Layered Element Tab ................................................................................. 215
2.1.16.2.3.2.1. Limitations ...................................................................................... 218
2.1.16.2.3.3. Reinforcing Tab ........................................................................................ 219
2.1.16.2.3.3.1. Design Tips and Best Practices .......................................................... 220
2.1.16.2.3.3.2. Limitations ...................................................................................... 220
2.1.16.2.4. Quality Check .................................................................................................... 221
2.1.16.2.5. Miscellaneous ................................................................................................... 221
2.1.17. Lay-Up Plots ....................................................................................................................... 222
2.1.17.1. Interface Options ....................................................................................................... 223
2.1.17.2. Thickness Plots .......................................................................................................... 226
2.1.17.3. Angle Plot .................................................................................................................. 227
2.1.17.4. Draping Mesh Plot ..................................................................................................... 227
2.1.17.5. Look-Up Table Plot ..................................................................................................... 229
2.1.17.6. Field Definition Plot ................................................................................................... 231
2.1.17.7. Lay-Up Mapping Plot ................................................................................................. 231
2.1.17.8. Material Plots ............................................................................................................. 233
2.1.17.9. User-Defined Plot ...................................................................................................... 233
2.1.18. Scenes ............................................................................................................................... 233
2.1.19. Views ................................................................................................................................. 233
2.1.20. Ply Books ........................................................................................................................... 234
2.1.20.1. Creating Chapters ...................................................................................................... 234
2.1.20.2. Chapter Properties ..................................................................................................... 235
2.1.20.3. Editing the Ply Book Template .................................................................................... 235
2.1.20.3.1. Python Expressions ........................................................................................... 237
2.1.20.4. Modifying the Ply Book Snapshots ............................................................................. 238
2.1.20.5. Exporting the Plybook ............................................................................................... 238
2.1.20.6. Sample Ply Book Page ................................................................................................ 239
2.1.20.7. Ply Book Limitations .................................................................................................. 241
2.1.21. Parameters ......................................................................................................................... 241
2.1.21.1. Settings for an Expression Output .............................................................................. 243
2.1.22. Material Database .............................................................................................................. 244
2.2. Exchanging Composite Definitions with Other Programs ............................................................... 245
2.2.1. HDF5 Composite CAE Format ............................................................................................... 245
2.2.1.1. Export ......................................................................................................................... 246
2.2.1.2. Import ......................................................................................................................... 248
2.2.1.2.1. Import Projection Types ...................................................................................... 249

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2.2.1.2.2. Import Settings ................................................................................................... 250

2.2.2. Mechanical APDL File Format ................................................................................................ 252
2.2.3. Import of Legacy Mechanical APDL Composite Models ......................................................... 254
2.2.3.1. Special Cases ............................................................................................................... 256
2.2.3.2. Known Limitations ....................................................................................................... 257
2.2.4.Tabular Data Format for Excel ................................................................................................ 257
2.2.5. CSV Format .......................................................................................................................... 258
2.2.6. ESAComp ............................................................................................................................. 258
2.2.6.1. Export ......................................................................................................................... 259
2.2.6.2. Import ......................................................................................................................... 259
2.2.7. LS-Dyna ............................................................................................................................... 259
2.2.8. BECAS .................................................................................................................................. 260
3. Composite Modeling Techniques ........................................................................................................ 261
3.1. T-Joint .......................................................................................................................................... 261
3.2. Local Reinforcements .................................................................................................................... 267
3.3. Ply Tapering and Staggering .......................................................................................................... 269
3.3.1. Ply Tapering ......................................................................................................................... 269
3.3.1.1. Edge Tapering ............................................................................................................. 269
3.3.1.2. Tapered Core .............................................................................................................. 270
3.3.1.3. Tapered Edges ............................................................................................................. 270
3.3.1.4. Tapering of Multiple Plies ............................................................................................. 272
3.3.2. Ply Staggering ...................................................................................................................... 272
3.4. Variable Core Thickness ................................................................................................................. 273
3.4.1. Solid CAD Geometry ............................................................................................................ 274
3.4.2. Look-Up Table ...................................................................................................................... 275
3.4.3. Geometry Cut-Off Selection Rule .......................................................................................... 277
3.4.4. General Application .............................................................................................................. 278
3.5. Draping ........................................................................................................................................ 279
3.5.1. Internal Draping Algorithm of ACP ........................................................................................ 279
3.5.2. User-Defined Draping ........................................................................................................... 281
3.5.3. Visualization ......................................................................................................................... 282
3.6. Guide to Solid Modeling ................................................................................................................ 283
3.6.1. When to Use a Solid Model ................................................................................................... 284
3.6.2. How to Use the Solid Model Feature ..................................................................................... 284
3.6.3. Principles of Solid Model Generation .................................................................................... 285
3.6.4. Drop-Off and Cut-Off Elements ............................................................................................. 285
3.6.5. Workflow ............................................................................................................................. 286
3.6.6. Practical Tips ........................................................................................................................ 287
3.6.7. Known Limitations ............................................................................................................... 288
3.7. Guide to Composite Visualizations ................................................................................................. 290
3.7.1. Model Verification ................................................................................................................ 290
3.7.2. Postprocessing Visualizations ............................................................................................... 291
3.8. Guide to Composite Failure Criteria ............................................................................................... 301
3.9. Element Choice in ACP .................................................................................................................. 302
3.9.1. Introduction ......................................................................................................................... 302
3.9.2. Shell Elements ...................................................................................................................... 302
3.9.3. Solid Elements ..................................................................................................................... 302
3.9.4. Solid-shell Elements ............................................................................................................. 303
3.10. Variable Material Data in Composite Analyses .............................................................................. 303
3.10.1. Element- or Layer-wise Field Definition ............................................................................... 303
3.10.2. Draping Shear .................................................................................................................... 304

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3.10.3. Degradation Factors ........................................................................................................... 304

3.10.3.1. Definition of the Degradation Factor Field .................................................................. 305
3.10.4. Definition of General User-Defined Fields in ACP (Pre) ......................................................... 305
3.10.5. Variable Data Interpolation Settings .................................................................................... 305
4. Example Analyses ................................................................................................................................ 307
4.1. Analysis of a Composite Shell Model .............................................................................................. 307
4.1.1. Preprocessing ...................................................................................................................... 308
4.1.1.1. Workbench Integration ................................................................................................ 308
4.1.1.2. Adding ACP Components to the Project ....................................................................... 308
4.1.1.3. Engineering Data ......................................................................................................... 309
4.1.1.4. Properties .................................................................................................................... 310
4.1.1.5. Geometry and Units ..................................................................................................... 312
4.1.1.6. Named Selections and Elements/Edge Sets .................................................................. 312
4.1.1.7. Starting and Running ACP ............................................................................................ 312
4.1.2. Workbench: Adding an Analysis System to the Project ........................................................... 313
4.1.3. Postprocessing ..................................................................................................................... 314
4.2. Analysis of a Composite Solid Model ............................................................................................. 314
4.2.1. Preprocessing ...................................................................................................................... 315
4.2.2. Workbench Application Analysis System ............................................................................... 316
4.2.3. Postprocessing ..................................................................................................................... 320
4.3. Analysis Using Variable Material Data ............................................................................................. 320
4.3.1. Workbench Application Engineering Data: Set-Up Variable Data ............................................ 321
4.3.2. ACP (Pre): Define Fields for Shear Angle, Degradation Factor, and User-Defined Field Vari-
ables ............................................................................................................................................ 324
4.3.3. Mechanical, Thermal Loading, and External Data ................................................................... 325
4.3.4. Postprocessing in Mechanical Application: Analysis Effect of Variable Data ............................. 326
4.4. Analysis of a Mapped Composite Solid Model ................................................................................ 326
4.4.1. Transfer External Solid Mesh to ACP (Pre) .............................................................................. 328
4.4.1.1. Geometry .................................................................................................................... 328
4.4.1.2. Meshing ...................................................................................................................... 329
4.4.1.3. Linking the Systems in the Workbench Application ....................................................... 330
4.4.2. Lay-Up Mapping in ACP (Pre) ................................................................................................ 330
4.4.3. Analysis of A Mapped Composite Model ............................................................................... 334
4.5. Shear Dependent Materials in Composite Analysis ......................................................................... 335
4.6. 3D Ply Workflow – Imported Plies .................................................................................................. 342
4.6.1. Inputs .................................................................................................................................. 342
4.6.2. Example of Use - HDF5 Composite CAE ................................................................................. 344
4.7. ACP for Workbench LS-DYNA: Bird Strike ........................................................................................ 346
4.7.1. Workbench Workflow ........................................................................................................... 347
4.7.2. Engineering Data – Material Model Definition ...................................................................... 347
4.7.3. SpaceClaim – Geometry ....................................................................................................... 349
4.7.4. Mechanical Model Setup ...................................................................................................... 350
4.7.5. ACP - Material Assignment and Lay-Up ................................................................................. 350
4.7.6. Setting Up the LS-DYNA Analysis System .............................................................................. 351
4.7.7. Post-Processing in Workbench LS-DYNA: ............................................................................... 352
4.8. Workflow with Equivalent Beam Models ........................................................................................ 353
4.8.1. Constant Composite Cross Section with a Straight Beam ....................................................... 354
4.8.2. Generic Composite Wind Blade ............................................................................................ 359
4.8.3. Conclusion ........................................................................................................................... 364
5. Guide for ACP Terminology ................................................................................................................. 365
Bibliography ............................................................................................................................................. 369

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List of Figures
1.1. Oriented Selection Set Properties ............................................................................................................ 4
1.2. Ansys Composite PrepPost GUI ............................................................................................................. 10
1.3. Ansys Composite PrepPost Menu Options ............................................................................................. 10
1.4. File Menu for Workbench Integration .................................................................................................... 11
1.5. Stand-Alone File Menu .......................................................................................................................... 12
1.6. View Menu ........................................................................................................................................... 12
1.7. Perspective Submenu ........................................................................................................................... 13
1.8. Show View ............................................................................................................................................ 13
1.9. Tools Menu ........................................................................................................................................... 14
1.10. Extract Materials From Composite CAE H5... Dialog .............................................................................. 14
1.11. Winding Wizard with the Inputs on Top and the Description at the Bottom ........................................... 16
1.12. Preferences Window ........................................................................................................................... 17
1.13. General ACP Preferences ..................................................................................................................... 18
1.14. Logger Preferences ............................................................................................................................. 18
1.15. Scene Preferences ............................................................................................................................... 19
1.16. Section Generation Preferences ........................................................................................................... 20
1.17. Units Menu ......................................................................................................................................... 20
1.18. Tree View ............................................................................................................................................ 22
1.19. Locked Rosettes and the Update Status ............................................................................................... 22
1.20. Excel Link Dialog ................................................................................................................................. 24
1.21. Orientation Visualizations in the Toolbar .............................................................................................. 26
1.22. Visualization of the Element Normals ................................................................................................... 27
1.23. Visualization of the OSS Normal ........................................................................................................... 27
1.24. Visualization of the OSS Reference Direction ........................................................................................ 28
1.25. Fiber Directions in the Toolbar ............................................................................................................. 28
1.26. Visualization of the Fiber Direction ...................................................................................................... 29
1.27. Visualization of the Transverse Ply Direction ......................................................................................... 29
1.28. Draping Directions in the Toolbar ........................................................................................................ 30
1.29. Fiber Directions (Defined and Draped) ................................................................................................. 30
1.30. Traverse Directions (Defined and Draped) ............................................................................................ 31
1.31. Material 1 Direction and Draped Fiber Direction for a Material with a 45° Fabric Fiber Angle .................. 31
1.32. Enclosed Box and Coordinate System .................................................................................................. 32
1.33. Distance Measure Tool ........................................................................................................................ 33
1.34. Properties from Right-Click Context Menu ........................................................................................... 43
1.35. Properties Menu: Setup ....................................................................................................................... 43
1.36. Sample Workflow of ACP – LS-DYNA within Workbench ....................................................................... 45
1.37. Create an LS-DYNA Keyword (.k) File from the Workbench Model within Mechanical ............................. 46
1.38. Multiple Load Cases and Analyses ....................................................................................................... 47
1.39. Two Analyses Share the Same ACP (Pre) Setup ..................................................................................... 48
1.40. Import Volume Mesh from Mechanical Model (E4 to C5) ...................................................................... 49
1.41. Import Volume Mesh from Third Party Application ............................................................................... 50
1.42. A Multi-System Analysis in Workbench ................................................................................................ 50
1.43. Write Input File ................................................................................................................................... 58
1.44. Import Ansys Model Using the Context Menu ...................................................................................... 59
2.1. Model Context Menu in Workbench Mode ............................................................................................. 62
2.2. Model Context Menu in Stand-Alone Mode ........................................................................................... 62
2.3. General Model Properties ...................................................................................................................... 64
2.4. Model Statistics .................................................................................................................................... 64
2.5. Solver Information (Solve.out) ............................................................................................................... 67

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2.6. Export Composite Definitions Window .................................................................................................. 67

2.7. Import Composite Definitions Window .................................................................................................. 67
2.8. Element-based vs. Node-based Piercing ................................................................................................ 69
2.9. Ply Extension and Element-wise Thicknesses of a Tapered Ply with Element-based (left) and Node-based
(right) Thicknesses ...................................................................................................................................... 69
2.10. Restriction for Node-based Thicknesses ............................................................................................... 70
2.11. Extrusion of a Tapered Ply without and with Node-based Thicknesses on the Left and Right, Respect-
ively ........................................................................................................................................................... 70
2.12. Solid Model Extrusion of a Tapered Ply without and with Node-based Thicknesses ............................... 71
2.13. Cut-Off Selection Rule with Ply Tapering Based on Element-based and Node-based Thicknesses ........... 71
2.14. Materials Class Context Menu in Stand Alone Mode ............................................................................. 75
2.15. Example of Woven Material with a 45° Fabric Fiber Angle ..................................................................... 79
2.16. Fabric Properties - General .................................................................................................................. 85
2.17. Fabric Properties - Analysis .................................................................................................................. 86
2.18. Fabric Properties - Solid Model Options ............................................................................................... 87
2.19. Fabric Properties - Draping .................................................................................................................. 88
2.20. Stackup Properties - General ............................................................................................................... 89
2.21. Stackup Sequence with Even Symmetry .............................................................................................. 90
2.22. Stackup Sequence with Odd Symmetry ............................................................................................... 91
2.23. Lay-Up Information and Polar Properties ............................................................................................. 92
2.24. CLT Analysis - Laminate Engineering Constants .................................................................................... 93
2.25. Sub Laminate Properties - General Tab ................................................................................................ 94
2.26. Element Set Selection ......................................................................................................................... 95
2.27. Element Set Context Menu .................................................................................................................. 96
2.28. Edge Set Definition ............................................................................................................................. 97
2.29. Example of three Cut-Off geometries ................................................................................................... 98
2.30. CAD Geometry Assembly and Virtual Geometries in the Tree View ....................................................... 98
2.31. Example of Multiple Virtual Geometries ............................................................................................. 100
2.32. Property Dialog CAD Geometry ......................................................................................................... 100
2.33. Project Schematic with a CAD Geometry Import in ACP ..................................................................... 101
2.34. Create Virtual Geometry Directly from CAD Geometry Part ................................................................ 102
2.35. Create Virtual Geometry Through CAD Geometry Parts in Tree ........................................................... 102
2.36. Create Virtual Geometry Through Face Selection in the Scene ............................................................ 103
2.37. Rosette Properties Dialog .................................................................................................................. 104
2.38. Oriented Selection Set with a Radial Rosette. ..................................................................................... 105
2.39. Oriented Selection Set with a Cylindrical Rosette ............................................................................... 105
2.40. Oriented Selection Set with a Spherical Rosette ................................................................................. 106
2.41. Edge-Wise Rosette ............................................................................................................................ 106
2.42. Schematic of 1-D Look-Up Table Function ......................................................................................... 112
2.43. Look-Up Table Values ........................................................................................................................ 113
2.44. Interpolated Values with Weighted Nearest Neighbor, Nearest Neighbor, and Linear Multivariate (From
Left to Right) ............................................................................................................................................. 113
2.45. Look-Up Table Interpolation Parameters ............................................................................................ 114
2.46. Setting the Dimension in the Column Properties Dialog ..................................................................... 115
2.47. Selection Rules Context Menu ........................................................................................................... 115
2.48. Definition of a Parallel Selection Rule ................................................................................................. 116
2.49. Example of a Parallel Selection Rule ................................................................................................... 117
2.50. Example of a tube rule with an outer and inner radius ........................................................................ 118
2.51. Tube Selection Rule Properties .......................................................................................................... 119
2.52. Edge with a long extension at the head of the edge and a short one at the tail ................................... 120
2.53. Cut-Off Selection Rule Properties ....................................................................................................... 121

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2.54. Trailing Edge with Cut-Off Plies (Ply Tapering Activated) ..................................................................... 122
2.55. Section of the Cut-Off Geometry ....................................................................................................... 122
2.56. Core Thickness Without Ply Tapering (Left) and With Ply Tapering (Right) ............................................ 123
2.57. Taper Cut-Off Selection Rule Definition .............................................................................................. 124
2.58. Section with The Production Ply Option ............................................................................................. 124
2.59. Section with the Analysis Ply Option .................................................................................................. 125
2.60. Section with the Analysis Ply with Tapering Option ............................................................................ 125
2.61. Example Geometrical Selection Rule .................................................................................................. 126
2.62. Geometrical Selection Rule Properties ............................................................................................... 126
2.63. Capture Tolerances ............................................................................................................................ 128
2.64. Look-Up Table Defines the Offset to Edge Set at a Given Length ......................................................... 129
2.65. Offset Correction ............................................................................................................................... 130
2.66. Offset Mapping Along a Direction Vector ........................................................................................... 130
2.67. Boolean Selection Rule ...................................................................................................................... 131
2.68. Boolean Operation Types .................................................................................................................. 131
2.69. Orientation Point Definition .............................................................................................................. 132
2.70. Definition ......................................................................................................................................... 133
2.71. Reference Direction of a Bonding Laminate Defined by Two Rosettes and a Minimum Angle Selection
Method .................................................................................................................................................... 135
2.72. Reference Directions Along an Edge and Perpendicular to an Edge .................................................... 136
2.73. Axial Reference Direction .................................................................................................................. 137
2.74. Selection Rules .................................................................................................................................. 137
2.75. Draping ............................................................................................................................................ 138
2.76. Object Tree of a Lay-Up Definition ..................................................................................................... 140
2.77. Context Menu of Modeling Groups .................................................................................................... 140
2.78. General Information .......................................................................................................................... 142
2.79. Internal Draping Definition ................................................................................................................ 144
2.80. Draping with Tabular Values Definition .............................................................................................. 145
2.81. Thickness Definition .......................................................................................................................... 146
2.82. Thickness Definition Options ............................................................................................................. 147
2.83. Core Geometry ................................................................................................................................. 147
2.84. Resulting Section Cut ........................................................................................................................ 148
2.85. Edge Tapering ................................................................................................................................... 149
2.86. Taper Edge Example .......................................................................................................................... 149
2.87. Right-Click Modeling Ply Menu .......................................................................................................... 150
2.88. Interface Layer Properties - General ................................................................................................... 152
2.89. Interface Layer Properties - Open Area ............................................................................................... 152
2.90. Drop-Off Elements and a Butt Joint Between Two Cores ..................................................................... 153
2.91. Production Ply Context Menu ............................................................................................................ 156
2.92. Analysis Ply Context Menu ................................................................................................................ 156
2.93. CSV Import with Update Options ....................................................................................................... 157
2.94. Export Ply Geometry Window ............................................................................................................ 159
2.95. General Properties Options ............................................................................................................... 162
2.96. Draping Properties Options ............................................................................................................... 163
2.97. Thickness Properties Options ............................................................................................................ 163
2.98. Imported Production Ply Dialog ........................................................................................................ 164
2.99. Imported Analysis Ply ........................................................................................................................ 165
2.100. Field Definitions Context Menu ....................................................................................................... 166
2.101. Field Definition Context Menu ......................................................................................................... 167
2.102. Field Definition Object Properties .................................................................................................... 168
2.103. Sampling Point Properties (General Tab) .......................................................................................... 169

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2.104. Sampling Point Properties (Analysis Tab Containing Lay-up Sequence and Polar Properties) ............. 170
2.105. General Section Cut Properties ........................................................................................................ 171
2.106. Wire Frame Options ......................................................................................................................... 172
2.107. Surface Options .............................................................................................................................. 172
2.108. Section Cut Crossing an Element Corner .......................................................................................... 173
2.109. Element Normals ............................................................................................................................. 174
2.110. Surface Normal vs. Surface Sweep Based Extrusion ........................................................................... 174
2.111. Ply-Wise Angles on the Surface Section Cut ..................................................................................... 175
2.112. Supported Lay-up for T-Joints .......................................................................................................... 175
2.113. Export Surface Section Cut Options ................................................................................................. 175
2.114. Elastic Properties after Running Analysis of the Sectional Properties (via Run Analysis Button) .......... 176
2.115. Section Cut Mesh and Results .......................................................................................................... 177
2.116. 3D Representation of a Beam Slice (with Respect to the Global Coordinate System) .......................... 178
2.117. Sensor Properties ............................................................................................................................ 182
2.118. Solid Model Folder with a Standard Solid Model and an Imported Solid Model ................................. 183
2.119. Solid Model Feature in the Tree View ................................................................................................ 184
2.120. Solid Model Properties - General ...................................................................................................... 185
2.121. Illustration of Solid Model Extrusion Methods .................................................................................. 187
2.122. Offset Direction - Schema ................................................................................................................ 187
2.123. Offset Direction - Example ............................................................................................................... 187
2.124. Solid Model Properties - Drop-Offs ................................................................................................... 189
2.125. Disable Drop-Offs ............................................................................................................................ 190
2.126. Connect Butt-Jointed Plies .............................................................................................................. 190
2.127. Solid Model Properties - Export ....................................................................................................... 191
2.128. Write Degenerated Elements ........................................................................................................... 192
2.129. Quadratic Tetrahedral Element on Top of a Hexahedral Element ....................................................... 192
2.130. Transferred Element Sets in Mechanical ........................................................................................... 193
2.131. Properties of the ACP-Pre Setup Cell in the Project Schematic .......................................................... 194
2.132. Extrusion with and without an Edge Set Guide ................................................................................. 195
2.133. Extrusion Guide Properties .............................................................................................................. 196
2.134. Reordering Extrusion Guides ........................................................................................................... 197
2.135. Mesh Morphing Diagram ................................................................................................................. 198
2.136. Example of a Direction-type Extrusion Guide with Different Mesh Morphing Radii ............................ 199
2.137. Example of a Geometry-type Extrusion Guide with Different Mesh Morphing Depths. ...................... 200
2.138. Extrusion without Snap Operation ................................................................................................... 201
2.139. Extrusion with Snap-To Geometry at the Top (Shell Geometry also Displayed) .................................. 202
2.140. Extrusion with Snap-To Geometry at the Top and Bottom (Shell Geometry also Displayed) ................ 202
2.141. Extruded Solid Model ...................................................................................................................... 203
2.142. Cut-Off Geometries Shown Alongside Extruded Solid Model ............................................................ 203
2.143. Solid Model with Cut-Off Features ................................................................................................... 203
2.144. Cut-Off Geometry Normal Direction ................................................................................................ 204
2.145. Example of three Cut-Off geometries ............................................................................................... 205
2.146. A Degenerated Hexahedral Element (left) is Decomposed into Several Tetrahedral Elements (right) ... 205
2.147. Solid Model with Highlighted Drop-Off elements ............................................................................. 207
2.148. Tree Object of the Imported Solid Model Feature ............................................................................. 208
2.149. Transfer of Mesh Components from an External Mesh via External Model, Mechanical to ACP Pre ...... 212
2.150. Element Normals of the Filler Elements Computed from Two Rosettes. ............................................. 217
2.151. Thickness Plot ................................................................................................................................. 226
2.152. Angle Plot ....................................................................................................................................... 227
2.153. Draping Mesh Plot Properties .......................................................................................................... 228
2.154. Draping Mesh ................................................................................................................................. 228

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2.155. Draping Plot for a Hemisphere ......................................................................................................... 229

2.156. Flatwrap Surface of the Ply .............................................................................................................. 229
2.157. Look-Up Table Plot General Properties Tab ....................................................................................... 230
2.158. Look-Up Table Plot of a 1-D Scalar Quantity with Supporting Points Shown as Circles ........................ 231
2.159. Lay-Up Mapping General Properties Tab .......................................................................................... 232
2.160. Deviation of the Normal Direction between Shell Elements and Layered Solid Elements ................... 232
2.161. Scene Properties ............................................................................................................................. 233
2.162. Connection of ACP and Workbench Parameter Interface .................................................................. 241
2.163. Parameter Properties ....................................................................................................................... 242
2.164. Material Database ........................................................................................................................... 245
2.165. Export and Import Options in Model Context Menu ......................................................................... 246
2.166. HDF5 Composite CAE File Export Settings ........................................................................................ 247
2.167. 3D Representation of a Lay-Up with Offset Ply Surfaces .................................................................... 247
2.168. The External Model Component in Workbench ................................................................................ 248
2.169. HDF5 Composite CAE File Import Settings ....................................................................................... 250
2.170. Schematic of Tolerance Settings for a Single Element ....................................................................... 252
2.171. SHELL181 Keyopts ........................................................................................................................... 253
2.172. SHELL281 Keyopts ........................................................................................................................... 254
2.173. SOLID185 Keyopts ........................................................................................................................... 254
2.174. SOLID186 Keyopts ........................................................................................................................... 254
2.175. Configuration Overview .................................................................................................................. 255
2.176. Configuration Overview .................................................................................................................. 256
2.177. A Four Ply Mechanical APDL Lay-up Where a Ply Crosses the Reference Surface is Converted to a Five
Ply ACP Lay-up .......................................................................................................................................... 257
2.178. ModelingGroup Tabular Format in Excel ........................................................................................... 257
2.179. Look-Up Table Tabular Format in Excel ............................................................................................. 258
3.1. T-Joint Lay-Up ..................................................................................................................................... 262
3.2. OSS for the Base Plate ......................................................................................................................... 262
3.3. OSS for the Stringer ............................................................................................................................. 263
3.4. OSS for Bonding Plies .......................................................................................................................... 263
3.5. Reference Direction ............................................................................................................................ 264
3.6. Laminate of the Base Plate .................................................................................................................. 265
3.7. Laminate of the Base Plate and Stringer ............................................................................................... 265
3.8. First Bonding Laminate ....................................................................................................................... 266
3.9. Second Bonding Laminate .................................................................................................................. 266
3.10. Cover Plies ........................................................................................................................................ 267
3.11. Tube Selection Rule ........................................................................................................................... 268
3.12. Rules Tab of the Modeling Ply Property Dialog ................................................................................... 268
3.13. Resulting Local Reinforcements ......................................................................................................... 269
3.14. Simple Edge Tapering ........................................................................................................................ 270
3.15. Tapered Edge .................................................................................................................................... 270
3.16. Tapering in Ply Definition .................................................................................................................. 271
3.17.Thickness Distribution After Core Tapering ......................................................................................... 271
3.18. Superposition of Modeling Plies with Identical Taper Angles. Schematic (Middle) and Section View Illus-
tration (Right) ........................................................................................................................................... 272
3.19. Thickness Distribution of a Laminate with a Cutoff Selection Rule ....................................................... 273
3.20. Template Selection Rule Definition .................................................................................................... 273
3.21. Imported Core Geometry .................................................................................................................. 274
3.22. Modeling Ply Thickness Definition ..................................................................................................... 275
3.23. Section with Variable Core Thickness ................................................................................................. 275
3.24. Table Definition ................................................................................................................................. 276

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3.25. Thickness Definition Through Tabular Values ...................................................................................... 276

3.26. Section Cut and Thickness Contour Plot ............................................................................................. 277
3.27. Imported Cut-Off Geometry .............................................................................................................. 278
3.28. Resulting Thickness Distribution (Ply Tapering Activated) ................................................................... 278
3.29. Flatwrap (Boundary) .......................................................................................................................... 279
3.30. Draping Mesh with Shear Energy ....................................................................................................... 280
3.31. Draping Definition in OSS .................................................................................................................. 281
3.32. Tabular Values Definition of Draping .................................................................................................. 282
3.33. Fiber and Draped Fiber Directions ..................................................................................................... 283
3.34. Analyzing a Solid Model Alongside a Shell Model ............................................................................... 286
3.35. Solid Model Assembly Workflow ........................................................................................................ 287
3.36. Conversion of the Named Selections in the Solid Model Workflow ...................................................... 288
3.37. A quadrilateral interface element surrounded by a brick element and two tetrahedral elements created
when the Drop-Off is split ......................................................................................................................... 290
3.38. T-Joint Section Cut ............................................................................................................................ 291
3.39. Class40 Section Cut ........................................................................................................................... 291
3.40. Insert Deformation Object under the Solution Group ......................................................................... 292
3.41. Modify the Display Time and/or Deformation Scale of the Result Object ............................................. 292
3.42. Insert a Composite Failure Tool under the Solution ............................................................................. 293
3.43. Configure the Failure Criteria definition in the Composite Failure Tool group ...................................... 293
3.44. Modify the Displayed Information (Failure Mode, Critical Layer) .......................................................... 294
3.45. Type of Failure Plot ............................................................................................................................ 294
3.46. IRF Value, Text Plot for Each Element, and Zoom on Area (Tutorial 1) ................................................... 295
3.47. Active Ply-Wise Scoping .................................................................................................................... 296
3.48. Select Ply Field .................................................................................................................................. 296
3.49. Select a Ply in the Imported Plies Group ............................................................................................. 297
3.50. Evaluate the Result of Ply-Wise Scoping (Tutorial 1) ............................................................................ 297
3.51. Promote the Failure Criteria Definition of the Composite Failure Tool .................................................. 298
3.52. Modify the Promoted Composite Failure Criteria Object when Necessary ........................................... 299
3.53. Insert a Composite Sampling Point Tool Object .................................................................................. 299
3.54. Select Failure Criteria under Sampling Point Tool Group ..................................................................... 300
3.55. Choose Sampling Point on Geometry and Apply Selection ................................................................. 300
3.56. Review the Selected Point ................................................................................................................. 300
3.57. Evaluate the Sampling Point’s Results ................................................................................................ 301
3.58. Field Definition Properties to Set Up a Degradation Factor Field ......................................................... 305
4.1. ACP Components ................................................................................................................................ 309
4.2. Engineering Data Sources ................................................................................................................... 309
4.3. Outline of Composite Materials ........................................................................................................... 310
4.4. Material Properties for ACP .................................................................................................................. 311
4.5. Context Menu of ACP (Pre) Setup ........................................................................................................ 313
4.6. Connecting a Static Structural Analysis to ACP (Pre) using a Drag and Drop Operation .......................... 314
4.7. Conversion of the Named Selections in the Solid Model Workflow ........................................................ 316
4.8. Workbench Software Workflow for Composite Solid Modeling with Mechanical Application ................. 317
4.9. Workbench Software Workflow for Composite Solid Modeling with Mechanical APDL Application ........ 317
4.10. Analysis of a Composite Doubly-Curved Specimen and Metal Grips Modeled with Mechanical Applica-
tion .......................................................................................................................................................... 318
4.11. One Layered Solid Specimen and Two Metal Grips in Mechanical Model ............................................. 318
4.12. Analysis of Composite Plate and T-joint Modeled with the Mechanical APDL Application .................... 319
4.13. Add Reference File ............................................................................................................................ 319
4.14. List of Used Files and Their Order in Mechanical APDL ........................................................................ 319
4.15. Race Car Setup in the Workbench Application .................................................................................... 321

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4.16. Predefined and User-Defined Field Variables in Engineering Data ....................................................... 322
4.17. Assigning a Field Variable to Material Property ................................................................................... 322
4.18. Populating the Tabular Material using the CSV Interface ..................................................................... 323
4.19. Setting Interpolation Options ............................................................................................................ 323
4.20. Draping Results ................................................................................................................................. 324
4.21. Distribution of the Curing Degree (Scalar Look-Up Table Plot) ............................................................ 325
4.22. Activating a Look-Up Table to Define Curing per Modeling Ply (Layer-Wise) ........................................ 325
4.23. Using External Data to Define Temperature Field ................................................................................ 326
4.24. Inverse Reserve Factor (Constant Material Data on the Left; Variable Material Properties on the
Right) ....................................................................................................................................................... 326
4.25. Geometry and Lay-Up of the Composite Spring ................................................................................. 327
4.26. Complete Project Schematic in the Workbench Application ............................................................... 328
4.27. Mechanical Application Model F4 with the Bodies Roving and Tube ................................................... 329
4.28. Detail View of the Final Solid Mesh with Hex Elements only in the Outer Body .................................... 330
4.29. Mesh Features and Solid Mesh with the Inflation Layers and Roving Cross Section .............................. 330
4.30. Imported Solid Model Properties Dialog ............................................................................................ 331
4.31. Figure: Lay-up Mapping Definition of the Mesh Component Tube ...................................................... 332
4.32. The Filler Options for the Roving ........................................................................................................ 332
4.33. Filler Elements and Fiber Directions ................................................................................................... 333
4.34. Using the Filler Option for the Roving ................................................................................................... 334
4.35. Ply-wise Failure Analysis .................................................................................................................... 335
4.36. Project Setup in the Workbench Application ...................................................................................... 336
4.37. Woven RVE defined in Material Designer Application ......................................................................... 336
4.38. Materials in the Engineering Data Component of the ACP system ...................................................... 337
4.39. Shear Dependent Fabric Fiber Angle .................................................................................................. 337
4.40. Ply Definition .................................................................................................................................... 338
4.41. Fiber (Light Green), Transverse (Dark Green) and Material 1 (Red) Directions ....................................... 338
4.42. Draping Definition ............................................................................................................................ 339
4.43. Draping Mesh in the ACP Application ................................................................................................ 340
4.44. Shear Angle Plot ............................................................................................................................... 340
4.45. Draped Fiber Direction (Light Blue), Draped Transverse Direction (Blue) and Material 1 Direction
(Red) ........................................................................................................................................................ 341
4.46. Shear-Dependent Young's Modulus ................................................................................................... 341
4.47. Deformation Plot (variable material on left, constant material on right) ............................................... 342
4.48. 3D Ply Workflow (Courtesy of 9T Labs) ............................................................................................... 343
4.49. HDF5 Composite CAE Imported as 3D Plies (Imported Modeling Plies) ............................................... 344
4.50. 3D Printing with Endless Fiber Reinforcement and Final Part (Courtesy of 9T Labs) .................... 344
4.51. Simulation of a 3D Printed Composite (Courtesy of 9T Labs) ............................................................... 345
4.52. Distribution of the Inverse Reserve Factors in the Mapped Composite Solid Model ............................. 346
4.53.The Drag-and-Drop Workflow Showing the Transfer of ACP Composite Models to a Workbench LS-DYNA
Analysis System ........................................................................................................................................ 347
4.54. Setting up an Automatic Conversion of LS-DYNA Material Models ...................................................... 348
4.55. Material Definition for LS-DYNA in Engineering Data .......................................................................... 349
4.56. Geometry Preparation in SpaceClaim ................................................................................................ 349
4.57. Mechanical Model - Assigning Part Properties to the Bird Body .......................................................... 350
4.58. Defining Materials in ACP .................................................................................................................. 351
4.59. Composite Lay-Up Modeling in ACP .................................................................................................. 351
4.60. : Setting Up the Analysis .................................................................................................................... 352
4.61. Accessing Input Files and Results Files ............................................................................................... 353
4.62. Workflow of a Model Analysis with an Equivalent Beam Model ........................................................... 354
4.63. Cross Section and Layup of the Box ................................................................................................... 355

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4.64. Computation Result of the Equivalent Beam Properties ...................................................................... 356

4.65. Mesh of the Cross Section and its Principal Properties ........................................................................ 356
4.66. APDL Snippet to Apply the Beam Properties ...................................................................................... 357
4.67. Comparison of Mode Shapes for the First and Fifth Frequencies ......................................................... 358
4.68. Geometry of the Generic Wind Turbine Blade ..................................................................................... 360
4.69. Wind Turbine Blade with the 101 Cross Sections ................................................................................. 361
4.70.Two Meshes of Different Cross Sections and the Corresponding Shear, Elastic, and Center of Gravity .... 361
4.71. APDL Snippet with the Generated Output from ACP .......................................................................... 362

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List of Tables
1.1. Predefined Unit Systems ....................................................................................................................... 20
2.1. Key Differences Between a Modeling Ply and Imported Modeling Ply ................................................... 160
4.1. Material Properties .............................................................................................................................. 355
4.2. Comparison of the 3D Solid Model and Equivalent Beam Model Results ............................................... 357
4.3. Material Properties .............................................................................................................................. 360
4.4. Comparison of the 3D Shell Model and Equivalent Beam Model Results ............................................... 362

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Chapter 1: Getting Started
The following sections describe how to begin using Ansys Composite PrepPost (ACP):
1.1. Overview
1.2.The Ansys Product Improvement Program
1.3. Graphical User Interface
1.4. Implementation in Workbench
1.5. Migrating ACP Projects from Previous Versions
1.6.The ACP Python Scripting User Interface
1.7. Stand Alone Operation
1.8.Tutorials and Examples

1.1. Overview
The following sections provide an overview of Ansys Composite PrepPost (ACP).
1.1.1. Introduction
1.1.2. Supported Platforms and Functional Add-ons
1.1.3. Known Limitations
1.1.4. First Steps

1.1.1. Introduction
Composite materials are created by combining two or more layered materials, each with different
properties. These materials have become a standard for products that are both light and strong.
Composites provide enough flexibility so products with complex shapes, such as boat hulls and
surfboards, can be easily manufactured.

Engineering layered composites involves complex definitions that include numerous layers, materials,
thicknesses and orientations. The engineering challenge is to predict how well the finished product
will perform under real-world working conditions. This involves considering stresses and deformations
as well as a range of failure criteria. Ansys Composite PrepPost provides all the necessary functional-
ities for preprocessing layered composite structures, while Mechanical provides postprocessing cap-
abilities for composite analyses.

ACP Workflows
Ansys Composite PrepPost (ACP) is an add-in to Ansys Workbench and is integrated with the standard
analysis features. As a result, the entire workflow for a composite structure can be completed from
design to final production information.

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Getting Started

The geometry of the tooling surfaces of a composite structure is the basis for analysis and production.
Based on this geometry and a FE mesh, the boundary conditions and composite definitions are applied
to the structure in the preprocessing stage. After a completed solution, the post-processing is used
to evaluate the performance of the design and laminate. In the case of an insufficient design or ma-
terial failure, the geometry or laminate has to be modified and the evaluation is repeated.

ACP has only a preprocessing mode, in which all composite definitions can be created and mapped
to the geometry (FE mesh). Then, these composite definitions are transferred to the FE model and
the solver input file. After the composite analysis is completed and the result file(s) are imported,
postprocessing results (failure, safety, strains, and stresses) can be evaluated and visualized in Mech-
anical.

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 Overview

1.1.2. Supported Platforms and Functional Add-ons

Supported Platforms
ACP is supported on both Windows and Linux systems. For information about specific operating
system versions and distributions, see the Platform Support section of the Ansys Website.

ACP has additional library dependencies in Red Hat Enterprise Linux, for information on how to install
those libraries, see Post-Installation Procedures for Other Products in the Ansys, Inc. Linux Installation
Guide.

Functional Add-ons
ACP provides functional add-ons for problem-specific functionality. These add-ons are not considered
appropriate for general use and should be used with caution. No standard documentation is provided
for these features, but additional information is available on request. For more information, contact
info-switzerland@ansys.com.

For information on how to activate these add-ons, see Add Ons (p. 17).

1.1.3. Known Limitations

ACP has the following known limitations. Note that feature-specific limitations are often documented
with the corresponding feature description throughout the ACP user's guide.

Support for Unicode

Unicode is supported in ACP except for these features:

• Names in CDB Export: Unicode (non-ASCII) characters in an ACP model are converted to underscores
when the model is exported as a CDB (coded database) file. This can cause two different names to
become the same after the conversion.

ACP issues a warning when a duplicate name is exported. This check for all names that are considered
equivalent in Mechanical APDL is stricter than the check for the conversion from Unicode to ASCII.

• File Paths in ACP to Mechanical APDL Workflows: In an ACP to Mechanical APDL workflow
within Workbench, the file path of the Workbench project must not contain Unicode (non-ASCII)
characters.

• Laminate Plot Labels: The labels in the laminate plots of stackups, sublaminates, and sampling
points support only a limited set of Unicode.

• User-Defined Plot Text: The user-defined text in user-defined plots supports only a limited set of
Unicode.

• Ply Books in PDF Format: When generating a Ply Book in PDF format, you must adjust the font
in case unsupported characters are used.

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Getting Started

Composite Failure Tool for Migrated ACP Projects

The Composite Failure Tool in Mechanical can only be used in migrated projects once the ACP (Pre)
Setup Workbench cell has been updated.

Coordinate System Naming for Migrated ACP Projects

In Version 2019 R2, naming is maintained when coordinate systems defined in Workbench are trans-
ferred to ACP as Rosettes. (See Rosettes (p. 103).) When migrating projects from previous versions, the
Oriented Selection Set Properties may lose the Rosette link due to the renaming. This will require lay-
up definitions to be updated manually as shown in Figure 1.1: Oriented Selection Set Properties (p. 4).
For more information on migrating projects from previous versions, see Migrating ACP Projects from
Previous Versions (p. 53).

Figure 1.1: Oriented Selection Set Properties

Export System(s) and Import to Workbench

The Export System(s) and Import of Workbench projects are not supported for ACP Systems. With
this current limitation, the imported ACP systems cannot be updated correctly after import.

Parameters
In ACP, Parameters, and how they are handled by the Parameter Manager, have certain limitations.
See the Parameters (p. 241) section for additional information.

Options for Objects with the Same Name

The application allows you to create objects with the same name. However, there are certain property
specification and graphical selection limitations for this scenario. Based on the object type, you may
not be able to define the properties to include objects with the same name. For example, you cannot
define Sub Laminates using a Fabric and Stackup that have the same name.

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 The Ansys Product Improvement Program

1.1.4. First Steps

The best way to get to know the features of ACP is to attempt one of the tutorials. There are two
tutorials that explain step-by-step how to define and analyze basic composite structures. The tutorials
both start off with existing Workbench projects. These sample projects and more information can be
found in the ACP Tutorials. Knowledge of Ansys Workbench is a prerequisite.

For information on how to build a composite model from new, see Analysis of a Composite Shell
Model (p. 307).

There are many ways to implement ACP in Workbench. The workflow for modeling composite solid
element models is described in Analysis of a Composite Shell Model (p. 307). Other examples are
shown in Implementation in Workbench (p. 38).

Composite Modeling Techniques (p. 261) offers an insight into modeling approaches for common
composite problems.

Explanations and specific information of the ACP features can be found in Features (p. 61).

Background information on the underlying theory used in ACP is available in Composites Theory
Reference in the Composites Theory Reference. This is especially of interest for the failure criteria.

1.2. The Ansys Product Improvement Program

This product is covered by the Ansys Product Improvement Program, which enables Ansys, Inc., to collect
and analyze anonymous usage data reported by our software without affecting your work or product
performance. Analyzing product usage data helps us to understand customer usage trends and patterns,
interests, and quality or performance issues. The data enable us to develop or enhance product features
that better address your needs.

How to Participate
The program is voluntary. To participate, select Yes when the Product Improvement Program dialog
appears. Only then will collection of data for this product begin.

How the Program Works

After you agree to participate, the product collects anonymous usage data during each session. When
you end the session, the collected data is sent to a secure server accessible only to authorized Ansys
employees. After Ansys receives the data, various statistical measures such as distributions, counts,
means, medians, modes, etc., are used to understand and analyze the data.

Data We Collect
The data we collect under the Ansys Product Improvement Program are limited. The types and amounts
of collected data vary from product to product. Typically, the data fall into the categories listed here:

Hardware: Information about the hardware on which the product is running, such as the:

• brand and type of CPU

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Getting Started

• number of processors available

• amount of memory available

• brand and type of graphics card

System: Configuration information about the system the product is running on, such as the:

• operating system and version

• country code

• time zone

• language used

• values of environment variables used by the product

Session: Characteristics of the session, such as the:

• interactive or batch setting

• time duration

• total CPU time used

• product license and license settings being used

• product version and build identifiers

• command line options used

• number of processors used

• amount of memory used

• errors and warnings issued

Session Actions: Counts of certain user actions during a session, such as the number of:

• project saves

• restarts

• meshing, solving, postprocessing, etc., actions

• times the Help system is used

• times wizards are used

• toolbar selections

Model: Statistics of the model used in the simulation, such as the:

• number and types of entities used, such as nodes, elements, cells, surfaces, primitives, etc.

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 The Ansys Product Improvement Program

• number of material types, loading types, boundary conditions, species, etc.

• number and types of coordinate systems used

• system of units used

• dimensionality (1-D, 2-D, 3-D)

Analysis: Characteristics of the analysis, such as the:

• physics types used

• linear and nonlinear behaviors

• time and frequency domains (static, steady-state, transient, modal, harmonic, etc.)

• analysis options used

Solution: Characteristics of the solution performed, including:

• the choice of solvers and solver options

• the solution controls used, such as convergence criteria, precision settings, and tuning options

• solver statistics such as the number of equations, number of load steps, number of design points,
etc.

Specialty: Special options or features used, such as:

• user-provided plug-ins and routines

• coupling of analyses with other Ansys products

Data We Do Not Collect

The Product Improvement Program does not collect any information that can identify you personally,
your company, or your intellectual property. This includes, but is not limited to:

• names, addresses, or usernames

• file names, part names, or other user-supplied labels

• geometry- or design-specific inputs, such as coordinate values or locations, thicknesses, or other

dimensional values

• actual values of material properties, loadings, or any other real-valued user-supplied data

In addition to collecting only anonymous data, we make no record of where we collect data from. We
therefore cannot associate collected data with any specific customer, company, or location.

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Getting Started

Opting Out of the Program

You may stop your participation in the program any time you wish. To do so, select Ansys Product
Improvement Program from the Help menu. A dialog appears and asks if you want to continue parti-
cipating in the program. Select No and then click OK. Data will no longer be collected or sent.

The Ansys, Inc., Privacy Policy

All Ansys products are covered by the Ansys, Inc., Privacy Policy.

Frequently Asked Questions

1. Am I required to participate in this program?

No, your participation is voluntary. We encourage you to participate, however, as it helps us create
products that will better meet your future needs.

2. Am I automatically enrolled in this program?

No. You are not enrolled unless you explicitly agree to participate.

3. Does participating in this program put my intellectual property at risk of being collected or discovered
by Ansys?

No. We do not collect any project-specific, company-specific, or model-specific information.

4. Can I stop participating even after I agree to participate?

Yes, you can stop participating at any time. To do so, select Ansys Product Improvement Program
from the Help menu. A dialog appears and asks if you want to continue participating in the program.
Select No and then click OK. Data will no longer be collected or sent.

5. Will participation in the program slow the performance of the product?

No, the data collection does not affect the product performance in any significant way. The amount
of data collected is very small.

6. How frequently is data collected and sent to Ansys servers?

The data is collected during each use session of the product. The collected data is sent to a secure
server once per session, when you exit the product.

7. Is this program available in all Ansys products?

Not at this time, although we are adding it to more of our products at each release. The program
is available in a product only if this Ansys Product Improvement Program description appears in the
product documentation, as it does here for this product.

8. If I enroll in the program for this product, am I automatically enrolled in the program for the other Ansys
products I use on the same machine?

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 Graphical User Interface

Yes. Your enrollment choice applies to all Ansys products you use on the same machine. Similarly,
if you end your enrollment in the program for one product, you end your enrollment for all Ansys
products on that machine.

9. How is enrollment in the Product Improvement Program determined if I use Ansys products in a cluster?

In a cluster configuration, the Product Improvement Program enrollment is determined by the host
machine setting.

10. Can I easily opt out of the Product Improvement Program for all clients in my network installation?

Yes. Perform the following steps on the file server:

a. Navigate to the installation directory: [Drive:]\v251\commonfiles\globalsettings

b. Open the file ANSYSProductImprovementProgram.txt.

c. Change the value from "on" to "off" and save the file.

Additional Notes specific to ACP

If you run ACP in standalone mode, you can opt out or in under Tools > Preferences > ACP > Ansys
Product Improvement Program.

1.3. Graphical User Interface

The user interface is split into the following parts:
1.3.1. Menus
1.3.2.Tree View
1.3.3. Scene
1.3.4.Toolbar
1.3.5. View Panes
1.3.6. Keyboard Shortcuts

The interface also contains View Panes (p. 34) that show how individual elements within the ACP interface
can be rearranged.

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Getting Started

Figure 1.2: Ansys Composite PrepPost GUI

1.3.1. Menus
ACP (Pre) provides the following menu options:
1.3.1.1. File
1.3.1.2. View
1.3.1.3.Tools

Figure 1.3: Ansys Composite PrepPost Menu Options

1.3.1.1. File
The File menu differs between Workbench and Stand Alone mode.
1.3.1.1.1. Workbench
1.3.1.1.2. Stand Alone

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1.3.1.1.1. Workbench
When you launch ACP (Pre) from Workbench, the File menu contains the following options:

Save Project: If the project was not already saved, specify the project name and location.
Saves the entire Workbench project.
Refresh All Data: Reloads the model in ACP. If the model is not up-to-date in the
Workbench schematic, changes on the model (mesh, Named Selections) are not transferred
to ACP. If you have made changes to the model, close ACP and update the model in
Workbench.
Run Script: Select a Python script to execute.
Exit: Exit from Ansys Composite PrepPost. Any newly defined ACP features are not deleted.

Figure 1.4: File Menu for Workbench Integration

1.3.1.1.2. Stand Alone

When you open the application in stand-alone mode (via the Start menu), the File menu contains
the following options:

Open: Open an existing database.

Save: Save the active database.
Save As: Save the active database, select location and file name.
Save All: Save all open databases.
Close: Close the active database.
Close All: Close all open databases.
Import Model: Import an Ansys model.
Run Script: Select a Python script to execute.
Exit: Exit from Ansys Composite PrepPost. Any newly defined ACP Features are not de-
leted.

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Getting Started

Figure 1.5: Stand-Alone File Menu

1.3.1.2. View
The layout of the GUI is managed through the View menu.
1.3.1.2.1. Perspectives
1.3.1.2.2. View Manager

Figure 1.6: View Menu

1.3.1.2.1. Perspectives
The Perspectives submenu allows you to manage different interface layouts:

Perspective: Activate a named Perspective. Available perspectives appear in a list in the

drop-down menu.
New Perspective: Create a new Perspective.
Save Perspective As: Save the current interface layout into a new Perspective.
Rename Perspective: Modify the name of the active Perspective.
Delete Perspective: Delete the active Perspective.
Reset Perspective: Reset the active Perspective to an empty Perspective.
Reset All Perspectives: Reset all defined Perspectives.

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 Graphical User Interface

Figure 1.7: Perspective Submenu

1.3.1.2.2. View Manager

Interface elements can be added or removed from a Perspective by clicking Other... to bring up
the View Manager. To activate a View, select it in the View Manager and click OK. The selected
View appears in the View menu for the selected perspective. Views present in the Perspective
can be activated or deactivated through the View menu.

Figure 1.8: Show View

1.3.1.3. Tools
You will find the following options in the Tools menu:
1.3.1.3.1. Extract Materials From Composite CAE H5...
1.3.1.3.2. Winding Wizard
1.3.1.3.3. Migration Helper
1.3.1.3.4. Preferences

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Figure 1.9: Tools Menu

1.3.1.3.1. Extract Materials From Composite CAE H5...

This option allows you to extract material data from an HDF5 Composite CAE (p. 245) file for use
in Workbench. Using the dialog box shown below, specify the HDF5 Composite CAE file which
contains the materials data. Then select the folder where you want to save it. ACP saves the
materials in MatML format so it can be imported into Engineering Data in Workbench.

Figure 1.10: Extract Materials From Composite CAE H5... Dialog

1.3.1.3.2. Winding Wizard

The Winding Wizard generates a winding lay-up for an axisymmetric body. The Wizard is useful
for creating a simple lay-up where the paths are geodesic. For more complex winding lay-ups,
consider importing the lay-up from a dedicated winding tool using ACP's feature Import from
HDF5 Composite CAE File … (See HDF5 Composite CAE Format (p. 245).) CADWIND, CADFIL ,and
μWind (Mefex GmbH) are all able to export Composite CAE H5 files and generate machine code.
Below are links to their websites.

• https://www.material.be/cadwind/intro/

• https://www.cadfil.com/

• https://mefex.de/software/wind

The Wizard uses the Origin (a point on the axis of symmetry), the Axial Direction, and the Reference
Radius to automatically generate a winding lay-up for an axisymmetric body. The radius is defined
as the minimal distance from any point on the surface to the axis of symmetry. The Reference
Radius is equal to the radius where the layers have the nominal thickness and angle. For a typical
winding body, this is the radius in the cylindrical region.

The thickness correction of each layer is calculated with:

(1.1)

The angle is calculated based on a geodesic path for which is constant:

(1.2)

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 Graphical User Interface

(1.3)

otherwise with
(1.4)

Each layer has the following properties, which can be defined in the table:

• Fabric: Fabric of the layer (Stackups and Sublaminates are not supported).

• Angle: Nominal angle at Reference Radius with respect to the axis of symmetry (in degrees).

• Ply limits: If "Has limits" is true, the ply ends at the locations defined by the "Upper Limit" and
"Lower Limit" column. The "Upper Limit" and "Lower Limit" values are interpreted as distance
from the origin along the axial_direction.

• Add mirrored ply: If set to True, an additional layer with the same properties but a negative
angle is generated. This implies that the resulting thickness is twice the original thickness of
the layer.

You can also import the layers from a CSV file with the Import from CSV button. Columns are
Fabric Id, Nominal Angle, Has Limits, Lower Limit, Upper Limit, and Add Mirrored Ply. Example
Row:

Fabric.1,30,True,0,1,False

The Wizard generates the following objects:

• A cylindrical Rosette

• An Oriented Selection Set which defines a reference direction along the axial direction of the
axisymmetric body

• A Lookup Table with the thickness corrections and angles

• A template Selection Rule if limits are defined

• A Modeling Group with the Plies

Once the lay-up is generated, you can manually adjust it. For example, you can edit the thicknesses
and angles in the Look-up Table or edit the parameters of the Selection Rule.

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Getting Started

Figure 1.11: Winding Wizard with the Inputs on Top and the Description at the Bottom

1.3.1.3.3. Migration Helper

The Migration Helper tool enables migrating previous composite analyses to the Mechanical
application. For more information, see ACP (Post) to Mechanical Software Migration (p. 54).

1.3.1.3.4. Preferences
You can configure the following application settings through the Preferences submenu:

• Add Ons (p. 17)

• Ansys Product Improvement Program (p. 17)

• General ACP Preferences (p. 17)

• Logger Settings (p. 18)

• Material Database (p. 18)

• Notifications and Pop-ups (p. 19)

• Scene Preferences (p. 19)

• Section Generation (p. 20)

• Units (p. 20)

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Figure 1.12: Preferences Window

1.3.1.3.4.1. Add Ons

Add-Ons: Activate or deactivate the available add-ons (p. 3).

1.3.1.3.4.2. Ansys Product Improvement Program

Ansys Product Improvement Program: Here you can opt to participate in the Ansys Product
Improvement Program. Refer to the section Ansys Product Improvement Program (p. 5) for
complete information.

The option applies only to workflows in ACP standalone operation. For Workbench workflows,
you must opt into the Ansys Product Improvement Program using the Workbench settings.

1.3.1.3.4.3. General ACP Preferences

In the General heading, the following options are available:

Ansys Executable Path: Path to the ansys.exe file (solver). If empty, ACP uses the
default path from the installation.
Ansys License: Defines which license will be used to solve the model. For more inform-
ation on licenses, see Product to License Feature Mapping in the Ansys, Inc. License
Management Guide. The Feature Name (from the Ansys Product to License Feature
Mapping Table) should be typed in this field. For example, enter struct for an Ansys
Mechanical Enterprise Solver. By default, the Ansys License field is empty, in which
case ACP uses the order of licenses defined in the LM Center.
Number of Threads to Use in Parallel: Specifies the number of cores/threads used
for computation. ACP uses all available cores when the option is zero (default).
H5 Compression Level: Specify the GZip compression level of HDF5 (storage format
of ACP). The default setting is 2. This setting provides good compression at an overhead
of about 35% when compared to no compression (setting of 0). The highest available
setting is 9. Note that processing requirements increase based on this setting. You will

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Getting Started

notice an increase in processing times with a setting of 4 and above. You need to
evaluate the benefits of increased processing time versus file size reduction.

Figure 1.13: General ACP Preferences

1.3.1.3.4.4. Logger Settings

Use the Logger Settings dropdown menu to set the severity level of messages displayed in
the Log Window. The levels are:

Debug: Log everything, including debugging information.

Info (default): Log everything, except debugging information.
Warning: Log errors and warnings.
Error: Log errors only.
Critical: Not used.

Number of Days to Keep Log Files: Specify how long the ACP log files are retained. By default,
ACP deletes files older than seven days. Note that keeping a large number of log files slows
down the ACP startup.

Figure 1.14: Logger Preferences

1.3.1.3.4.5. Material Database

Material Database: Define the path to the material database (.acpMdb file). See Material
Database (p. 244).

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 Graphical User Interface

1.3.1.3.4.6. Notifications and Pop-ups

Notifications and Pop-ups: Enable or disable notifications and confirmation dialogs.

1.3.1.3.4.7. Scene Preferences

In the Scene heading, some graphical properties of the model display can be modified. These
properties are grouped in three parts:

Figure 1.15: Scene Preferences

• Appearance: Background color of the Scene window can be defined as uniform or as a

gradient from bottom to top. To obtain a uniform background, Background Color and
Background Color 2 should have the same color definition. When defining a top to bottom
gradient, Background Color is the bottom color and Background Color 2 is the top color.
To modify these colors click Edit.

• Screenshot: By default, the size of the image captured by the Snapshot utility has the same
size as the Scene size. The size of the captured image can be fixed to a certain dimension.
This option should be used carefully.

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1.3.1.3.4.8. Section Generation

Section Generation: Define default tolerance values for the generation of sections
and the minimum analysis ply thickness. For more information see Lay-Up Computa-
tion (p. 65).

Figure 1.16: Section Generation Preferences

1.3.1.3.4.9. Units

You use the Units menu to change the active unit system.

Figure 1.17: Units Menu

The unit system can only be altered in preprocessing. It is locked in shared mode and postpro-
cessing. When changing from a predefined unit system to Undefined, or vice versa, no conver-
sions take place.

The unit system of the active model is displayed in the status bar at the bottom of the ACP
window.

Table 1.1: Predefined Unit Systems

Name Length Mass Time Length*Mass/Time2 Temperature Currency

BFT ft slug s lbf F USD
2
BIN in 1/in*lbf/s s lbf F USD
CGS cm g s dyn C USD
MKS m kg s N K USD

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 Graphical User Interface

Name Length Mass Time Length*Mass/Time2 Temperature Currency

MPA mm t s N C USD
SI m kg s N K USD
UMKS μm kg s μN C USD
Undefined - - - - - -

1.3.2. Tree View

The underlying Python Object Tree (see The ACP Python Scripting User Interface (p. 56)) is mapped
into the graphical Tree View. It provides an easy way of selecting objects or viewing/modifying the
state of an object. An explanation on how to modify specific objects in the Tree is provided in the
Usage Reference (p. 61).

Most Tree objects are associated with a context menu, which can be displayed by right-clicking the
object. Double-clicking a Tree object directly opens the Properties dialog for that object - providing
a shortcut from opening the context menu.

The Tree View is accompanied with a toolbar that is located at the top of the Tree View. The following
functions are available:

• Search allows you to search for Tree objects which have a name matching the search string.

• The collapse button folds the Tree back into its original state.

Note:

The search is case-insensitive and requires an exact match. Special characters are not
treated as wild cards and are not ignored in the search and object name strings. For ex-
ample, a search for "test object 1" will not return a match for an object named test_ob-
ject_1. Similarly, a search for "test_object_*" will not return a match for and object named
test_object_1.

Caution:

Care should be taken when defining objects while Tree filtering is active. The object selec-
tion must be consistent with what is displayed in the filtered Tree. It is recommended that
you clear any Tree filters while defining new objects.

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Getting Started

Figure 1.18: Tree View

A status symbol appears for each item.

Figure 1.19: Locked Rosettes and the Update Status

: Rosette is locked and up-to-date.

: Rosette is locked but not up-to-date.
: Rosette is updated.
: Rosette is hidden.

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 Graphical User Interface

: Rosette is not updated. It can be updated with the general update in the toolbar or
context menu.

The symbol indicates that this object is defined, but inactive and therefore not considered in any
evaluation. Among many others, Modeling Plies, Solid Models and Analysis Plies can be inactive.

You can move through the Tree using the arrow keys. The sub-trees are automatically reduced and
expanded.

Special shortcuts exist for the Modeling Group. For more information, see Usage Reference (p. 61)).

1.3.3. Scene
The Scene contains a 3D graphical representation of the model and all defined entities. There is no
limit to the number of Scenes that can be created, and changing from one Scene to another can be
done with a single click. You can navigate through the Scene by mouse or keyboard input. For more
information, see Scene Manipulation (p. 23).

1.3.3.1. Scene Manipulation

The view of the Scene can be manipulated using several buttons on the toolbar:

: Standard views along each axis.

: Zoom to fit the model.

: View full-screen.

: Active or deactivate perspective.

: Capture screenshot.

1.3.4. Toolbar
The toolbar interacts with the Scene by modifying camera views or displaying or hiding elements:
1.3.4.1. Updates
1.3.4.2. Edit Entities with Excel
1.3.4.3. Scene Options
1.3.4.4. Mesh Appearance
1.3.4.5. Orientation Visualization
1.3.4.6. Fiber Directions
1.3.4.7. Draping
1.3.4.8. Other Features
1.3.4.9. Configure Plots

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Getting Started

1.3.4.1. Updates
After some operations (for example, reloading the model, modification of one or more plies, or
activating postprocessing), an update ( ) of the Scene is necessary.

1.3.4.2. Edit Entities with Excel

: Create, edit, or save the entities such as Look-up Tables or Modeling Plies with Excel.

The Excel Link interface allows you to define, modify, or save the lay-up definition in an Excel
spreadsheet. The lay-up can be transferred to a spreadsheet using the push function or a lay-up
which has been defined in a spreadsheet can be imported into ACP using the pull function. By
default, all lay-up data is synchronized between Excel and ACP. Alternatively, you can select specific
Modeling Groups for which the lay-up is synchronized. In addition, Pull Mode controls how the lay-
up is transferred to ACP. The lay-up can be linked to a new spreadsheet or to an existing one. The
latter functionality gives you the ability to restore a lay-up from pre-defined data.

Figure 1.20: Excel Link Dialog

The main functions of the Excel Link are:

• Open Excel: Open an existing Excel file if specified. If no path is specified, a new worksheet is
opened and filled with the current lay-up information.

• Push to: Sync lay-up definition data from ACP to Excel.

• Pull from: Read definition data from Excel and update the definition in ACP.

• Close All: Close Excel and the ACP Dialog Box.

The following options are available for Pull Mode:

• Update Entities: During a Pull from operation, definitions are updated, additional plies are
generated and deleted according to Excel data.

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• Update Properties Only: During a Pull from operation, definitions are updated with properties
given.

• Recreate Entities: During a Pull from operation, existing lay-up is deleted and generated from
scratch. The ACP Tree order corresponds to the Excel spreadsheet order.

1.3.4.3. Scene Options

In the ACP application, the scene can be modified with the following buttons:

• : Camera positions. Place the camera along the coordinate system axes,
pointing towards the rotation center.

– : Camera placed along the positive x axis.

– : Camera placed along the negative x axis.

– : Camera placed along the positive y axis.

– : Camera placed along the negative y axis.

– : Camera placed along the positive z axis.

– : Camera placed along the negative z axis.

• : Zoom to fit the model in the Scene.

• : Show the Scene in Fullscreen mode. Press Esc to exit full screen mode.

• : Switch between parallel and perspective projection.

• Change the lighting mode of the scene:

– : (Dark mode) The model geometry is highlighted with pronounced shadows. This mode
matches the lighting mode of ACP version 2024 R2 and before.

– : (Light mode) Show only reduced shadows.

– : (No shadows) All surfaces are fully lit. This mode should be preferred when comparing
colors in a plot.

• : Create a View that captures the current Scene

• : Create a screenshot from the current Scene

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Getting Started

1.3.4.4. Mesh Appearance

Appearance of the mesh can be modified using several buttons on the toolbar:

• : Show or hide element edges.

• : Show or hide the mesh surface.

• : Show or hide the silhouette of the mesh. For huge meshes, this function is computa-
tionally expensive. This will prevent Scene manipulation while it is processing.

• : Highlight elements.

• : Highlight silhouette of selected elements even if it is hidden by mesh.

• Element Selection Mode: The button icon changes depending on which mode is active:

– : Automatically highlight shell or solid elements when an object of a shell or solid model
is selected. For example, when an Analysis Ply under a Solid Model (p. 184) is selected, that
element on the model is highlighted.

– : Highlight only shell elements. When an object of a solid model is selected (for example,
a Mesh Component of a Solid Model (p. 184)), nothing is highlighted.

– : Highlight only solid elements. If the selected object is not part of a solid model (for
example, a Modeling Ply or a Production Ply), nothing is highlighted.

• : Display probe values when hovering over model.

1.3.4.5. Orientation Visualization

You can display the surface orientations using the orientation buttons on the toolbar.

Figure 1.21: Orientation Visualizations in the Toolbar

: Display element normals or normal direction of CAD geometry parts.

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 Graphical User Interface

Figure 1.22: Visualization of the Element Normals

: Display orientation of an Oriented Selection Set (OSS).

Figure 1.23: Visualization of the OSS Normal

: Display reference direction of an Oriented Selection Set (OSS).

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Getting Started

Figure 1.24: Visualization of the OSS Reference Direction

1.3.4.6. Fiber Directions

The ply angles can be visualized with the fiber direction buttons on the toolbar.

Figure 1.25: Fiber Directions in the Toolbar

: Display the fiber direction of the selected ply.

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 Graphical User Interface

Figure 1.26: Visualization of the Fiber Direction

: Display the transverse ply direction.

Figure 1.27: Visualization of the Transverse Ply Direction

1.3.4.7. Draping
You can highlight the draping effect by comparing the fiber direction (see Fiber Directions (p. 28))
with the draped fiber direction as well as the transverse fiber direction with the transverse draped

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Getting Started

fiber direction. Moreover, if the Fabric Fiber Angle (p. 78) property is active, its effect can be visu-
alized by plotting the Material 1 Direction of the selected analysis ply.

Figure 1.28: Draping Directions in the Toolbar

: Plot Draped Fiber Directions.

Figure 1.29: Fiber Directions (Defined and Draped)

: Plot Draped Transverse Fiber Directions.

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 Graphical User Interface

Figure 1.30: Traverse Directions (Defined and Draped)

: Plot Material 1 Directions.

Figure 1.31: Material 1 Direction and Draped Fiber Direction for a Material with a 45° Fabric
Fiber Angle

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Getting Started

1.3.4.8. Other Features

The toolbar displays the following additional features:

• : Display or hide the coordinate system axis.

A coordinate system axis is displayed by default in the bottom left corner of the graphics window
for a better 3D orientation.

• : Plot box with coordinate system.

Figure 1.32: Enclosed Box and Coordinate System

• : Distance measure tool. Select two points of the mesh and the distance and point coordinates
will be displayed in the bottom left.

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Figure 1.33: Distance Measure Tool

1.3.4.9. Configure Plots

Configure the objects displayed in the Scene.

• Plot Properties: Configure vector density and length for the direction plots. In addition,
you can specify whether vectors and contour plots are always shown in front of the mesh.

• Show Legend: Show / hide the plot legend.

• Toggle Text Plot: Show / hide text labels in plots, such as Failure Mode or User-Defined
Text.

• Show Min/Max Labels: Show / hide labels highlighting the minimum and maximum value
of a plot. Note that the labels are not shown when Ply Offsets are active.

• Show Description: Show / hide the plot description in the top left corner of the scene.

• Show Deformed Shape: Select whether the plot is shown on the original or deformed mesh.

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Getting Started

1.3.5. View Panes

The View panes displayed at the bottom of the interface contain specific information about the pro-
cesses performed. You can rearrange the Views using drag and drop. A red highlight displays the
new (drop) position for placing the View. Each View is described below.

1.3.5.1. Shell View

All commands performed through GUI interactions are executed by the internal Python interpreter.
The same commands can be entered manually in the Shell View window. The Shell View window
also provides standard text editing features such as copy and paste, history, and tab completing.

A detailed overview about scripting in ACP and a command reference can be found in ACP Python
Scripting User Interface (p. 56).

Code Completing and Help

The period (".") activates the code completing. Use the Up Arrow, Down Arrow, or the mouse to
navigate through the drop-down menu. [TAB], [ENTER] or double-clicking inserts the selected
command.

Enter an opening parentheses "(" to get help on the selected method. Press [ENTER] to insert the
function header.

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The context menu of the Shell View windows is accessible by a right-click and it allows you to copy
and paste commands. Use "Paste and Run" to execute multi-line or multiple statements.

1.3.5.2. Keyboard Shortcuts

Here is the list keyboard shortcuts of the Shell View window that allow you to access the history,
copy, and paste commands, and so on.

Selection
Home Go to the beginning of the command or line.
End Go to the end of the line.
Shift + Home Select back to the beginning of the command or line.
Shift + End Select to the end of the line.

Copy and Paste

Ctrl + C Copy selected text, removing prompts.
Ctrl + Shift + C Copy selected text, retaining prompts.
Ctrl + V Paste from clipboard.
Ctrl + Shift + V Paste and run multiple commands from clipboard.

History
Ctrl + Up-Arrow Retrieve previous history item.
Ctrl + Down-Arrow Retrieve next history item.
Shift + Up-Arrow Insert previous history item.
Shift + Down-Arrow Insert next history item.

Font Size
Ctrl + ] Increase font size.
Ctrl + [ Decrease font size.
Ctrl + Wheel Edit font size.
Ctrl + = Default font size.

1.3.5.3. Logger
The information saved in the file %APP_DATA%\Ansys\v251\acp\ACP.log is shown in this
View. The severity level of the logged events is defined in Logger Settings (p. 18).

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Getting Started

1.3.5.4. History View

All commands processed during the existing session are stored in the Python command history.
They can be inspected in the History View window, where each text line refers to an executed
command. The command history is also available in the Shell View by using the Ctrl + Up / Ctrl +
Down keys.

1.3.6. Keyboard Shortcuts

ACP provides keyboard shortcuts for executing common operations.
1.3.6.1. General Shortcuts
1.3.6.2. Scene View Shortcuts
1.3.6.3.Tree View Shortcuts
1.3.6.4. Shell View
1.3.6.5. Properties Windows

1.3.6.1. General Shortcuts

Workbench mode
Ctrl+S Save Project (entire WB project)
Ctrl+Shift+S Save ACP Database as new file
Ctrl+R Run Script
Ctrl+H Open ACP Documentation

In Standalone mode
Ctrl+O Open ACP Database
Ctrl+S Save ACP Database
Ctrl+Shift+S Save ACP Database as new file
Ctrl+W Close active Model
Ctrl+Shift+W Close all Models
Ctrl+I Import Model
Ctrl+R Run Script
Ctrl+H Open ACP Documentation

1.3.6.2. Scene View Shortcuts

The following keyboard shortcuts are available in the Scene View pane. See also the section,
Scene (p. 23).

Scene View
Left-Click Select Element
Left-Click (drag) Select multiple Elements
Middle-Click Set rotation center

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 Graphical User Interface

Middle-Click (drag) Rotate Camera

Ctrl+Middle-Click (drag) Move Camera
Right-Click (drag) Zoom to selected area
Scroll wheel Zoom in / out

1.3.6.3. Tree View Shortcuts

The following shortcuts are available in the Tree View pane. Also Tree View (p. 21).

Tree View
Up-Arrow Go up in tree
Down-Arrow Go down in tree
Right-Arrow Expand tree group
Left-Arrow Collapse tree group
[ Go to previous ply of the same kind
] Go to next ply of the same kind
F2 Rename object
Ctrl+C Copy object(s)
Ctrl+X Cut object(s)[a]
Ctrl+V Paste object(s)
Del Delete object(s)
Mouse-Click+Drag Drag-and-drop object(s)[b]
[a] Cut-and-paste and drag-and-drop are implemented only for the following object types:
Script, Modeling Group, Modeling Ply, Interface Layer, Butt Joint Sequence, and Extrusion
Guide.
[b] See Reordering Modeling Plies, Interface Layers, and Butt Joint Sequences (p. 155) for details
on how cut-and-paste and drag-and-drop affect the Global Ply Number.

1.3.6.4. Shell View

The following shortcuts are available in the Shell View pane. See also View Panes (p. 34).

Selection
Home Go to the beginning of the command or line.
End Go to the end of the line.
Shift+Home Select back to the beginning of the command or line.
Shift+End Select to the end of the line.

Copy and Paste

Ctrl+C Copy selected text, removing prompts.
Ctrl+Shift+C Copy selected text, retaining prompts.
Ctrl+V Paste from clipboard.
Ctrl+Shift+V Paste and run multiple commands from clipboard.

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Getting Started

History
Ctrl+Up-Arrow Retrieve previous history item.
Ctrl+Down-Arrow Retrieve next history item.
Shift+Up-Arrow Insert previous history item.
Shift+Down-Arrow Insert next history item.

Font Size
Ctrl+] Increase font size.
Ctrl+[ Decrease font size.
Ctrl+Wheel Edit font size.
Ctrl+= Default font size.

1.3.6.5. Properties Windows

Properties Window Shortcuts
Esc Discard changes and close the Properties window
Ctrl+Enter Save changes and close the Properties window.

In the Properties Windows, mouse interactions can be used to quickly define properties.

• Select Position: Click the model to define a coordinate.

– Selecting a node returns its coordinates.

– Selecting an element returns its centroid.

Application example: Defining the origin of a Rosette.

• Select Direction:

– Option 1: Ctrl+Click the start point, then Ctrl+Click the end point of the vector. Points can
be either nodes or elements. For nodes, its coordinates are used. For elements, its centroid is
used.

– Option 2: Click an element to get the normal direction of the element.

Application example: Defining the directions of a Rosette.

1.4. Implementation in Workbench

In Workbench, the ACP analysis component can be used from basic analysis to complex load cases and
analyses. The following sections contain some examples of common use of the ACP analysis system.
1.4.1. Basic Workflow
1.4.2. ACP Component Properties
1.4.3. Supported Analysis Types
1.4.4. Multiple Load Cases and Analyses

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1.4.5. Shared Composite Definition for Different Models

1.4.6. Solid Modeling
1.4.7. Assembly
1.4.8. Limitations

1.4.1. Basic Workflow

A composite shell defined using ACP can be imported into Mechanical for analysis by importing the
mesh and composite definitions from an upstream ACP system. To import a composite shell from
ACP into Mechanical, use the following procedure:

1. From the Component Systems list, drag and drop an ACP (Pre) system into the Project Schem-
atic. For more information on Component Properties available in Workbench, see ACP Component
Properties (p. 42).

2. Select the Geometry cell and specify your geometry. Make sure that you properly define your
mesh, Named Selections, etc. before opening the geometry in ACP. Note that ACP only uses a
linear or quadratic shell mesh.

3. Select the Setup cell of the ACP system. Right-click the cell and select the Properties option. As
needed, activate the Load Model Properties option contained in the Geometry category of the
Properties of Schematic. Selecting this property makes your geometry available in ACP's CAD
Geometries (p. 99) object.

4. Perform all of the steps to fully define your ACP (Pre) system.

5. Return to the Workbench. Drag and drop a supported Mechanical system into the Project
Schematic.

6. Drag and drop the ACP (Pre) Setup cell onto the Mechanical system Model cell to create a
transfer of the model. A context menu gives you options to Transfer Solid Composite Data or
Transfer Shell Composite Data. The connection enables the transfer of Mesh, Geometry, Engin-
eering Data, and composite definitions from ACP to Mechanical. When you create this link, the
Geometry and Engineering Data cells no longer display for the Mechanical system. ACP provides
this system data.

You can change the Transfer Type if you pass the Solid Model (p. 183) to the analysis instead of
the Shell Mesh, or vice-versa. For more information, see section Transfer Types (p. 42).

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7. Double-click the Model cell of the Mechanical system. In the Mechanical application, an Imported
Plies object is already inserted. Analysis Ply objects, corresponding to the Analysis Plies in ACP,
are created under the Imported Plies object.

The Analysis Ply objects are grouped in Production Plies, and Production Plies are further grouped
into Modeling Plies to mimic the ply structure defined in ACP:

8. Perform all the steps to fully define and solve the Mechanical system.

The following should be noted when performing an analysis with imported ACP data:

• Since the mesh is imported from an upstream ACP system, any operations that affect the mesh
state are blocked inside Mechanical.

• It is recommended that you do not edit the mesh inside Mechanical. However, the Clear Gen-
erated Data option is available on the Mesh object and performs the action of cleaning up
the imported mesh. The Generate Mesh/Update operation restores the imported mesh that
was previously modified.

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• Since the material is assigned to elements/bodies through the upstream ACP system, the Ma-
terial Assignment field is read-only and set to Composite Material.

• If the Setup cell of the upstream ACP system is modified, refreshing the downstream Model
re-imports the meshes and resynthesizes the geometry. This action has the following effects:

– Any properties set on the bodies imported from the ACP system are reset to default.

– For solids, any scoping to geometry (bodies/faces/edges/vertices) is lost and any

loads/boundary conditions scoping to geometry are lost.

Tip:

Any criterion-based Named Selections defined in the downstream Mechanical system

are updated on refresh after any modification in the upstream ACP system. Since cri-
terion-based Named Selections are automatically updated, and any direct scoping is
lost, you should create criterion-based Named Selections and then scope any loads or
boundary conditions to these Named Selections. This will result in persistence of
scoping during modify/refresh operations.

9. Review the results.For postprocessing the layered results in the Mechanical application, see Dis-
playing Surface Body Results (including Layered Shell Results) and the Composite Failure Tool.
The postprocessing is done in the same Mechanical system where the solution was performed.

Analyses that require upstream results from Eigenvalue Buckling or Pre-Stress Modal analyses are
also supported and can be transferred from the solution. Note that while postprocessing Eigenvalue
Buckling or Pre-Stress Modal analyses is possible, some features such as the Composite Failure
Tool are not supported.

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Getting Started

1.4.1.1. Transfer Types

One function of ACP is to model the lay-up for shell meshes or convert them into 3D layered
models where the transfer type defines which lay-up definitions are passed to the downstream
analysis system. For both cases, ACP (Pre) (A5) only shows the shell meshes (surfaces) of the loaded
Mechanical Model (B2). If the Mechanical Model has any solid parts, they are hidden from view.

If the transfer type is Transfer Shell Composite Data, then the shell ACP lay-up model along with
the (isotropic) solid parts of the initial Mechanical Model (B2) are passed to the downstream
Mechanical system. The lay-up definitions of ACP (Pre) (A5) overwrite the initial configuration
(thickness, material assignment, etc.) of the shell parts of Mechanical Model (B2). Shell elements
that are not covered by the lay-up in ACP keep their initial properties. In addition, the solid parts
of Mechanical Model (B2) are transferred along with the initial configuration. Therefore, they are
not edited by ACP but are available in the downstream Mechanical Model (B2) system.

If the transfer type is Transfer Solid Composite Data, then the downstream Mechanical Model (B2)
only contains the composite Solid Models (p. 183) that were added in ACP. Therefore, the initial
shell and solid parts of the Mechanical Model (B2) are ignored.

If there is a hybrid model (with shell and solid parts) that must become a full 3D model, then the
initial model must be split into two models to process both parts separately. The final model is an
assembly as described in the Assembly (p. 50) workflow.

1.4.2. ACP Component Properties

The following section describes properties of an ACP component in Workbench. Properties can be
accessed through the right-click context menu over each component cell, as shown below in Fig-
ure 1.34: Properties from Right-Click Context Menu (p. 43).

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 Implementation in Workbench

Figure 1.34: Properties from Right-Click Context Menu

From the Setup Properties Menu, shown below in Figure 1.35: Properties Menu: Setup (p. 43), the
following options are available.

Figure 1.35: Properties Menu: Setup

• Load Model Geometry: Imports the geometry from ACP's Mechanical model.

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• Editor Startup Timeout (s): Timeout to catch an ACP start-up error. (Example: No license is available.)
You can increase this value to account for license server delays.

• Batch Mode: Specifies the Batch Mode of ACP between True Batch Mode and GUI Without Win-
dow. By default, ACP runs in True Batch Mode so it can support cluster environments (Windows
or Linux) where no graphics support is present. Note that ACP Snapshot functionality is only sup-
ported in the GUI Without Window option. If your analysis is generating Snapshots and is run by
mistake in True Batch Mode, the analysis will still run to completion.

Notice that the Editor Startup Timeout and Batch Mode options are also available in the ACP Post
properties.

The Transfer Type, which defines whether the Shell or Solid Composite model is passed to the
downstream analysis, can be changed through the Properties of the downstream Mechanical model.
See Assembly (p. 50).

1.4.3. Supported Analysis Types

The ACP (Pre) system can be linked with the following Mechanical analysis systems:

• Static Structural

• Transient Structural

• Steady-State Thermal

• Transient Thermal

• Modal

• Harmonic Response

• Random Vibration

• Response Spectrum

• Eigenvalue Buckling

• Explicit (LS-DYNA)

Composite postprocessing in the Mechanical application currently supports the following analysis
systems:

• Static Structural

• Transient Structural

Note:

• Although both Structural and Thermal layer modeling are available, the particular degrees
of freedom results on corresponding layers could behave differently in structural and
thermal environments. For more information, see the Element Reference for the specific
elements, particularly SOLID185 and SOLID278.

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 Implementation in Workbench

• To execute Steady-State Thermal and Transient Thermal analyses using the shell workflow,
you must enable the Beta Options. Do this by opening the Workbench application, se-
lecting the Tools menu from the toolbar, and clicking the Options cell. In the window,
under the Appearance tab, ensure the field Beta Options is selected.

• Steady-State Thermal and Transient Thermal analysis systems are fully supported by the
solid workflow (p. 48)only. For the shell workflow, the number of layers per element is
limited to 31 for a linear temperature distribution through-the-thickness and 15 for a
quadratic distribution.

• Postprocessing Steady-State Thermal and Transient Thermal analyses is partially supported

in the Mechanical application since some capabilities are not fully functional yet. To
postprocess these types of analyses, they must be connected to a downstream structural
analysis and use PyDPF Composites for postprocessing the RST file. RTH files are not
supported by PyDPF Composites yet. For more information on postprocessing, see .

• Explicit analyses are not supported because the composite failure tools predict a first
ply failure and therefore do not consider damage or material degradation.

• In component mode synthesis (CMS) analyses, composite tools are only supported for
non-condensed parts. They are not compatible with condensed components.

1.4.3.1. ACP–LS-DYNA
Using the ACP – LS-DYNA workflow, you can analyze composite structures with respect to crash
and impact. This workflow has been improved for various areas in recent releases. It supports the
transfer of shell models as *ELEMENT_SHELL and solid models as *ELEMENT_TSHELL between the
two applications (see Solid Modeling (p. 48) and Solid Models (p. 183)). Assemblies are supported
as well (see Assembly (p. 50)) .

Figure 1.36: Sample Workflow of ACP – LS-DYNA within Workbench

Several LS-DYNA material cards are available in Engineering Data. Once defined, they are automat-
ically transferred to the LS-DYNA solver. This allows you to define a material card for each material.
Among others, the following composite specific material cards are supported:

• MAT_001 MAT_ELASTIC

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Getting Started

• MAT_002 Option ORTHO MAT_ORTHOTROPIC_ELASTIC

• MAT_002 Option ANISO MAT_ANISOTROPIC_ELASTIC

• MAT_054/055 MAT_ENHANCED_COMPOSITE_DAMAGE

• MAT_058 MAT_LAMINATED_COMPOSITE_FABRIC

• MAT_059 Option SHELL MAT_COMPOSITE_FAILURE_SHELL_MODEL

• MAT_059 Option SOLID MAT_COMPOSITE_FAILURE_SOLID_MODEL

• MAT_221 MAT_ ORTHOTROPIC_SIMPLIFIED_DAMAGE

The LS-DYNA analysis type (system C in the figure above (p. 45)) creates an LS-DYNA model (.k
file) from the Mechanical model, including lay-up definitions from ACP, and runs the LS-DYNA
solver in the background. LS-DYNA features which are not available in Workbench can be added
to the model through LS PrePost by doing the following: Export the LS-DYNA input file (use the
Write Input File Tool in Mechanical, as shown below) and load it in LS PrePost to further preprocess
the model. An alternative is to use the Commands object and the Input File Include constraint.
For more details, see How to use LS-DYNA in Workbench in the LS-DYNA User's Guide.

Figure 1.37: Create an LS-DYNA Keyword (.k) File from the Workbench Model within Mechanical

Note:

Not all material cards can be used for layered shells or solids. Here are some of the lim-
itations. Refer to the LS-DYNA documentation carefully for all details.

• MAT_002/ MAT_ORTHOTROPIC_ELASTIC

Cannot be used with angles other than 0 on integration points. Not valid in general
for ACP to LS-DYNA.

Note: This material does not support specification of a material angle, β1, for each
through-thickness integration point of a shell.

• MAT_221/MAT_ORTHOTROPIC_SIMPLIFIED_DAMAGE

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 Implementation in Workbench

Only valid for 3D_Solid Elements. Not valid in general for ACP to LS-DYNA.

• MAT_059/MAT_COMPOSITE_FAILURE_{OPTION}_MODEL, Option=SHELL/SOLID

Cannot be used with TSHELL. So, valid for ACP to LS-DYNA shell models only.

1.4.4. Multiple Load Cases and Analyses

Complex workflows with multiple load cases and/or analyses are defined in the same way as standard
analyses. In most of the cases, the links to share the data are set automatically by the Workbench
application. Some links must be manually added. In the following example, the links from the Setup
cell of the ACP (Pre) system to the Model cells of the downstream Mechanical systems have been
added manually.

Figure 1.38: Multiple Load Cases and Analyses

1.4.5. Shared Composite Definition for Different Models

The ACP (Pre) Setup cell can be shared across multiple models. This means the same composite lay-
up can be applied to models of different geometries and meshes. This functionality can be used in
design studies where the composite definition remains the same but different geometries are evaluated.

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Getting Started

Submodeling is another situation where this functionality can be used. In a scenario where two
models are to share the same ACP (Pre) Setup, one setup cell is dragged on to the other. ACP maps
as much information onto the second model as possible. It is advised to use common Named Selections
as well as the same Engineering Data. The figure below shows an example of a shared ACP (Pre)
setup.

Figure 1.39: Two Analyses Share the Same ACP (Pre) Setup

1.4.6. Solid Modeling

Similar to composite shells, composite solids defined using ACP can be imported into Mechanical for
analysis by importing the mesh from upstream ACP systems and synthesizing the geometry from the
imported meshes. The import of a composite solid from ACP into Mechanical follows the same pro-
cedure for shells except that the transfer option Transfer Solid Composite Data must be selected
as shown below.

ACP distinguishes between two different approaches: the first approach is an extrusion algorithm
that generates a solid mesh based on the Composite Definitions and the shell reference surface. This
feature is simply called Solid Model (p. 183). In this scenario the solid mesh is completely generated

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 Implementation in Workbench

by ACP (Pre). For more information, refer to the Guide of Solid Modeling (p. 283) and the Analysis of
a Composite Solid Model (p. 314) sections of the Help.

In the second approach, the Composite Definitions are mapped onto an external solid mesh that is
loaded in ACP. This feature is called Imported Solid Model (p. 208).

Load an External Solid Mesh in ACP (Pre)

External solid meshes can be transferred to ACP (Pre) by linking a Mechanical Model component to
ACP Setup as shown in the Figure below. This allows you to map the composite definitions onto the
Imported Solid Model. (p. 208)

Figure 1.40: Import Volume Mesh from Mechanical Model (E4 to C5)

Solid meshes from third party applications can also be loaded into ACP (Pre). In that scenario the
mesh is loaded via External Model and Mechanical Model as shown in the next figure.

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Getting Started

Figure 1.41: Import Volume Mesh from Third Party Application

Note:

The internal link between the MechanicalModel and ACP Setup within an ACP (Pre)
System (C4 to C5 in the figure above) transfers the shell mesh only.

1.4.7. Assembly
You can import meshes from multiple systems into Mechanical. It is possible to combine composite
shell, composite solid, and non-layered shell and solid meshes to perform a mixed analysis. Mechan-
ical does not allow the overlap of node/element numbers from multiple systems. The import fails if
the mesh node/element numbers from different systems overlap. Meshes from upstream to downstream
Mechanical models are renumbered automatically to avoid overlapping. For every analysis system
(mesh), you have the choice between automatic renumbering (default) and manual configuration.
(See Renumbering and Transfer Type (p. 51).) If automatic renumbering is disabled, you must ensure
that the element/node numbering is unique for each mesh.

Figure 1.42: A Multi-System Analysis in Workbench

Additional topics in this section:

1.4.7.1. Renumbering and Transfer Type
1.4.7.2. Creating a Mixed Assembly

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 Implementation in Workbench

1.4.7.1. Renumbering and Transfer Type

The Properties menu of the Mechanical Model allows you to turn automatic renumbering on or
off and also to change the Transfer Type of ACP (Pre) systems from shell to solid.

1.4.7.2. Creating a Mixed Assembly

To create a mixed assembly:

1. From the Analysis Systems panel, drag and drop an ACP (Pre) Analysis system into the project
schematic.

2. Drag and drop a supported Mechanical system into the Project Schematic and create a link
from the ACP (Pre) Setup cell to the Mechanical Model cell.

3. Add other ACP (Pre) systems as needed.

4. Drag and drop a Mechanical Model component into the Project Schematic for the non-layered
parts. Create a transfer link from the Model cell of the upstream system to the Model cell of
any downstream systems.

5. Double-click the downstream Model cell to edit the model. For every upstream mesh, a Geo-
metry, Imported Plies, and Named Selections folder are inserted in the Tree View of Mechan-
ical.

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Getting Started

6. Perform all the steps to fully define and solve the Mechanical Analysis system.

1.4.8. Limitations
• A connection from an upstream ACP (Pre) Setup or Mechanical Model cell is only possible if the
Engineering Data cell of the intended downstream Mechanical system is not modified. If the En-
gineering Data cell of the downstream system is modified by creating/modifying an existing ma-
terial in the Engineering Data interface, a data transfer cannot be created.

• ACP composite definitions are not supported in nested assemblies as shown below. For instance,
the Imported Plies of System B are not passed to System C, and therefore the ply definitions are
lost.

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 Migrating ACP Projects from Previous Versions

1.5. Migrating ACP Projects from Previous Versions

General Updates
In Version 2019 R2, the coordinate system naming is maintained between Mechanical and ACP. When
migrating Workbench archives from previous versions, minor manual input may be required to maintain
Rosette reference links. See Known Limitations (p. 3) for more information.

A new serialization format for ACP was introduced in Version 2019 R1 in order to improve performance
and usability. Therefore, any ACP database created with version 19.2 or older must upgraded. The sections
below describe how to upgrade ACP projects from previous versions:

ACP into Workbench

When opening ACP projects generated in a previous version, you should perform a Clear Generated
Data on the ACP (Pre) Setup cell.

Upgrading Projects from Version 17.1 or Older

Projects older than version 17.2 should be opened and saved in any version from 17.2 to 19.2 to ensure
a robust upgrade to the current release. Please ensure that every ACP-Pre, -Shared, and -Post system
is completely updated and saved. This intermediate upgrade is supported starting from version 14.0.

Upgrading Projects from Versions 17.2 to 19.2 to the Current Release

If you open or restore a Workbench project that has been created with any version from 17.2 to 19.2,
then the ACP systems turn to a `refresh required` state. This ensures that the upgrade happens auto-
matically on refresh or update of the ACP systems. This also leads to the situation that Shared systems
cannot be launched before the corresponding (upstream) ACP-Pre system has been updated. Once the
upgrade is done, up-to-date status, etc. are maintained.

Miscellaneous

Version 17.0 introduced a new workflow for ACP (composites). The existing workflow from previous
versions is still valid. If you wish to upgrade your projects from previous versions to the new composite
workflow, please contact your technical support representative.

ACP Standalone
Upgrading ACP Databases from Version 17.1 or Older

ACP databases older than version 17.2 should be opened and saved in any version from 17.2 to 19.2
to ensure a robust upgrade to the current release.

Upgrading ACP Databases from Versions 17.2 to 19.2 to the Current Release

ACP models that have been generated with any version from 17.2 to 19.2 can be upgraded easily. Open
the .acp file in the current release and perform a `Save As` in order to generate the new .acph5
database file.

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Getting Started

Python UI
Version 18.0 changed the material scripting interface for ACP. A material's properties (for example en-
gineering constants and stress and strain limits) are no longer members of the Material class, but each
property forms its own class instance of the type PropertySet. This is to better reflect the individually
closed data basis for data interpolation in case the properties depend on user-defined field variables
(see Variable Material Data in Composite Analyses (p. 303)). The PropertySet instances can be accessed
by their string key on the Material class. ACP scripts using materials must be updated to be compatible
with the new material properties.

In 2019 R1, The model attribute create_cad_selection_rule() has been replaced with cre-
ate_geometrical_selection_rule(geometrical_rule_type='geometry'). Scripts that
used the CAD Selection Rule in previous versions need to be adapted accordingly for this release.

ACP (Post) to Mechanical Software Migration

The ACP (Post) system is now retired and removed from the ACP application. Ansys recommends using
the Mechanical software to postprocess composite simulations. This optimizes workflows since the
postprocessing is done in the same Mechanical system.

Starting from Release 25 R1, the Ansys documentation reflects composite postprocessing in Mechanical
software. This section covers:

• Link to Composite Postprocessing in the Mechanical Software

• ACP (Post) Migration Tool

• PyDPF Composites

Composite Postprocessing in the Mechanical Software

For thorough information on composite postprocessing in the Mechanical software, see Composite
Postprocessing in the Mechanical User's Guide.

ACP (Post) Migration Tool

ACP (Post) has a migration tool available to help migrate failure criteria definitions to the Mechanical
software.

Migrate a failure criteria definition from ACP (Post) to the Mechanical software through the following
steps:

1. In the current release's software, open the Workbench project that you want to migrate. Then,
start ACP (Post).

2. In ACP (Post), go to the Tools tab and select the Migration Helper... cell from context menu.

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 Migrating ACP Projects from Previous Versions

3. Click the Save to File button and choose a file to store the migration script in.

4. In the Mechanical software, from the Automation tab, click the Scripting icon to show the
Mechanical scripting view.

5. In the Mechanical scripting view, click the Open Script icon and select the previously saved
file.

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Getting Started

6. Click the Run Script icon to create the failure criteria in the Mechanical software.

7. Once the migration is complete, delete the ACP (Post) system in the Workbench application.

You can repeat steps 3 to 7 for each instance where the failure criteria definition must be imported to
the Mechanical software.

Starting from Release 2024 R2, the Run Script feature uses failure criteria scripting capabilities in the
Mechanical software. For more information on these capabilities, see Ansys.ACT.Automation.Mechanic-
al.Results.CompositeFailureResults Namespace in the ACT API Reference Guide.

PyDPF Composites

You can also postprocess composite structures using the PyDPF Composites Python module. For more
information, see the documentation.

1.6. The ACP Python Scripting User Interface

The ACP Python Module provides the scripting user interface of ACP. This scripting interface provides
programmable control of the ACP application. You can build complete ACP models from scratch, facil-
itating the creation of comprehensive ACP models directly from external data sources. You can also use
scripting for parameter studies and building complex lay-ups apart from the ACP GUI.

For documentation on the ACP scripting interface, including its object tree and classes, see ACP scripting
interface 2024 R2 in the Ansys Developer Portal.

1.7. Stand Alone Operation

ACP can be used as a Stand Alone application. This section describes how ACP can be operated in Stand
Alone mode. It is important to know that the Stand Alone mode does not support all features that are
available within Workbench (For instance, the user fields and variable materials are not supported.)

Version 2019 R1 introduced a new serialization format. This changes the handling of external sources
(shell input mesh or CAD geometries) when ACP is run in standalone mode. Modifications of the input
files are no longer automatically detected by ACP and are not considered on update or open. Therefore,
you must refresh the inputs explicitly:

• Reference Surface (shell): perform a Reload of the model (Model> Reload)

• CAD Geometry: press Refresh button in the property dialog of the object

• Imported Solid Model (solid mesh): press Refresh button in the property dialog of the object

1.7.1. Starting ACP in Windows

1.7.2. Starting ACP in Linux
1.7.3. Command Line Options and Batch Mode

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 Stand Alone Operation

1.7.4. Workflow in Stand Alone Operation

1.7.1. Starting ACP in Windows

To start ACP in Stand Alone mode in Windows, use the shortcut in the Start Menu. The shortcut can
be found in Programs\ANSYS 2025 R1\ACP

1.7.2. Starting ACP in Linux

On a standard installation, ACP can then be started by entering the following command into the
command prompt:
/ansys_inc/v251/ACP/ACP.sh

Command line options listed in Command Line Options and Batch Mode (p. 57) are also valid in
Linux.

1.7.3. Command Line Options and Batch Mode

ACP can also be used on a command line level. The general usage of the ACP start script is:
ACP.exe [options] [FILE]

The supported command line options are:

Long Form Short Form Description

--version Display the program’s version number and exit.
--help -h Display the program’s command line options and exit.
--batch=BATCH_MODE -b BATCH_MODE Run the ACP program in Batch Mode.

0 - Batch Mode disabled.

1 - True Batch Mode. (No GUI will be created.
Snapshot functionality is not supported.)
2 - Batch Mode with GUI toolkit but hidden
window. (Snapshot functionality is supported.)
--debug -d Enable debug output.
--num- -t Number of threads to be used. 0 for max available
threads=NUM_THREADS NUM_THREADS threads.
--logfile=LOGFILE -o LOGFILE Specify file to be used for log messages.
--mode=MODE -m MODE Application starts up in the specified mode (‘pre’ or
‘shared’).
--workbench -w Run the ACP application in Workbench mode.
--port=PORT -p PORT Specify port number for remote access server.
[FILE] [FILE] If the specified file is an ACP project, it is opened. If it
is a Python script it is executed.

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Getting Started

1.7.4. Workflow in Stand Alone Operation

The difference between Stand Alone operation and Workbench Integration is that the several steps
or operations have to be performed manually. The following is an overview of these steps:

1. Generate the Ansys input file in the Workbench application or Mechanical APDL, including the
loads and boundary conditions (.inp, .dat, or .cdb).

From the Workbench Application:

In the Mechanical application, select the analysis folder. Then, click the Environment tab and select
Write Input File to write a .dat or a .inp file.

Figure 1.43: Write Input File

Alternatively, in the project schematic, you can update the Setup status. A ds.dat file is written
in the project folder SYS-X/MECH. This file can also be used as Preprocessing Model in ACP.

From Mechanical APDL:

In Mechanical APDL, use the command CDWRITE to write a .cdb file, which can be used as a
preprocessing model in ACP.
cdwrite,db,file,cdb

2. Start ACP

3. Import the Ansys Model in ACP.

ACP supports the .dat, .inp and .cdb file formats. Import the model into ACP by selecting
File > Import Model or by right-clicking the Models object in the Tree View and selecting Import
Model.

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 Tutorials and Examples

Figure 1.44: Import Ansys Model Using the Context Menu

4. Define the Materials, or copy the materials from the ACP Material Databank.

For more information on defining materials, see Material Data (p. 74).

For more information on using the Material Databank, see Material Database (p. 244).

5. Create laminate sequences.

See Usage Reference (p. 61) and Composite Modeling Techniques (p. 261) for detailed information.

6. Update the model after any change in the ACP definition (lay-up definitions) or change of the
input model.

After any modification in the input model, the input file must be reloaded (see Model (p. 62)).

After any change in the ACP definition, the database must be updated. Use the Update (p. 24)
button in the toolbar.

7. Send the model to the Ansys solver (Solve Current Model) or export the new analysis file (Save
Analysis Model). For more information, see Model (p. 62).

8. Perform composite postprocessing.

Use the Mechanical application or for postprocessing.

9. Save the ACP (Pre) composite definitions.

Use the File menu or right-click the Models object in the Tree View to use the contextual menu.

1.8. Tutorials and Examples

The Tutorials describe the basic features of ACP and provide a quick start to the software. The Example
Analyses (p. 307) describe special workflows. You must be familiar with the basics of the software to
understand the examples.

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Chapter 2: Usage Reference
This chapter consists of the following sections:
2.1. Features
2.2. Exchanging Composite Definitions with Other Programs

2.1. Features
The features described are in the following sections:
2.1.1. Model
2.1.2. Scripts
2.1.3. Material Data
2.1.4. Element and Edge Sets
2.1.5. Geometry
2.1.6. Rosettes
2.1.7. Look-Up Tables
2.1.8. Selection Rules
2.1.9. Oriented Selection Sets (OSS)
2.1.10. Modeling Groups
2.1.11. Imported Modeling Group
2.1.12. Field Definitions
2.1.13. Sampling Points
2.1.14. Section Cuts
2.1.15. Sensors
2.1.16. Solid Models
2.1.17. Lay-Up Plots
2.1.18. Scenes
2.1.19. Views
2.1.20. Ply Books
2.1.21. Parameters
2.1.22. Material Database

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Usage Reference

2.1.1. Model
Right-click the context menu of the model for access to model properties, save options, and import/ex-
port interface options. The context menu options are different when ACP is run in Workbench compared
to Stand-Alone Mode.

In Workbench mode, these options are:

Figure 2.1: Model Context Menu in Workbench Mode

In Stand-Alone mode, the options are:

Figure 2.2: Model Context Menu in Stand-Alone Mode

This is an overview of the items in the model context menu. Selected items are explained in more
detail below.

• Properties: Display the Model Properties dialog where information about the model, input file,
tolerances and unit system can be found and modified (see Model Properties - General (p. 63))

• Update: Update the entire model.

• Clear Generated Data: Delete all results of the previous update and remove the serialized cached
data.

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 Features

• Save (Stand Alone only): Save the selected model.

• Reload (Stand Alone only): Reload the input file into the database (return to the last saved state).

• Close (Stand Alone only): Close the selected model.

• Save Analysis Model (Stand Alone only): Save the Ansys input file including the lay-up defined in
ACP.

• Save APDL Commands (Stand Alone only): Save the lay-up definition as APDL Command Macro,
modifies the model from isotropic material monolithic elements to orthotropic layered composite
elements with some adjustments on results save.

• Solve Current Model (Stand Alone only): Submit the Ansys input file including the composite lay-
up definition to the Ansys solver.

• Export Composite Definitions to ACP File: Export the lay-up definitions to a different ACP file
(see Import/Export of ACP Composite Definitions File (p. 67)).

• Import Composite Definitions from ACP File: Import the lay-up definitions from an other ACP
file (see Import/Export of ACP Composite Definitions File (p. 67)).

• Export to HDF5 Composite CAE File: Export the mesh with the Composite Definitions to a .HDF5
file (see Import From/Export to HDF5 Composite CAE File (p. 68)).

• Import from HDF5 Composite CAE File: Import a mesh with Composite Definitions from a .HDF5
file (see Import From/Export to HDF5 Composite CAE File (p. 68)).

• Import Section Data from Legacy Model: Import section data from a Mechanical APDL legacy
model (see Import Section Data from Legacy Model (p. 68)).

2.1.1.1. Model Properties - General

The following figures show the Model Properties dialog window in both Workbench and Stand
Alone mode.

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Usage Reference

Figure 2.3: General Model Properties

In Stand-Alone mode, the Format, Input File Path, and Input File Unit System properties become
editable and are used to import the shell reference surface (shell mesh). The Model Statisticstab
gives an overview of model statistics including number of materials, stack-ups, etc. The full list of
Model Statistics are shown in Figure 2.4: Model Statistics (p. 64) below.

Figure 2.4: Model Statistics

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 Features

2.1.1.1.1. ACP Model

The ACP Model section of the Model Properties dialog displays the path to the ACP model file.
The unit system of the ACP model is also displayed. This unit system can be changed in the
Units (p. 20) menu. The selected unit system is displayed in the status bar at the bottom of the
ACP window.

The property Cache Update Results controls whether the update results (i.e ply extents, analysis
plies, solid models) are stored. This allows you to reopen the most recently used lay-up model
state and improves the application's performance. You can disable this feature in order to reduce
the size of the .ACPH5results file. Note, if the feature is disabled, you will be prompted for a
model update whenever the ACP Model is reopened.

2.1.1.1.2. Reference Surface

The file path to the input file of the reference surface is set in the Reference Surface section of
the Model Properties dialog.

In Workbench, the reference surface is automatically transferred to ACP in the Ansys HDF format.
In this case, the reference surface unit system is fixed.

In Stand Alone mode, the input file path for the reference surface is set here. The input file can
be a .DAT (generated by Workbench), .INP, or .CDB (generated by Mechanical APDL with
CDWRITE). The unit system for the reference surface can be set if it is not defined in the input
file.

The unit system must be defined in Stand Alone mode when importing or exporting a model in
.HDF5 format and also when exchanging material data with the database or ESAComp.

The bounding box describes the dimensions of the reference surface in xyz-space.

2.1.1.1.3. Lay-Up Computation

The options defined in this section are described below:

Angle and Relative Thickness Tolerance

ACP transfers the Composite Definitions into Section Data so that they can be interpreted by
Ansys Mechanical. In the case of curved surfaces or draped laminates, sections may change con-
tinuously with every element as their orientations change. This generates information which can
reduce the performance of data transfers and solvers. To avoid this, ACP groups section data of
multiple elements together within a certain tolerance range.

The Angle Tolerance field sets the allowable ply angle tolerance between the same layers of
neighboring elements. The Relative Thickness Tolerance field applies to the individual layer
thickness as well as the global lay-up thickness. For two elements to be included in the same
section definition, the difference of the angle and the relative thickness of every ply must be
within the defined tolerance. Core materials are typically thicker than a laminate by a factor of
10 or more. As such, the thickness tolerance is defined as a relative rather than an absolute value.
The default tolerance values are very small compared to the manufacturing tolerances of com-
posites. The loss of accuracy is negligible.

Minimum Analysis Ply Thickness

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Usage Reference

Cutting operations used in ACP can cut an analysis ply to a thickness thinner than the specified
ply thickness. For example, if a Cut-Off geometry intersects a ply at its vertical mid-point, it will
slice the ply in half. When the intersection occurs at ply boundaries, an extremely thin layer can
appear as the result of geometric tolerances of CAD files. These extremely thin layers are of the
order of magnitude of 109 and are purely the results of numerical imprecision. The Minimum
Analysis Ply Thickness field sets a thickness threshold below which no such plies can arise.

The global default values for the above mentioned tolerances and thickness are set in the Section
Generation (p. 20) dialog but can be overridden in the Model Properties dialog.

Use Nodal Thicknesses

ACP supports ply with variable thickness (p. 273) and Ply Tapering (p. 269). By default, the thicknesses
are evaluated at the element centers, but for Ply Tapering and Cut-Off operations, and plies with
variable thicknesses, it can be worthwhile to evaluate them on a per-node basis. This additional
data further refines the lay-up representation in ACP and is used in shell and solid model analysis.
The option Use Nodal Thicknesses enables the node-based thicknesses evaluation. For more
information, see Element- vs. Node-based Thicknesses (p. 68).

Use Draping Offset Correction

By default, during draping simulation, the application lays the draping mesh on the reference
surface of the model independently of the lay-up thickness. However, for thick laminates, such
as sandwich structures, with Ply Tapering and Drop-Offs, this approach can lead to inaccurate
results. If you enable the Use Draping Offset Correction option, the draping mesh follows the
bottom offset (relative to the reference surface orientation) of the selected ply. This allows the
application to account for the lay-up thickness and, as a result, provides a more accurate draping
simulation. Enabling offset correction for thick and curved laminates also improves the precision
of the boundary and area for the flat wrap of the ply.

2.1.1.1.4. Model Summary

Global information about the model is displayed in this section of the dialog. The Number of
Elements field includes both layered shell and layered solid elements.

2.1.1.2. Solve
In Stand Alone, mode the Model Properties dialog has a second tab: Solve. On it, you can define
the file path of the analysis model and the working directory used by the solver. The Solver Status
and the Output File information are also located on the Solver tab. In the case of an incomplete
run, warning and error massages from the solver can be found here.

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 Features

Figure 2.5: Solver Information (Solve.out)

2.1.1.3. Import/Export of ACP Composite Definitions File

The ACP Composite Definitions file contains all the information stored in an ACP model. The model
is defined in the ACP file in the ACP Python scripting language. During import, you will be asked
specify how ACP should handle objects having the same name.

Figure 2.6: Export Composite Definitions Window

Figure 2.7: Import Composite Definitions Window

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2.1.1.4. Import From/Export to HDF5 Composite CAE File

You can exchange composite models across different CAE and CAD platforms using the HDF5
Composite CAE specification. For more information, see HDF5 Composite CAE Format (p. 245).

2.1.1.5. Import Section Data from Legacy Model

The Import Section Data from Legacy Model menu option automatically loads the section data
from a legacy Mechanical APDL layered shell model. This option converts the data into standard
ACP Composite Definitions. The conversion is based on the element labels, so the meshes of the
legacy and ACP model have to be equal. See the Import of Legacy Mechanical APDL Composite
Models (p. 254) section for a detailed explanation for importing legacy models.

Parameters
The parameters for the menu include:

• Path: This is the file path to the legacy file.

The Workbench framework does not allow ACP to add materials to the Workbench project
during the import process. Therefore, the materials have to be created and/or imported in
an upstream Engineering Data system before you can import the legacy model into ACP.
This makes sure that a full transfer of the section-based lay-up of the legacy model is per-
formed. The External Model component enables you to import materials easily (see Import
of Legacy Mechanical APDL Composite Models (p. 254)). However, the material IDs get con-
verted following a certain pattern. The Material ID pre- and suffix property of the import
options allows you to define this pattern. The mapping is case independent.

• Materials Mapping Mask: This area of the dialog provides the following entries:

– Prefix: A text-based string displayed before the legacy material ID in Workbench.

– Suffix: A text-based string displayed after the legacy material ID in Workbench.

2.1.1.6. Element- vs. Node-based Thicknesses

By default, ACP stores the thicknesses per ply and element. In other words, the ply's thickness is
constant per element. This representation is consistent with the solver capabilities of layered shells,
since they do not support varying ply thickness within one element. Therefore, geometry features
(for example thickness by geometry or taper edge) calculate the ply thickness at the element centers
(element-based thicknesses). ACP also supports node-based thicknesses. When node-based thickness
evaluation is enabled, thicknesses are evaluated supplementary to the element-based thicknesses.

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This involves some performance losses but gives benefits when working with tapered plies (see
Thickness (p. 146) and Cut-Off Selection Rules (p. 120)) or ply thicknesses (see Look-Up Table (p. 275)).

Shell Lay-Up

The differences between element- and node-based thicknesses are best explained with a tapered
ply. The nominal ply covers the entire plate and a defines the tapering as shown in the figure below.
The figure on the left shows the element-based piercing where the computed ply thickness at the
element centers is negative for the upper two elements (red arrows). The right image shoes the
node-based piercing that brings a more precise resolution. In that specific case, all elements have
at least one node with a positive (valid) thickness.

Figure 2.8: Element-based vs. Node-based Piercing

The final result for both optiomns is shown in the following figure. The ply is cropped if the thick-
nesses are only evaluated at the element corners since two elements have a negative thickness. In
contrast, the ply covers the entire plate if the thicknesses are evaluated for each node because at
least one node of each element has a valid ply thickness. If the node-based piercing determines
that only some nodes of an element have a valid piercing but not the element center, then the
thickness at the element center becomes the average node-based thickness.

Figure 2.9: Ply Extension and Element-wise Thicknesses of a Tapered Ply with Element-based
(left) and Node-based (right) Thicknesses

In summary, node-based thicknesses bring some benefit for shell models, but also bring certain
restrictions. Node-based thicknesses cannot be evaluated if a ply covers more than two components,
as shown in the figure below. In other words, a ply is not allowed to cover three elements that
share one edge.

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Figure 2.10: Restriction for Node-based Thicknesses

Solid Extrusion

The usage of node-based thicknesses brings more benefits if you perform a solid model analysis
instead of a shell analysis because the extrusion of the solid model is performed on a per-node
basis. Additionally, layered solid elements support plies with variable thickness. The figure below
shows the solid model from an example discussed in a previous section. As for the shell model, the
solid model with element-based thicknesses does not cover the entire reference surface. In contrast,
the node-based extrusion represents the ply extension more precisely. Additionally, it also captures
the variable ply thickness over one element and therefore reproduces the taper much better.

Figure 2.11: Extrusion of a Tapered Ply without and with Node-based Thicknesses on the Left
and Right, Respectively

There are two additional examples where you can benefit from node-based thicknesses:

• Tapered edge: Only nodal thicknesses can represent tapers with 0 thickness correctly.

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Figure 2.12: Solid Model Extrusion of a Tapered Ply without and with Node-based Thicknesses

• Cut-Off selection rules with Ply Tapering: By default, tapering evaluated at the element centers
can cause ripples in the extrusion. Node-based thicknesses result in a smoother shape and more
accurate ply representation. In this specific case, it even allows you to proceed without a Snap-
To operation, since the surface is of good quality.

Figure 2.13: Cut-Off Selection Rule with Ply Tapering Based on Element-based and
Node-based Thicknesses

2.1.1.7. Winding Wizard

Refer to the section Winding Wizard (p. 14).

2.1.2. Scripts
Scripts enable more complex parametrization than is possible with Input Parameters (p. 241) alone.
You can use scripts to execute arbitrary Python code (p. 56) as part of updating the model. Scripts
are marked for execution whenever a parameter or the script itself changes.

To create a script, select Create Script... in the context menu of the Scripts object in the ACP Tree
View.

The following sections describe Scripts in detail:

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2.1.2.1. Executing Scripts

2.1.2.2. Script Properties
2.1.2.3. Limitations
2.1.2.4.Tips and Best Practices
2.1.2.5. Sorting Scripts

2.1.2.1. Executing Scripts

By default, scripts are marked for execution whenever a parameter or the script itself changes. The
Unbound Input parameter category is meant for parameters that are used inside a script.

For scripts that should execute with every model update even if no parameters have changed, set
the Update Mode property to Always.

For scripts that should never execute automatically, set the Update Mode property to manual.
These scripts can be run manually either from the properties dialog, or the context menu of the
script as shown below.

2.1.2.2. Script Properties

You can edit a script and set its execution properties in the Properties dialog:

• Active: Activates or suppresses the script. Only active scripts can be executed.

• Update mode: Determines when the script is executed. Possible options are:

– On Triggers: Execute when updating the model, if a parameter or the script has changed.

– Manual: Execute only when instructed by the user.

– Always: Execute on every model update.

• Source: Contains the Python code to be executed.

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In addition to the default buttons (OK, Apply, and Cancel), the Script has a Save button which
saves the modifications without closing the window or updating the model.

2.1.2.3. Limitations
Because scripts can execute arbitrary Python code, it is important to be aware of their limitations:

• Scripts are executed only when a parameter or the script itself changes. If the script implicitly
depends on values in other parts of the model, they will still be shown as up-to-date when these
values change.

• New objects created by a script are not tracked. If the script runs again, objects created in a
previous execution are not deleted.

2.1.2.4. Tips and Best Practices

Based on the above limitations, adhere to the following guidelines for writing scripts to ensure
consistent behavior:

1. Dependencies: The values set by the script should only depend on the input parameters.

2. Idempotency: If the script is designed to execute multiple times, the model should not change.
For example, if the script generates new objects, it must also delete those objects created during
the previous execution.

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2.1.2.5. Sorting Scripts

When updating the model, out-of-date scripts are executed in the order shown in the Tree View.
You can change this order in the following ways:

1. From the context menu of the Scripts folder, sort the scripts alphabetically:

2. Select one or more Scripts in the Tree View, and move them after another Script by doing one
of the following:

• Use the cut-and-paste options from the target Script’s context menu (shown below).

• Use the Cut (Ctrl+X) and Paste (Ctrl+V) hotkeys.

• Use the mouse to drag-and-drop the Scripts.

3. From the context menu of an individual Script (as shown below), choose Reorder Scripts …
to place it before or after another Script.

2.1.3. Material Data

ACP differentiates between four material classes: Materials (p. 75), Fabrics (p. 84), Stackups (p. 88)
and Sublaminates (p. 93).

• The Materials (p. 75) class is the material database in ACP.

• The Fabric (p. 84) class is where Materials can be associated with a ply of a set thicknesses.

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• The Stackup (p. 88) class is used to combine fabrics into a non-crimp fabric, such as a [0 45 90]
combination.

• The Sublaminate (p. 93) class is used to group fabrics and stackups together for frequently used
lay-ups.

A Stackup or a Sublaminate can only be defined if a fabric and material have been defined previously.

2.1.3.1. Materials
The Materials database is only editable within ACP in Stand Alone mode. Otherwise, it draws all
material properties from Engineering Data within Workbench. In this case, the material properties
can be viewed- but not altered- in ACP.

2.1.3.1.1. Materials Context Menu

The context menu of the Materials class has the following options:

• Create Material (Stand Alone only): Open a Material Properties dialog for creating a new
material.

• Paste (Stand Alone only): Paste a copied material into the material database.

• Sort: Sort the list of materials alphabetically.

• Export: Export the material database into a .csv file, ESAComp XML file, or an Ansys Workbench
XML file.

• Import (Stand Alone only): Import materials from a .csv file or ESAComp XML file.

More information on the import and export of ESAComp XML file can be found in ESAComp (p. 258).
Stackups and Sublaminates can also be exported to an ESAComp XML file format but are con-
verted to laminates in the process.

Figure 2.14: Materials Class Context Menu in Stand Alone Mode

2.1.3.1.2. Temperature Dependent and General Variable Material Properties

Engineering constants, density, fabric fiber angle, as well as stress and strain limits, can be set to
depend on scalar field variables, including Temperature, Shear Angle, and Degradation Factor.
Other properties can only depend on temperature. The material properties are always shown at
the reference point in the Materials object. Variable material data can be edited in Workbench
Engineering Data.

In ACP, variable material data are considered in ACP-Post when evaluating failure criteria. Tem-
perature-dependence comes into effect if the solution contains a temperature data block.
Shearing of plies is considered if the material is dependent on the Shear Angle variable and at

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least one ply is draped. All other dependencies require the respective field variable to be defined
by means of Look-Up Tables. For more information, see Variable Material Data in Composite
Analyses (p. 303) and Analysis Using Variable Material Data (p. 320).

Within the Workbench workflow, variable data are passed to and from ACP. In Stand-Alone mode,
temperature-dependent data are passed to and from ACP if the import and export is in an Ansys
file format, such as .CDB.

General variable material properties are read only from the Workbench Engineering Data (.ENGD)
file. Export and import of material data within the Materials object via .csv or .XML file formats
do not support general variable material data.

2.1.3.1.3. Material Properties Dialog

Here is the Material Properties dialog.

In the Material Properties dialog, the following preprocessing data is required:

• Name: Name of the material.

• ρ: Density of the material.

• Ply Type: Defines the material type and controls which failure criteria evaluates the safety of
a certain material (see Failure Criteria vs. Ply Type Table in the Composites Theory Reference).
Depending on the extrusion method (e.g. sandwich-wise extrusion) in the Solid Model, it also
affects the volume mesh of the solid model .

– Adhesive: Materials of this type are post-processed with specific failure criteria. An ad-
hesive has isotropic mechanical properties.

– Honeycomb Core: Sandwich core material with a honeycomb pattern.

– Isotropic: Isotropic material and post-processed with the von Mises criterion.

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– Isotropic Homogeneous Core: Sandwich core material, such as foam, with isotropic
elasticity. Note that orthotropic strength limits have to be defined for post-processing
(failure criteria evaluation).

– Orthotropic Homogeneous Core: Sandwich core material, such as balsa, with an ortho-
tropic material characteristic.

– Regular (uni-directional): Uni-directional reinforced material.

– Undefined: If the material type is not known or not defined, then the ply type becomes
undefined. This material type is not post-processed.

– Woven: Weave material.

• Orthotropic Young's Modulus:

– E1: In-plane, in fiber direction (fiber direction is corresponding to angle 0 for the ply's
definition)

– E2: In-plane, orthogonal to fiber direction

– E3: Out of plane direction

• Orthotropic Poisson's Ratio:

– ν12: In-plane

– ν13: Out of plane, in fiber direction

– ν23: Out of plane, normal to fiber direction

• Orthotropic Shear Modulus:

– G12: In-plane

– G13: Out of plane, in fiber direction

– G23: Out of plane, normal to fiber direction

Further failure properties can be activated. Depending on the Ply Type some properties are de-
activated automatically.

Note:

Engineering Data can only be modified in preprocessing. Once postprocessing has

been initiated the data is frozen.

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2.1.3.1.4. Thermal Expansion Coefficients

For thermal stress analyses, the thermal expansion coefficients of the material and the reference
temperature must be given:

• Reference Temperature: Temperature at which strain in the design does not result from
thermal expansion or contraction

• alpha X: In-plane, in fiber direction (fiber direction is corresponding to angle 0 for the ply's
definition)

• alpha Y: In-plane, orthogonal to fiber direction

• alpha Z: Out of plane direction

2.1.3.1.5. Fabric Fiber Angle

The Fabric Fiber Angle represents the angle between the Material 1 Direction and the Draped
Fiber Direction. When no draping is specified, the Draped Fiber Direction coincides with the Fiber
Direction. By default, the Fabric Fiber Angle is set to zero so that the Material 1 Direction coincides
with the (draped) fiber direction.

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Figure 2.15: Example of Woven Material with a 45° Fabric Fiber Angle

When the Fabric Fiber Angle property is active and nonzero, you need to specify the Material
Properties, Thermal Expansion Coefficients, Strain Limits and Stress Limits with respect to the
material directions rather than the fiber directions. For instance, E1 and E2 would represent the
Young’s moduli in the material 1 and 2 directions, respectively. However, the fiber direction is
still the nominal modeling direction in ACP. For more information, see the Shear Dependent
Materials in Composite Analysis (p. 335) example and the Material Designer User's Guide.

You can highlight the effect of the Fabric Fiber Angle by plotting the draped fiber direction and
the material 1 direction of a selected analysis ply (see Draping (p. 29)).

2.1.3.1.6. Strain Limits

The Strain Limits are used to calculate the IRF if the Max Strain criteria is selected in the failure
criteria definition. Compressive strain limits must be negative.

For orthotropic materials, 9 strain limits (5 in-plane and 4 out-of-plane strains) can be entered:

• eXc: Normal strain, in-plane, in fiber direction, compression limit

• eXt: Normal strain, in-plane, in fiber direction, tension limit

• eYc: Normal strain, in-plane, orthogonal to fiber direction, compression limit

• eYt: Normal strain, in-plane, orthogonal to fiber direction, tension limit

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• eZc: Normal strain, out of plane, compression limit

• eZt: Normal strain, out of plane, tension limit

• eSxy: In-plane shear strain

• eSxz: Transverse (interlaminar) shear strain, plane in fiber direction

• eSyz: Transverse (interlaminar) shear strain, plane normal to fiber direction

If the material is defined as isotropic, the von Mises Strain Limit can be entered:

2.1.3.1.7. Stress Limits

All the other Failure Criteria definitions are based on values defined in the Stress Limits dialog.
Compressive stress limits must be negative.

For orthotropic materials, 9 stress limits (5 in-plane and 4 out-of-plane strains) can be entered:

• Xc: Normal stress, in-plane, in fiber direction, compression limit

• Xt: Normal stress, in-plane, in fiber direction, tension limit

• Yc: Normal stress, in-plane, orthogonal to fiber direction, compression limit

• Yt: Normal stress, in-plane, orthogonal to fiber direction, tension limit

• Zc: Normal stress, out of plane, compression limit

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• Zt: Normal stress, out of plane, tension limit

• Sxy: In-plane stress strain

• Sxz: Transverse (interlaminar) shear stress, plane in fiber direction

• Syz: Transverse (interlaminar) shear stress, plane normal to fiber direction

If the material is defined as isotropic the von Mises Stress Limit can be entered (equivalent to
Tensile Yield Strength in Engineering Data):

2.1.3.1.8. Puck Constants

The Puck failure criterion requires internal parameters, which depend on the material. The Mater-
ial Classification drop-down menu offers a selection of pre-defined constants and also allows
for the definition of custom constants. The menu has the following options:

• Carbon: Sets pre-defined Puck constants for carbon fiber materials.

• Glass: Sets pre-defined Puck constants for glass fiber materials.

• Material-specific: Allows you to set your own Puck constants.

• Ignore Puck Criterion: No constants are set.

• p21(+): Tensile inclination XZ

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• p21(-): Compressive inclination XZ

• p22(+): Tensile inclination YZ

• p22(-): Compressive inclination YZ

• s and M: Degradation parameters

• Interface Weakening Factor: Scales the interlaminar normal strength

2.1.3.1.9. Puck for Woven

ACP’s Puck for Woven functionality allows you to evaluate the Puck failure criterion for woven
materials. You specify two UD plies to represent the woven ply. During the failure evaluation,
ACP evaluates the stresses for theses plies in the new material directions and computes the Puck
failures. The relative ply angles, engineering constants, stress limits, and Puck constants must be
defined for both plies.

This approach, proposed by Puck (p. 369), has been validated by experiments. Warp dominated
woven fabrics have yielded good results. Puck described that fabrics with similar amounts of re-
inforcement in the warp and weft direction (50%/50%)– and therefore having higher fiber undu-
lation– need additional material characterization.

An alternative to Puck for Woven is the Maximum Stress Criterion. It does not require additional
material properties (or characterization), and it has been successfully applied in different commer-
cial projects.

Note:

This specification does not affect the analysis model and is only considered in the
failure analysis for the Puck criterion.

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2.1.3.1.10. Tsai-Wu Constants

The Tsai-Wu constants are constants used into the interaction coefficient of the quadratic failure
criteria for Tsai-Wu formulation. For more details, refer to Tsai-Wu Failure Criterion in the Composites
Theory Reference.

In ACP the Tsai-Wu constants correspond to:

• 2 F12 = XY, default -1

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• 2 F13 = XZ, default -1

• 2 F23 = YZ, default -1

2.1.3.1.11. LaRC Constants

The LaRC failure criteria requires the following parameters to evaluate the failure in matrix and
fiber:

• Fracture Angle Under Compression: The value for α0 used in the LaRC fiber and matrix failure.
Default value is 53°.

• Fracture Toughness Ratio: The ratio of the mode I to mode II fracture toughness, which is
used in the fiber failure criteria.

• Fracture Toughness Mode I

• Fracture Toughness Mode II

• Thin Ply Thickness Limit (set to 0.7 mm in Workbench mode)

For more information, see LaRC03/LaRC04 Constants in the Composites Theory Reference.

2.1.3.2. Fabric
The settings for the Fabric Properties dialog are described in the sections below:

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2.1.3.2.1. General
Figure 2.16: Fabric Properties - General

• Material: Material of the fabric

• Thickness: Ply thickness

• Price/Area: The surface price can be given to provide global information. For more information,
see Sensors (p. 181).

• Weight/Area: The weight per unit area is calculated based on the thickness and material
density.

• Ignore for Post-Processing: If active, all the analysis plies with this fabric are not considered
in the failure criteria analysis during postprocessing. This does not affect the analysis model.

2.1.3.2.2. Polar Properties

The Polar Properties (Classical Laminate Theory in the Composites Theory Reference) of the fabric
can be plotted as graphical information.

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Figure 2.17: Fabric Properties - Analysis

This plot can be exported as a picture ( ) or in a .csv file ( )

2.1.3.2.3. Fabric Solid Model Options

Solid model options set which material is used for diminished (Drop-Off and Cut-Off ) elements
during solid model generation. Material handling is determined by the settings in every Fab-
ric/Stackup definition, the global Drop-Off/Cut-Off material handling setting, and the extrusion
method in the Solid Model definition. For more information, see Material Handling for Different
Extrusion Methods (p. 207).

Note:

The Solid Model Options tab is the same for both Fabrics and Stackups.

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Figure 2.18: Fabric Properties - Solid Model Options

• Drop-Off Material Handling:

– Global: The global Drop-Off material in the Solid Model Properties is used. (default)

– Custom: Select a material from the Drop-Off Material drop-down menu.

• Drop-Off Material: The list becomes active when Drop-Off Material Handling is set to Custom.

• Cut-Off Material Handling:

– Computed: The Fabric/Stackup material is used for analysis ply-wise extrusion. Otherwise,
the global material is used and a warning is generated that computed materials for Cut-Offs
are currently not supported if the element points to more than one Analysis Ply. (default)

– Global: The global Drop-Off material in the Solid Model Properties is used.

– Custom: Select a material from the Cut-Off Material drop-down menu.

• Cut-Off Material: The list becomes active when Cut-Off Material Handling is set to Custom.

2.1.3.2.4. Draping
The Draping settings are used if draping is activated in the Modeling Ply definition. For more
details about the draping calculation, see Draping Simulation.

Note:

The Draping tab is the same for both Fabrics and Stackups.

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Figure 2.19: Fabric Properties - Draping

• Material Model:The material model used in the draping simulation, either Woven (default) or
Unidirectional. Note that the draping material model can be set independently of the Ply Type
of the fabric’s material.

• UD Coefficient: A parameter between 0 and 1 which controls the amount of deformation in

the transverse draping direction. This property is active only when Material Model is set to
Unidirectional.

2.1.3.3. Stackup
A stackup is a non-crimp fabric with a defined stacking sequence. From a production point of view,
it is considered as one ply, which is applied on the form. For the analysis, all plies forming the
stackup are considered. For every ply of the stackup, the fabric and its orientation must be given:

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Figure 2.20: Stackup Properties - General

These stackups have different Price/Area and solid model options than a laminate of single plies.
For this reason, Price/Area can be entered again. Stackups can be exported to an ESAComp XML
file format and are converted to laminates in the process.

2.1.3.3.1. Top-Down or Bottom-Up Sequence

The definition of the stackup can be given in both directions (Bottom-Up and Top-Down). In
the Top-Down sequence, the first defined ply (the first one in the list) is placed first on the mold
and is the bottom of the stackup. The other plies are placed over it. During analysis, the sequence
can be checked. In the above figure, the ply 45 direction is on top (see Figure 2.20: Stackup
Properties - General (p. 89)).

2.1.3.3.2. Symmetries
For a quicker definition, the stackup can be defined with symmetries.

The Even Symmetry option defines the symmetry axis on the top of the sequence, and uses all
plies.

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Figure 2.21: Stackup Sequence with Even Symmetry

In the Odd Symmetry option, the ply on the top is not used for the symmetry. So the middle of
the top ply is the symmetry axis of the final sequence.

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Figure 2.22: Stackup Sequence with Odd Symmetry

2.1.3.3.3. Analysis
The Analysis tab provides evaluation of the laminate properties of the stackup, which can be
plotted as graphical information.

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Figure 2.23: Lay-Up Information and Polar Properties

This plot can be exported as a picture ( ) or as a .csv file ( ). It is possible to translate and
zoom into the lay-up distribution with the mouse button. To come back to a fit view, click . In
addition, laminate properties (stiffness matrix or flexural stiffness), which are based on Classical
Laminate Theory (CLT), can be calculated.

The following results based on Classical Laminate Theory can be calculated by selecting them
from the CLT Analysis drop-down:

• Laminate Stiffness and Compliance Matrices

• Normalized Laminate Stiffness and Compliance Matrices

• Laminate Engineering Constants

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Figure 2.24: CLT Analysis - Laminate Engineering Constants

2.1.3.3.4. Stackup Solid Model Options

The material handling settings for Solid Models are identical for Fabrics and Stacks. For more in-
formation, see Fabric Solid Model Options (p. 86).

2.1.3.3.5. Draping Options

The Draping settings are identical for Fabrics and Stacks. For more information, see Draping
(p. 87).

2.1.3.4. Sublaminates
A sublaminate is a sequence of plies defined by fabrics and stackups with relative angles. This
sublaminate can be used later in the lay-up definition. As with stackups, you can choose the sequence
direction and symmetry. Refer to Symmetries (p. 89) for more information. Sublaminates can be
exported to an ESAComp XML file format and converted to laminates in the process.

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Figure 2.25: Sub Laminate Properties - General Tab

The Analysis tab is exactly the same as for a stackup. Refer to Analysis (p. 91) for information on
the content of this tab.

Important:

If the sublaminate definition uses stackups and symmetry, the stackup is not reversed
in the ply sequence. For example, for a stackup S1 defined as [45,-45,0], and a sub-lam-
inate defined with even symmetry and the stackup ([S1]s), the sub-laminate sequence
is [45,-45,0,45,-45,0], not [45,-45,0,0,-45,45].

2.1.4. Element and Edge Sets

Named selections defined in Mechanical or components defined Mechanical APDL can be imported
into ACP. These selections are imported with the same names. Faces (element components in Mech-

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anical APDL) are imported as Element Sets (p. 95) and edges (node components in Mechanical APDL)
as Edge Sets (p. 96).

Important:

After the definition of a new Named Selection in Mechanical, the model must be updated.

2.1.4.1. Element Sets

New Element Sets can be manually defined by selecting individual elements. Element Sets store
the element labels and are therefore not associated with the geometry. If the mesh changes, the
element numbering changes and the element set must be redefined to avoid erroneous lay-ups.

Figure 2.26: Element Set Selection

• Middle Offset: If the mesh is generated at the mid-plane surface, activate this option such that
the section definition is translated to where the middle of the section corresponds to the element.
The lay-up definition - in particular the definition of Oriented Selection Sets - is not influenced.
Solid Model extrusion and Draping Offset Correction do not support the Middle Offset setting.
To verify a lay-up with Middle Offset, use a Section Cut (p. 170) or Sampling Point (p. 168).

• Operation: Add or Remove elements in the list.

• Mode: Define the selection mode by dragging the mouse from one corner to the other.

– Box on Surface: Only visible elements are selected.

– Box Prism: All elements included in the box are selected, depth included.

– Point: Element at the picking location is selected.

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2.1.4.1.1. Context Menu

Several options are available in the Element Set context menu:

• Properties: Open the Element Set property window.

• Update: Update any changes into the database

• Hide/Show: Hide or show this Element Set. The elements of the hidden Element Sets are no
longer visible in the Scene.

• Copy: Copy the selected Element Set to the clipboard.

• Paste: Paste an Element Set from the clipboard.

• Delete: Delete the selected Element Set

• Export Boundaries: Export the boundaries of the Element Set to a STEP or an IGES file

• Partition: Create partitioned Element Sets for any Element Set that can be divided in different
zones, due to a geometrical separation (for example, three elements share the same edge).

Figure 2.27: Element Set Context Menu

2.1.4.2. Edge Sets

Named Selections of connected edges in Mechanical are transferred to ACP as Edge Sets. New Edge
Sets can also be defined manually in ACP-Pre:

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Figure 2.28: Edge Set Definition

• Edge Set Type: How the Edge Set is defined:

– By Reference: Defined the Edge Set using an existing Element Set (activates the following
options):

→ Element Set: The Element Set of which the Edge Set is part.

→ Limit Angle: The Edge Set is extended from the origin in both directions until the angle
between two elements is bigger than the Limit Angle. If the Limit Angle is set to a negative
value, the Edge Set is the whole boundary of the selected Element Set.

→ Origin: Origin to determine the closest boundary.

• By Reference: An existing Element Set is used to define a new Edge Set through one boundary
limited by an angle diffusion.

• By Nodes: Manually select the nodes to define the Edge Set.

2.1.5. Geometry
Geometries can be used to build complex lay-ups during preprocessing in ACP. For example, core of
variable thickness can be modeled as a ply whose thickness is set by an imported geometry of the
core. Cut-Off Rules can be based on geometry, therefore controlling the lay-up by a CAD surface or
at a pre-defined offset to a CAD surface. Geometries are particularly helpful in generating solid
models where geometry-based Extrusion Guides, Snap-To and Cut-Off operations can create intricate
shapes.

For more information on the use of geometries in a lay-up definition, see the following sections:

• Ply thickness definition (p. 146) in Modeling Groups

• Geometry-based Cut-Off Selection Rule (p. 121)

• Extrusion Guides (p. 195), Snap-To (p. 200) and Cut-Off Geometries (p. 202) in Solid Models (p. 185)

CAD geometries are incorporated in an ACP model by creating a link to a Geometry in the Workbench
Project Schematic or by directly importing an external geometry (IGES or STP format). These CAD

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geometries may be surfaces, bodies, or assemblies of parts. The concept of virtual geometries allows
you to select and group specific regions or bodies of the imported CAD geometry and use them for
subsequent modeling operations. All geometry-based operations are based on virtual geometries.
Virtual geometries act as a reference to one of more faces or bodies of one CAD geometry.

Note:

Typically, operations based on CAD geometries are computationally intensive, so it is im-

portant to define your geometries efficiently. For example, it is much more efficient to
have multiple small geometrical operations rather than a single large one. Small geometries
process faster because ACP, prior to running the calculation, filters out all extraneous points
and elements. The figure below illustrates three smaller Cut-Off geometries defined instead
of one large one. The principle also applies to all other operations based on geometry.

Figure 2.29: Example of three Cut-Off geometries

Figure 2.30: CAD Geometry Assembly and Virtual Geometries in the Tree View

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2.1.5.1. CAD Geometries

There are two ways to import an external geometry into ACP:

• The first option is directly through ACP, directly importing copies of the CAD file into the
user_files directory in the Workbench file structure. Any further changes to the original
file are not transferred.

• By selecting the Setup cell of your ACP system and then selecting the Load Model Properties
option (Geometry category of the Properties of Schematic) in Workbench. The advantage
of this option is that the CAD geometry can be refreshed inside DesignModeler or Discovery
Modeling.

For either case, the geometry remains intact when a project is archived and restored.

The parts included in an imported CAD geometry are displayed once the CAD geometry is up-to-
date. If the imported CAD geometry is an assembly of parts, multiple parts are shown in the Tree
underneath the CAD geometry. ACP makes the distinction between four different types of parts:

• Face ( ): Single face

• Surface ( ): Single surface body

• Solid ( ): Single volume body

• Compound ( ): Combination of multiple connected surfaces and/or bodies

Performance:

– Features based on a CAD geometry can demand a lot of computational resources if you
apply them to areas with many elements and/or nodes. You can improve computational per-
formance by splitting the CAD Geometry into smaller parts so you are working with multiple
Virtual Geometries (p. 101) as shown below. The reason is that costly computations are only
performed for the elements and/or nodes which are inside the bounding box of the selected
geometry. Of course, this improves performance only if the intersection between the bounding
box of the geometry and shell mesh is small.

In the example below, it is more efficient to work with two Virtual Geometries (p. 101) because
the bounding box of each individual shape is much smaller than the shell mesh and so the
costly computations are performed only for a few shell elements instead of the entire mesh.

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Figure 2.31: Example of Multiple Virtual Geometries

→ Loading a CAD Geomety can become slow if the CAD file contains many separate
shapes due to a system limitation. The workaround is to import multiple smaller CAD
files.

2.1.5.1.1. Direct Import

Geometry import has the following options:

Figure 2.32: Property Dialog CAD Geometry

• Name: Name of geometry for use in the database.

• External Path: Location of the geometry file to be imported.

• Refresh: Reload the file from the external path. The file is automatically copied to the Workbench
project folders.

• Scale Factor: Scale the geometry in the global coordinate system (useful for change of units).

• Precision: Precision of the imported geometry. This value is used to evaluate intersections and
other geometrical operations.

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• Offset: Sets the default capture tolerance value associated with the CAD geometry for operations
such as the Geometrical Selection Rule (p. 125).

• Use Default Offset: Boolean which sets the offset to 10% of the average element size.

• Visualization Color: Color in which the imported geometry is displayed.

• Transparency: Transparency of the imported geometry (value between 0 and 1).

Assemblies should be imported as a single .STP file rather than individual ones containing links.

2.1.5.1.2. Workbench Geometry Link

The geometry component in Workbench can be used to link CAD geometries with ACP-Pre. The
linked geometry is scaled automatically if its units do not match those of the project. The required
steps for geometry import are:

1. Add a Geometry component to the project.

2. In the context menu of the Geometry select Import Geometry

3. Link the Geometry cell to the ACP (Pre) Setup cell

The imported geometry appears under CAD Geometries in ACP.

Figure 2.33: Project Schematic with a CAD Geometry Import in ACP

2.1.5.2. Virtual Geometries

Virtual Geometries group together sub-shapes of CAD Geometry parts. The sub-shapes are referenced
by linking to the features of CAD Geometry parts. See CAD Geometries (p. 99) for information on
how working with geometries impacts system performance.

There are three ways to define virtual geometries:

• Directly from CAD parts through the CAD part context menu.

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Figure 2.34: Create Virtual Geometry Directly from CAD Geometry Part

• By selecting multiple CAD parts from the Tree when the Virtual Geometry Properties dialog is
open.

Figure 2.35: Create Virtual Geometry Through CAD Geometry Parts in Tree

• Through face selection in the Scene.

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Figure 2.36: Create Virtual Geometry Through Face Selection in the Scene

Note:

Virtual geometries can only reference parts from one CAD geometry.

2.1.6. Rosettes
Rosettes are coordinate systems used to set the Reference Direction of Oriented Selection Sets.
Rosettes define the 0° direction for the composite lay-up. Coordinate systems defined in Mechanical
are imported by default and the naming is maintained between Mechanical and ACP. Additional
Rosettes can be defined in ACP. There are 5 different types of Rosettes. The origin and directions of
Rosettes are given in the global coordinate system. Rosettes are independent of the mesh, even if
you select nodes and elements to define their properties.

One or more Rosettes can be used to set the Reference Direction for elements in an Oriented Selected
Set (OSS). The Selection Method in the OSS definition controls which Rosette determines the Reference
Direction for the elements. The Reference Direction for a single element is determined by a projection
of the applicable Rosette onto the element. Different Rosette types can be used to define the Reference
Direction.

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Figure 2.37: Rosette Properties Dialog

• Flip Buttons: Reverse the direction

• Shuffle Axes: Rotate coordinate system to exchange the X, Y, and Z axis.

• Swap 1 and 2 Direction: Exchange direction 1 with 2.

Rosette Types
• Parallel: Analogous to a Cartesian coordinate system. The Reference Direction is given by the
Rosette's X direction.

• Radial: the Reference Direction for a radial Rosette is perpendicular to the Z direction. The Z direction
lies orthogonal to Direction 1 and Direction 2 in the Rosette properties. The Reference Direction
for an individual element is defined by the vector of Rosette origin to element center which is
projected onto the element. If the direction vector cannot be projected the alternate Direction 1
is chosen.

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Figure 2.38: Oriented Selection Set with a Radial Rosette.

• Cylindrical: Based on a cylindrical coordinate system. The Reference Direction runs circumferentially
around the Rosette's Z direction according to the right hand rule. The Z direction is defined by the
X and Y direction vectors. Flip the Z direction to reverse the Reference Direction.

Figure 2.39: Oriented Selection Set with a Cylindrical Rosette

• Spherical: Based on a spherical coordinate system. The Reference Direction runs circumferentially
around the Z axis of the Rosette.

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Figure 2.40: Oriented Selection Set with a Spherical Rosette

• Edge Wise: Requires the selection of an Edge Set in addition to the usual Rosette definition. The
Reference Direction is given by a projection of the Rosette's X direction and the path of the Edge
Set. The X direction of the Rosette coordinate system is projected on to the point on the Edge that
is closest to the origin of the Rosette. This determines Reference Direction along the Edge Set. The
Reference Direction is reversed by switching the coordinates of the Rosette's X direction. An element
within an Oriented Selection Set gets its Reference Direction from the direction of the point on the
edge that is closest to the element centroid.

Figure 2.41: Edge-Wise Rosette

2.1.6.1. Rosette Definition

Each Rosette is defined by an origin and two vectors. Enter the origin by clicking on an element
or a node, or by typing the coordinates. When selecting an element, the coordinates of the center
of the element are used.

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If a direction field is selected in the dialog, the selection of an element returns the normal direction
of the element. By pushing down the Ctrl key and clicking on a second element, you can select the
direction defined by the two element centers.

2.1.7. Look-Up Tables

Several features in ACP can be defined as tabular values. Look-up tables can be used for thickness
definition of plies (p. 146), selection rules (p. 128), draping angles (p. 142), and field definitions (p. 165).
In such cases, the Look-up Table contains values (scalars) or direction (vectors) at specified points in
3D space or along a single direction.

Look-Up Tables require at least a Location column (1 or 3 components, one for each coordinate).
Direction columns (3 columns) and/or Scalar columns can be added. The Look-Up Table can be edited
efficiently by exporting and importing an .xls(x) file (see Edit Entities with Excel (p. 24)) or a .csv
file.(see CSV Format (p. 258)).

Note:

Look-up Table rows cannot be directly added or removed in the ACP GUI. The values in
existing cells can only be modified.

Populating Look-Up Tables

The easiest way is to populate Look-up Tables is with the help of the Edit Entities with Excel (p. 24)
on Windows. The set-up with exporting and importing a .csv file is similar and ideal for Linux. Data
can also be entered into Look-up Tables using The ACP Python Scripting User Interface (p. 56).

There are three approaches to populating a Look-Up table. This can be done with:

• The Excel Link (p. 107)

• Exporting/Importing .csv Files (p. 109)

• A Python Script (p. 111)

2.1.7.1. 3D Look-Up Table With The Excel Link

The set-up of a 3D Look-up Table is demonstrated in the figures below:

From the right-click context menu, select Create a 3D Look-Up Table (p. ?) .

An empty 3D Look-Up Table (p. ?) is created with XYZ-location columns.

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Create Direction Columns (p. ?) from the right-click context menu of the new Look-Up Table.

The empty Look-up Table (p. ?) now has three additional columns for three directional components
of the vector.

Populate the table in Excel with your values. Ensure the data set is followed by the END DATA
and END TABLE rows. An example of a populated Look-Up Table (p. ?) in Excel is shown below.

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Use the Excel Link (p. ?) to import and export the data from Excel to ACP.

2.1.7.2. 1D Look-Up Table with .csv Files

The Look-up Table definition with a .csv file follows the same process as the Excel Link (p. 107):
create Look-Up table, add desired columns, export data to Excel, populate the Excel data and re-
import. The .csv file approach for setting up a 1D look-up table is demonstrated with the figures
below.

From the right-click context Look-Up Table menu in the Outline, select Create 1D Look-Up
Table (p. ?).

An empty 1D Look-Up table is created with a single column. Specify the origin and direction of the
table as shown below.

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From the right-click context menu of the new Look-Up Table, select Create Scalar Column (p. ?)
.

Export the empty Look-Up Table to a .csvfile using the right-click context menu.

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Open the exported .csv file (p. ?) in an editor or spreadsheet program.

Add the entries and save the CSV file. Note that you may need to verify the deliminator type if your
regional settings use a comma as a decimal separator.

In ACP, re-import the CSV File by selecting Import from CSV File (p. ?).

2.1.7.3. Look-Up Table with a Python Script

The set-up of a 1D Look-Up Table with a script:
table = db.active_model.create_lookup_table1d(name='LookUpTable1D.1')
table.origin=(0.0, 0.0, 0.0)
table.direction=(1.0, 0.0, 0.0)
table.create_column(name='Value', type='scalar')
table.dimensions=['length', 'dimensionless']
table.columns['Location'].values = [0., 1., 2., 3.]
table.columns['Value'].values = [0., 1., 2., 3.]

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2.1.7.4. 1-D Look-Up Table

A 1-D Look-Up Table can be used to create a distribution of a scalars or vectors in one direction.
Such a distribution can be used in:

• the definition of an Oriented Selection Set (p. 132) Reference Direction.

• the definition of the draping angle (p. 279).

• the definition of the ply thickness (p. 146).

A 1-D Look-Up Table is defined by an origin, a direction vector, and a column of at least one
quantity varying along the direction vector. Location points can be defined in an arbitrary order.
They are automatically sorted and duplicate location points are permitted for the definition of step
functions. The values of the defined quantity are linearly interpolated to the element centers in the
mesh. The 1-D Look-Up Table uses a scalar product to project the vector between origin and element
center on to the Look-Up Table direction vector and look-up the desired value at that point.

Figure 2.42: Schematic of 1-D Look-Up Table Function

2.1.7.5. 3D Look-Up Table

A 3D Look-Up Table can be used to define field data, such as the variation of fiber directions or
variable layer thicknesses. This table can be used for:

• The definition of an Oriented Selection Set (p. 132) Reference Direction.

• The definition of the draping angle (p. 279) (Modeling Ply).

• The definition of the ply thickness (p. 146) (Modeling Ply).

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Figure 2.43: Look-Up Table Values

The values in the Look-Up Table are interpolated to the element centers. The Interpolation Al-
gorithm tab allows you to choose between different interpolation algorithms and adjust their
properties. By default, the interpolation uses the Shepard's method (a 3D inverse distance weighted
interpolation) with a reasonable search radius, and the number of interpolation points is 1.

The interpolation algorithm and properties can have a significant effect on the computed values.
The selection of the algorithm depends on the distribution of the supporting points and the FE
mesh. The example below shows the interpolation with different algorithms for the same field. The
spheres are the supporting points, and the color represents the values of the supporting points.
The color of the elements represents the interpolated values. Visualize the interpolation on the
mesh using the Look-Up Table Plot (p. 229), which also generated these figures. For more information
on interpolation, see General Interpolation Library.

Figure 2.44: Interpolated Values with Weighted Nearest Neighbor, Nearest Neighbor, and
Linear Multivariate (From Left to Right)

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Figure 2.45: Look-Up Table Interpolation Parameters

The Look-Up Table properties are:

• Algorithm Type: Selection of the interpolation algorithm. The supported options are Weighted
Nearest Neighbor, Nearest Neighbor, and Linear Multivariate. For more details, see General Inter-
polation Library.

• Options for Weighted Nearest Neighbor:

– Use Default Search Radius: Compute the initial search radius based on the "characteristic
distance" of the supported points. Validate this search radius and adjust it if needed.

– Search Radius: Only the element centers within this radius are used in the interpolation.

– Min. Number of Interpolation Points: If there are no element centers (or not enough if > 1)
in the radius, the Search Radius increases until the pinball includes at least the minimum
number of interpolation points (element centers) defined in this value.

Note:

If a 3D Look-Up Table contains points without real numbers (i.e. nan or blank), these
values are automatically computed on update by interpolating the valid results.

2.1.7.6. Look-Up Table Column Properties

The dimension of the data columns must be set for unit conversion to work correctly. The column
properties can be accessed through the context menu of the column in the Tree View.

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Figure 2.46: Setting the Dimension in the Column Properties Dialog

2.1.8. Selection Rules

Selection Rules enable you to select elements through geometrical operations. These selections can
be combined with Oriented Selection Sets (see OSS Selection Rules (p. 137)) or Modeling Plies (p. 142)
to define plies of arbitrary shape. The final extension of the ply is the combination of the Selection
Rules and the selected Oriented Selection Sets. This feature can be used to define local reinforcements
(patches) or staggering. You can select between different selection rule types which are explained in
the sections below. It is also possible to combine different rules and to define Boolean operations
between rules.

Figure 2.47: Selection Rules Context Menu

The .csv file interface of ACP offers the ability to create or modify selection rules externally, share
them with other ACP users working on the same model, or even on a different project. Limitation:
The Variable Cut-Off Selection Rule and Boolean Selection Rule are not supported by the CSV interface.
2.1.8.1. Basic Selection Rules
2.1.8.2.Tube Selection Rule
2.1.8.3. Cut-Off Selection Rules
2.1.8.4. Geometrical Selection Rule
2.1.8.5. Variable Offset Selection Rule
2.1.8.6. Boolean Selection Rules

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2.1.8.1. Basic Selection Rules

Figure 2.48: Definition of a Parallel Selection Rule

Parallel, Cylindrical, and Spherical Selection Rules are simple shapes which can be defined by a
few parameters:

• Parallel: Defined by two parallel planes. The planes are defined by an origin, a normal vector
and two distances (offsets of the planes from the origin along the normal vector).

• Cylindrical: The cylinder is defined by an origin and the vector of the axial direction and the ra-
dius. The cylinder has infinite height.

• Spherical: The sphere is defined by the center and the radius.

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Figure 2.49: Example of a Parallel Selection Rule

Selection Rule based on Rosettes

Parallel, Cylindrical, and Spherical Selection Rules can be defined in terms of the coordinate relative
to a specific Rosette. To choose a Rosette, uncheck "Use global Coordinate System" and select a
Rosette from the drop-down menu. If a Rosette is selected, Origin and Direction are in the Rosette's
reference frame. Only parallel Rosettes can be used to define Selection Rules.

Relative Selection Rule

It is possible to define a Selection Rule as relative. In this case, the Selection Rule parameters define
the ratios of the selection rule relative to the Modeling Ply dimensions. Take care that the Plotted
Selection rule is evaluated from the global geometry dimensions and that this plot does not represent
the final shape of the Selection Rule which depends on the Modeling Ply. Select the ply and check
the highlighted elements which represent the final shape of the ply.

Include Selection Rule

The Include Selection Rule Type option can be used to select the elements inside the geometry
or outside. By default the option is active (as shown in Figure 2.49: Example of a Parallel Selection
Rule (p. 117)). If the option is inactive, the inverse selection takes effect. Plies with a hole can be
created through a Cylindrical Selection Rule and disabled Include Selection Rule Type option.
This option applies to all geometrical rules as well as the Tube Selection Rule.

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2.1.8.2. Tube Selection Rule

A Tube Selection Rule is a cylinder of variable axial direction with a constant inner and outer radius.
The longitudinal direction is defined by an Edge Set (p. 96), and the radii define the diameters of
the inner and outer cylinder. All elements between the inner and outer radius are selected if Include
Rule Type is enabled (shown below in Figure 2.51: Tube Selection Rule Properties (p. 119)). Otherwise
the inverse selection is used.

Figure 2.50: Example of a tube rule with an outer and inner radius

Note: The Variable Offset Selection Rule (p. 128) allows the definition of a tube with a variable radius.

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Figure 2.51: Tube Selection Rule Properties

Tube Selection Rule settings are:

• Edge Set: Defines the center line (longitudinal direction) of the tube.

• Outer Radius: Defines the outer radius of the tube.

• Inner Radius: Defines the inner radius of the tube.

• Include Rule Type: If enabled (as shown above), elements inside the tube will be selected. If not
enabled, elements outside the tube will be selected.

• Extend Endings: Enable this option to extend the endings of the tube.

• Symmetrical Extension: If enabled, the length of the extensions will be equal on both sides.

• Head: The free end which is closer to this point becomes the head of the tube. It is only needed
if Symmetrical Extension is disabled.

• Head Extension: Defines the length of the extension at the head of the tube. If Symmetrical
Extension is enabled, it defines both sides.

• Tail Extension: Defines the length of the extension at the tail of the tube if Symmetrical Exten-
sion is disabled.

Notes:

• An extension set to zero or a negative automatically disables the feature at the corresponding
side.

• When the end of a tube is extended, the extension is oriented in the same direction as the last
edge segment.

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Figure 2.52: Edge with a long extension at the head of the edge and a short one at the tail

2.1.8.3. Cut-Off Selection Rules

A Cut-Off Selection Rule acts as a cutting operation on the composite lay-up. In contrast to other
Selection Rules that affect the in-plane directions of the ply, a Cut-Off Selection Rule also considers
the laminate thickness. A Cut-Off Selection Rule can be defined by a geometry or a taper. Using
a Geometry Cut-Off Selection Rule, the ply is cut at the intersection with a CAD Geometry, taking
into account the thickness of the laminate. An example of this is a skew-whiff surface being used
to define the tapering near a trailing edge of a blade. A Taper Cut-Off Selection Rule cuts plies
based on an edge and a taper angle.

Only Analysis Plies are cut off as a result of the selection rule. Modeling and Production Plies are
not affected. The Cut-Off Selection Rule is similar to a milling operation on built-up structure. In
that sense, the full size Modeling and Production Plies are required before the machining operation.
The Analysis Plies are the only decisive plies for any structural computation.

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Figure 2.53: Cut-Off Selection Rule Properties

Cut-Off Selection Rule settings are:

• Name: Name of the Selection Rule.

• Cut-Off Geometry: The CAD geometry defining the Cut-Off.

• Offset: CAD / taper surface offset. The intersection of the CAD Geometry/taper edge and the lay-
up can be moved by an offset. The direction and orientation of the offset is defined by the normal
direction of the Oriented Selection Set.

• Edge Set: Selection of an Edge Set (Taper).

• Angle: Taper angle (Taper).

• Ply Cut-Off Type: Either the complete production ply is cut off or individual analysis plies are
cut off. Ply Tapering can only be activated in the latter case.

• Example Cut-Off (p. 124)

• Ply Tapering: Control of the Cut-Off resolution.

2.1.8.3.1. Geometry Cut-Off Selection Rule

For each element, ACP determines the position of the ply (including its offset) in relation to the
imported surface. There are two possibilities of how the model geometry is cut by a CAD geometry
- one cutting operation follows the geometry contour, the other divides the ply into either its
maximum thickness or zero thickness. This is controlled by the Ply Tapering option in the Cut-
Off Selection Rule Properties dialog.

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Figure 2.54: Trailing Edge with Cut-Off Plies (Ply Tapering Activated)

In the first method, the ply is cropped if it intersects with the geometry. The ply is cut to match
the external geometry.

In the second method, the ply is cut at a discrete point. The ply cannot have a varying thickness
- it is either at its maximum thickness or it has been entirely cut off. The ply is cut if the intersection
of CAD geometry and ply is less than half of the ply's thickness.

The following figures are taken from Tutorial 4 and are presented to explain the concept further.
In the tutorial, a Geometry Cut-Off Selection Rule is applied to the core. A section view of the
Cut-Off Geometry, applied to two edges, is shown in the figure below. The Cut-Off has a nominal
thickness of approximately two thirds of the core thickness and, towards the outside, it has a
multi radii edge. The dashed yellow line in the figure denotes the ply's centerline.

Figure 2.55: Section of the Cut-Off Geometry

When Ply Tapering is activated, the core is cropped to match the Cut-Off Contour, as shown in
the right figure below. If Ply Tapering is deactivated, the resulting core thickness is at its full
thickness everywhere the intersection of the geometry is above the core centerline. Everywhere
else, the core is completely cut off.

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Figure 2.56: Core Thickness Without Ply Tapering (Left) and With Ply Tapering (Right)

2.1.8.3.2. Taper Cut-Off Selection Rule

The second way of using the Cut-Off Selection Rule is to define a taper with an Edge Set and
a tapering angle. The area close to the edge has to be sufficiently meshed for the taper Cut-Off
to work. Similar to the Geometry Cut-Off (p. 121), the ply is cut off in the taper zone. Only if Ply
Tapering is selected will there a be a gradual taper over thickness. The Taper Cut-Off Selection
Rule allows the same definition as the Taper Edges feature for modeling plies. For a detailed
explanation of taper angle and offset, see Edge Tapering (p. 269).

By default, ACP analyzes the Cut-Off selection rule at the element centers. Each element is cropped
from the ply if the ply thickness at the element center is negative. This binary representation may
not be sufficiently accurate in certain cases. If the Use Nodal Thickness (p. 65) is enabled, the
Cut-Off and ply tapering (if enabled) will be refined, which in turn results in a more accurate
model. For more information, see Element- vs. Node-based Thicknesses (p. 68).

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Figure 2.57: Taper Cut-Off Selection Rule Definition

2.1.8.3.3. Example Cut-Off

Consider a Stackup of three Fabrics for this example. In the pictures below, a laminate of one
Stackup is shown marked with the green lines. The blue lines highlight the Analysis Plies of the
Stackup. The black lines represents the mesh and the red line indicates the final laminate resulting
from the Cut-Off Selection Rule.

Figure 2.58: Section with The Production Ply Option

The Cut-Off Selection Rule with the Analysis Ply Cut-Off option will result in a smoother section
as each Analysis Ply of the Stackup is cut individually.

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Figure 2.59: Section with the Analysis Ply Option

The Cut-Off Selection Rule with Ply Tapering will result in an even smoother section. The ratio
between the area of the section cut by the CAD Geometry and the uncut section is calculated.
The same ratio is applied to the ply thickness for the considered element.

Figure 2.60: Section with the Analysis Ply with Tapering Option

2.1.8.4. Geometrical Selection Rule

The Geometrical Selection Rule allows you to define the extent of a modeling ply or OSS based on
a CAD surface or solid geometry. Elements are selected if they lie within the enclosure of a defined
volume. The volume is set by the size of the CAD solid geometry or the CAD surface geometry in
combination with specified Capture Tolerances. This means that a flat CAD surface geometry can
be used to define a ply on a curved mesh surface. Figure 2.61: Example Geometrical Selection
Rule (p. 126) shows a selection inside a curved mesh enclosed by a flat surface with relatively high
negative and positive capture tolerances. See CAD Geometries (p. 99) for information on how
working with geometries impacts system performance.

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Figure 2.61: Example Geometrical Selection Rule

Geometrical Selection Rules have the following settings:

Figure 2.62: Geometrical Selection Rule Properties

• Rule Type: Define whether the rule extent is defined by a geometry of Element Sets. The value
can be geometry or element_sets. The default is setting is geometry.

• Geometry: Virtual Geometry (p. 101) defining the basic selection (only relevant for Rule Type:
Geometry).

– Geometry:

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Virtual Geometries (p. 101)

defining the basic selection (only relevant for Rule Type: Geometry).

• Element Sets: Preselection of elements in the form of an Element Set where the rule is applied
on (only relevant for Rule Type: Element Sets). Multiple Element Sets can be parsed as input by
holding the [Ctrl] button while making your selections.

• Include Rule Type (p. 117)

Capture tolerances are necessary for non-solid geometries, such as surfaces. They evaluate whether
a point is within the geometry by creating an envelope as shown below. The unit values are in
length. All three tolerances support negative values.

• Use Defaults: Defines if the default value is used. The default value is the Offset property of the
CAD geometry (p. 99).

• In-plane: Increase the in-plane extension of the geometry by this value. A negative value will
shrink the surface.

• Negative: Capture tolerance in the reverse direction of the surface normal. A negative value
offsets the geometry in the surface normal direction.

• Positive: Capture tolerance in the direction of the surface normal. A negative value offsets the
geometry in the opposite direction of the surface normal.

The in-plane tolerance can also be adjusted on the Modeling Ply level by template rule parameters.
This may be useful when defining ply tapering. For more information, see Selection Rules (p. 145).

Note:

In principle, the in-plane tolerance is used to extend to the boundary of the geometry.
It is also used to fill gaps between adjacent surfaces that may cause sampling issues.
Therefore, it is recommended to use an In-plane tolerance > 0 when the selection is
missing some elements inside the capturing geometry.

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Figure 2.63: Capture Tolerances

2.1.8.5. Variable Offset Selection Rule

The Variable Offset Selection Rule is defined on the basis of an Edge Set and a 1-D Look-Up Table
containing a list of offsets at different locations. Elements adjacent to the Edge Set are selected if
their centroids lie within the specified offset at the given locations. The offsets are linearly interpol-
ated between locations. In this way, the rule behaves like an advanced Tube Selection Rule where
the outer radius can be varied.

There are two different ways in which the Look-Up Table data can be interpreted: the location of
each offset can be mapped on to a direction vector (default), or on to the length of the Edge Set.

The rule is not called the variable radii rule is because you can deifine the offset over a curved
surface defined by an Element Set. The offsets are initially evaluated as a radius at each element
adjacent to the Edge Set. The Offset Correction then adjusts the offset so that the offset is measured
over the curvature of the surface.

The template rule functionality is not available for the Variable Offset Selection Rule; however there
is a way to accommodate ply staggering with this rule. In addition to the offsets, varying ply taper
angles can also be defined in the form of a 1-D Look-Up Table. Ply Tapering can be used when
multiple Modeling Plies share the same Variable Offset Selection Rule. In such cases, the first Mod-
eling Ply will cover the area defined by the offset definition. The subsequent plies will be tapered
based on the angle definition. The tapering is applied not on the Edge Set side, but on the offset
side, away from the Edge set.

Note:

The angle definition can be used to decrease, fix, or increase the covered areas of the
subsequent Modeling Plies.

Complex patch shapes can be realized with the help of this selection rule.

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Figure 2.64: Look-Up Table Defines the Offset to Edge Set at a Given Length

Parameters

• Edge Set: The offsets are measured along this Edge Set.

• Offsets: 1-D Look-Up Table with a list of offsets at different locations.

• Angles: (optional) 1-D Look-Up Table with a list of angles at different locations. Only active
when same rule is applied to multiple Modeling Plies. Does not affect the first Modeling Ply.
Depending on the local angle, the covered area of the subsequent plies is changed.

– Angle equals 90 deg: Plies are not changed.

– Angle less than 90 deg: Ply coverage decreases with number of modeling plies.

– Angle greater than 90 deg: Ply coverage increases with number of modeling plies.

• Include Rule Type: The selection envelope can be inverted with this option.

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Offset Correction

Figure 2.65: Offset Correction

• Use Offset Correction: The offset is measured along the surface curvature of the selected
Element Set in a segmented arc when this option is active.

• Element Set: The offset correction is calculated on the curvature of this Element Set. The
selection rule can be applied to other Element Sets also, but retains the offset correction.

Table Properties

Figure 2.66: Offset Mapping Along a Direction Vector

• Origin: This replaces the origin in the 1-D Look-Up Table definition.

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• Direction: This replaces the direction in the 1-D Look-Up Table definition.

• Distance Along Edge: When active, the 1-D Look-Up Table data is mapped along the distance
of the Edge Set. In this case, the origin is used to determine the start and the end of the
Edge Set. The mapping will start at the corner of the edge which is closest to the origin. The
zero location in the Look-Up Table coincides with the start of the selection rule.

2.1.8.6. Boolean Selection Rules

The Boolean Selection Rule enables you to combine rules based on Boolean operations. Supported
operators are Intersect, Add, and Remove. (See the dialog below in Figure 2.67: Boolean Selection
Rule (p. 131).) The order you apply the rules is important because they are processed as sequential
filters. Each Boolean operation is applied to the previous intermediate result. Also, because the first
rule applies to all shell elements, using the ADD operator in the first rule will have no effect.

Template Rules: You can redefine some Selection Rule parameters in the Boolean Selection Rule
definition. Set the Template (A, below) to True for those selection rules that should be treated as
a template rule, and then set the values manually. The same feature can be applied to Modeling
Plies. Details are documented in Modeling Ply - Selection Rules (p. 145).

Figure 2.67: Boolean Selection Rule

Figure 2.68: Boolean Operation Types

Note the following limitations:

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• Cut-Off Selection and other Boolean Rules cannot be used within a Boolean Selection Rule.

• The CSV interface does not support Boolean Selection Rules.

2.1.9. Oriented Selection Sets (OSS)

Oriented Selection Sets (OSS) are a key concept in ACP.

The OSS define the basis for the lay-up definition. Plies are applied on Oriented Selection Sets and
not on Element Sets. The OSS give you an independence from your finite element model and its
element normals. OSS combine the following important entities for your composite lay-up:

• The area that plies are applied to.

• The orientation, or side of the shell mesh on which the plies are applied.

• The reference direction defining the 0° fiber direction. All ply angles are relative to this direc-
tion.

The Selection Rules, defined in the Rules tab, can further control the area of an OSS. You may also
use the draping algorithm, in the Draping tab, to define the reference direction on the OSS.

The following figure shows an example of an Orientation Point selected on the mesh and pointing
outwards. The section cut indicates that the lay-out is built in the outwards direction.

Figure 2.69: Orientation Point Definition

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 Features

Figure 2.70: Definition

An Oriented Selection Set is defined by:

• Name: Name of the OSS.

• Element Sets: Underlying elements for the OSS definition

• Orientation Point: Offset direction is defined at this point. The point should be inside and close
to the reference surface, otherwise the mapping of the offset direction can result in wrong results.

• Orientation Direction: Vector defining the offset (normal) direction at the Orientation Point.

• Reference Direction: Defines the 0° direction of the OSS.

– Selection Method: Defines the mapping algorithm for the Rosettes if more than one Rosette is
used. For more information, see Reference Direction (p. 134).

– Rosettes: One or more Rosettes defining the Reference Direction for each element through the
selected method.

– Reference Direction Field: Defines the direction column of a 3D Look-Up Table. Only applicable
to the tabular values method.

– Rotation Angle: Angle (in degrees) to rotate the Reference Direction around the Orientation
Direction. For more information, see Use Cases for Rotation Angle (p. 135).

Use the Flip button to reverse the offset direction.

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2.1.9.1. Reference Direction

The Reference Direction can be defined by Rosettes or from tabular values. A single Rosette is suf-
ficient for the definition of the Reference Direction. Multiple Rosettes can be selected for one Oriented
Selection Set to obtain complex Reference Direction definition. In this case, a Selection Method
must be used to determine which Rosette is applicable to what part of the Element Set. The Selection
Method offers several interpolation algorithms listed below:

• Ansys Classic: Coordinate system is projected on the elements as defined in Ansys (see Coordinate
Systems).

• Maximum Angle: Coordinate system in which the Z direction has the maximum angle with the
element orientation defines the Reference Direction of the Oriented Selection Set.

• Maximum Angle Superposed: Same as Maximum Angle but all the chosen coordinate systems
are considered and weighted by the maximum difference angle direction.

• Minimum Angle: Coordinate system in which the Z direction has the minimum angle with the
element orientation defines the Reference Direction of the Oriented Selection Set. (default)

• Minimum Angle Superposed: Same as Minimum Angle but all the chosen coordinate systems
are considered and weighted by the minimum difference angle direction.

• Minimum Distance: Nearest coordinate system of the element defines the Reference Direction
of the Oriented Selection Set

• Minimum Distance Superposed: Same as Minimum Distance but all the chosen coordinate
systems are considered and weighted by the distance to the element.

• Tabular Values: Interpolated from the values put in a Look-Up Table (p. 107). The table must in-
clude the location values and a direction column.

Note:

If the determination of an element's Reference Direction fails, an alternate computation

method is used and a warning is issued. In this case, it is recommended to verify the
Reference Directions of the affected Oriented Selection Set.

The bonding laminates of the T-Joint example are a case where a Minimum Angle Selection
Method is suitable.

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Figure 2.71: Reference Direction of a Bonding Laminate Defined by Two Rosettes and a
Minimum Angle Selection Method

2.1.9.1.1. Use Cases for Rotation Angle

Reference Directions Perpendicular to Edges

Edge-wise Rosettes (p. 103) can define a Reference Direction along an edge as shown in the left
model in Figure 2.72: Reference Directions Along an Edge and Perpendicular to an Edge (p. 136).
To create a Reference Direction perpendicular to an edge as shown in the right model, you may
use the same Rosettes and set the Rotation Angle to 90.0 degrees as shown below.

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Figure 2.72: Reference Directions Along an Edge and Perpendicular to an Edge

Axial Reference Directions

You may also use Rotation Angle to define a Reference Direction parallel to the axis of an
axisymmetric structure as shown in Figure 2.73: Axial Reference Direction (p. 137). In this case,
define the initial Reference Direction using a cylindrical Rosette and rotate it by 90 degrees as
shown below.

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Figure 2.73: Axial Reference Direction

2.1.9.2. Selection Rules

The OSS can be intersected with one or several Selection Rules. The intersection of all selected
entities (Element Sets (p. 95) and Selection Rule (p. 115)) defines to new extension of the OSS.

Figure 2.74: Selection Rules

Note:

Although the Cut-Off Selection Rules (p. 120) use the lay-up definition to calculate the
cut location, this Selection Rule has no influence in this case.

2.1.9.3. Draping
If the Draping option is activated, the reference direction of the Oriented Selection Set is adjusted
and all associated modeling plies use this draped reference direction. Note that the model property

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Use Draping Offset Correction doesn’t have any effect on the OSS draping. For more information
about draping, see Draping (p. 279) and Draping Simulation in the Composites Theory Reference.

Figure 2.75: Draping

The following parameters control the Internal Draping of the OSS:

• Seed Point: Starting point of the draping process.

• Auto Draping Direction: Uses the reference direction of the oriented selection set.

• Draping Direction: Sets the primary draping direction for the draping scheme. The secondary
direction is always orthogonal to the primary.

• Use Default Mesh Size: Enable this property to use the default size for the draping mesh. The
default size is the average element size of the shell mesh.

• Mesh Size: A user-defined mesh size for the draping mesh can be set if Use Default Mesh Size
is disabled.

• Material Model: The material model used in the draping simulation, either Woven (default) or
Unidirectional.

• UD Coefficient: A parameter between 0 and 1 that controls the amount of deformation in the
transverse draping direction. This property is active only when Material Model is set to Unidirec-
tional.

For more information on the Draping feature, see Draping Algorithm and its Limitations.

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2.1.10. Modeling Groups

The ply definition can be organized into Modeling Groups. These Groups do not affect the ply-ordering
and definition, but they provide a way for you to better organize Composite Definitions and streamline
your workflow. For example, you might choose to define one Ply Group for each substructure of a
boat project- one for the hull, one for the deck, and one for the bulkhead.

Before working with a Modeling Group, you must specify an Oriented Selection Set and a Material
(Fabric, Stackup, or Sublaminate). Within a Modeling Group, plies can be created. The lay-up is defined
as it would be in production. The first ply is also first in the stacking sequence. The lay-up can be
tailored by specifying the Orientation, Layering, geometrical Selection Rules, Draping Settings, and
Edge Tapering for each ply.

A lay-up can also include an Interface Layer for carrying out a fracture analysis of a composite solid
model in Mechanical. The interface layer is a separation layer in the stacking sequence, used to analyze
the crack growth of existing cracks. The crack topology is defined with an interface layer in ACP while
all other fracture settings are specified in Mechanical. The interface layers are exported as INTER204
or INTER205 elements and can be used to set up a Cohesive Zone Model (CZM) or a Virtual Crack
Closure Technique (VCCT) analysis. They can also be used to define contacts zones between two layers.
For more information, see Interface Delamination and Contact Debonding in the Mechanical User's
Guide.

Lay-ups can also be defined or changed using the Excel Link interface (p. 24). Changes can also be
made by importing or exporting the lay-up as a CSV file (p. 258).

2.1.10.1. Modeling Group Structure

The Modeling Group node has three sub-levels:

• Modeling Ply (MP): The ACP lay-up is defined at this level. The other two levels are built auto-
matically from information defined in this level.

• Production Ply (PP): Production Plies are generated derived from the Modeling Ply definition
(Material and Number of Layers). A Fabric and Stackup is one Production Ply. A Sublaminate
typically contains more than one Production Ply. In addition the Number of Layers option is
also propagated to this level.

• Analysis Ply (AP): The analysis plies describe the plies used in the section definition for the Ansys
solver. A Fabric results in one Analysis Ply. A Production Ply without an Analysis Ply indicates
that the resulting Analysis Ply contains no elements and is therefore not generated.

In the example below, there are three different MP separated by one interface layer:

• ModelingPly 1: Defined with a single Fabric

• ModelingPly 2: Defined with a Stackup of two Fabrics

• ModelingPly 3: Defined with a Sublaminate containing three production plies (Stackup, Fabric,
Stackup), which results in five analysis plies.

The interface layer lies between the second and third modeling plies.

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Figure 2.76: Object Tree of a Lay-Up Definition

You can easily navigate through the ply definition with a shortcut. Use the square brackets keys (
[ and ] ) to move up and down through the plies.

Modeling Plies can be reordered or moved between Modeling Groups using cut-and-paste or drag-
and-drop. See Reordering Modeling Plies, Interface Layers, and Butt Joint Sequences (p. 155) for
details.

2.1.10.2. Modeling Group Tree Object Context Menu

The context menu of Modeling Group in the top level of the object Tree contains the following
options:

• Create Modeling Group: Create a Ply Group with the default name.

• Create Imported Modeling Group: Create an Imported Ply Group with the default name.

• Export to CSV file: Export all plies with all modeling ply definitions to a .csv file (see Import
from / Export to CSV File (p. 157)).

• Import from CSV file: Import plies from a .csv file (see Import from / Export to CSV File (p. 157))

Figure 2.77: Context Menu of Modeling Groups

2.1.10.3. Individual Modeling Group Context Menu

The context menu of an individual Modeling Group has these options:

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• Properties: Display the Modeling Ply Properties dialog.

• Create Ply: Create and define a new ply.

• Create Interface Layer: Create and define an interface layer for fracture analysis.

• Create Butt Joint Sequence: Create and define a new butt joint sequence.

• Update: Update the model until all Modeling Plies of this group are up-to-date.

• Paste Ply or Modeling Group: Paste objects from the clipboard.

– If any Plies, Interface Layers, or Butt Joint Sequences are on the clipboard, paste them into the
selected Modeling Group.

– Otherwise, paste Modeling Groups from the clipboard after the selected Modeling Group.

See Reordering Modeling Plies, Interface Layers, and Butt Joint Sequences (p. 155) for details on
how cut-and-paste affects the Global Ply Number.

• Reorder Modeling Groups: Move the selected Modeling Group(s) before or after another group.
Note that the order of the Modeling Groups does not affect the stacking sequence. The stacking
sequence is based on the Global Ply Number and the Orientation of the Oriented Selection
Set (p. 132).

• Delete: Delete the selected Modeling Group.

• Export to CSV file: Export the whole Modeling Group with all modeling ply definitions to a .csv
file (see Import from / Export to CSV File (p. 157)).

• Import from CSV file: Import a Modeling Group from .csv file (see Import from / Export to CSV
File (p. 157)).

• Export Plies: Export the ply offset geometry as a .STP, .IGES, or STL file (see Export Ply Geo-
metry (p. 158)).

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2.1.10.4. Modeling Ply Properties

The following properties are needed for a Modeling Ply definition:

Figure 2.78: General Information

• Name: Name of the Modeling Ply.

• Oriented Selection Sets: Defines the offset and material direction.

• Material: Modeling Ply Material (Fabric, Stackup or Sublaminate).

• Ply Angle: The design angle between the reference direction and the ply fiber direction.

• Number of Layers: Number of times the plies are generated.

• Active: Active plies are considered in an analysis, inactive plies are present but not considered.

• Global Ply Nr: Defines the global ply order. Per default a new Modeling Ply is added after the
last Modeling Ply of the Modeling Group. The order of the Modeling Plies in the Modeling Groups
is equal to this value.

2.1.10.4.1. Draping
Consider the draping effects during the production process in the lay-up definition. The draping
approach can be specified in the Draping tab of the Modeling Ply Properties dialog. The follow-
ing types of draping are available:

• No Draping (default)

• Internal Draping: The draped fiber directions are determined by the internal ACP draping al-
gorithm.

• Tabular Values: Draped fiber directions are interpolated from a Look-Up Table.

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The parameters for Internal Draping and Tabular Values are explained below.

Note:

Draping can also be assigned to an Oriented Selection Set (OSS) (p. 137). In this case,
the Reference Direction of the OSS is adjusted. All associated modeling plies use this
draped reference direction. This avoids running multiple draping simulations on the
same surface. If Internal Draping is applied to a modeling ply associated with a draped
OSS, then an independent draping simulation is started for the Modeling Ply.

Internal Draping

The following parameters control the Internal Draping:

• Seed Point: Starting point of the draping process.

• Draping Direction: Sets the primary draping direction for the draping scheme. The secondary
direction is always orthogonal to the primary.

– Auto Draping Direction: Uses fiber direction of the production ply.

– User-Defined Direction: Uses the defined vector.

• Default Mesh Size: Enable this property to use the default size for the draping mesh. The default
size is the average element size of the shell mesh.

• Mesh Size: A user-defined mesh size for the draping mesh can be set if Default Mesh Size is
disabled.

• Thickness Correction: The thickness of the draped ply is corrected based on the shearing (see
Thickness Correction in the Composites Theory Reference).

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Figure 2.79: Internal Draping Definition

For more information on the Draping feature, see Draping Algorithm and its Limitations.

Tabular Values

The tabular value draping options lets you choose the draped fiber directions from vectors in a
Look-Up Table:

• Correction Angle 1: Sets the draped fiber direction.

• Correction Angle 2: Sets the draped transverse direction.

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Figure 2.80: Draping with Tabular Values Definition

2.1.10.4.2. Selection Rules

Like in the definition of an Oriented Selection Set, a Modeling Ply can have one or more Selection
Rules (p. 115). The combination of all Element Sets (p. 95) and active Selection Rules (p. 115) defines
the extension of the Modeling Ply. Each rule has its own Boolean operator (intersect, add, or re-
move) which allows you to define arbitrary combinations of rules (see Boolean Operation
Types (p. 131)).

Template Rules

In addition, the Selection Rule parameters can be redefined in the Modeling Ply definition. This
prevents the same Selection Rule from being defined multiple times and allows staggering to be
defined with a single Selection Rule. In the Rules tab, activate Template as True for those selection
rules that have to be treated as template rule and set the values.

The template parameters for each selection rule type are given in the table below:

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Rule Type Parameter 1 Parameter

2
Parallel Selection Rule Lower Limit Upper
Limit
Tube Selection Rule Outer Radius Inner
Radius
Cylindrical Selection Rule Radius -
Spherical Selection Rule Radius -
Cut-Off Selection Rule - -
Geometrical Selection Rule (Geometry) In-plane capture -
tolerance
Variable Offset Rule - -
Boolean Selection Rule - -

2.1.10.4.3. Thickness
The thickness of the ply is defined by default by the thickness of the ply material.

Figure 2.81: Thickness Definition

For Fabrics the ply thickness can also be defined by a CAD Geometry or Tabular Values. The
thickness options are:

• Type: Thickness definition method.

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Figure 2.82: Thickness Definition Options

– Nominal: The thickness defined in Fabrics is used for the thickness definition.

– From Geometry: CAD Geometry (p. 97) calculates the thickness. In the case of a complex
core ply, it can be helpful to work with a CAD Geometry defining the thickness distribution
of the core. ACP samples through the CAD Geometry for each element and maps the thickness.
The thickness is evaluated in the element normal direction.

Figure 2.83: Core Geometry

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Figure 2.84: Resulting Section Cut

– From Table: A data field evaluates the thickness. ACP inter- or extrapolates the thicknesses
for each element. One data point contains the global coordinates and the thickness values.
The values in the table can be used as absolute or relative thickness. See Look-Up
Tables (p. 107) for more information on how to define this table.

• Core Geometry: Thickness of the CAD geometry is mapped to the mesh.

• Thickness Field: Thickness is determined by mapping a value field to the mesh.

• Thickness Field Type:

– Absolute Values: Values in the Look-Up Table define the thickness.

– Relative Scaling Values: Values in the Look-Up Table are scaling factors.

• Taper Edges: adds an edge tapering to the selected Edge Set.

Core plies are commonly tapered along the boundary. The Taper Edges option allows you to
define a taper angle and a taper offset for each edge. The figure below shows a 15 degree
tapering along the edge on the left. The thickness is 0 at the selected edge and grows with
the specified angle. The Taper Edges option is intended for applying a taper angle to a single
ply, for example, a core material. When applied to multiple Modeling Plies the thickness distri-
butions of all plies are superposed. For more information, see Edge Tapering (p. 269) and
Tapering of Multiple Plies (p. 272).

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Figure 2.85: Edge Tapering

Figure 2.86: Taper Edge Example

By default, ACP analyzes ply tapering at the element centers. Each element is cropped from
the ply if the ply thickness at the element center is negative. This binary representation may
not be sufficiently accurate in certain cases. If the Use Nodal Thickness (p. 65) is enabled, the
ply tapering will be refined, which results in a more accurate model. For more information, see
Element- vs. Node-based Thicknesses (p. 68).

2.1.10.4.4. Modeling Ply Context Menu

The context menu for Modeling Ply has the following options:

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Figure 2.87: Right-Click Modeling Ply Menu

• Properties: Display the Modeling Ply Properties dialog.

• Update: Updates the selected Modeling Ply.

• Active/Inactive: Activate or deactivate the selected Modeling Ply. Inactive plies are defined in
the database but not considered in the analysis.

• Create Ply Before: Create a new ply before the selected one.

• Create Ply After: Create a new ply after the selected one.

• Reorder: Move the selected Modeling Ply (or plies if several are selected) before or after another
defined ply.

• Copy: Copy the selected Modeling Plies to the clipboard.

• Paste at End: Paste Modeling Plies from the clipboard to the end of the selected Modeling
Group.

• Paste Before: Paste Modeling Plies from the clipboard before the selected ply.

• Paste After: Paste Modeling Plies from the clipboard after the selected ply.

• Delete: Delete the selected Modeling Plies.

• Export Ply (p. 158)

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2.1.10.5. Interface Layer Properties

Introduction
A lay-up can also include an Interface Layer for carrying out a fracture analysis of a composite solid
model in the Mechanical application. The interface layer is a separation layer in the stacking sequence.
It can be used to analyze the growth of existing cracks. The crack topology is defined with an inter-
face layer in ACP while all other fracture settings are specified in Engineering Data (material models)
or Mechanical application.

Note:

Interface Layers are only taken into consideration in solid model generation and further
processes. All shell-based analyses ignore any Interface Layers.

Mechanical APDL Solver

The interface layers are exported as INTER204 or INTER205 elements and can easily be used to set
up a Cohesive Zone Model (CZM) or a Virtual Crack Closure Technique (VCCT) analysis. They can
also be used to define contact zones between two layers. For more information, see Interface
Delamination and Contact Debonding in the Mechanical User's Guide.

LS-DYNA Solver

Supported since Release 2025 R1.

Interface Layers are converted into zero volume LS-DYNAA cohesive elements (ELFORM=19) with
a material model *MAT_COHESIVE_MIXED_MODE. In the Engineering Data, it is defined by mater-
ial model Bilinear for Interface Delamination.

While contact debonding between plies is not supported yet, debonding between bodies is sup-
ported. The setup can be done directly in the Mechanical application (Interface Layer is not needed).

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Bonded contacts are converted into LS-DYNA tiebreak contacts with a fracture model based on
*MAT_COHESIVE_MIXED_MODE. In the Engineering Data, the supported cohesive zone material
model is Fracture-Energies based Debonding.

For more information, see LS-DYNA User's Guide.

LS-DYNA Solver Limitation: The Open Area feature of the ACP Interface Layers is not supported.

Definition
The Interface Layer is defined by two sets of surfaces:

• The first set is the total surface of the open interface. This is the surface along which a crack can
propagate. It is defined by an Oriented Selection Set in Interface Layer Properties dialog under
the General tab.

Figure 2.88: Interface Layer Properties - General

• The second set is the surface of the open interface. It is defined by an Oriented Selection Set in
Interface Layer Properties dialog under the Open Area tab.

Figure 2.89: Interface Layer Properties - Open Area

The Interface Layer can be activated or deactivated with a check box. You can also change the
global number of an Interface Layer (Global Ply Number).

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2.1.10.6. Butt Joint Sequence

The Butt Joint Sequence allows you to define butt joints between Modeling Plies. A butt joint
consists of sequences (primary and secondary plies) which specify the lay-up on both sides of a
butt joint. The Butt Joint Sequence object automatically detects where the selected plies join and
generates butt joints instead of drop-offs.

Figure 2.90: Drop-Off Elements and a Butt Joint Between Two Cores

The Butt Joint Sequence Properties window contains the following options:

• Active: Active plies are considered in an analysis. Inactive plies are present but not considered.

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• Global Ply Number: Defines the global ply order. By default, a new Sequence is added after the
last one in the Modeling Group. The order of the Plies in the Modeling Groups is equal to this
value.

• Primary Plies: Sequences which pass their thickness onto the other plies of a Butt Joint Sequence.
A Primary Ply can be a Modeling Ply or a Modeling Group. The Level column specifies which
sequence defines the thickness at a butt joint. The sequence with the lower level is dominant
where the other sequence inherits the thickness. Potential differences in the thickness between
the sequences are graduated over one element within the sequence with the higher level (the
transition zone in the following image). No butt-joint is created between plies with equal level.

• Secondary Plies: Secondary plies inherit the thickness from Primary Plies, but do not pass it
further. So, drop-offs are generated where two secondary plies join.

In most cases, you can define a Butt Joint Sequence without the use of secondary plies. An example
where secondary plies may be necessary would be a butt joint on a cylinder where you need
drop-offs:

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2.1.10.6.1. Butt Joint Sequence Notes and Limitations

The following is a list of notes limitations of the Butt Joint Sequence:

• A Modeling Ply can only be used in one Butt Joint Sequence

• Butt Joint Sequences do not affect shell models. They are only considered in Section Cuts (p. 170)

• Solid model extrusion (p. 183) does not consider butt joints

• A Butt Joint Sequence can only be linked to Modeling Plies with a lower Global Ply Number.

• The butt joint can not be updated if a ply sequenced between the first and last ply of the butt
joint covers the node where the plies join, shown in the following diagram:

• Modeling groups (p. 139) may be easier to work with if a butt joint consists of a large number
of plies

2.1.10.7. Reordering Modeling Plies, Interface Layers, and Butt Joint Sequences
Modeling Plies, Interface Layers and Butt Joint Sequences can be reordered using cut-and-paste
(Ctrl+X, Ctrl+V) or drag-and-drop. This affects the Global Ply Number as follows:

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• If you paste or drop objects onto another Modeling Ply, Interface Layer, or Butt Joint Sequence,
they are inserted after the selected target. Global Ply Numbers after the target are automatically
updated, so the list remains sequential. Conflicting Global Ply Numbers of other plies are also
renumbered automatically.

• If the objects are pasted or dropped onto a Modeling Group, they retain their original Global Ply
Number.

2.1.10.8. Production Ply

The context menu of the Production Ply has the following options:

Figure 2.91: Production Ply Context Menu

• Properties: Display the Production Ply Properties dialog. These properties cannot be edited,
but can be viewed or printed for informational purposes.

• Export Flat Wrap: Export the flat wrap as a .DXF, .IGES, or .STP file for production or design.
The draping option must be activated to obtain a flat wrap. Refer to Draping (p. 279) for more
information on draping and flat wrap.

• Export Ply (p. 158)

2.1.10.9. Analysis Ply

The context menu of the Analysis Ply has the following options:

Figure 2.92: Analysis Ply Context Menu

• Properties: Display the Analysis Ply Properties dialog. These properties cannot be edited, but
can be viewed or printed for informational purposes.

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• Export Ply (p. 158)

2.1.10.10. Import from / Export to CSV File

The CSV interface allows you to create a comma separated value file to be edited in a spreadsheet
program such as Excel or OpenOffice. This can be efficient if you wish to edit the parameters of
many plies.

For additional information on the format, see CSV Format (p. 258).

2.1.10.10.1. Export
All the information are exported to a .csv file. This file can be used to give the lay-up information
back to a CAD System or can be modified and imported.

2.1.10.10.2. Import
The modified .csv file can be imported. There are three different import options to handle the
update of the lay-up:

• Update Lay-up: During the import operation, definitions are updated, additional plies are
generated and deleted according to the .csv file.

• Update Properties Only: During the import operation, definitions are updated with
properties given.

• Recreate Lay-up: During the import operation, existing lay-up is deleted and generated
from scratch.

Figure 2.93: CSV Import with Update Options

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2.1.10.11. Export Ply Geometry

You can export the ply geometry and fiber directions o a CAD file format. Using this feature, you
can check geometry clashes in CAD assemblies. Other uses may include using the data for CNC
programming or for the projection of orientation vectors of the fibers onto tooling surfaces. It is
possible to export the surfaces or boundaries with an offset. This gives you full control over surfaces
to be exported.

The Export Ply Geometry feature has the following settings:

• Format: The geometry file format (STEP, IGES or STL). The STL format only supports the ply sur-
faces. Directions and boundaries can only be exported in the STEP or IGES format.

• Path: Specify the file name and file path.

• Ply Level (only available for Export Ply Geometry at Modeling Group level):

– Modeling Ply Wise: Every Modeling Ply is exported.

– Production Ply Wise: Every Production Ply is exported.

– Analysis Ply Wise: Every Analysis Ply is exported.

• Offset Type:

– No Offset: Ply geometry is exported with no offset to the reference surface (Oriented Selection
Set).

– Bottom Offset: Bottom surface of the ply relative to the direction of the reference surface is
exported.

– Middle Offset: Middle surface of the ply is exported. (default)

– Top Offset: Top surface of the ply relative to the direction of the reference surface is exported.

• Export Ply Surface: Ply surface is exported as a shell surface.

• Export Ply Contour: Outlining contour of the ply surface is exported as perimeter lines.

• Export Fiber Directions: Fiber orientations are exported as orientation vectors.

– Export Draped Fiber Direction: Include the draped fiber direction (the fiber direction is included
if draping is not enabled).

– Export Draped Transverse Direction: Include the draped transverse direction (the transverse
direction is included if draping is not enabled).

– Arrow Type: Choose between No Arrow (line without an arrowhead), Standard Arrow and
Half Arrow.

– Arrow Length: Specify the arrow length.

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Figure 2.94: Export Ply Geometry Window

2.1.11. Imported Modeling Group

Imported Modeling Groups organize plies which are independent of the shell reference surface. Im-
ported Modeling Groups and the attached Imported Plies do not contribute to the standard lay-up
that is defined by the Modeling Plies applied to a shell reference surface. The table below, Table 2.1: Key
Differences Between a Modeling Ply and Imported Modeling Ply (p. 160), lists the major differences
when compared to a Standard Modeling Ply (p. 142).

The structure of the Imported Modeling Group follows the pattern of the standard Modeling Group
and is described in the section above, Modeling Group Structure (p. 139). The equivalent to Modeling
Ply, Production Ply and Analysis Ply are Imported Modeling Ply, Imported Production Ply and Imported
Analysis Ply, respectively.

An example workflow is available in Chapter 4: 3D Ply Workflow - Imported Plies (p. 342).

2.1.11.1. Tree Object Context Menu

The context menu of the Imported Modeling Group contains the following options:

• Properties: Show the dialog window.

• Update: Update the model until all Imported Modeling Plies of this group are up to date.

• Create Imported Ply: Add a new Imported Modeling Ply.

• Paste: Create a new Imported Modeling Ply by copying the object on the clipboard.

• Delete: Remove all attached Imported Modeling Plies. Then remove the group object itself.

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2.1.11.2. Imported Modeling Ply

An Imported Modeling Ply represents a single ply with a 3D surface mesh which is independent of
the reference surface. This allows you to model thick and/or complex 3D laminates in ACP based
on separate ply geometries. The Imported Modeling Ply can be used in combination with an Imported
Solid Model (lay-up mapping). The section 3D Ply Workflow - Imported Plies (p. 342) in chapter four
provides a sample workflow and instructions on how to work with Imported Plies.

The table below lists the key differences between a standard Modeling Ply and an Imported Mod-
eling Ply:

Table 2.1: Key Differences Between a Modeling Ply and Imported Modeling Ply

Modeling Ply Imported Modeling Ply

Mesh and Scoped to the shell reference Holds its own imported mesh (surface)
Extension surface that is independent of the reference
surface
Orientation The lay-up orientation is defined The orientation is defined by the element
by Oriented Selection Sets normals of the imported mesh and the
offset type (bottom, middle, or top)
Reference The reference directions of the ply Supports the same features as an
Direction are defined by Oriented Selection Oriented Selection Set, but the definition
Sets is part of the Imported Modeling Ply
object
Material Supports Fabrics, Stackups and Supports Fabrics only
Sub-Laminates
Shell Model / Contributes to the shell lay-up Is ignored in any shell analysis
Analysis
Solid Model Considered in the standard Solid The standard solid model extrusion
Extrusion Model feature ignores imported plies
Imported Solid Considered in the lay-up mapping Considered in the lay-up mapping of the
Model / Lay-Up of the Imported Solid Model if the Imported Solid Model if the scope is set
Mapping scope is set to Element Sets to Use Imported Plies

The context menu of an Imported Modeling Ply contains these actions:

• Properties: Display the ply properties dialog.

• Update: Update the model until this ply is up-to-date.

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• Active/Inactive: Choose whether an Imported Ply is active or suppressed in all subsequent ana-
lyses.

• Copy: Copy into the clipboard.

• Paste: Create a new Imported Modeling Ply by copying the object in the clipboard.

• Delete: Delete the selected ply.

2.1.11.2.1. Imported Modeling Ply Properties

Standard features in ACP are used to define the thickness distribution, reference and fiber direc-
tions. An Imported Modeling Ply contains the properties listed below. Since the meaning is often
identical if compared with an Oriented Selection Set or Modeling Ply, it is classified with the same
wording.

General Properties

Refer to the figure below, General Properties Options.

• Offset: Determines if the surface mesh defines the bottom, mid or top surface of the ply.

• Mesh Input: Indicates whether the mesh was imported from a HDF5 Composite CAE or from
a CAD geometry. This is automatically set by the application based on the input source and is
therefore read-only.

• CAD Surface: If the Mesh Input is From Geometry, then the selected Virtual Geometry defines
the surface of the ply.

• Selection Method: Defines the mapping algorithm for the Rosettes if more than one Rosette
is used. For more information, see Reference Direction in the section above, Oriented Selection
Sets (p. 132).

• Rosettes: Select which method one or more Rosettes (p. 103) will define the Reference Direction
for each element.

• Reference Direction Field: Defines the direction column of a 3D Look-Up Table. Only applicable
to the tabular values method.

• Rotation Angle: Angle (in degrees) to rotate the Reference Direction around the Orientation
Direction. For more information, see Use Cases for Rotation Angle (p. 135).

• Ply Material: Select the Fabric that defines the material of the ply and nominal thickness.

• Ply Angle: Set the design angle between the reference direction and the ply fiber direction.

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Figure 2.95: General Properties Options

Draping Properties

Refer to the figure below, Draping Properties Options.

• Type: Specifies the type of draping

– No draping: Constant thickness defined by the Fabric

– Tabular values: Variable thickness by mapping a LookUp Table field

• Correction Angle 1: Sets the draped fiber direction

• Correction Angle 2: Sets the draped transverse direction

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 Features

Figure 2.96: Draping Properties Options

Thickness Properties

Refer to the figure below, Thickness Properties Options.

• Type: Thickness definition method

– Nominal: The thickness defined in Fabrics is used for the thickness definition.

– From Table: A data field evaluates the thickness. ACP interpolates or extrapolates the
thicknesses for each element.

• Thickness Field: Thickness is determined by mapping the selected LookUp Table Column to
the mesh.

• Thickness Field Type:

– Absolute Values: Values in the Look-Up Table define the thickness.

– Relative Scaling Values: Values in the Look-Up Table are scaling factors.

Figure 2.97: Thickness Properties Options

Limitations

• StackUps and Sublaminates are not supported as ply material.

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• The ACP model always needs a reference surface, even if it is not relevant in the lay-up mapping
(Imported Solid Model) workflow in combination with Imported Plies.

• The CAD geometry must be a surface. Solid geometries are not supported.

• Export Composite Definitions to ACP File … does not support Imported Ply objects

• The Excel Interface cannot be used in combination with Imported Plies.

• The features Sensor and Ply Book do not take Imported Plies into account.

• The variable material workflow is not supported. That includes the field definitions and mater-
ial plots.

• The HDF5 Composite CAE Export does not support Imported Plies.

2.1.11.3. Imported Production Ply

An Imported Production Ply is the output of an Imported Modeling Ply update. The context menu
contains the following option:

Properties: Display the Imported Production Ply Properties dialog. These properties cannot be
edited but can be viewed or printed for informational purposes.

Figure 2.98: Imported Production Ply Dialog

2.1.11.4. Imported Analysis Ply

An Imported Analysis Ply is the result of an Imported Modeling Ply update. The context menu
contains the following option:

Properties: Display the Imported Analysis Ply Properties dialog. These properties cannot be
edited, but can be viewed or printed for informational purposes.

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 Features

Figure 2.99: Imported Analysis Ply

2.1.12. Field Definitions

During the Variable Material Data (p. 303) workflow, you can define the variation of the scalar variables
controlling the local state of the material properties over the finite element model using Field Defin-
ition objects. You can scope Field Definition objects to Element Sets, Oriented Selection Sets, and
Modeling Plies.

If your field definition is based on Elements Sets or Oriented Selection Sets, all of the layers within
your scoping are affected. When scoping to Modeling Plies, only the associated Analysis Plies are af-
fected. Therefore, it is possible implement both a “layer-wise” as well as a “element-wise” application
of field definitions in your finite element model. Parts of the finite element model not covered by
Field Definition Objects assume default values of the field variables.

In order to understand the effect of a Field Definition Object, contour plots of the field variables are
available Field Definition Plot (p. 231) topic of the Lay-Up Plots (p. 222) section.

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Figure 2.100: Field Definitions Context Menu

As illustrated below, once you create a Field Definition object, you use the context menu to define
its features. Menu options include:

• Properties: Display the properties window of the selected Field Definition.

• Update: Update the selected Field Definition.

• Active/Inactive: Toggle field definition object active or inactive

• Copy: Copy the selected Field Definition to the clipboard.

• Paste: Paste a table Field Definition from the clipboard.

• Delete: Delete the selected Field Definition.

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 Features

Figure 2.101: Field Definition Context Menu

Field Definition Object Properties

Field Definition objects can be used for element-wise and layer-wise specification of the variation of
a scalar variable controlling Variable Material Data on subparts of your finite element model. You can
scope layer-wise specifications to specific Modeling Plies. The properties dialog is illustrated below.
Properties include:

• Name: Name of the Field Definition. This field is initially populated with an default name.

• Active: This selection indicates that the application processes the Field Definitions during your
analysis. Inactive definitions are ignored.

• Field Variable Name: This drop-down menu provides a list of available Field Variables as
defined in the Engineering Data Workspace. Note that the Temperature and Shear Angle field
variables are not available for Field Definitions. Temperature is defined externally to ACP, and
the Shear Angle is defined via draping calculations.

• Scope Entities: Entry field to define the applicable element-wise field definitions. You can use
a combination of Element Sets and Oriented Selection Sets in order to scope the definition to
subparts of your model. For layer-wise field definitions, you can use a combination of Modeling
Plies to scope the definition to subparts of your model; the Field Definition will only be applied
to Analysis Plies attached to the Modeling Plies.

• Look-Up Table Column: Select the scalar Look-Up Table column from which the state of the
field variable is interpolated from.

• Include Shell Offset: Specify whether or not to include the shell offset of each analysis ply
for the interpolation process. The default is to interpolate the state of the field variables at the

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shell element centroid. For solid elements, the actual position of each analysis ply is automat-
ically considered and this behavior cannot be changed.

Figure 2.102: Field Definition Object Properties

Element-Wise Field Definition Layer-Wise Field Definition

2.1.13. Sampling Points

The Sampling Point functionality provides lay-up, through-the-thickness, and laminate elastic property
information.

ACP samples through the element near the given coordinates. After the update, all plies (Modeling
Ply, Production Ply, and Analysis Ply) are listed for review. In the General tab of the Sampling Point
Properties dialog the sampling point and direction can be defined.

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Figure 2.103: Sampling Point Properties (General Tab)

• Sampling Point: The sampling point in global coordinates. The nearest element to the point is the
sample.

• Sampling Direction: Normal direction of the sampling point. The ply sequence will be given in
this direction.

• Element ID (Label): Element number closest to the defined sampling point. (informational only)

A detailed description of the options Offset is Middle and Consider Coupling Effect can be found
in Analysis Options in the Composites Theory Reference. Use the arrow buttons to navigate easily
through the ply definition.

The Analysis tab of the Sampling Point Properties dialog provides extended laminate analysis
functionality. The lay-up can be visualized and analyzed by evaluating the polar properties, equivalent
laminate stiffness matrices, and resulting engineering constants based on the classical laminate theory.

The lay-up visualization can be set to display Modeling, Production, and Analysis Plies present in the
Sampling Point. The Material, Thickness, and Angle can be displayed additionally as text labels for
every ply in the plot. The angle displayed for Modeling and Production Plies always matches the
design angle in the Modeling Ply and Material definitions. Note that the angle for the Analysis Ply is
always given in relation to the reference direction of the Sampling Point. This reference direction is

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Usage Reference

indicated by a yellow arrow at the Sampling Point in the Scene. Meanwhile, the sampling direction
is indicated by the purple arrow, which you can change in the General tab if desired.

Note:

Classical Laminate Theory is described in Composites Theory Reference.

Figure 2.104: Sampling Point Properties (Analysis Tab Containing Lay-up Sequence and Polar
Properties)

2.1.14. Section Cuts

Section Cuts enable a visual verification of the lay-up definition on an arbitrary section plane through
the model. The lay-up definition at the Section Cut can be exported to Mechanical APDL or BE-
CAS (p. 260).

The Section Cut Properties dialog contains the following options:

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Figure 2.105: General Section Cut Properties

• Name: Name of the Section Cut.

• Active: Set to false to suppress the computation of the Section Cut.

• Interactive Plane: If active, modify the section plane directly in the Scene. If inactive, the following
options are required:

– Origin: Origin of the section plane.

– Normal: Normal direction of the section plane.

– Reference Direction 1: First in-plane reference direction (in-plane transverse direction). The
normal and this direction define the coordinate system of the section cut. It is used to compute
the section cut measures and to export the surface section cut.

• Show Plane: Plot the section plane.

• Entire Model: If active, the Section Cut applies to all shell elements in the model. Otherwise, only
the selected Element Sets are considered.

• Element Sets: List of Element Sets to which the Section Cut is scoped.

• Type: Mode of extrusion (p. 173).

• Scale Factor: Scale the offsets of all plies.

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• Core Scale Factor: Thickness of the core plies are scaled by this factor.

• Section Cut Type: Select which ply type is plotted:

– Modeling Ply Wise: Modeling Plies are plotted.

– Production Ply Wise: Production Plies are plotted.

– Analysis Ply Wise: Analysis plies are plotted.

Figure 2.106: Wire Frame Options

• Interaction Type: Define the intersection of the section plane and the model:

– Normal to Surface: Plies are plotted as normal to the intersected elements.

– In Plane: Plies are plotted in the section plane.

Figure 2.107: Surface Options

• Use Default Tolerance: Use the default tolerance (0.1% of the average element size). If unselected,
you should specify the Tolerance:

– Tolerance: Defines the minimum length of the line segments in a Section Cut. Segments
shorter than the tolerance are merged. Small segments can occur if a Section Cut crosses
an element corner as shown below. In some cases, the Section Cut can be relocated to avoid
small segments.

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Figure 2.108: Section Cut Crossing an Element Corner

Sweep based extrusion:

• Use Default Interpolation Settings: Use default interpolation settings. If unselected, you must
specify Search Radius and Number of Interpolation Points. For more information, see 3D
Look-Up Table (p. 112).

2.1.14.1. Types of Extrusion

The following extrusion types are available:

• Wire Frame: This type can be used to investigate the lay-up of shell elements. The mid-
surface of the plies are represented by lines, as shown below.

• Surface Section Cut: For this type, the plies are shown as surface elements. A surface Section
Cut generates a continuous mesh w can be used for 2D analyses. Therefore, Drop-Off elements
are generated by default at the ply boundaries (like the solid model extrusion). If this does
not represent the real structural behavior, then you can use the Butt Joint Sequence (p. 153)
to control the connectivity of the adjacent plies and Drop-Off behavior. The surface Section
Cut supports two types of extrusion:

– Surface Normal: The extrusion follows the element normals of the reference surface.
The offset direction does not change during the extrusion.

– Surface Sweep Based: The offset direction follows the interpolated element normals
(potential field defined by the shell normals). The interpolation is based on a Look-
Up Table (p. 107) that specifies the Search Radius and Number of Interpolation Points.

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In general, the sweep-based algorithm is more robust in sharp corners with thick
laminates; however, the extrusion of t-joints may be less accurate. The sharp corner
in Figure 2.99 illustrates the difference between the extrusion algorithms.

• Surface Normal: The plies are illustrated by surface elements. The extrusion follows the
element normals.

• Surface Sweep Based: The plies are shown as surface elements. The offset direction follows
the interpolated element normals (potential field defined by the shell normals).

Figure 2.109: Element Normals

The interpolation is based on a Look-Up Table (p. 112) which specifies the Search Radius
and Number of Interpolation Points.

Figure 2.110: Surface Normal vs. Surface Sweep Based Extrusion

Section Cuts can also be used to plot ply-wise properties such as angles (p. 222). For more information,
see Lay-Up Plots (p. 222).

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Figure 2.111: Ply-Wise Angles on the Surface Section Cut

2.1.14.2. Section Cut Notes

• The line segments are locally enlarged (if necessary) to improve the quality of the surface elements.

• Plies covering more than 3 components cannot be extruded (see figure below):

Figure 2.112: Supported Lay-up for T-Joints

2.1.14.3. Section Cut Export

The Section Cut can be exported in two formats:

Figure 2.113: Export Surface Section Cut Options

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Usage Reference

• The becas.in format includes the 2D mesh, material properties, and element orientations.

• The mapdl.cdb format supports only the 2D mesh and the named selections (top and bottom
node sets derived from the Element Sets of the shell mesh). This can be useful to fill the Section
Cut with a core material (for example).

2.1.14.4. Computation of Equivalent Sectional Properties

The section cut feature implements the computation of the equivalent sectional properties. You
can use sectional properties to model slender structures, such as wind turbine blades or helicopter
blades, with beam elements. This significantly improves the efficiency of analyses, especially non-
linear or transient analyses. The computed values can be used in combination with the preintegrated
composite beam section of Mechanical APDL (see Using Preintegrated Composite Beam Sections
in the Structural Analysis Guide) and element types BEAM188 and BEAM189.

The computation can be run either by the Python shell of ACP or context menu of the Section Cut.
Select the Compute Equivalent Beam Properties... item to open the analysis dialog.

Figure 2.114: Elastic Properties after Running Analysis of the Sectional Properties (via Run
Analysis Button)

The dialog contains the following buttons:

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 Features

• Run Analysis: Generate the input file for the Mechanical APDL solution, run the analysis, parse
the results, and update the figure.

• Copy Mechanical APDL Section Type: Convert the stiffness and mass matrix into the Mechanical
APDL SECTYPE command for a preintegrated composite beam and copy it to the clipboard. The
command (string) can be used in Mechanical APDL or Mechanical via a command snippet to
define the properties of beam elements.

• Copy Results to Clipboard: Copy all elastic and mass properties to the clipboard.

• Close: Close the dialog. Note that the results are not saved.

The sectional properties are computed with respect to the section cut's coordinate system that is
defined by the origin, normal, and first reference direction of the section cut. The results are shown
at the top of the Elastic Properties and Mass Properties tabs.

Both tabs have a user-defined section to convert the matrix with respect to the Position and Axes
system. You can use the Matrix Format to order the entries of the matrices for the corresponding
application. The computed matrices can be used in combination with the preintegrated composite
beam section of Mechanical APDL (see Using Preintegrated Composite Beam Sections in the Struc-
tural Analysis Guide), if the Format is set to Ansys. For more information about the format of the
stiffness and material matrix, see the Theory (p. 178) section.

The Figure tab shows the section cut mesh and the positions of the shear center, CoG, and elastic
center with respect to the section cut's origin.

Figure 2.115: Section Cut Mesh and Results

In case of errors, use the Mechanical APDL Output File and Result File to investigate the analysis.

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2.1.14.4.1. Theory
The computation is based on the theories of [Giavotto et al. (1983)] (p. 369) and [Ghiringhelli et
al. (1994)] (p. 369).

A 3D mesh slice (SOLID186 element) of the beam section is generated using section cuts, as
represented in the figure below. The computational model of the section cut is automatically
converted to the reference coordinate system, where x and y are the beam section in-plane axes,
while the beam longitudinal axis follows the global z (positive).

Figure 2.116: 3D Representation of a Beam Slice (with Respect to the Global Coordinate
System)

The global FE stiffness and mass matrix of the slice are then computed using the Mechanical
APDL Solver.

The global mass matrix is used to compute the equivalent beam mass matrix per unit length.

The global stiffness matrix is used as the starting point to compute all the matrices required
by the theory explained in [Giavotto et al. (1983)] (p. 369).

The global stiffness matrix is split into four submatrices (the subscripts 1 and 2 refer to face-1
and face-2 of the solid slice):

These four K-sub-matrices are then combined following the implementation explained in [Ghir-
inghelli et al. (1994)] (p. 369) to build the system of equations of [Giavotto et al. (1983)] (p. 369),
solve them, and finally compute the stiffness matrix of the beam section.

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2.1.14.4.2. Results
The results of the computation are the stiffness matrix of the cross section, mass matrix, and
other section properties such as shear center and center of gravity. The primary results are with
respect to the origin of the section cut and the global coordinate system of the section cut which
is defined by the normal and reference direction 1.

The standard output stiffness matrix produced by this feature has the following form:

where,

• and are the shear forces along the x and y directions

• is the force along the beam longitudinal axis (axial force)

• and are the bending moments around the x and y axes

• is the torsional moment around the beam axis

• and are the transverse shear strains

• is the axial strain

• and are the curvatures in the x and y axes

• is the twist

All the represent a stiffness value. The ones on the main diagonal are:

Shear stiffness in x plane

Shear stiffness in y plane
Axial stiffness
Bending stiffness in x
plane
Bending stiffness in y
plane
Torsional stiffness

This feature also computes the following important quantities:

• Elastic center coordinates

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• Shear center coordinates

• Center of gravity coordinates

• Angle of the elastic axes

• Angle of the barycentric principal axes

The results of the computation are the stiffness matrix of the cross section, mass matrix, and
other section properties such as shear center and center of gravity.

2.1.14.4.3. Best Practices

You can request for the stiffness and mass matrix to be printed out and reordered to follow the
specific Ansys beam section type form SECTYPE,,COMB,MATRIX, which can be used to assign the
computed equivalent beam properties to an Ansys beam element (such as BEAM188 or BEAM189).
See the get_transformed_sectional_properties_matrix() function of the Section
Cut. There is an example at the end of this section which generates an input file for Mechanical
APDL.

The get_sectional_stiffness_behavior() extracts the equivalent stiffness values from

the matrix.

Reordering Example

The value in the standard output becomes the value in position (1,1) of the SEC-
TYPE,,COMB,MATRIX, while the value becomes the value in position (3,3).

For a detailed description of the stiffness and mass matrix form in this case, see Using Preintegrated
Composite Beam Sections in the Structural Analysis Guide.

The position and orientation of the section cut are important. Typically, the section cut plane is
perpendicular to the mesh and the origin is placed in the center of the mesh. The section cut
provides methods to transform points from the global coordinate system to the coordinate system
of the section cut, and vice versa.

Export Section Cut Example

Export section cut properties to Mechanical APDL as a preintegrated composite beam.

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 Features

model = db.active_model
model.update()

with open("D:\\tmp\\composite_sections.cdb", "w") as mapdl_file:

for index, sc in enumerate(model.section_cuts.values()):
# compute equivalent beam properties
results = sc.compute_equivalent_beam_properties(check_status=True)
sectype_command = sc.get_sectype_command_from_sectional_properties(
properties=results.properties,
stiffness_matrix_position="elastic center",
stiffness_matrix_angle="elastic axes",
mass_matrix_position="center of gravity",
mass_matrix_angle="principal axes",
sectype_id=index+1
)
mapdl_file.write(sectype_command)

2.1.14.4.4. Limitations
This feature has the following limitations:

• The computation becomes expensive (RAM and time) if the section cut has many nodes
(over 5000). The number of nodes can be reduced by combining plies with equal material
and orientations.

• The default properties of variable materials are used for the calculation of the equivalent
beam properties. For instance, the effect of draping is ignored if material properties vary
with respect to the shear angle.

2.1.14.4.5. References
The computation of the respective sectional properties based on Ghiringhelli's theory (see [Ghir-
inghelli et al. (1994)] (p. 369)) was compared with that of Becas. The comparison contains various
cross sections with different materials and lay-ups, and the results are almost identical.

2.1.15. Sensors
A Sensor provides the evaluation of global results like price, weight, or area. Results can be evaluated
for specific parts, materials or plies.

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Figure 2.117: Sensor Properties

The Sensor Properties dialog contains the following options:

• Name: Name of the Sensor.

• Active: Set to false to suppress the Sensor computations.

• Sensor Type: Define the evaluation type.

– Sensor by Area: Select one or several Element Sets or Oriented Selection Sets.

– Sensor by Material: Select Fabric(s), Stackup(s) and/or Sublaminates. If a Fabric is selected, the
plies in the Sublaminates are also considered in the evaluation; plies in a Stackup are not.

– Sensor by Modeling Ply: Select one or more plies.

– Sensor by Solid Model: Select one or more solid models. For a solid model sensor type, only
weight and center of gravity are computed.

• Entities: Select the corresponding entities by clicking them in the Tree.

• Measure: Display results of different quantities.

– Weight: Mass of the selected entity.

– Covered Area: Surface area of a selected Element Set, Oriented Selection Set, or tooling surface
area that is covered by the composite lay-up of the selected Material or Modeling Ply.

– Modeling Ply Area: Surface area of all Modeling Plies of the selected entity.

– Production Ply Area: Surface area of all Production Plies of the selected entity.

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 Features

– Price: Price for the composite lay-up of the selected entity. The price per area is set under Ma-
terial Data > Fabrics or Material Data > Stackups.

– Center of Gravity: Center of gravity of the selected entity in the global coordinate system.

2.1.16. Solid Models

Topics in this section:
2.1.16.1. Solid Model
2.1.16.2. Imported Solid Model

ACP knows two different types of solid models: the first type is simply called Solid Model and is based
on an extrusion algorithm that generates a volume mesh from the shell mesh and its Composite
Definitions. The second type is named Imported Solid Model and maps the Composite Definitions
onto an external (imported) solid mesh.

Because of its geometrical limitations, you can only use the standard Solid Model for simple to mod-
erately complex lay-up models and shapes. You can customize the extrusion of the lay-up using Ex-
trusion Guides, Snap-To Geometries, and Cut-Off Geometries. Still, the extrusion can result in highly
distorted layered solid elements if the shell reference surface is highly curved and the laminate is
thick.

The Imported Solid Model is a good alternative because the solid mesh is generated independently
of the lay-up. The solid mesh is loaded in ACP, and the lay-up (Composite Definitions) from ACP is
mapped onto the external solid mesh. With the Imported Solid Model, you can choose to map the
lay-up using layered or reinforcing elements. The latter eases the solid mesh constraints since it enables
the use of any solid element type (brick, tetra, etc.). Meanwhile, layered elements require a solid mesh
with brick or prism elements.

Figure 2.118: Solid Model Folder with a Standard Solid Model and an Imported Solid Model

The context menu of the Solid Models object contains these actions:

• Create Solid Model: creates a new solid model object

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• Paste: adds a new solid model object from the clipboard

Note:

The Imported Solid Models can only be created via the Workbench Project Schematic. See
the Solid Modeling (p. 48) workflow section.

2.1.16.1. Solid Model

The Solid Model feature creates a layered solid element model from a composite shell model. The
solid element model can be integrated into a Workbench workflow or exported for use outside of
Workbench. Analysis of a Composite Solid Model (p. 314) explains the Solid Model workflow in
Workbench, and Guide to Solid Modeling (p. 283) provides general information on solid modeling.

The settings for the solid model generation are adjusted under the Solid Model context menu item
Properties. The Solid Model Properties (p. 185) dialog covers what Element Sets are extruded, the
extrusion method, Drop-Off elements handling and numbering offsets, among other things.

You can use Extrusion Guides, Snap-To, and Cut-Off Geometries to shape the Solid Model as desired.
They are specified in the respective subfolders in the Solid Model Tree View. The Analysis Plies
sub-folder shows which plies are incorporated in the Solid Model. The sub-folder Mesh Components
contains internal Element Sets which are created during the extrusion.

Figure 2.119: Solid Model Feature in the Tree View

Subtopics:
2.1.16.1.1. Properties
2.1.16.1.2. Export Solid Model
2.1.16.1.3. Extrusion Guides
2.1.16.1.4. Snap-To Geometry
2.1.16.1.5. Cut-Off Geometry

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 Features

2.1.16.1.6. Mesh Components

2.1.16.1.7. Material Handling for Different Extrusion Methods
2.1.16.1.8. Save & Reload Solid Models
2.1.16.1.9. Node-based Thicknesses

2.1.16.1.1. Properties
The Solid Model Properties dialog is divided into the following tabs:
2.1.16.1.1.1. General
2.1.16.1.1.2. Drop-Offs
2.1.16.1.1.3. Export

2.1.16.1.1.1. General

The General tab has the following properties:

Figure 2.120: Solid Model Properties - General

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Element Sets

Starting with a shell model and the lay-up definition, the shell elements are extruded to a
layered solid element model. Select an Element Set to define the region of the extrusion.

Important:

The mid-offset option of Element Sets is not supported for Solid Model extrusion.
The ply definition must be defined without this option to obtain the correct
solid model position.

Extrusion Properties

The lay-up extrusion can be organized in different ways to merge plies with different criteria:

• Extrusion Method:

– Analysis Ply Wise: Extrude each Analysis Ply as one solid element layer.

– Material Wise: All sequential plies containing the same material are grouped in one
solid element layer. A maximum element thickness can be specified that will subdivide
the single element layers if necessary.

– Modeling Ply Wise: Extrude each Modeling Ply as one solid element layer (for example,
every Stackup or Sublaminate is extruded as one solid element layer).

– Monolithic: Extrude the whole lay-up in one solid element layer.

– Production Ply Wise: Extrude each Production Ply as one solid element layer if possible.
Depending on the model topology, monolithic Modeling Groups may be split in order
to ensure the cohesion of the resulting solid model.

– Specify Thickness: Plies are grouped by iterating through the laminate from the inside
out..

– User Defined: Plies are grouped by iterating through the laminate from the inside
out.

– Sandwich Wise: Plies on either side of a core material are grouped into single element
layers. The core material is extruded as one element layer.

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 Features

Figure 2.121: Illustration of Solid Model Extrusion Methods

For extrusion methods other than analysis ply-wise, see Material Handling for Different
Extrusion Methods (p. 207).

• Max Element Thickness: Thickness at which a new Modeling Group will be introduced.
If a single ply is thicker than this value it is split into layers of equal thickness no thicker
than this value.

• Start Ply Groups at: A new Modeling Group is introduced each time the iteration meets
one of the plies specified in this option (User Defined Extrusion Method only)

• Offset Direction: With the Surface Normal option, the extrusion direction is re-evaluated
after each row of solid elements. With Shell Normal option, the extrusion direction stays
defined as shell normal.

Figure 2.122: Offset Direction - Schema

An example of both options is shown in the following figure:

Figure 2.123: Offset Direction - Example

The effect is visible in the element rows above the drop-off elements.
Solid Model with Surface Normal Direction

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Solid Model with Shell Normal Direction

• Skip Elements Without Plies: Enable this option to automatically remove elements
without plies from the region of extrusion. This ensures that no drop-off elements are
created between the elements without plies and the adjacent elements. An application
example is when holes are filled and meshed but do not contain a lay-up.

Drop-Offs and Cut-Offs

The Drop-Offs and Cut-Offs section controls the global material handling for Drop-Off and
Cut-Off elements in the solid model. The following options are available:

• Global Drop-Off Material: This setting is used when the material handling settings for
fabrics and stackups are set to Global.

• Global Cut-Off Material: This setting is used when the material handling settings for
fabrics and stackups are set to Global.

Element Quality

ACP performs shape checks during the solid model generation. The checks are similar to
Element Shape Testing in Mechanical APDL, and bad elements are deleted if they fail the
check. You can adjust some of the limits and tolerances:

• Delete Bad Elements: When enabled, ACP will perform shape checks. Disable this option
to suppress the shape checks.

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• Warping Limit: Solid elements with a warping factor above this limit are removed from
the solid model. The default value is 0.4. Twisting the top face of a unit cube by 22.5°
and 45° relative to the base produces warping factors of about 0.2 and 0.4, respectively.

• Minimum Volume: Elements with a volume equal to or smaller than this limit are deleted.
The default value is 0 so only elements with a negative or zero volume are removed.
You can adjust this parameter accordingly should the solver produce error messages
about small elements with a volume close to zero. For instance, the Mechanical APDL
solver logs this error: *** ERROR *** Zero volume in element...

2.1.16.1.1.2. Drop-Offs

The Drop-Offs Tab has the following properties:

Figure 2.124: Solid Model Properties - Drop-Offs

• Drop-Off Method: Define the ply's Drop-Off before or after the edge.

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• Disable Drop-Offs on Top Surface: Deactivates Drop-Off elements on the top face sheet of
the laminate for the selected (oriented) Element Sets.

• Disable Drop-Offs on Bottom Surface: Deactivates Drop-Off elements on the bottom face
sheet of the laminate for the selected (oriented) Element Sets.

Figure 2.125: Disable Drop-Offs

Disable Drop-Offs option deactivated

Disable Drop-Offs option activated

• Connect Butt-Joined Plies: If a composite layer ends away from a mesh boundary, it tails
off with a Drop-Off Element. These Drop-Off elements are degenerated brick elements that
are reduced from bricks into prisms. This option can prevent an element Drop-Off of two
adjacent, sequential plies in the same modeling group. By default, it is active.

The feature is limited to plies that appear sequentially in the same Modeling Group. It is not
possible to connect all butt-jointed plies that are arranged in a circle. This is a known limita-
tion.

An example of a sandwich structure with divided core material is shown below to demonstrate
the use of a ply connection.

Figure 2.126: Connect Butt-Jointed Plies

Connect Butt-Joined Plies activated

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 Features

Connect Butt-Joined Plies deactivated

2.1.16.1.1.3. Export

The Export Tab has the following properties:

Figure 2.127: Solid Model Properties - Export

Global Options

• Write Degenerated Elements: Include Drop-Off elements and Cut-Off elements in the
solid model export. Deactivating this option can lead to holes in the mesh and prevent
import into Mechanical. Deactivating this option is not advised during a Workbench
workflow.

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Figure 2.128: Write Degenerated Elements

Export with Drop-Off Elements

Export without Drop-Off Elements

• Use SOLSH Elements: Create the model with Solid-Shell elements (SOLSH190).

• Drop Hanging Nodes: Remove hanging nodes from model before solve (default on).

Hanging nodes are not connected to all the neighboring elements. Hanging nodes can
occur when quadratic hexahedral, tetrahedral, and prism elements are connected together.
Hanging nodes can lead to discontinuous deformation fields and are therefore not desir-
able. When this option is active, element edges containing a hanging node are described
as a linear shape function. The following figure shows a quadratic tetrahedral element
on top of a quadratic hexahedra element. There is a hanging node on the tet element,
highlighted by the red square:

Figure 2.129: Quadratic Tetrahedral Element on Top of a Hexahedral Element

• Use Solid Model Prefix: This option makes element components begin with the name
of the defined solid model. For example, if the solid model is BULKHEAD, the elements
are grouped into components in the following way:

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 Features

CMBLOCK,BULKHEAD_P9L1_Plies_Top,ELEM, 600! users element compon-

ent definition

Transferred Sets

• Transfer All Sets: All Edge and Element Sets are transferred.

• Transferred Element Sets: Specify Element Sets for transfer. Element Sets become two
separate element components with the designation _TOP and _BOT. One element
component coincided with the original Element Set and the other one lies at the end of
the extrusion path.

• Transferred Edge Sets: Specify Edge Sets for transfer. Edge Sets are extruded to form
surfaces (an Edge Set transfers to a surface element component).

Figure 2.130: Transferred Element Sets in Mechanical

Numbering Offset

ACP automatically performs entity numbering within your Workbench project. To avoid
overlap, entities of multiple solid models in one ACP setup are automatically renumbered.
When different ACP or Mechanical models are combined in a single analysis system, there
is also automatic renumbering.

The automatic renumbering is activated by default and can be deactivated in the properties
of the downstream Mechanical Model cell (see Renumber Mesh Nodes and Elements
Automatically).

The entity numbering offset can also be controlled manually. Deactivate the Default option
to define the offset manually for each of the entities (elements, nodes, materials, sections,
coordinate systems). The numbering starts at the defined index and is incremented by one
at a time.

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Figure 2.131: Properties of the ACP-Pre Setup Cell in the Project Schematic

2.1.16.1.2. Export Solid Model

The context menu of Solid Model and Imported Solid Model enables you to export the solid
mesh itself or the skin (envelope) of the mesh in different formats.

You can export the skin of the solid model as STEP, IGES, STL, or Mechanical APDL (CDB). These
representations can be used, for instance, to construct the geometry of adjacent structures to

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the solid model or to construct the geometry of filling material in an airfoil structure. Note that
the STEP and IGES geometries are built from a mesh based tessellation of the skin. Therefore, it
might be worth to work with the STL format and the usage of reverse engineering tools to con-
struct a proper geometrical representation. The CDB format brings the benefit that you work
without a geometry.

The analysis solid model itself can be exported as a CDB file. Element shape checking is deactivated
in the exported file. Check that the material properties are consistent with the mesh units of the
CDB file.

Midside Nodes: If available and active, the tessellation of the mesh includes the midside nodes
of the quadratic elements. If not, only the corner nodes are considered. This option is only available
for the formats skin:stp, skin:igs and skin:stl.

2.1.16.1.3. Extrusion Guides

Solid Model generation for curved geometries and thick lay-ups can lead to boundary edges
which are extruded in undesirable directions. For example, the extrusion of a dome with a hole
at the top results in a solid model with a hole that is not cylindrical. The Extrusion Guide feature
allows you to control the extrusion direction of the edges in order to rectify this. The edge of the
hole can be used as an Extrusion Guide in the vertical direction to create a cylindrical hole.

Figure 2.132: Extrusion with and without an Edge Set Guide

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Multiple Extrusion Guides can be used for one Solid Model. The extrusion itself is controlled with
an edge set and a direction vector or with a geometry. The Extrusion Guide feature also contains
a Curvature Control. The Extrusion Guide Properties dialog has the following options:

Figure 2.133: Extrusion Guide Properties

• Edge Set: Define the Edge Set along which the Extrusion Guide acts.

• Type: The type of Extrusion Guide.

– Direction: Defines a direction vector of the extrusion direction of the Edge Set.

→ Orientation Direction: By default, the normal direction of the Edge Set is calculated and
defined when an Edge Set is selected. It can also be entered manually.

– Geometry: CAD file of a boundary surface is used to define the extrusion path.

→ CAD Geometry: Select a previously generated Virtual Geometry (p. 101). See CAD Geomet-
ries (p. 99) for information on how working with geometries impacts system performance.

– Free: No extrusion path is defined but a curvature correction can be activated independently.

• Radius: Controls the sphere of influence for mesh morphing.

• Depth: controls the bias of the mesh morphing.

• Use Curvature Correction: Apply a curvature correction during the solid model extrusion
which results in a smoother extruded surface. Under certain circumstances, deactivating
curvature correction can lead to better extrusion results.

Extrusion Guides are excuted in the order they appear in the Tree. This has significant effects
when Extrusion Guides intersect. You can change the order of Extrusion Guides from the Tree
View, in one of the follows ways:

• Use the cut-and-paste options in the context menu.

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• Use the cut (Ctrl+X) and paste (Ctrl+V) hotkeys.

• Use the mouse to drag-and-drop the Extrusion Guides.

• Use the Reorder option in the context menu, as shown below.

Figure 2.134: Reordering Extrusion Guides

2.1.16.1.3.1. Mesh Morphing

The generation of a solid model is by extrusion of a shell mesh. By default, extrusion is in the
direction of the shell normal direction. The 2D shell mesh is used as a base for the 3D solid
element mesh, which can have one or more element layers depending on the ply thickness
and extrusion method.

The Extrusion Guide only affects the extrusion of the element edges that are part of the guided
Edge Set. It is either defined by an Edge Set and direction vector or by an Edge Set and a CAD
geometry. While the CAD geometry already is a surface, the Edge Set and direction vector helps
define a surface. In both cases, these surfaces serve as target surfaces in the extrusion.

The guided edge is initially extruded in the normal direction. Then, the nodes on the resulting
free surface are moved to coincide with the target surface of the Extrusion Guide.

Mesh morphing is a way to control the propagation of the Extrusion Guide effect through the
entire mesh.

Mesh morphing is governed by the morphing law, shown in Equation 2.1 (p. 198). It relates the
displacement of internal nodes to the displacement of a node of the guided free surface. Mesh
morphing can be controlled with the two parameters:

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• Radius: All elements within the defined Radius from the Edge Set are extruded with a mesh
morphing correction.

• Depth: Defines the bias of the mesh morphing (linear with 1, quadratic with 2,...).

(2.1)

where:

m0 is the distance a node on the free surface has to move in-plane to coincide with
the Extrusion Guide.
mi is the distance the inward node of the ith shell element moves in-plane as a result
of the mesh morphing.
di is the distance between the node in the guided Edge Set and the inward node of
the ith shell element.

Figure 2.135: Mesh Morphing Diagram

2.1.16.1.3.2. Extrusion Guide Examples

The following is an example of a direction-type Extrusion Guide with different mesh morphing
radii. The location of the edge set is indicated by the circle in the bottom left corner. The mesh
morphing is only applied to nodes on the shell surface whose distance to the Edge Set is
smaller than the radius.

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Figure 2.136: Example of a Direction-type Extrusion Guide with Different Mesh Morphing
Radii

The following is an example of a geometry-type Extrusion Guide with different mesh morphing
depths:

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Figure 2.137: Example of a Geometry-type Extrusion Guide with Different Mesh Morphing
Depths.

2.1.16.1.4. Snap-To Geometry

The Snap-To Geometry feature can alter an extruded Solid Model to align with an imported CAD
Geometry (p. 99). The layered Solid Model is locally stretched or compressed so that its selected
faces coincide with the CAD geometry. Multiple Snap-To Geometries can be assigned to one
Solid Model. The adaptation occurs at the first intersection that is found. See CAD Geomet-
ries (p. 99) for information on how working with geometries impacts system performance.

The feature is only applied to the selected Oriented Selection Set and its selected face (top or
bottom). The normal orientation of the Oriented Selection Set defines which face is top or bottom.
The height of all the elements through the thickness is altered to an even distribution.

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In the following example, the first picture shows the extrusion without any Snap-To Geometry
operation. The lay-up is defined from two Oriented Selection Sets which point in opposite direc-
tions. In the second figure, the first Modeling Ply (oriented to the top) is defined to be extruded
to a CAD Geometry. Only the nodes which meet the surface are extruded until the surface. The
other nodes are extruded normally. The second Modeling Ply is extruded to another CAD Geometry
in the last figure. For both cases, the orientation of the Snap-To Geometry operation must be
top as the Oriented Selection Sets both point outward.

Figure 2.138: Extrusion without Snap Operation

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Figure 2.139: Extrusion with Snap-To Geometry at the Top (Shell Geometry also Displayed)

Figure 2.140: Extrusion with Snap-To Geometry at the Top and Bottom (Shell Geometry
also Displayed)

Caution:

The Snap-To Geometry operation occurs after the Extrusion Guide operations. It is
possible that the nodes moved during the Extrusion Guide operations are translated
again, and do not match with the previous Extrusion Guide definition.

2.1.16.1.5. Cut-Off Geometry

The Cut-Off Geometry feature uses CAD Geometries (p. 99) to shape the Solid Model by cutting
off elements. The operation is analogous to machining a composite part after curing. Refer to
Guide to Solid Modeling (p. 283) for more information. The following figures illustrate the Cut-Off
Geometry feature:

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Figure 2.141: Extruded Solid Model

Figure 2.142: Cut-Off Geometries Shown Alongside Extruded Solid Model

Figure 2.143: Solid Model with Cut-Off Features

2.1.16.1.5.1. Defining Cut-Off Geometry

Add a Cut-Off Geometry by selecting Create Cut-OffGeometry in the context menu of the
Cut-Off Geometry folder.

Define the Cut-Off operation with either a CAD surface geometry of CAD body geometry. The
orientation flag specifies which side of the surface or the body the elements are cut off. The
up orientation specifies that elements in the reverse normal direction of the geometry are cut
off. A visualization of the surface normal direction of a CAD body geometry can be displayed
with the Show Normals button in the toolbar.

You can use multiple Cut-Off Geometries for one solid model. The cut offs are applied sequen-
tially in order off Cut-Off Geometries creation.

The following properties must be defined in the Cut-Off Geometry Properties dialog:

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Cut-Off Geometry Properties

• CAD Geometry: CAD geometry for surface or body geometry.

• Orientation: Determines the cutting orientation of a surface/body geometry.

Figure 2.144: Cut-Off Geometry Normal Direction

• Relative Merge Tolerance: Set the merging tolerance for neighboring nodes relative to the
element size. If two nodes fall within this tolerance they are merged, which avoids very small
element edges.

Note:

Cut-Off operations are computationally intensive, so it is important to define your

geometries efficiently. The Cut-Off algorithm runs faster if you create a for each part
instead of creating a single geometry containing all parts. This is because ACP, prior
to running the calculation, filters out all extraneous points and elements. The figure
below illustrates the principle: Instead of one large geometry, three Cut-Off geomet-
ries have been added, one for each feature.

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Figure 2.145: Example of three Cut-Off geometries

2.1.16.1.5.2. Decomposition of Degenerated Elements

The cutting operation can reshape elements in such a way that they are no longer able to be
handled by the solver. The Cut-Off elements are therefore decomposed into homogenous prism
and tetrahedral elements following the Cut-Off operation. An example of such a decomposition
is shown in the figure below. The decomposition takes place automatically during Solid Model
generation.

Figure 2.146: A Degenerated Hexahedral Element (left) is Decomposed into Several

Tetrahedral Elements (right)

2.1.16.1.5.3. Limitations

The Cut-Off Geometry feature modifies elements by cutting off nodes. However, it does not
refine the local mesh to conform precisely to the Cut-Off Geometry.

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The sketch below illustrates how the Cut-Off Geometry Feature works: A node (a) of the finite
element is within the Cut-Off Geometry, so it is removed from the element. But no additional
nodes are added where the element edges intersect with the Cut-Off Geometry. Instead, the
element is converted into a degenerated shape (B), in this case from a quad to a triangle. This
also happens for 3D elements (prisms and hexes).

In many cases, the resulting element mesh will not represent all the features of the Cut-Off
Geometry. This is especially true when the Cut-Off Geometry has sharp edges or features that
are below the resolution of the elements. In the sketch shown below, for example, the finite
element retains its shape because none of its nodes fall within the Cut-Off Geometry. To remedy
this, you must refine the solid mesh by modifying the original shell mesh.

Another limitation is that degenerated elements (tetra elements, for example) do not support
layered section data. Instead, the cut-off material, which is defined either in the Solid Model
Properties (p. 185) or in the Fabric Properties (p. 86), is assigned to the element. You can
manage this by using the Analysis Ply-Wise Extrusion Method. Ansys recommends that you
assess the results of cut-off elements carefully.

2.1.16.1.6. Mesh Components

This folder contains Element Sets which were generated during the extrusion. For instance, the
DropOffSet contains all Drop-Off elements. This is the area where the thickness of the solid ele-
ments drops to zero, and homogeneous elements are generated at the boundary.

You can select and highlight the mesh components in the Scene if the Element Selection Mode
is set to Automatic or Solid (see Mesh Appearance (p. 26)).

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 Features

Figure 2.147: Solid Model with Highlighted Drop-Off elements

2.1.16.1.7. Material Handling for Different Extrusion Methods

The material handling for an analysis ply-wise extrusion follows the rules outlined in Fabric Solid
Model Options (p. 86). The following additional rules apply for other extrusion methods where
plies of different materials are grouped together in one solid element layer.

Drop-Off Material Handling in Non-Analysis-Ply-Wise Extrusions

• If the material handling option of at least one ply is set to Global, the global Solid Model Drop-
Off material is used.

• If all ply material handling options are set to Custom and refer to the same custom material,
the custom Drop-Off material is used.

• In all other cases (for example, a multi-layered solid with material handling options Custom
and Global), the global Solid Model Drop-Off material is used.

Cut-Off Material Handling in Non-Analysis-Ply-Wise Extrusions

• If the material handling option of at least one ply is set to Global, the global Solid Model Cut-
Off material is used.

• If all ply material handling options are set to Custom and refer to the same custom material,
the custom Cut-Off material is used.

• In all other cases, the global Solid Model Cut-Off material is used.

2.1.16.1.8. Save & Reload Solid Models

ACP Solid Models are saved as .H5 files. An update of ACP (Pre) component initiates a check of
the current and previous laminate lay-up. While the laminate lay-up does not change no new
solid model is generated.

2.1.16.1.9. Node-based Thicknesses

By default, the solid model extrusion and the 3D lay-up representation used for the lay-up mapping
within the Imported Solid Model are based on the ply thicknesses at the element center. If the

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Use Nodal Thickness is on (see Lay-up Computation (p. 65)), the solid model extrusion and 3D
lay-up representation directly consume the node-based thicknesses, which can improve the ac-
curacy. For more information, see the Element- vs. Node-based Thicknesses (p. 68) section.

2.1.16.2. Imported Solid Model

Topics in this section:
2.1.16.2.1. Imported Solid Model Properties
2.1.16.2.2. Mesh Components
2.1.16.2.3. Lay-up Mapping Objects
2.1.16.2.4. Quality Check
2.1.16.2.5. Miscellaneous

The Imported Solid Model feature enables you to map the Composite Definitions of ACP (Pre) onto
the mesh of an external (imported) solid model. This approach can be used if the standard solid
model approach, that is based on an extrusion algorithm and post operations, fails or produces a
mesh of poor quality. In that case, it is more robust to mesh the final composite solid structure
first, independent of the lay-up data and, in a second step, to map the Composite Definitions. See
the Guide to Solid Modeling (p. 283) section for solid model workflows as well as tips used when
working with a solid model.

Figure 2.148: Tree Object of the Imported Solid Model Feature

The Imported Solid Model (containing lay-up mapping data) can be used in combination with
structured elements (such as brick, prism, or wedge) and degenerated shapes (tetra and pyramid).
The Lay-Up Mapping Objects feature provides several options to control the mapping. For more
information on the element technologies, material handling, and element orientations, see Lay-up
Mapping Objects (p. 212). The imported solid mesh with the mapped lay-up data is exported for
downstream analyses using the standard solid model workflow in Workbench.

The lay-up mapping feature is the 3D representation of the lay-up model computed immediately
after the imported solid model updates. This 3D representation always follows the surface normal
of the shell mesh. The imported solid model does not support the Extrusion Guides (p. 195) feature.
If you need to manage the free edges in curved areas, one recommended approach is to enlarge
the shell surface and plies in the in-plane direction.

The elemental component sets that are defined in the external solid mesh are listed in the Mesh
Components sub-folder and are used to define the scoping of the Lay-up Mapping Objects (p. 212).
All component sets (also node sets) of the initial solid mesh are passed as Named Selections to the
downstream analyses (Mechanical Model) and can be used to maintain correct associations (such
as boundary conditions or contacts).

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See the Analysis of a Mapped Composite Solid Model (p. 326) section for an example analysis.

Cut-Off Geometries can be used to shape the Imported Solid Model in a desired way. They are
specified in the respective subfolders in the Imported Solid Model Tree View. The Cut-Off feature
behaves in the same way for the Imported Solid Model as it does for the standard Solid Model. It
is described in Cut-Off Geometry (p. 202). The Analysis Plies sub-folder shows which Analysis Plies
are incorporated in the lay-up mapping.

This Cut-Off feature allows you to shape the imported solid mesh after the lay-up mapping. It gives
you further control of geometry and mesh. You can add details and geometrical features to the
Imported Solid Model. Therefore, the generation of a structured mesh will be easier and more robust
for many cases.

The context menu of the Imported Solid Model contains these actions:

• Properties: Opens the Properties dialog of the imported solid model.

• Update: Runs the lay-up mapping algorithm and updates all dependencies of the Imported Solid
Model.

• Active/Inactive: Toggle whether the Imported Solid Model is suppressed or not.

• Import Initial Mesh: Loads the initial mesh of the solid model without performing the lay-up
mapping.

• Clear Generated Data: Removes all elements and mapped lay-up data from the object.

• Hide: Hide the solid model in the Scene.

• Show: Show the solid model in the Scene.

• Delete: Delete the Imported Solid Model. Not possible if the object is locked.

• Export Solid Model: Export the mesh or skin of the solid model as a geometry or as a Mechan-
ical APDL input file.

2.1.16.2.1. Imported Solid Model Properties

You can configure the settings for the Imported Solid Model under the Imported Solid Model
context menu item Properties. The properties dialog covers some basic settings where the scope
of the lay-up mapping is configured through the Lay-up Mapping Objects.

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2.1.16.2.1.1. General Tab

2.1.16.2.1.2. Export Tab
2.1.16.2.1.3. Mapping Statistics

2.1.16.2.1.1. General Tab

• Name: Name of the object

• Format: This property specifies the format of the input file. Within a Workbench project,
solid meshes are imported via a Mechanical Model (p. 48) component. The import automat-
ically completes the Format, Unit System, and File Path properties, so as a result, these
properties are read-only.

If you are running ACP in standalone, you can directly import Ansys CDB files in ACP Pre. For
this scenario, you need to specify the Unit System of the volume mesh.

• Unit System: This property specifies the unit system of the external solid mesh which is used
to automatically convert the solid mesh into the unit system of ACP.

• File Path: Specifies the location of the mesh file to be imported.

• Refresh From Source: Only enabled in ACP standalone. Click to prompt ACP to reread the
mesh from the source file. Use this feature whenever the source file is modified because ACP
does not re-read the data automatically.

• Import Initial Mesh: Loads the initial mesh of the solid model into the ACP Model without
performing the lay-up mapping. This can be used, for example, after using the Clear Gener-
ated Data feature, to show the initial mesh once again.

• Element Quality (Delete Bad Elements, Warping Limit, Minimum Volume): See the explan-
ation for Element Quality under Solid Model Properties (p. 188).

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• Global Cut-Off Material: Controls the global material handling for Cut-Off Elements in the
solid model. Cut-Off Elements which have a degenerated shape (tetra) do not support layers
and therefore are filled with a Cut-Off material. This setting is used when the material
handling settings for fabrics and stackups are set to Global. See Fabric Solid Model Op-
tions (p. 86).

2.1.16.2.1.2. Export Tab

The export tab options are a limited set of the standard solid model options. See Export (p. 191)
in the Solid Model Properties section.

2.1.16.2.1.3. Mapping Statistics

The Mapping Statistics tab includes basic results regarding the lay-up mapping such as total
mass, volume, resin volume content, and so on. The Ply-Wise Data table shows the volume
per analysis ply and the difference compared to the lay-up definition based on the shell mesh.
The solid mesh ply volume is greater if the difference is positive, smaller if negative.

2.1.16.2.2. Mesh Components

Mesh Components (Element Sets) in the external solid mesh are listed in this folder. Mesh Com-
ponents are either:

• Named Selections in Mechanical

• Component sets in Mechanical APDL

• Or components of elements in the external mesh generated by a third-party meshing application

Note that Mesh Components cannot be visualized in the Scene until the initial mesh is loaded.
This happens when you Import Initial Mesh or Update the Imported Solid Model. Mesh Com-
ponents cannot be edited nor copied, and they are read-only.

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Figure 2.149: Transfer of Mesh Components from an External Mesh via External Model,
Mechanical to ACP Pre

2.1.16.2.3. Lay-up Mapping Objects

This folder contains the Lay-up Mapping Objects used to define mapping scopes and to configure
material handling. An Imported Solid Model can have multiple Lay-up Mapping Objects defining
which plies are mapped to which components of the solid mesh. Note that the node connectivity
remains unchanged, regardless of the number of Lay-up Mapping Objects.

The Analysis Plies folder under a Lay-Up Mapping Object lists all the imported (p. 164) and/or
simple Analysis Plies (p. 156) of the source scope. The list becomes available after updating the
object and helps to verify the source scope.

The properties of the Lay-up Mapping Object are split into General, Layered Elements, and
Reinforcing.
2.1.16.2.3.1. General Tab
2.1.16.2.3.2. Layered Element Tab
2.1.16.2.3.3. Reinforcing Tab

2.1.16.2.3.1. General Tab

The General tab configures the source and target scopes of the lay-up mapping. The source
scope is defined by a set of shell elements and a list of plies. The mesh components of the

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solid mesh define the target scope. This enables a component-wise mapping of the lay-up
model onto the solid mesh.

The Element technology for Imported Solid Models is the lay-up mapping feature that supports
layered and reinforcing elements. You can configure it in the General tab or the respective
option's tab. The following contains more information on the two Element technology options:

Layered Elements

• The layered element technology should only be used if the solid mesh consists mainly of
brick or prism elements, which are then treated as layered ones. These elements are auto-
matically aligned according to the normal direction of the lay-up and are filled with layers.

Note:

If the layered element faces are not parallel to the lay-up direction, there might
be inaccuracy since its normal direction would differ from the lay-up direction.

• Degenerated elements (pyramid, tetra, etc.) are filled with the filler material and become
homogeneous elements, as well, because they do not support layered data. The element
coordinate system of homogeneous elements can be defined by one or several rosettes (p. 103).

• Elements that do not intersect with the mapped lay-up can be deleted or filled with a filler
material. In that case, they are handled as homogeneous elements.

Reinforcing Elements

• The reinforcing element technology adds material to an existing element by intersecting the
element with basic shapes (link, shell, etc.). For more information, see Reinforcing Elements
in the Element Reference. This technology uses the REINF265 element which enables adding
material to a 3D solid element. Therefore, it can be used with any solid mesh type. The solid
elements are always homogenous, and their coordinate system is also defined by
rosettes (p. 103). Also, the reinforcing plies and their material direction are independent of
the base element.

The Source Scope is defined by a set of shell elements and a list of plies, while the Target
Scope is defined by the mesh components of the solid mesh. This enables a component-wise
mapping of the lay-up model onto the solid mesh.

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Source Scope: Lay-up

• Shell Element Sets: Select one or several Element Set(s) to define the region of interest.
Starting with a shell model and the lay-up definition, the 3D representation of the laminate
is generated for the selected region.

Note:

The Middle Offset (p. 95) option for Element Sets is not supported. The ply
definition must be defined without this option to obtain an accurate mapping.

• Use Imported Plies: If enabled, Imported Plies are mapped onto the solid mesh instead of
the standard Modeling Plies. In this situation, the Shell Element Sets option becomes irrel-
evant.

• Select All Plies: By default, this property maps all plies of the selected shell mesh (Shell
Element Sets) onto the solid mesh. Clear this box to select a user-defined set of plies for the
mapping. Modeling Groups and/or Modeling Plies can be selected.

If Use Imported Plies and Select All Plies are both enabled, all Imported Plies are selected.

• User Defined Set: This field allows you to specify a set of Modeling Plies and/or Modeling
Groups when selecting the plies to be mapped onto the solid mesh. The equivalent object
types can be selected if Use Imported Plies is enabled.

Target Scope: Solid Mesh

• Entire Solid Mesh: If selected, the source scope (lay-up) and materials are applied to the
entire solid mesh. This also means that no other Lay-up Mapping Object can be configured
because the Target Scope cannot overlap.

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• Solid Element Sets: Use this field to select the specific Mesh Components of the solid mesh
to which the Lay-up Mapping Object will be applied. Mesh Components are Named Selections
or Element Sets which are defined in the initial (external) solid mesh.

2.1.16.2.3.2. Layered Element Tab

In most cases, the lay-up does not fill the entire selected target scope (solid elements), or there
are voids (gaps between layers). Use the options in the Layered Element tab to configure how
voids are handled as well as the lost elements which do not intersect with the lay-up. Because
these layered elements are defined per Lay-up Mapping Object, an Imported Solid Model can
have multiple void and filler materials.

Void Handling

• Scale Ply Thicknesses: The thickness of the mapped lay-up and the geometrical thickness
of layered elements can differ for various reasons (drop-offs, numerical differences, and so
on). If this option is enabled, the thickness of the mapped laminate will be scaled to match
the element as shown below. Note that the scaling is done per element and not on a global
scope. Below is a side view of a layered solid with void space (A) and the same element after
the ply thickness has been scaled (B).

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• Global Void Material: Instead of scaling the laminate, you can fill the void space with a
specific material. To do so, be sure to clear the option Scale Plies and then define a void
material. Use an isotropic material since the in-plane orientation cannot be defined.

Note that you can access elements with void material through the analysis ply void_<mater-
ial id> within the Analysis Plies folder of the Imported Solid Model. There are as many void
layers in the folder as the maximum number of void layers in a layered element. For instance,
in the illustration below, there are two void spaces in a layered solid element.

• Minimum Void Material Thickness: Void spaces, like those shown above, can be caused by
drop-offs or differences between the shell and solid mesh, especially in curved areas– to
name some examples. You can further refine the void handling by specifying the Minimum
Void Material Thickness. If the thickness of the void space is less than the specified value,
the void will not be filled. Instead, the regular plies are scaled to fill the void space.

In the illustration below, scaled layers and filled void space are both applied.

This raises a possible point of confusion: Why does ACP scale the plies if the option Scale
Plies has been disabled? The fact is, the solver automatically scales the laminate whenever
the total laminate thickness does not correspond with the element height, so ACP is perform-
ing the scaling already. The Minimum Void Material Thickness feature allows you to visu-
alize and express numerically this effect in ACP.

Filler

Elements which do not intersect with the lay-up are called lost elements. They are either deleted
or filled and oriented with a Filler Material and Rosette(s), respectively.

• Delete Lost Elements: Use this option to control whether solid elements without mapped
lay-up data are removed or retained. Note that unstructured elements such as tets or pyramids
are ignored in the mapping algorithm and are always treated as lost elements (elements
without data).

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• Global Filler Material: If the property Delete Lost Elements is disabled, a filler material
must be assigned to the solid elements that do not have mapped lay-up data. Lost elements
are handled as non-layered (homogeneous) elements. The characteristic of the filler material
can be isotropic or anisotropic.

Note:

The homogeneous elements with filler material can be accessed through the
analysis ply filler_<material id> within the Analysis Plies folder of the Imported
Solid Model.

Orientation: Select one or several Rosettes (p. 103) to orient the filled elements. Note that
the Rosettes are used to evaluate the fiber directions (local x-axis) and the normal directions
(local z-axis) of the elements. This is slightly different compared to Oriented Selection
Sets (p. 132) where the Rosettes are used to apply the reference directions only.

If the Normals and Fiber Directions plot is enabled, you can visualize the element's x and z
axes by selecting the filler layer.

Figure 2.150: Element Normals of the Filler Elements Computed from Two Rosettes.

• Selection Method: Supported options include Minimum Distance and Minimum Distance
Superposed as described in Oriented Selection Set (p. 132).

Use Filler Option Only: The Lay-Up Mapping Object also allows you to fill Mesh Components
or the entire solid mesh with a filler material and to orient the elements so that no plies from
the lay-up are mapped. To do so, define an empty Source Scope in the General tab (A, below).

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Usage Reference

In the Materials tab (B), clear the Delete Lost Elements option, and select a Filler Material
and Rosettes.

The mapping algorithm, based on the 3D representation of the lay-up, consists of three main
steps:

1. Aligns the structured solid elements according to the local offset direction of the 3D
representation.

2. Evaluates the ply-wise intersections between the solid elements and plies. The mapping
algorithm also detects if an element is completely within a ply. The output contains
the element-wise plies' materials, thicknesses, and orientations. Thus, the element-wise
section data.

3. Stores the data for downstream analyses.

Note:

The mapping algorithm evaluates the intersection at the center of the solid elements,
therefore, the ply thicknesses are constant for the whole element.

2.1.16.2.3.2.1. Limitations

The following limitations are specific to the layered element technology:

• The projection of the failure results to the reference surface is not supported. Either do ply-
wise analyses or use the Section Cut feature in Mechanical to investigate results inside the
solid.

• Laminate failure criteria such as Wrinkling and Shear Crimping are not supported since the
reconstruction of the stacking sequence of the laminate is not possible for mapped lay-up
data.

• The mapping algorithm assumes that an analysis ply intersects only once with a solid element.
Therefore, the scenario on the left side of the image is not supported, and the generated
data is incorrect. A workaround is to split the ply as shown on the right side.

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2.1.16.2.3.3. Reinforcing Tab

This tab becomes active when the Element technology is set to reinforcing. It enables the
control of reinforcing elements' section properties and the configuration of the 3D solid elements'
material and orientation.

Use the following options to configure the reinforcing elements' structural behavior. For more
information, see SECCONTROL:

• Reinforcing Behavior: Specifies whether the reinforcing elements carry tension and
compression load, or only one of them.

• Base Material Handling: Removes the base material from the solid element where it
intersects with the reinforcing elements or, otherwise, retains the base material. It is
recommended to select remove if a high-volume fraction of reinforcing elements is
expected.

• Stress State: Specifies if the reinforcing elements should behave like a link, membrane,
or shell element (with or without bending). For more information, refer to SECCONTROL–
Type: REINF.

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Reinforcing elements use the stiffness of the plies for the solid elements. An initial material
must be assigned to the solid elements because it is possible that some elements are not rein-
forced. The following options enable the specification of the initial material and orientation (if
the material is orthotropic):

• Base Material: Specifies the solid elements' material before the reinforcing elements
are applied. The base material characteristic can be either isotropic or anisotropic.

• Orientation: Selects one or more rosettes to orient the solid elements. Here, rosettes
are used to evaluate the material 1 directions (local x-axis) and normal directions (local
z-axis) of the elements. These characteristics are different from Oriented Selection Sets
(OSS) (p. 132), where the rosettes are only used to apply the reference direction.

• Selection Method: Supported options are Minimum Distance and Minimum Distance
Superposed as described in Oriented Selection Sets (OSS) (p. 132).

2.1.16.2.3.3.1. Design Tips and Best Practices

Mesh Quality

You can use the reinforcing technology with all solid element types (brick, prism, pyramid, or
tetra). Nevertheless, their shape must be of good quality, and not too distorted, so the reinforcing
elements can successfully apply to the base elements.

Element Size vs Ply Thickness

You can independently define the reinforcing elements of the base elements, including their
size, shape, and element formation. It is essential that the plies' thickness is smaller than the
base elements' size. This ensures that the reinforcing elements' stiffness accurately applies to
the base elements. For instance, you can model thick plies, such as core materials, with multiple
thin plies instead of one thick ply. For more information, see Number of Layers in Modeling
Ply Properties (p. 142).

Cut-Off Geometry

You can use the Cut-Off Geometry (p. 202) feature with the reinforcing elements. The algorithm
might result in solid elements with reduced shape quality and cause issues when combining
the reinforcing elements with the base elements. Therefore, you should mesh the final geometry
instead of shaping the solid mesh in ACP with cut-off geometries.

2.1.16.2.3.3.2. Limitations

The following limitations are specific to the reinforcing element technology:

• The standard composite post-processing features (failure tool, ply-wise result visualization,
etc.) are not supported for reinforcing elements. Use Mechanical APDL for post-processing
your analysis.

• The composite workflows (p. 39) in Workbench does not support reinforcing elements
and will skip all of their instances. The complete solid model with reinforcing elements
can be exported to Mechanical APDL via Export Solid Model from the context menu
of the Imported Solid Model.

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• The analysis ply thickness should be smaller than the solid elements' height. Otherwise,
the contribution of the reinforcing elements to the element stiffness might be incorrect.
For more information, see Design Tips and Best Practices (p. 220).

2.1.16.2.4. Quality Check

The application offers several options to verify the quality of the mapped lay-up.

• You can examine the fiber directions and element normals using the Orientation Visualiz-
ations options on the Toolbar.

Make sure that the solid elements are highlighted by having these mesh appearance set-
tings:

or

• You can use the Thickness Plot (p. 222) to display the ply-wise thicknesses on the solid
elements. You can also select the Component option Relative Thickness Correction to
plot the ply-wise scaling factors.

• lay-up Mapping Plot (p. 222) enables you to plot ply-wise volume contents and the deviation
of the normal direction between the shell mesh and solid mesh. This plot works only if
the Element technology is set to layered elements.

• You can get a general overview using the mapping statistics if the Element technology
is set to layered elements.

• Reinforcing Elements: A model that can also be reviewed in Mechanical APDL. These
Mechanical APDL commands show the reinforcing elements together with the reinforced
solid elements.
alls
esel,u,ename,,REINF265
/trlcy,elem,0.9
esel,all
! Enable the expanded element shapes.
/eshape,0.05
eplot

The following commands are used to plot the main material (reinforcing) direction.
/dev,vect,1
! Select only reinforcing elements (optional)
esel,s,ename,,REINF265
/psymb,layr,-1
eplot

2.1.16.2.5. Miscellaneous
The global model property 'minimum analysis ply thickness' also counts for the lay-up mapping.
A layer is only added to an element if the mapped layer thickness is greater than this value.

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The lay-up representation (shell) is ignorant to the concept of Drop-Off elements (solid) and this
can lead to 'voids' if you have steps in the lay-up as shown in the figure below. If the drops are
low, this can be neglected, if they are high you might have to refine the tapering or adjust the
void handling of the imported solid model.

In general, the mapping is mesh independent and the shell and solid mesh do not have to be
coincident. However, too big of a difference in the meshes might cause inaccurate results.
Therefore you should work with meshes with similar element sizes, especially in curved regions.

The shape functions of the shell and solid elements can differ. For instance a Composite Definition
of a linear shell mesh can be mapped onto a quadratic solid mesh.

Full cross-sections: The mapping might does not work as expected for plies that shrink into a
very small tube as pictured below on the left hand side. In that case, it is more robust to have
several plies of moderate thickness instead of one thick ply as shown by the right picture.

2.1.17. Lay-Up Plots

Lay-Up Plots enable you to verify and visualize element and ply-wise data, such as thickness and
angle, of the Composite Definition in ACP (Pre). Available Lay-up Plots include:

• Thickness Plot (p. 226)

• Ply Angle Plot (p. 227)

• Draping Mesh Plot (p. 227)

• Look-Up Table Plot (p. 229)

• Field Definition Plot (p. 231)

• Lay-Up Mapping (p. 231)

• Material Plots (p. 233)

• User-Defined Plot (p. 233)

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 Features

2.1.17.1. Interface Options

The right-click context menu for the Lay-Up Plots object provides the following options:

• Create Thickness: plot thicknesses per element or ply-wise

• Create Lay-Up Angle: plot ply-wise angles (fiber, shear angle etc.)

• Create Draping Mesh and Flatwrap: plot draping mesh and flatwrap

• Create Scalar Look-up Table: plot scalar look-up tables and interpolations

• Create Field Definition: plot field definition data

• Create Lay-Up Mapping: plot lay-up mapping data

• Create User-Defined: plot a custom set of data on the mesh

• Paste: paste a lay-up plot from the clipboard.

The context menu for each individual Lay-Up Plot option includes the following selections:

• Properties: Display the Plot Properties dialog.

• Update: Update the selected plot.

• Copy: Copy the selected plot definition to the clipboard.

• Paste: Paste a lay-up plot from the clipboard.

• Delete: Delete the selected plot.

• Hide: Hide the selected plot.

• Show: Show the selected plot.

All plots can display the information for all or a selection of elements through the data scope. A
thickness and angle plot for all Element Sets is predefined by default. The plot definition for lay-up
plots follows the same definition as solution plots.

The properties for plots, such as Thickness properties illustrated below, have two tabs: General and
Legend. You can use the General tab to configure the plot's basic settings. Once you deselect the
Use Default check box, the Legend tab enables you to specify minimum and maximum values as
well as changing the legend title, range, and color display.

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General Tab Legend Tab

The following general settings can be Property descriptions include:

found in most of the plots:
• Use Defaults: Uncheck this option
• Name: Name of the plot. to manually configure the color bar.
Otherwise, the default settings are
• Entire Model: If enabled, the scope used.
of the plot is the entire shell- or all
the solid elements of the model if • Min Value: Defines the value of the
Show on Solids is active. Otherwise first label. Disable Auto to set a
you can define the scope through user-defined value.
the Data Scope property. By default,
Entire Model is enabled. • Max Value: Defines the value of the
last label. Disable Auto to specify a
• Data Scope: Determines what user-defined value.
scope is used in the plot. Element
sets, OSS, Modeling Plies & • Use as Threshold: If enabled, the
Sampling Points can be selected in min and max labels become the
the data scope. The data scope of second and second-to-last labels in
a sampling point covers all plies the color bar, respectively.
that are intersected by the sampling
point. • Grey Below Value: Grey is inserted
in the color bar. All values below
• Ply-Wise: Activates a ply-wise plot the min label are then shown in
display. Thickness and angle plot grey. If Use as Threshold is on also,
are only shown if a ply is selected. then the min label becomes the
Angle plots are automatically set to third label, and the second and first
ply-wise. The plies can be selected are evaluated accordingly.
from the Modeling Groups,
sampling points or solid model • Violet Above Value: Violet is
analysis plies. appended to the color bar. All

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General Tab Legend Tab

• Show on Solids: Shows plot data values above the max label are then
on solid elements and for solid shown in violet. If Use as Threshold
elements only. is checked as well, then the max
label becomes the third-last label,
• Component: Allows you to select and the second-last and last are
different components evaluated accordingly.

• Ply Offsets: Visualize the results of • Legend Title: Specifies the title that
a ply-wise plot on the selected plies is shown above the color bar. By
at their true or scaled offset from default, the name of the plot is
the reference surface (Angle Plot used.
only).
• Number of Colors: Sets the number
of colors for the color bar.

• Color Scheme: Chooses one of the

preconfigured color schemes.

• Fixed Color Bar Range: Activates

the Fixed Color Bar Range option
to prevent the color bar from
changing when you switch from
one ply to another. If enabled, the
overall min and maximum values of
the scope are set as color bar min
and max labels. If ply-wise is
enabled as well, the global min and
max are used.

Note:

Only a subset of the plots support Imported Plies. Currently, these are Thickness Plot,
Angle Plot and Lay-up Mapping Plot. To plot data on Imported Plies, the Entire Model
and Ply-Wise options must be enabled.

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Usage Reference

Thickness plot with "Use as Threshold" on for both the Min and Max Value.

Thickness plot with "Grey Below Value" and "Violet Above Value" on.

2.1.17.2. Thickness Plots

The Thickness Plot shows the thickness distribution for an entire lay-up or single plies. The Angle
Plot is purely a ply-wise plot and shows the orientation angle of a selected ply. The Look-Up Table
Plot enables you to explore the interpolation result of scalar columns. Scalar columns can be used
to define thickness, angle, or degradation fields.

Figure 2.151: Thickness Plot

Components

The component of the plot include:

• Thickness: show the element thickness or ply-wise thickness

• Relative Thickness Correction: show the thickness scaling due to draping or lay-up mapping

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2.1.17.3. Angle Plot

The Angle Plot is purely a ply-wise plot and shows the orientation angle of a selected ply. For ex-
ample, an Angle Plot showing the shear angle of a draped ply is illustrated below.

Figure 2.152: Angle Plot

Components

The component of the plot include:

• Design Angle: The angle between the Reference Direction and the Fiber Direction. This is
the angle between the element lay-up reference defined through the Oriented Selection
Set and the user-set Ply Angle.

• Draped Fiber Angle: The angle between the Reference Direction and the Draped Fiber
Direction. This is the angle between the lay-up reference defined through the Oriented Se-
lection Set and the effective fiber direction due to draping.

• Draped Shear Angle: The local ply shear value due to draping.

• Draped Transverse Fiber Angle: The angle between the Reference Direction and the Draped
Transverse Direction. This is the angle between the lay-up reference defined through the
Oriented Selection Set and the effective transverse fiber direction due to draping.

2.1.17.4. Draping Mesh Plot

The Draping Mesh Plot enables you to control if the Draping Mesh or the Flatwrap of a draping
simulation are shown in the active Scene. You need to select a Production or Analysis Ply in order
to show the draping mesh and/or the flatwrap.

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Figure 2.153: Draping Mesh Plot Properties

For this plot type, specific options of the General tab include:

• Show Draping Mesh: Shows the Draping Mesh Plot. The worst distortion is located in red
areas of the draping mesh. If the model property Use Draping Offset Correction (p. 65) is
active, the draping mesh is displayed at the bottom offset (relative to the reference surface
orientation) of the selected ply.

• Show Flatwrap: Shows the Flatwrap surface that is a result of the draping in ACP.

The Draping Plot shows the average shear (distortion) angle of each element. The angles are given
in degrees and they are the average absolute values of the corner angles differing from 90 degrees.
Therefore, no distortion is equal to zero degrees. More information on draping can be found in the
section Composite Modeling Techniques under Draping (p. 279).,

The following illustrations show examples of Draping Mesh, Draping Plot for a Hemisphere, and
Flatwrap Surface of the Ply.

Figure 2.154: Draping Mesh

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 Features

Figure 2.155: Draping Plot for a Hemisphere

Figure 2.156: Flatwrap Surface of the Ply

2.1.17.5. Look-Up Table Plot

The Look-Up Table Plot enables you to explore the interpolation result of scalar columns. Scalar
columns can be used to define thickness, angle, or degradation fields for instance.

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Figure 2.157: Look-Up Table Plot General Properties Tab

For this plot type, specific options of the General tab include:

• Look-up Table Column: Select the Look-up Table column data that is to be plotted.

• Supporting Points:

– Show Points: Visualize the location of the supporting points of the plotted look-up table
data.

– Show Labels: Show labels indicating the row index in the respective look-up table.

– Scale Factor: Scale the size of the supporting points.

• Show Labels: Show labels indicating the row index in the respective look-up table.

• Scale Factor: The supporting points can be scaled in size.

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Figure 2.158: Look-Up Table Plot of a 1-D Scalar Quantity with Supporting Points Shown as
Circles

2.1.17.6. Field Definition Plot

The Field Definition plot enables you to visualize and investigate the effect of a Field Defini-
tion (p. 165). This plot is only available ply-wise.

For this plot type, the specific option of the General tab is the Field Variable Name. You select the
field variable to be plotted from this drop-down menu.

2.1.17.7. Lay-Up Mapping Plot

The purpose of the lay-up mapping plot is to show the result of the lay-up mapping (mapped
Composite Definitions onto a solid mesh). It also allows you to check the quality of the mapping
result. Therefore, the scope only accepts Imported Solid Models and the property `Show on Solids`
is always checked.

For this plot type, the specific option of the General tab is the Data Scope option. Using this entry
field, specify one or more Imported Solid Models.

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Figure 2.159: Lay-Up Mapping General Properties Tab

Components

The component options for this plot include:

• Volume Content: show the ply-wise volume contents

• Deviation in Normal Direction: show the difference between the shell normal and layered
solid normal direction. If ply-wise is disabled, the average normal deviation of the element
is shown.

Figure 2.160: Deviation of the Normal Direction between Shell Elements and Layered Solid
Elements

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 Features

2.1.17.8. Material Plots

The Material Plot allows you to visualize ply-wise variable material properties (p. 303). You must select
an Analysis Ply to display the distribution of the material properties.

2.1.17.9. User-Defined Plot

With the User-Defined Plot, you can a specify arbitrary scalar quantities for plotting.

2.1.18. Scenes
Scenes are windows that contain the visualization settings of the composite model. New Scenes can
be added or existing ones can be modified by hiding or showing visualization features. The visualiz-
ation of the following features is saved in a Scene:

• Element Sets

• Edge Sets

• CAD Geometries

• Rosettes

• Section Cuts

• Solid Models

In a new Scene, all Element Sets, Section Cuts and Solid Models are shown.

In the Scene Properties dialog you can set the Name and Title which are displayed in the top right
corner of the Scene.

Figure 2.161: Scene Properties

2.1.19. Views
Views can be used to save a certain view. The selection of a view automatically updates the Scene
and transfers the properties of the View to the active Scene. New Views can be created with the
button in the toolbar (see Scene Manipulation (p. 23)) or via the object Tree. Different parameters
can also be defined manually.

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2.1.20. Ply Books

A Ply Book is a document you can create which describes the production plies in your model. It is a
convenient way to forward production data to other members of your project such as designers or
manufacturers.

The Ply Book is separated into Chapters. Each Chapter lists the production plies belonging to a selected
set of Modeling Groups or Modeling Plies. You can also add to the Chapter a Snapshot image of
the plies. For each Chapter you will assign a specific View which determines the camera angle for the
Snapshot.

You can customize the content of the Ply Book by defining templates for the different sections as
described below in Editing the Ply Book Template (p. 235).

The following sections explain the Ply Book in detail:

2.1.20.1. Creating Chapters
2.1.20.2. Chapter Properties
2.1.20.3. Editing the Ply Book Template
2.1.20.4. Modifying the Ply Book Snapshots
2.1.20.5. Exporting the Plybook
2.1.20.6. Sample Ply Book Page
2.1.20.7. Ply Book Limitations

2.1.20.1. Creating Chapters

Before creating any Chapters for the Ply Book, at least one View must be defined. See Views (p. 233)
for more information.

Next, you create a Chapter or Chapters by selecting the Automatic Setup or the Create Chapter
option found in the Ply Book context menu.

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 Features

• Create Chapter: This option creates one new Chapter and opens its Chapter Properties (p. 235)
dialog.

• Automatic Setup: This option creates one Chapter for each Modeling Group in your model. If
needed, you can change any of the Chapter Properties later.

2.1.20.2. Chapter Properties

You can set the following properties for each Chapter:

• Name: A descriptive title for the Chapter.

• Chapter View: The View used when the ply Snapshot is taken.

• Modeling Groups / Plies: Select a list of Modeling Groups or Modeling Plies. The Chapter will
contain all production plies contained in these Modeling Groups or Modeling Plies, in the selected
order.

• Show rosettes: If this check box is ticked, the rosettes associated with a given production ply
(through its modeling ply's oriented selection sets) will be shown in the Snapshot images

2.1.20.3. Editing the Ply Book Template

The format and content of the Ply Book is determined by three templates, each for a different part
of the Ply Book:

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• Title page: Information shown at the very beginning of the Ply Book

• Chapter: Information shown at the start of each Chapter

• Ply: Information for each individual production ply

To edit the templates, right-click Ply Book in the Tree View and select Properties. This opens the
Ply Book Properties window shown below. Use the dropdown menu (A) to select the template
for the title page, the chapter, or the ply.

When you select the chapter or the ply template from the menu (A), additional menus (as shown
in the image below) appear in the Ply Book Properties window so you can select the specific
Chapter and/or production ply template which will appear in the Preview.

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 Features

Use the Source panel (B) to edit the template using reStructuredText markup format. Your modi-
fications will appear in the Preview panel below.

• Save: Saves the reStructuredText template to an external text file.

• Open: Allows you to open an external text file as a reStructuredText template.

• Default: Restores the template to its default format and content.

• OK: Save the templates and close the Properties dialog.

• Apply: Save the template and update the ACP model.

The Scene dropdown menu is explained below in Modifying the Ply Book Snapshots (p. 238).

2.1.20.3.1. Python Expressions

For the Chapter and Ply Templates, you can use Python expressions (p. 56) to print information
about the current Chapter and/or ply.

• A Python statement must be enclosed in vertical bars: |<statement>|

• The following literals must be present in the statement for it to be evaluated as a Python ex-
pression:

– In the Chapter Template: chapter

– In the ply section, any one of chapter, modeling_group, modeling_ply, or produc-

tion_ply

These are also the variables defined in the Python context.

• The statement |chapter.view| has special meaning: It will be replaced by a Snapshot image.

Example:

The following example shows two uses of Python expressions:

• |modeling_ply.draping_seed_point|: Adds information about the Draping Seed Point

to the Ply Book.

• |f"{production_ply.thickness:.4f}"|: Uses Python formatted string literals to set

the precision shown in the ply book.

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2.1.20.4. Modifying the Ply Book Snapshots

The Snapshot images in the Ply Book use the Scene inked to the Ply Book. You can change which
Scene is used in the Ply Book Properties window (p. 235).

By changing the Scene itself, you can control how the model is rendered, that is, which plots and
supporting information are shown. For details on manipulating the Scene, see the following sections:
Scene (p. 23) and Scene Preferences (p. 19).

You can define the size of the image in the Ply Book using Scene Preferences (p. 19). If you do not
specify its size, it will default to the size of the Scene in the ACP window.

2.1.20.5. Exporting the Plybook

To export the Ply Book, right-click the Ply Book object in the Tree View and select Generate the
Ply Book from the context menu. You can export Ply Books in .html, .pdf, .odt or .txt formats. The
export operation can take several minutes, depending on how many Snapshots are taken.

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For the .pdf output, the paper orientation and size can be selected.

Note:

See the section below, Ply Book Limitations (p. 241), regarding exporting to .odt.

2.1.20.6. Sample Ply Book Page

Below shows a sample Ply Book page. The Scene displays the fiber directions, flat wrap, and rosette
used for the ply.

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2.1.20.7. Ply Book Limitations

.odt export: When exporting to .odt format, the page numbers in the table of contents will be in-
correct. To generate the correct page numbers, open the file in a word processor and update the
table of contents. For example: In Microsoft Word, right-click the table of contents and choose
Update Field. In LibreOffice Writer, the command is Update Index.

2.1.21. Parameters
The Parameter feature connects inputs and outputs to the parameter interface in the Workbench
project schematic (see Working with Parameters in the Workbench User's Guide). You can use this, for
example, for creating parametric studies and for optimizing a model.

Figure 2.162: Connection of ACP and Workbench Parameter Interface

A Parameter is created by selecting Create Parameter... in the context menu of the Parameters
object in the ACP Tree View.

The Parameter connection is then defined in the Parameter Properties dialog:

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Figure 2.163: Parameter Properties

• Category:

– Input: Input parameter taken from the Workbench Parameter interface

– Unbound Input: Input parameters that are not directly linked to other ACP objects. They are
mainly used in combination with Scripts (p. 71). Note that unbound inputs do not have the
Object or Property properties.

– Output: Output parameter given to the Workbench Parameter interface

– Expression Output (p. 243): Output parameter that can contain a regular ACP script

• Object: The object on which the parameter acts.

• Property: The property of the object to be parameterized.

• Type: The parameter format. Determined automatically if there is only one possible option. Units
are not transferred from ACP to Workbench. Parameters appear as dimensionless numbers in the
Workbench interface.

– Bool: Boolean (true or false).

– Float: Real number.

– Int: Integer.

– None: Default selection if multiple options are available.

– String: Text string from a list of strings. The values in the string list can be called up via an index
number in the Workbench interface. The first entry in the string list has the index value 1. The
rest follows sequentially.

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• Value: The current value of the parameter. This option can be modified depending on if a parameter
is an Input or an Output.

Caution:

The ACP systems do not automatic convert Parameter units in the Parameter Manager.
Always verify that the units of any ACP-related Parameter are consistent with the unit
system selected in the ACP system.

For Parameters in ACP (Post), linked to an object in ACP (Pre), the Parameter will become
invalid if you rename the ACP (Pre) object. To correct, redefine the source object for the
Parameter.

2.1.21.1. Settings for an Expression Output

The formulation of an expression output requires a basic understanding of The ACP Python
Scripting User Interface (p. 56).

The Parameter Properties dialog displays a Source field that accepts Python code. Various inform-
ation stored in the ACP database can be accessed. It is possible to enter a script and perform most
of the operations available within ACP's Shell View.

The script's result can be returned by assigning a value to the global return_value variable.

Example 2.1: Simple Expression Output

An example of a simple expression output is shown here. In it, the maximum inverse reserve factor
is retrieved from the active contour plot.

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Example 2.2: Complex Expression Output of Maximum Thickness in the Kiteboard Model

# Get active model

model = db.active_model

# Create new selection of all elements attached to a specific ply

modeling_ply = model.modeling_groups['Core'].plies['mp_4']
model.select_elements(selection='sel0',op='new',attached_to=[modeling_ply])

# Get total thickness of the first entity of selection sel0

thicknesses = list(model.mesh_query(name='thickness',position='centroid',selection='sel0', entities=[modeli

# Get maximum thickness

max_thickness = max(thicknesses)

# Pass the found maximum thickness as the script's result.

return_value = max_thickness

2.1.22. Material Database

It is possible to build a Material Database which can be used in different projects. The database can
also be saved on an intranet drive for sharing to other ACP users.

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The structure of the Material Database is exactly the same as in the model. For more information, see
Material Data (p. 74). The database is stored as .acpMdb and it can be managed through the context
menu:

Figure 2.164: Material Database

The units of the database and the model can be different. Use Copy and Paste to transfer a material
from one to the other. Values of the materials are converted automatically to the correct unit system.

A default Material Database is installed with ACP: ANSYS_INSTALL_DIR\v251\ACP\databases.

2.2. Exchanging Composite Definitions with Other Programs

This section describes how data can be exchanged between ACP and other programs. The following
interfaces are available:
2.2.1. HDF5 Composite CAE Format
2.2.2. Mechanical APDL File Format
2.2.3. Import of Legacy Mechanical APDL Composite Models
2.2.4.Tabular Data Format for Excel
2.2.5. CSV Format
2.2.6. ESAComp
2.2.7. LS-Dyna
2.2.8. BECAS

2.2.1. HDF5 Composite CAE Format

HDF5 Composite CAE is a vendor-independent specification that allows an accurate exchange of
composite lay-ups between different CAE and CAD packages. The specification uses HDF5 for data
storage, an open and widely used file format that efficiently stores binary data (http://www.hdf-
group.com/). Many specialized simulation tools (for forming and winding simulation, for example)
support this format, which enables a seamless data transfer into Ansys Workbench – ACP to run a
structural, thermal, modal, or buckling analysis. The format and interface contain all the necessary
information such as ply surfaces, fiber directions, thicknesses, stacking sequence, and materials.

ACP supports the export and import of the HDF5 Composite CAE format. The interfaces are accessible
through the ACP Model context menu (p. 62).

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Figure 2.165: Export and Import Options in Model Context Menu

Note:

The HDF5 Composite CAE format does not take the Fabric Fiber Angle (p. 78) property
into account. As a result, if the Fabric Fiber Angle property is active in ACP when the
composite lay-up is exported, Mechanical properties might not be accurate.

2.2.1.1. Export
Only the effective lay-up in ACP is extracted during the HDF5 Composite CAE export. This means,
for example, ACP will export the ply's thickness distribution but not the taper definitions that affect
the ply's thickness. Neither will it export the reference shell surface. It will, however, extract Inform-
ation on the ply's material, coverage, dimensions, thickness distribution, reference direction field,
as well as the overall ply sequencing. All this information gets stored in the .H5 file.

You can then import the extracted data into a program such as FiberSIM for further design and
production management.

For Export Settings, refer to the dialog box below and the explanations which follow.

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Figure 2.166: HDF5 Composite CAE File Export Settings

• File Path: Specify the destination file name and file path.

• Remove Midside Nodes of Quadratic Elements: By default, midside nodes of the quadratic
elements are not exported.

• Export 3D Representation: If enabled, a 3D representation of the ply surfaces (including the

offsets from the reference surface) and is computed and exported. (An example is shown in the
figure below.) The reference surface, the stacking sequence, and the ply thicknesses of the other
plies in the laminate determines the exact 3D location of the ply surface. If Export 3D Repres-
entation is not enabled, the ply geometry is based on the reference surface only.

Note:

If you intend to import the HDF5 Composite CAE file into an external application, you
must verify which representation it requires. The standard representation is shell surface,
in which case you should not enable Export 3D Representation.

Figure 2.167: 3D Representation of a Lay-Up with Offset Ply Surfaces

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• Offset: Select the surface for export: the bottom, mid, or top surface of the plies. The default is
Bottom Offset. The Offset option is available only when Export 3D Representation is enabled.

• Scope:

– All Elements: Uncheck this option to restrict the lay-up export to a region of interest.

– User Defined Set of Elements: Here you can limit the exported plies to the specific Element
Sets and/or Oriented Element Sets that interest you.

– All Plies: By default, all plies of the scope are exported. Uncheck this option to select a user-
defined set of plies to be exported.

– User Defined Set of Plies: Specify the set of Modeling Plies and/or Modeling Groups to be
exported.

Note:

The 3D lay-up representation cannot be generated for complex shapes and topologies.
In those cases, it can help to export sub-areas only by using the user-defined set of ele-
ments and user-defined set of plies options in the export dialog. See Figure 2.166: HDF5
Composite CAE File Export Settings (p. 247).

2.2.1.2. Import
When importing an HDF5 Composite CAE, you must have a model already loaded in ACP. This is
because ACP will take the lay-up definitions from the HDF5 Composite CAE and apply them to the
model as explained in the next section.

When using ACP within Workbench, the model of the upstream Mechanical component is automat-
ically loaded in ACP as described in Basic Workflow (p. 39). You can use the External Model com-
ponent in Workbench to import an external mesh model of almost any format, and then you can
transfer it to ACP as shown here.

Figure 2.168: The External Model Component in Workbench

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If ACP runs in standalone mode, you can load a mesh model from a .cdb file (Mechanical APDL
format) as shown in the section Workflow in Stand Alone Operation (p. 58). It is important to un-
derstand, the mesh(es) from a HDF5 Composite CAE cannot be loaded directly as a model.

Furthermore, when using ACP within Workbench, materials are not directly imported into ACP be-
cause materials are always loaded from Engineering Data. This can cause a newly generated Fabric
to lose the link to its material if no material with a matching name exists in Engineering Data. Here
is a workaround:

1. First, extract the materials from the HDF5 Composite CAE file as explained in the section, Extract
Materials From Composite CAE H5 (p. 14).

2. Then import the generated MatML file into Engineering Data.

3. Finally, import the HDF5 Composite CAE file into ACP.

Another option is to add the materials to Engineering Data manually. You can use HDF View (a
third-party application) to open the HDF5 Composite CAE file and look up the material names.

2.2.1.2.1. Import Projection Types

The HDF5 Composite CAE Import supports two types of projections. The first one maps lay-up
data onto the shell mesh (reference surface) in ACP. The second option directly converts the ply data
from the Composite CAE H5 into Imported Plies Objects (p. 160) in ACP. Below is a more detailed ex-
planation of each projection type.

Mapping onto The Reference Surface

During the import process, the mapping algorithm in ACP begins by computing the ply extent
with respect to the reference surface in ACP. It then maps the fiber directions, thicknesses, and
other properties onto the surface. Ply material information gets transferred to the Material Data
object in ACP, and Oriented Selection Sets are generated based on ply coverage. Finally, thickness
distributions and reference direction fields are stored in Look-Up Tables which are then used to
define the modeling plies in the lay-up reconstruction.

A ply in the Composite CAE H5 has its own mesh that typically differs from the reference surface
in ACP, requiring an adjustment to the mapping parameters. For example, different mesh sizes
on curved surfaces can cause element normals to deviate. Nodal locations in the out-of-plane
and in-plane directions can also vary, depending on mesh sizing

You can manage these effects with appropriate import tolerances. Large tolerances can result in
mapping issues, especially with convergent meshes, as with a T-joint. If the tolerances are too
large, ply boundaries cannot be accurately replicated.

Exposed as 3D Plies (Imported Plies)

Instead of mapping the composite data of the HDF5 Composite CAE onto the reference surface
in ACP, the data is directly converted into Imported Ply objects if the projection is set to Expose
as 3D Plies. Since each Imported Ply has its own mesh that is independent of the reference surface,
the meshes of the HDF5 and Imported Plies are identical.

This enables you to build complex 3D lay-up models in a CAD environment and load it into ACP
for detailed analyses.

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The remaining data, such as Thicknesses and Reference Direction, are stored in the same manner
as the Mapping onto the Reference Surface import option.

Ply material information gets transferred to the Material Data object in ACP. Thickness Distributions
and Reference Direction Fields are stored in look-up tables which are then used to define the
Imported Plies.

2.2.1.2.2. Import Settings

A number of settings and tolerances control the import of the composite model. Refer to the
dialog box below and the explanations which follow.

Figure 2.169: HDF5 Composite CAE File Import Settings

Path

Specify the path to the .h5 file you wish to import.

Import Mode

• Append: Imported data and objects will be appended to the existing model/lay-up.

• Overwrite: Replaces existing objects that have the same id, unless objects are locked. Note:
To preserve the ply ordering specified in the HDF5 Composite CAE file, imported plies will
be added to the top of the existing lay-up, or moved to the top if they already exist.

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Projection

For additional information on Projection types, see the detailed explanation above. (p. 249)

• Map onto Reference Surface: This option maps the plies onto the shell surface in ACP
and exposes them as Modeling Plies.

• Expose as 3D Plies (Imported Modeling Plies): This option converts the plies into Imported
Modeling Plies, uncoupled from the reference surface.

Ply Angles

• Minimum Angle Tolerance: Minimum angle tolerance for which tabular correction angles
are computed for plies.

• Recompute Reference Directions: When this option is selected, reference directions are
recomputed from tabular angle data.

Mapping Scope

• All Elements: By default, the lay-up data specified in the .h5 file is mapped onto all the
elements of a reference shell mesh in ACP. Uncheck this Boolean to restrict the lay-up
mapping to a user-defined region of interest.

• User-Defined Set: The lay-up data is mapped onto the Element Sets specified here.

Ply Area Mapping

Refer to the Figure below (p. 252) for an illustration of the Tolerance Settings.

• Relative Thickness Tolerance: This sets the mapping tolerance in the element thickness
direction relative to a minimum element edge length. In the dialog box (p. 250) shown
above, assuming a minimum edge length of 1mm, elements will be mapped if their deviation
in the element thickness direction is between -0.5 and 0.5 mm.

• Relative In-Plane Tolerance: This sets the mapping tolerance in the element in-plane
direction relative to a minimum element edge length. In the dialog box (p. 250) shown
above, assuming a minimum edge length of 1mm, elements will be mapped if their in-
plane coordinates are within the shell mesh with a maximum allowable tolerance of 0.01mm.

• Angle Tolerance: Mapping tolerance for angles between element normals (in degrees).

• Small Hole Threshold: Holes in plies/Element Sets with an area smaller than this threshold
times the area of the Element Set/ply are filled.

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Figure 2.170: Schematic of Tolerance Settings for a Single Element

Coordinate Transformation

The imported Composite Definitions are transformed according to the inputs given here. The
transformation order is as follows:

1. Rotation around X-Axis

2. Rotation around Y-Axis

3. Rotation around Z-Axis

4. Translate X, Y, Z

The X, Y and Z rotation happens around three axes of ACP’s global coordinate system. All
angles must be specified in degrees.

Show/Update Mesh Preview

Clicking this button displays a preview of all the meshes in the hdf5 file after the coordinate
transformation has been applied.

2.2.2. Mechanical APDL File Format

A Mechanical APDL input file requires specific element settings if it is to be used with ACP in Stand
Alone mode. This applies to preprocessing models that are used to define a composite lay-up as well
as postprocessing models where reading stresses and strains in future analyses is required. For more
information, see Workflow in Stand Alone Operation (p. 58).

Nodal solutions can be loaded from:

• PRNSOL file formats. An example export could be:

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/format,10,G,25,15,1000,1000
prnsol,u
prnsol,rot

• The .rst file interface allows ACP to load nodal and element results directly from the Ansys result
file.

Use these options for element result import:

– SHELL181: Keyopt(8) = 2 (See Figure 2.171: SHELL181 Keyopts (p. 253) )

– SHELL281: Keyopt(8) = 2 (SeeFigure 2.172: SHELL281 Keyopts (p. 254) )

– SOLID185/SOLID186: Keyopt(3) = 1 (See Figure 2.173: SOLID185 Keyopts (p. 254) and Fig-
ure 2.174: SOLID186 Keyopts (p. 254))

Keyopt(3) must be defined via the command line: KEYOPT,ET_NUM,3,1

– SOLSH190: Keyopt(8) = 1

– ERESX,NO (copy integration point results to nodes)

Supported shell and solid (for post-processing only) element types: SHELL181, SHELL281, SOLID185,
SOLID186

Supported element property definition commands: SECTYPE, SECOFFSET, SECCONTROL, RLBLOCK

Figure 2.171: SHELL181 Keyopts

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Figure 2.172: SHELL281 Keyopts

Figure 2.173: SOLID185 Keyopts

Figure 2.174: SOLID186 Keyopts

2.2.3. Import of Legacy Mechanical APDL Composite Models

You can import composite shell models with section definitions created in Mechanical APDL to ACP.
Upon import, the lay-ups are converted into ACP Composite Definitions (Rosettes, Oriented Selection

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Sets and Modeling Plies). The converted model can be subsequently used in Workbench projects. See
the Special Cases (p. 256) and the Known Limitations (p. 257) sections for more information.

Review the following import scenarios. The scenarios are different based upon whether or not you
are working with the mesh of the legacy model in ACP.

Equal Meshes
In this case, the section definitions of the legacy model are mapped according to the element labels
It also assumes that also the element normals are equal.

To import a legacy model that can be used in Workbench projects:

1. Add an External Model system to the Workbench project page and load the legacy file.

2. Add a new ACP (Pre) system to the Workbench project page.

3. Link the External Model system with the Engineering Data cell of the ACP system. This
loads the materials (cells A2-B2).

4. Link the External Model system with the Model cell of the ACP system in order to load the
mesh (cells A2-B3).

5. Refresh the ACP system Setup cell. Launch ACP.

6. Make sure that the unit system in ACP and the legacy model are the same.

7. From the action menu of the Model folder in ACP, select the option Import Section Data
from Legacy Model. Select the file you have opened in the External Model system (see
Import Section Data from Legacy Model (p. 68)). Verify that you have the correct material
mapping mask.

Figure 2.175: Configuration Overview

Note:

• Engineering Data renames the materials. The pre- and suffix masks enables the automatic
mapping between legacy material IDs and WB material IDs.

• Import each legacy model separately because the mapping is based on the element labels.
You can assemble the legacy files in a downstream Mechanical Model as needed.

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To import a legacy model in ACP standalone mode:

1. Start ACP in ACP standalone.

2. Load the file using the Import Model option from the Models action menu or File tab in the
application toolbar and select the Convert Section Data check box.

Different Meshes
If you are working with different meshes, you have to convert the legacy model by using the Com-
posite CAE H5 file format.

To convert a legacy model onto a different mesh:

1. In Workbench, import and convert the legacy model as described above (system A and B)

2. Update ACP Setup cell (A4) and export the lay-up to a HDF5 Composite CAE file (p. 68).

3. Create the ACP system (C) where you want to map the legacy lay-up to.

4. Link the External Model with the Engineering Data component to load the materials (A2-
C2).

5. Open the ACP Setup cell (C5) and import the Composite CAE H5 file (p. 68).

Figure 2.176: Configuration Overview

2.2.3.1. Special Cases

Lay-ups in ACP are either stacked on the top or the bottom of a shell surface. If the shell offset
direction of a Mechanical APDL model is not set to top or bottom, then the ply lying on the shell
surface is split into two plies on either side of the shell surface during the conversion.

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Figure 2.177: A Four Ply Mechanical APDL Lay-up Where a Ply Crosses the Reference Surface
is Converted to a Five Ply ACP Lay-up

2.2.3.2. Known Limitations

The conversion of the composite lay-up of legacy Mechanical APDL models to ACP models only
works for shell models.

The proper translation of Mechanical APDL sections to ACP modeling plies can only be guaranteed
if the Mechanical APDL section points to a connected region of elements where all element normals
are oriented the same way. If this is not the case, a warning is issued on export and the resulting
lay-up may not be entirely correct.

The material transfer from External Model to Engineering Data is not supported on Linux. Alternatively
you can load the model in ACP standalone and export the materials in the Ansys Workbench XML
format (p. 75) and import from this file.

2.2.4. Tabular Data Format for Excel

A definition block starts with a cell value of BEGIN TABLE and ends with END TABLE. This cell is in the
first column (A) of the worksheet. The block DEFINITION is used to identify the type of tabular data
defined in the block. ModelingGroup, LookUpTable3D, and LookUpTable1D are currently the only
supported definition types.

Empty lines are not allowed inside of sub-blocks. Lines between sub-blocks are ignored. When the
lay-up is pushed from ACP, the formatting of existing cells is not changed. Missing field in the DATA
block are ignored and not set when synchronized with ACP. Hidden cells are not ignored and are
synchronized with ACP.

Figure 2.178: ModelingGroup Tabular Format in Excel

In the case of Look-Up Tables, if you add the text string "(Read Only)" to the column name, the cor-
responding Excel column is ignored.

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Figure 2.179: Look-Up Table Tabular Format in Excel

References to other objects (ply material, oriented selection sets, etc.) are defined by the object's ID.
In the case of ply material, the type of material and the material's ID are joined with a forward slash
(for example, fabrics/E-Glass). For the angle and thickness fields, the column name and the ID of the
lookup table must be provided (LookUpTable.1/Angle).

Communication to Excel is accomplished through the COM interface. The identifier used to connect
to Excel is Excel.Application.

You can find more information on how to exchange model data with Excel in Edit Entities with Ex-
cel (p. 24).

2.2.5. CSV Format

Materials, Look-Up Tables, Selection Rules definitions, and Modeling Groups can be exported and
imported using a .csv format (comma separated value file).

The .csv file format for the import and export of Look-Up Tables and Modeling Groups follows the
same format as the Tabular Data Format for Excel (p. 257).

Caution:

The CSV format uses a '','' as list separator. In some Regional Options in Windows, the list
separator is defined by another character (very often '';''). In this case, the .csv files will
not be properly read and written by Excel. Change the list separator in Windows Settings.

2.2.6. ESAComp
Model format: ESAComp XML files.

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The following operations are available:

2.2.6.1. Export
2.2.6.2. Import

2.2.6.1. Export
Material data (Fabrics, Stackups and Sublaminates) and Sampling Points can be exported to ESAComp
XML. A Fabric represents a Ply in ESAComp and Stackups; Sublaminates and Sampling Points are
exported as Laminates.

To be sure that the imported values in ESAComp are in accordance to the ACP model, the FE import
units in ESAComp should be checked first.

• Open FE import and export units in ESAComp.

• Adjust units in the Model Properties dialog (see ACP Model (p. 65)).

2.2.6.2. Import
Import
As for the export, check that the units match in ESAComp and Ansys Composite PrepPost.

In ESAComp, there are 2 ways to export the data:

Script Format (recommended)

In ESAComp, you can export Plies and Laminates through the FE Export / ANSYS ACP option in the
menu. It generates a Python script, in which all the information is stored in ACP format.

XML Format
In ESAComp, export your data as .XML file using the File menu. Import this data in Ansys Composite
PrepPost with the context menu for the Material object in the Tree (see Material Data (p. 74)).

Only material data can be imported.

Important:

The Import from ESAComp XML operation does not create the material in Ansys Com-
posite PrepPost. It only changes the properties. So the material must be created before
with the same name as in ESAComp.

2.2.7. LS-Dyna
There are three ways to exchange an ACP composite model with LS-Dyna:

• LS-DYNA (Extension Library): This approach allows you to convert a Workbench model, including
Composite Definitions, to an LS-Dyna model. This is the recommended approach.

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• LS-Dyna Interface (ACP Add-on): Allows you to define Composite Definitions for LS-Dyna
meshes/models.

• LS-Dyna Solid Model (ACP Add-on): Allows you to export to the solid model in the .K file format.

Caution:

The add-on features described in this section are not recommended for general use. It is
strongly suggested that you use the Workbench interface to transfer information between
ACP and LS-Dyna.

2.2.8. BECAS
ACP can export the 2D mesh of a surface section cut to the cross-section analysis tool BECAS. This
allows you to derive a beam model from an ACP shell model.

The 2D mesh is built with linear elements and includes material information and lay-up orientations.
As a result, consider both geometric and material-dependent coupling.

The 2D mesh can also be exported to Mechanical APDL. In this case, no lay-up information is trans-
ferred.

For more details on exporting surface section cuts, see Section Cuts (p. 170).

For more information on the BECAS tool, see the BECAS website.

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Chapter 3: Composite Modeling Techniques
The various composite modeling techniques available in ACP are described in the sections below:
3.1.T-Joint
3.2. Local Reinforcements
3.3. Ply Tapering and Staggering
3.4. Variable Core Thickness
3.5. Draping
3.6. Guide to Solid Modeling
3.7. Guide to Composite Visualizations
3.8. Guide to Composite Failure Criteria
3.9. Element Choice in ACP
3.10. Variable Material Data in Composite Analyses

3.1. T-Joint
T-joints are used to bond a primary structure to a secondary one. A good example is a frame with a
stringer of a boat hull. Oriented Selection Sets (OSS) allow you to define complex laminates by an in-
tuitive approach. For an example of a T-Joint analysis, see T-Joint Tutorial.

The laminate of a T-joint can be split into several sublaminates:

• Base plate (skin)

• Stringer (frame)

• Bonding

• Cover

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Figure 3.1: T-Joint Lay-Up

The laminate is modeled by defining different Oriented Selection Sets for the different regions. The
modeling plies are then associated with the OSS and their order defines the stacking sequence of the
laminate.

The first OSS is defined for the base. The offset direction of this OSS shows from top to bottom as shown
in Figure 3.2: OSS for the Base Plate (p. 262).

Figure 3.2: OSS for the Base Plate

The OSS of the string has an orientation parallel to the global X-direction as shown in Figure 3.3: OSS
for the Stringer (p. 263).

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 T-Joint

Figure 3.3: OSS for the Stringer

The OSS feature allows you to define several offset directions for one element: OSS can overlap and
can have different orientations. This functionality is used to define the offset direction for the bonding
layers as shown in Figure 3.4: OSS for Bonding Plies (p. 263). The offset direction of the base plate is
different if compared with Figure 3.2: OSS for the Base Plate (p. 262).

Figure 3.4: OSS for Bonding Plies

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Composite Modeling Techniques

In addition, the OSS feature allows you to define the reference directions for complex shapes (twisted
surfaces, right angles). The reference direction is computed from one or several reference coordinate
systems (CSYS) as shown in Figure 3.5: Reference Direction (p. 264). In this case two CSYS are selected.

Figure 3.5: Reference Direction

After all the necessary OSS are defined, define the Modeling Plies in the same order as the structure is
produced later. First, the base lay-up is defined using the OSS of the base plate.

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 T-Joint

Figure 3.6: Laminate of the Base Plate

The next plies are added to the stringer.

Figure 3.7: Laminate of the Base Plate and Stringer

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Composite Modeling Techniques

It is important to define the base plate and stringer laminate before the bonding plies are defined because
the order is responsible for the final offset. As shown in Figure 3.8: First Bonding Laminate (p. 266), the
bonding layers are applied to the top of the base plate and onto the plies of the stringer.

Figure 3.8: First Bonding Laminate

On the other side, the second bonding laminate is offset to the top (base plate) and to the left (stringer).

Figure 3.9: Second Bonding Laminate

Cover plies complete the lay-up definition of the T-joint. Figure 3.10: Cover Plies (p. 267) shows that ACP
can also handle Drop-Offs.

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 Local Reinforcements

Figure 3.10: Cover Plies

3.2. Local Reinforcements

Regions with cut-outs, holes or load introduction elements are normally highly stressed and require
local reinforcements to prevent failure. ACP offers different ways to define local patches. Selection
Rules can be used to apply reinforcements to selected areas of the structure's geometry. The shape of
a reinforcing ply is defined by the intersection of an Oriented Selection Set and the selected Selection
Rules.

The examples Tutorial 3 and Tutorial 4 use Parallel Selection Rule and Tube Selection Rule to define
patches. Tutorial 4 describes how a Tube Selection Rule can be defined to add a ply following an edge.
The procedure involves these steps:

1. Define an Edge Set from the boundaries of an Element Set.

2. Create a Tube Selection Rule along the defined Edge Set with a certain inner and outer radius.

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Composite Modeling Techniques

Figure 3.11: Tube Selection Rule

3. Create a new ply and configure the Selection Rules in the Rule tab of the Modeling Ply Properties
dialog.

Figure 3.12: Rules Tab of the Modeling Ply Property Dialog

The selection rule parameters can be modified for each Modeling Ply. This allows you to work with
one Selection Rule to define the staggering of a laminate. You can activate a template and set the
new parameters. The final result can be double-checked with Section Cuts or a thickness contour
plot as shown in the figure below.

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 Ply Tapering and Staggering

Figure 3.13: Resulting Local Reinforcements

Selection Rules can also be combined with Oriented Selection Sets and other Selection Rule types
like Parallel, Spherical, or Cylindrical are also implemented in ACP. Any combination of these selection
rules allows you to create plies with complex shapes.

3.3. Ply Tapering and Staggering

Ply tapering and staggering can be quickly defined within ACP. Several examples are shown below.

3.3.1. Ply Tapering

Core plies are generally much thicker than regular or woven plies. This means that core edges must
be tapered for structural and manufacturing reasons. When a taper is applied to an edge of a ply in
ACP and the corresponding thicknesses are evaluated and mapped automatically onto the finite ele-
ments.

3.3.1.1. Edge Tapering

This section gives an overview of how the edge tapering feature works. The Taper Edges option
can be applied to modeling plies (p. 146). Its definition requires a constant taper angle along an
edge set. Optionally, a taper offset can be specified. Based on this definition, a virtual taper plane
is evaluated to taper the thickness of plies. The effective tapering or thickness distribution over the
taper is further dependent on the resolution of the mesh.

Figure 3.14: Simple Edge Tapering (p. 270) shows a schematic of a simple edge tapering. An Edge
Set runs along the side of a square of elements. Ply tapering is evaluated at each element along
the edge set. The taper edge offset specifies the normal (thus out-of-plane) distance from each
element adjacent to the element set. This offset forms a plane parallel to the underlying element.
The taper angle specifies the angle between this offset plane and the resulting taper plane. In the
figure, the resulting taper plane is the same for the whole edge set. The resulting taper planes are
oriented differently if the Edge Set follows a curved path. The offset direction is set to be positive
in the orientation direction of the oriented selection set of the modeling ply. Depending on the
mesh and application, it may have to be specified as a negative value.

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Composite Modeling Techniques

Figure 3.14: Simple Edge Tapering

3.3.1.2. Tapered Core

The Tutorial 3 example uses a tapered core. Open the model and check the Modeling Ply core_bwl
in the Modeling Group Hull. In the Thickness tab of the properties dialog a taper angle of 15
degrees is defined for the edge edgeset.2. A Section Cut or thickness contour plot illustrates
the final result as shown in Figure 3.15: Tapered Edge (p. 270).

Figure 3.15: Tapered Edge

3.3.1.3. Tapered Edges

In Tutorial 4, a Ply Tapering is defined along 2 edges. The procedure involves these steps:

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 Ply Tapering and Staggering

1. Define an Edge Set. In this case, the Edge Set is defined through a Named Selection in
Mechanical.

2. Open the Thickness tab in the Modeling Ply Properties dialog.

Figure 3.16: Tapering in Ply Definition

3. Select the edge and define the taper angle.

Figure 3.17: Thickness Distribution After Core Tapering

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Composite Modeling Techniques

3.3.1.4. Tapering of Multiple Plies

The Taper Edges option for Modeling Plies is suitable for defining individual taper angles for
specific modeling ply. Its intended purpose is for use with a single tapered ply, such as a core,
however it can be used for tapering multiple plies. If the Modeling Ply tapering option is used for
multiple layers the taper angle is applied to each Modeling Ply and the vertical ply thickness dis-
tribution is superimposed. In such a case, the total taper angle of the lay-up is generally higher
than the individual taper angles. The total taper angle scales non-linearly with the number of plies
and their thicknesses. Furthermore, the taper size is a dependent on the size of the mesh. For this
reason, care should be taken when using the Taper Edges option for multiple plies. When modeling
a composite with a defined total taper angle a Selection Rule definition may be more suitable.
The trailing edge of an airfoil blade is an example for such an application.

The example below shows the effects of superposing multiple modeling plies that have the same
taper angle. The middle column shows a lay-up schematic while the right column displays the
corresponding representation of a section cut in ACP. The superposition of two different ply thick-
nesses results in two taper angles of which one is steeper than the nominal angle.

Figure 3.18: Superposition of Modeling Plies with Identical Taper Angles. Schematic (Middle)
and Section View Illustration (Right)

3.3.2. Ply Staggering

Cutoff Selection Rule

A Cutoff Selection Rule is used to cut plies and is suitable to define a ply staggering. This feature is
not limited to an edge because the staggering is derived from a CAD Geometry. The intersection
between the ply and geometry defines where the plies are cut. The ply offsets are taken into consid-
eration. This allows you to define a laminate where the total thickness follows a 3D shape.

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 Variable Core Thickness

Figure 3.19: Thickness Distribution of a Laminate with a Cutoff Selection Rule

Template Selection Rule

The template selection rule feature of the Modeling Ply allows you to use one Selection Rule to
define plies of different extensions. You can redefine the parameters of a selection rule in the Modeling
Ply Properties dialog. A wind turbine blade, for example, has hundreds of similar plies that only differ
in their the axial extension. Such plies can be defined with one Oriented Selection Set and one
Parallel Selection Rule and the use of template parameters. The template parameters are easily ad-
justed using the Import from / Export to CSV file feature in the context menu of the Modeling
Group.

Figure 3.20: Template Selection Rule Definition

3.4. Variable Core Thickness

In many cases, the thickness of a sandwich panel is constant or single plies have a constant thickness.
For structural efficiency, cores with variable thickness are used more often since CNC milling allows the
production of core plies with complex shapes.

In ACP there are three different ways to define a laminate with variable thickness:
3.4.1. Solid CAD Geometry

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Composite Modeling Techniques

3.4.2. Look-Up Table

3.4.3. Geometry Cut-Off Selection Rule
3.4.4. General Application

3.4.1. Solid CAD Geometry

An external core geometry can be used to define the variable core thickness. The 3D shape of the
core is modeled in a CAD tool as a 3D solid or a closed shell. This CAD Geometry can be imported
directly into ACP or via Workbench.

Figure 3.21: Imported Core Geometry

In the Thickness tab of the Modeling Ply Properties dialog, the thickness definition can be changed
from Nominal to From Geometry. In this case, ACP samples through the geometry in the normal
direction and evaluates the thickness of the core for each element. The original thickness defined in
the Fabric definition becomes obsolete. This method is used in the Tutorial 3 example..

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 Variable Core Thickness

Figure 3.22: Modeling Ply Thickness Definition

Figure 3.23: Section with Variable Core Thickness

3.4.2. Look-Up Table

The variable core thickness can also be defined with a Look-Up Table. A Look-Up Table is used to
define a data field or tabular values. Thicknesses, angles and directions can be defined in a Look-Up
Table and the 3D mapping function of ACP inter- or extrapolates the values for each element. You
define the thickness of the ply material for certain support points. The figure below shows a list of
different angles and thicknesses for selected data points.

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Composite Modeling Techniques

Figure 3.24: Table Definition

Following on, the corresponding tabular field can be selected in the Thickness tab of the Modeling
Ply Properties dialog.

Figure 3.25: Thickness Definition Through Tabular Values

The final result can be investigated with Section Cuts or a thickness contour plot as per usual.

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 Variable Core Thickness

3.4.3. Geometry Cut-Off Selection Rule

Another way of achieving a variable core thickness is to use a Cut-Off Selection Rule. Even if the
cutting operation only applies to a core layer, it is dependent on the entire lay-up. If the thickness of
the bottom laminate is changed, the thickness of the core is cutoff at a different height. In this way,
a laminate thickness limit can be set. This can be a very useful in places where the laminate thickness
is limited, near a trailing edge of a blade for example.

Figure 3.26: Section Cut and Thickness Contour Plot

The core thickness can be set to be cut in different ways depending on the Ply Tapering option of
the Selection Rule. It can either follow the exact intersection with the CAD Geometry or can be cut
off to two discrete size - its nominal thickness or no thickness at all.

The Cut-Off Selection Rule has to be used with precaution as any modification of the underlying
plies might modify the core.

An example of a Cut-Off Selection Rule can be found in Tutorial 4.

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Composite Modeling Techniques

Figure 3.27: Imported Cut-Off Geometry

Figure 3.28: Resulting Thickness Distribution (Ply Tapering Activated)

3.4.4. General Application

The described features can also be used in combination with regular or woven materials and are not
restricted to core materials. The selection of the method is often derived from the manufacturing
process. Tabular values can be used for a winding process and CAD geometries for a CNC milling
process. A Cut-Off Selection Rule (p. 277) is often used in regions of sharp tapered edges (trailing edge
of a wind turbine blade).

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 Draping

3.5. Draping
The ply application (draping) on doubly curved surfaces changes the theoretical fiber orientations. In
many cases the effect is small and can be neglected. On the other side it is important to know how big
this effect can be and if it has to be considered. ACP allows you to evaluate the draped fiber directions.
These angles can be visualized and are considered in all analyses, resulting in more accurate evaluations.
The draping is evaluated on the Production Ply level. In addition the draping algorithm of ACP evaluates
the flatwrap of the Production Plies which can be exported for manufacturing purposes.

Figure 3.29: Flatwrap (Boundary)

3.5.1. Internal Draping Algorithm of ACP

The draping algorithm is described in Draping Simulation in the Composites Theory Reference.

Draping Method Definition

The draping effect depends highly on the manufacturing process. Process-relevant values can be
defined in the ACP draping algorithm.

Seed Point
The Seed Point is the starting point where the ply is laid into the mold. At this location the fiber
direction is unchanged and the draped fiber direction is equal to the theoretical one. The Seed Point
can have a big influence on the final result of the draped fiber angles. Assuming a half sphere and a
Seed Point located on the pole, the maximum draped fiber angle is much smaller than the same
evaluation with a Seed Point on the equator. The Seed Point corresponds to the first element of the
draping mesh (left representation in Draping Scheme in the Composites Theory Reference).

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Composite Modeling Techniques

Draping Direction
After the first point is applied on the mold, the Draping Direction defines along which route the ply
is laid into the mold. The draping algorithm first walks along the Draping Direction, then orthogonal
and finally proceeds with the 45-degree zones. Draping Scheme in the Composites Theory Reference
shows the scheme in which the ply is applied.

Draping Mesh
The draping algorithm minimizes the shear energy dissipation where an internal Draping Mesh is
used for the evaluation. This mesh is independent from the structural mesh and has its own size.
Analog to the structural mesh, the optimal Draping Mesh size is established by balancing the precision
of the draping evaluation and the computational cost.

In the case of an incomplete draping, select another Seed Point, define a different Draping Direction
and/or change the Draping Mesh size. The draping mesh is built as shown in Draping Scheme in the
Composites Theory Reference.

Figure 3.30: Draping Mesh with Shear Energy

Draping Definition on OSS Level

The draping can be activated in the Draping tab of the Oriented Selection Set Properties dialog.

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 Draping

Figure 3.31: Draping Definition in OSS

If draping is activated on the OSS level, the Reference Direction of the OSS is adjusted and all associated
modeling plies use this draped reference direction. If the Modeling Ply also has an active draping
definition, then an independent draping simulation is started for the modeling ply.

Draping Definition on Modeling Ply Level

Just like OSS, draping can be activated on the Modeling Ply level. To activate the draping you toggle
the Draping check box and define a Seed Point. By default, the Mesh Size and Draping Direction
are evaluated automatically.

By default, during the draping simulation the draping mesh is laid on the reference surface of the
model independently of the lay-up thickness. If the model property Use Draping Offset Correction
is enabled, the draping mesh follows the bottom offset (relative to the reference surface orientation)
of the selected ply, thus taking into account the lay-up thickness.

An additional feature, Thickness Correction, is implemented in the Internal Draping algorithm. Due
to the shear deformation, the fiber direction and thickness of the ply change. This change can also
be considered by activating the Thickness Correction option.

3.5.2. User-Defined Draping

ACP can also handle user-defined draping results. The draped fiber directions can be imported as a
Look-Up Table and used instead of Internal Draping.

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Figure 3.32: Tabular Values Definition of Draping

The first angle Correction Angle 1 defines the correction of the material reference direction and is
also considered in the analysis. The second value Correction Angle 2 can be used to define the cor-
rection angle of the material 2 direction for woven materials. In ACP, the second correction is not
considered in any evaluation and is just for information or third party products.

3.5.3. Visualization
The result of the draping evaluation can be visualized on the Production Ply and the Analysis Ply
level. The flatwrap and the draping mesh can be visualized through the use of a Draping Mesh
Plot (p. 222). The contour plot of the draping shows the average shear (distortion) angle of each element
(in degree). Zero means no shear deformation. Depending on the Scene configuration the flatwrap
is also available in the Ply Book (p. 234). In addition the Production Ply functionality allows you to
export the flatwrap as a .dxf file.

The last result of the draping are the draped fiber directions which are considered in the analysis.
These directions can be visualized with the Show Draped Fiber Directions button. This visualization
combined with Show Fiber Directions highlights the influence of the draping.

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 Guide to Solid Modeling

Figure 3.33: Fiber and Draped Fiber Directions

3.6. Guide to Solid Modeling

This section describes when and how to work with the Solid Model (p. 283) feature in ACP (Pre). In this
context we are talking about the solid model extrusion and not the lay-up mapping feature within the
Imported Solid Model.

In the case of thick composites, the layered shell theory can cause significant errors in the obtained
results. In some cases it is necessary to work with 3D models (solid models). ACP has the advanced
features to generate layered solid models based on the shell lay-up definitions. Based on the shell mesh
and the ACP composite definitions, ACP generates layered solid elements representing one-to-one the
composite part. Drop-Offs, staggering and tapering are also considered. In addition the solid model
extrusion allows to define extrusion directions, boundary curves, and cut-outs. Finally, virtual cracks
(fracture analysis) and contacts between plies can be modeled by Interface Layers (p. 151).

In general we recommend working with the "standard" Solid Model because the extrusion approach
allows you to generate a one-to-one solid model. If this is not feasible, then the lay-up mapping approach
within the Imported Solid Model (p. 208) is a great alternative. Modeling full cross-section composites
such as composite springs or turbine blades, for instance. Example analyses for both approaches are
available: Composite Solid Model (p. 314) and Analysis of a Mapped Composite Solid Model (p. 326).

The following sections give a brief guide to Solid Modeling:

3.6.1. When to Use a Solid Model
3.6.2. How to Use the Solid Model Feature

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3.6.3. Principles of Solid Model Generation

3.6.4. Drop-Off and Cut-Off Elements
3.6.5. Workflow
3.6.6. Practical Tips
3.6.7. Known Limitations

3.6.1. When to Use a Solid Model

From an analysis point of view, the choice between a shell or solid element analysis models largely
depends on the structure and the type of structural investigation.

Solid models are inherently larger and computationally more expensive than shell models. It is
therefore wise to start an analysis with a shell model before moving on to a solid model. It provides
a basis for comparison but it is also a good check on whether the model is solvable.

Typically, a solid model describes the behavior of a structure more precisely when its out-of-plane
response becomes significant. ACP has the unique feature of representing the 3D stress state for a
shell model. Shell model stress behavior can therefore be taken as a first indication of the 3D stress
state. If the out-of-plane stresses are significant then it may be worthwhile analyzing the structure as
a solid element model.

The following list shows cases where are a solid element model can be used. The solid modeling
feature is not limited to these examples.

• Analysis of thick structures

• Investigation into 3D stresses (high element resolution necessary)

• Investigation into debonding

• Investigation into edge effects

• Buckling analysis of sandwich structures

There are no hard rules on this matter. It remains entirely the choice of the designer when to use a
solid model in addition to or instead of a shell model.

3.6.2. How to Use the Solid Model Feature

The intention of the solid model feature is to generate analysis models for structures that are built
in one piece.

The feature itself makes no distinction between generating solid element models that are analyzed
in isolation or ones that are analyzed in combination with other components. There is however a
distinct difference in how the analysis of a solid element model of multiple components can be ap-
proached. The components of an assembly can either be extruded individually or extruded as one
assembly. Both approaches are possible within ACP yet they both have advantages and limitations.

The recommended approach is to generate individual components and connect them using contacts
in a Workbench Analysis System. This follows the intention that Solid Models are only created for

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 Guide to Solid Modeling

components that are to be built in one piece. Additional connecting structures can be also fully
modeled or dimensioned with the help of substitute model.

The other approach is the extrusion of an entire assembly in one solid model generation. This method
is not only limited by the topological complexity of a geometry but also by a reduced stiffness at
transitions as a result of Drop-Off elements. On the other hand, this approach offers the ability to
model all connecting structures in full.

3.6.3. Principles of Solid Model Generation

The solid model feature requires a reference shell geometry and a composite definition to construct
a solid element model.

Solid model settings control how the solid model is divided into elements in the thickness direction
and how Drop- and Cut-Off elements are handled. The level of detail required in the solid model
depends on how accurate certain features are to be modeled. This depends on the judgment of the
designer.

The feature has additional ways to enhance the resulting solid model to be as detailed as necessary:
ply staggering and tapering are transferred from the composite definitions. Extrusion Guides add
more complex possibilities in shaping the model. The Snap-To functionality makes an alignment with
an external CAD geometry possible. Arbitrary cut-outs or cut-offs can be created with Cut-Off Geo-
metries. The Cut-Off operation is analogous to machining a composite part after curing.

Geometry operations (Extrusion Guides, Snap-To and Cut-Off geometries) help to shape a solid
model into the desired shape. These operations are applied sequentially to the solid model. You
should explore all possibilities of shaping the solid model first with the help of Extrusion Guides and
Snap-To geometries before moving on to Cut-Off features. While Cut-Off geometries allow great
freedom in shaping a solid model, they also introduce degenerated elements which are limited in
representing a layered composite. For more information, see Drop-Off and Cut-Off Elements (p. 285).

Details of the solid model feature are explained in the Usage Reference (p. 61).

3.6.4. Drop-Off and Cut-Off Elements

Drop-Off and Cut-Off elements cannot store any layered information and therefore must be associated
with a homogenous material.

Drop-Off elements are created when ply boundaries exist inside the part. When the plies come to an
end, the solid model extrusion creates a Drop-Off element in the shape of a triangular prism. The
Drop-Off Elements can be modeled with either the ply (or core) material, a different material such as
resin, or as a void.

Cut-Off elements are created when a hexahedral element is diminished by a Cut-Off operation and
decomposed into prism or tetrahedral elements. These elements can also be modeled with different
homogenous materials.

The Cut-Off features offer great freedom in shaping a solid model. The trade-off when using the Cut-
Off feature is that elements diminished by the cutting operation are decomposed into homogenous
tetrahedral and prism elements. These elements cannot store any layered information and the post-
processing results for Cut-Off regions must be interpreted with care.

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Both Drop- and Cut-Off elements can cause steps in the structural stiffness, which may lead to stress
peaks and higher IRFs. This affects the homogenous elements as well as the layered elements in their
proximity.

For information on the postprocessing of stresses and strains of homogeneous elements, see Postpro-
cessing of Drop-Off and Cut-Off Elements in the Mechanical User's Guide.

3.6.5. Workflow
A solid model is easily created alongside an existing shell model in Workbench. Once a solid model
has been generated in ACP (Pre) it can be linked to new Analysis System. A single ACP (Pre) system
can be used to create a shell and a solid model analysis. This workflow is shown below:

Figure 3.34: Analyzing a Solid Model Alongside a Shell Model

The analysis of an assembly requires multiple solid model components to be connected in a Workbench
system. The components can be connected with contacts in Mechanical, for example. As a consequence,
the connections can be modeled and analyzed in detail. The Composite Failure Tool in Mechanical
permits the analysis of all composite parts at once or for a selected scope of interest.

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 Guide to Solid Modeling

Figure 3.35: Solid Model Assembly Workflow

3.6.6. Practical Tips

The solid modeling process is generally more complicated than shell modeling is. The shape and
mesh of a structure have a strong influence on the robustness of the solid modeling process. Generally
speaking, the less complex the model the more robust the process. The challenges of composite
modeling can vary greatly. Following composite design principles for structural concepts will aid the
solid modeling process. Abrupt changes in shape and sharp edges are not advisable in composite
design and also cause problems in composite modeling.

You can use Named Selections to define boundary conditions, contacts, and much more. Named Se-
lections also contribute to making your model associative which automates the update process. For
this reason Named Selections of the shell geometry are converted and maintained in the solid model
workflow as shown in the figure below. An edge becomes a wall (edge_1 ⇒ EDGE_1_WALL) and a
surface is converted into a bottom and top surface (face ⇒ FACE_BOT and FACE_TOP) in the solid
of the downstream Mechanical system.

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Composite Modeling Techniques

Figure 3.36: Conversion of the Named Selections in the Solid Model Workflow

3.6.7. Known Limitations

Awareness of the limitation of solid modeling can help you build a better solid model. It is worth
spending time thinking about aspects of your model such as mesh sizing, extrusion methods, and
geometry operations. For example, it can often be more robust to extrude from the inside out.

This section gives an overview of the limitations of these advanced modeling features:

Mesh Extrusion

The solid model relies on the extrusion of a shell geometry mesh. As the extrusion directions and
operations increase the solid model generation reaches a limit of how heavily a shell mesh can
be distorted. If the topology of the structure is complex then the extrusion operations can result
in ill-formed elements which are subsequently deleted in the element check.

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 Guide to Solid Modeling

Drop-Off Elements

There are transition regions where an edge of a solid model extrusion is reduced to a series of
Drop-Off elements. This reduction in thickness will result in a local reduction in stiffness that
should not be overlooked.

Cut-Off Elements

Cut-Off elements are decomposed into homogenous tetrahedral and prism elements. These ele-
ments can cause abrupt changes in the structural stiffness which may lead to higher stresses and
IRFs. The results in the proximity of Cut-Off elements should be evaluated with care.

Connect Butt-Jointed Plies

The ability to connect adjacent plies is currently restricted to plies that appear sequentially in the
same Modeling Group. Consequently, there a certain arrangement where a ply drop-off cannot
be evaded.

Solid Model Extrusion Offset

The solid model extrusion starts from a reference shell and the lay-up definition. An extrusion
with an offset to the reference geometry is not possible.

Sampling Points, Section Cuts, and Sensors

Sampling points, Section Cuts, and Sensors give information about the lay-up as it was defined
in the Modeling Ply Group. The changes as a result of geometric operations in the solid model
are not reflected in these features. While Cut-Off plies still appear in the sampling point, these
plies show zero stress and strain during postprocessing.

Recomputation of ISS

The recomputation of interlaminar shear stresses only corrects the stresses of layered elements.
Homogenous elements (Drop-Off and Cut-Off elements) retain the interlaminar shear stresses of
the .RST file.

Interface Layers / Elements

Element faces located above and below an interface element must have the same shape (quadri-
lateral or tetrahedral). If their shapes are not the same, the interface element is removed. This can
happen due to the effect of Drop-Off elements (p. 285) (as shown in the figure below). It can also
happen when interface elements intersect a Cut-Off Geomety (p. 285) and the interface element
is not updated. As a result, the interface element does not conform to the new shapes of the
adjacent top and bottom elements.

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Composite Modeling Techniques

Figure 3.37: A quadrilateral interface element surrounded by a brick element and two
tetrahedral elements created when the Drop-Off is split

3.7. Guide to Composite Visualizations

There are several features available in ACP that help in visualizing a composite model. Some features
aid in the verification of the lay-up definition. Others provide an insight into the stresses, strains, and
failures and can thus help in the optimization of a structure.

This section aims to be a brief guide to the some of the available functionality.

3.7.1. Model Verification

Two features are very useful for checking the lay-up definition before solving the model. One is the
Orientation Visualization, the other is the Section Cut feature.

The Orientation Visualization can display the direction and/or orientation of the elements, Oriented
Selection Sets, and plies. Refer to Scene Manipulation (p. 23) for more information.

After the whole definition of the lay-up, a visual verification of the lay-up sequence can be very useful.
Section Cuts offer a useful visual check once the lay-up has been determined. By defining one or
several Section Cuts, the ply position (number in the sequence) and orientation can easily be verified.
Refer to Section Cuts (p. 170) for more information.

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 Guide to Composite Visualizations

Figure 3.38: T-Joint Section Cut

Figure 3.39: Class40 Section Cut

3.7.2. Postprocessing Visualizations

There are several features that can be used for viewing the results of a simulation. They all can give
a different insight into the behavior of the composite structure. The different postprocessing visualiz-
ations mentioned below are also described in the last part of Tutorial 1.

Composites are significantly more complex than isotropic materials because of their orthotropic ma-
terial behavior and multiple possible failure modes (different types of fiber, matrix failure, etc.).
Therefore, composites are evaluated based on standard results (such as deformation, stress, and strain)
and on failure criteria to identify the first ply failure of the structure.

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This section describes the use of the standard result objects in the Mechanical software for composite,
ply-wise scoping, and failure criteria evaluation.

Deformation
In the Mechanical application, you can visualize the deformation of a structure with the following
result objects: Total Deformation or Directional Deformation. The Display Time field in the Details
panel enables you to plot the result at a specific time. The plot can be scaled by using the Deformation
Scale in the Result tab's Display group.

Figure 3.40: Insert Deformation Object under the Solution Group

Figure 3.41: Modify the Display Time and/or Deformation Scale of the Result Object

Failure Criteria
The failure plot displays the critical safety factors (reserve factors, inverse reserve factors, and margin
of safety) to first ply failure for a given failure criteria definition.

The safety factors are evaluated for every element of each layer and the critical value through the
thickness of the lay-up is then projected on to the reference shell mesh. A failure plot for an envelope
solution works in the same way and is a display of the most critical failure of all included solution
sets. Alternatively, the safety factors can be displayed ply-wise for each analysis ply.

Before creating a failure plot, you must insert a Composite Failure Tool under the Solution and
complete the failure criteria definition.

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 Guide to Composite Visualizations

You can insert a Composite Failure Tool by right clicking the Solution group object, navigating to
the Composites cell, and selecting the Composite Failure Tool.

Figure 3.42: Insert a Composite Failure Tool under the Solution

When you click the Composite Failure Tool group object, you can enable/disable the failure criteria
in its Details panel. The failure criteria definition (such as the IRF) must be performed before creating
the failure plot. When creating the failure criteria group, the IRF is inserted by default.

Figure 3.43: Configure the Failure Criteria definition in the Composite Failure Tool group

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Composite Modeling Techniques

Additionally, you can display the critical failure modes and critical plies as element labels. To configure
the display setup, select the result object (for example, IRF) under the Composite Failure Tool and
modify the respective fields in the Details panel.

Figure 3.44: Modify the Displayed Information (Failure Mode, Critical Layer)

In the Details panel, you may also change the Type of failure (Inverse Reserve Factor, Safety Factor,
Safety Margin).

Figure 3.45: Type of Failure Plot

You can view and zoom in on the results.

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 Guide to Composite Visualizations

Figure 3.46: IRF Value, Text Plot for Each Element, and Zoom on Area (Tutorial 1)

Ply-Wise Results
The structural behavior throughout the lay-up at each layer is of great interest in composite design.
Ply-wise information helps to identify and optimize layers that are critical and ones that are not.

All the solution plots except the deformation plot have the option of displaying results ply-by-ply. If
a result object supports ply-scoping, then the Sub Scope By field will be exposed in the Details
panel. Its options are Layer and Ply. To postprocess across the entire envelope of the selected geo-
metries, select Layer. To evaluate only a selected ply, select Ply.

Evaluate the ply-wise results through the following steps:

1. In the respective solution plot Details panel, select Ply as the definition of the Sub Scope By
field.

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Composite Modeling Techniques

Figure 3.47: Active Ply-Wise Scoping

2. Select the respective Ply field.

Figure 3.48: Select Ply Field

3. Navigate to the Imported Plies group and select the desired ply.

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 Guide to Composite Visualizations

Figure 3.49: Select a Ply in the Imported Plies Group

4. Return to the result object's Ply field and click Apply.

5. The result object can now be evaluated on the selected ply.

Figure 3.50: Evaluate the Result of Ply-Wise Scoping (Tutorial 1)

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Composite Modeling Techniques

Sampling Point Results

Sampling Points are an alternative way of analyzing a lay-up on a ply level. A point of interest on the
composite part is selected and its local lay-up is sampled. This feature can display failure criteria,
stresses, and strains through the thickness of the laminate. In this way, the Sampling Point gives a
detailed insight into the laminate behavior ply-by-ply.

Insert and evaluate a Sampling Point result through the following steps:

1. Insert a Composite Failure Tool group object and define the Failure Criteria using the steps
explained in the Failure Criteria (p. 292) section.

2. Select the Composite Failure Tool group, then right-click and select the Promote to Com-
posite Failure Criteria cell. That places a Composite Failure Criteria Definitions group
under the Model in the Tree View, which contains the user-defined Composite Failure Criteria
object.

Figure 3.51: Promote the Failure Criteria Definition of the Composite Failure Tool

a. In the Details panel of the Composite Failure Tool, the Defined By field now contains
Composite Failure Criteria Definitions instead of Direct Input. This enables the Failure Tool
to refer to the Criteria Definitions group for the Failure Criteria definition. By default, the
promoted Composite Failure Criteria object is selected.

b. The Composite Failure Criteria objects under the Composite Failure Criteria Definitions
group can be modified, and the Failure result objects under the Solution which refer to
them will be updated accordingly.

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 Guide to Composite Visualizations

Figure 3.52: Modify the Promoted Composite Failure Criteria Object when Necessary

3. Right-click the Solution group object, navigate to the Composites field, and select the
Composite Sampling Point Tool.

Figure 3.53: Insert a Composite Sampling Point Tool Object

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Composite Modeling Techniques

4. In the Details panel of the Composite Sampling Point Tool, select the promoted Composite
Failure Criteria.

Figure 3.54: Select Failure Criteria under Sampling Point Tool Group

5. You can now choose a point and evaluate:

a. Select the Composite Sampling Point result object that has been automatically
created under the respective group.

b. Click the Geometry field which is currently undefined.

c. Click any area of the Geometry and then Apply. The white cross on the Geometry
represents the selected point.

Figure 3.55: Choose Sampling Point on Geometry and Apply Selection

d. The details of the selected point are reported under the Scope group of the object.
You can redefine the point by navigating to the Geometry, selecting another target,
and re-applying the selection.

Figure 3.56: Review the Selected Point

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 Guide to Composite Failure Criteria

6. After evaluating the result, the Worksheet view is activated, where you can select which type
of layup to postprocess, the results (strain, stress, failure, and polar of the material), and an-
notation. You can also scale the core to modify the layup plot visualization.

Figure 3.57: Evaluate the Sampling Point’s Results

3.8. Guide to Composite Failure Criteria

The Composite Failure Criteria Definitions in the Mechanical application provide a number of failure
criteria for the strength assessment of composites. Both established and basic as well as recent and
advanced failure criteria are included in the program. This section provides some guidance on the se-
lection of failure criteria.

• It is advised that you use failure criteria that distinguish between different failure modes (for example,
fiber failure or matrix failure).

• The use of all-inclusive quadratic failure criteria is not advised (for example, Tsai-Wu, Tsai-Hill, or
Hoffman). In most situations, these criteria are less accurate than others and provided minimal inform-
ation on any failure.

• It is more conservative to combine different failure criteria (Puck, Max Stress, and LaRC) than using
any single criterion.

• In general, failure criteria that consider all in-plane stresses (s1, s2, s12) and the out-of-plane interlam-
inar shear stresses (s13, s23) should be used, as these results are available in a shell model.

• 3D stresses (s3) can often be ignored in thin laminates with moderate curvature. Otherwise, Puck 3D
can be used to investigate delamination.

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Composite Modeling Techniques

• 3D solid models can be used to get more accurate results, especially if out-of-plane stresses are being
investigated.

• Wrinkling and Core Failure should be evaluated for sandwich structures.

• The use of Puck 2D is recommended over the use of Puck Simplified.

For more information, see Failure Analysis in the Composites Theory Reference and Postprocessing Usage
Reference in the Mechanical User's Guide. A comprehensive comparison of composite failure criteria was
carried out in the worldwide failure exercise [10 (p. 369)].

3.9. Element Choice in ACP

This section describes the composite modeling techniques for the use of shell, solid, and solid-shell
elements.
3.9.1. Introduction
3.9.2. Shell Elements
3.9.3. Solid Elements
3.9.4. Solid-shell Elements

3.9.1. Introduction
The underlying principle of ACP is that a composite lay-up is defined on a shell geometry. The model
of the lay-up that is passed from the ACP preprocessor to the solver can be a shell element mesh but
also a solid or a solid shell element mesh. The solid model mesh is an extrusion of the shell element
input mesh. If this input shell mesh uses linear elements (SHELL181) the solid model mesh generated
in ACP can have either layered solid elements (SOLID185) or layered solid shell elements (SOLSH190).
If it is quadratic (SHELL281) the solid model mesh can only have quadratic layered solid elements
(SOLID186).

The geometry and loading of the engineering problem ultimately dictate what element type is best
suited for the analysis. The following sections outline a few general considerations about the element
types in ACP. For more detailed information, see Element Library in the Mechanical APDL Theory Ref-
erence.

3.9.2. Shell Elements

Shell elements are suited for modeling thin-walled to moderately thick-walled structures. Shell elements
are compliant in bending and give good deformation results while being computationally inexpensive.

3.9.3. Solid Elements

Solid elements are aimed at modeling thick walled structures. As laminate thicknesses increase, out-
of-plane stresses become more significant; Solid elements are better at approximating these effects.
Furthermore, layered solid elements allow the incorporation of composite parts in larger solid model
assemblies.

A shortcoming of these element types is that they are typically too stiff in bending when elements
are thin. Displacements can be wrong by an order of magnitude as the elements undergo a phenomen-

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 Variable Material Data in Composite Analyses

on called locking. Element technologies such as Enhanced Strain Formulation try to remedy this nu-
merical locking but are not sufficient to do so in linear 3D solid elements. Quadratic solid elements
(SOLID186) offer a better solution, however, this comes at an increased computational cost.

3.9.4. Solid-shell Elements

Solid-shell elements cover the spectrum between shell and solid elements and are best suited for
modeling thin to moderately thick structures. Thin solid-shell elements do not undergo locking and
are able to give good results for out-of-plane stresses and strains.

3.10. Variable Material Data in Composite Analyses

Composite modeling in Workbench provides the possibility to account for variability in the mechanical
properties of composite materials due to any scalar user-defined quantity. Temperature, Shear Angle
(defined through ACP (Pre) draping (p. 279)), and Degradation Factor are predefined variables in Work-
bench Engineering Data to be used for refining a composite material's behavior. You are free to define
your own field variables.

The following mechanical properties can be defined as variable:

• Isotropic elasticity

• Orthotropic elasticity

• Orthotropic stress limits

• Orthotropic strains limits

Dependencies are specified in tabular form in Engineering Data.

An interpolation scheme is used to evaluate the locally effective properties given the local field variable
states in the model. For information on how the interpolation scheme is controlled, see Variable Data
Interpolation Settings (p. 305).

Once the dependencies are defined in Engineering Data, they are accounted for in subsequent composite
analyses and postprocessing. The Shear Value is defined by draping simulation in ACP (Pre), the Tem-
perature is computed or defined in Structural, Transient Thermal, or External Data systems. The state
of all other fields should be defined in ACP (Pre). The state of all other fields can be defined by means
of Field Definitions in ACP (Pre) or External Data systems.

Variable material data is compatible with both shell and solid elements.

An example analysis using variable material data is given in Analysis Using Variable Material Data (p. 320).

3.10.1. Element- or Layer-wise Field Definition

You can specify the distribution of any variable used in the definition of a Variable Material in ACP.
This is done by means of Look-up Tables. A scalar Look-up Table column can be associated with a
field variable. The state of the field variable is interpolated from the scalar Look-up Table column over
the finite element model. To this end, you can specify whether this interpolation is applicable for the
entire model or only specific parts of it. The field definition can be scoped to a combination of:

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• Element Sets

• Oriented Selection Sets

• Modeling Plies

Element Sets or Oriented Selection Sets as scope of the field definition always affect all layers of their
underlying finite elements. In contrast, scoping to Modeling Plies refines the selection to specific
layers of their underlying finite elements. The Field Definition then applies to the layers of the covered
finite elements associated with the Analysis Plies of each Modeling Ply. Elements and layers not
covered with a field variable definition assume the default value for this variable.

Altogether, a Field Definition can be scoped to the full FE-model or refined to affect only subparts
and, furthermore, only layers.

See the Field Definition (p. 165) for additional information about the object as well as object set-up.

3.10.2. Draping Shear

Ply draping on arbitrarily shaped surfaces leads to local shearing of the plies. This manufacturing-in-
duced artifact can lead to significant deviation between the assumed and effective mechanical
properties. This is because the shearing can be on the order of several degrees before ply wrinkling
becomes an issue. Thus, the configuration of the composite can vary considerably from point to point,
as can the mechanical properties.

In order to reflect the mechanical properties’ dependence upon draping shear, ACP (Pre) provides a
draping simulation tool. Upon specifying shear-dependent material properties in Engineering Data
and enabling draping (p. 279) in ACP (Pre) for individual plies or Oriented Selection Sets, downstream
analysis systems take this effect into account.

The draping shear angle is defined as:

|draped_transverse_angle - draped_fiber_angle| - 90

Where "draped_fiber_angle" and "draped_transverse_angle" denote the angles of the draped fiber
and transverse directions with respect to the reference direction, respectively. Thus, a shear angle of
0 degrees indicates that the ply at the corresponding location is unsheared.

3.10.3. Degradation Factors

Composite parts can exhibit a number of artifacts leading to local degradation of mechanical properties.
Such flaws can be the result of a manufacturing process or can develop during operation. Examples
of these types of flaws include voids, imperfect resin impregnation of fibers, deviation of the fiber
alignment from the design angle, and resin traps.

If such artifacts are known, you can account for them using degradation factors. The typical assumption
is that a degradation factor of 1.0 indicates a sound material, while a degradation factor of 0.0 implies
a disintegrated material. Degradation-dependent material properties can be specified in Engineering
Data.

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 Variable Material Data in Composite Analyses

3.10.3.1. Definition of the Degradation Factor Field

The degradation factor fields are defined by means of a Field Definition object. If Degradation Factor
has been used to define one of the materials in Engineering Data for the current composite analysis,
you can select it from the drop-down menu under Field Variable Name, as shown in the Figure
below. The scope of applicability of this Field Definition is set under Scope Entities to a combination
of Element Sets, Oriented Selection Sets and Modeling Plies. The degradation factors are interpolated
from the selected Look-up Table Column upon update of the ACP system: for shell elements the
field state values are evaluated at the element centroid taking into account the actual ply offsets
if Include Shell Offset is activated; for solid elements the actual ply position is always considered
and this behavior cannot be changed.

All downstream analysis systems will make use of the information provided for the Degradation
Factor in the Field Definition object.

Figure 3.58: Field Definition Properties to Set Up a Degradation Factor Field

3.10.4. Definition of General User-Defined Fields in ACP (Pre)

The Engineering Data enables you to define Isotropic and Orthotropic Elasticity as well as Stress and
Strain limits as a function of up to nine user-defined scalar field variables. Engineering Data pre-defines
Temperature, Degradation Factor and Shear Angle fields. If necessary, you can add custom field vari-
ables. From within ACP, the custom field variables have to be defined as described by Field Definition
Object Properties (p. 165) for Element- or Layer-wise definitions. From the Workbench-level, External
Data components can be used to define custom field variables. Please note, however, that External
Data components do not permit layer-wise field definitions.

3.10.5. Variable Data Interpolation Settings

The interpolation algorithm and its settings can be controlled from Workbench Engineering Data. For
details on the interpolation schemes available and settings of the interpolation engine, see General
Interpolation Library in the Composites Theory Reference.

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Chapter 4: Example Analyses
The following examples demonstrate some of the commonly used features and workflows in ACP.
Other examples and tutorials can be found in the ACP Tutorials. You must be familiar with the basics
of the software to understand the analysis examples in this section.
4.1. Analysis of a Composite Shell Model
4.2. Analysis of a Composite Solid Model
4.3. Analysis Using Variable Material Data
4.4. Analysis of a Mapped Composite Solid Model
4.5. Shear Dependent Materials in Composite Analysis
4.6. 3D Ply Workflow – Imported Plies
4.7. ACP for Workbench LS-DYNA: Bird Strike
4.8. Workflow with Equivalent Beam Models

4.1. Analysis of a Composite Shell Model

Tutorials 1 and 2 give a good insight into the ACP functionality. While the tutorials always start with
an existing model this section outlines the generic build-up of a composite shell model. Selected steps
are explained in more detail below and highlighted with a link.

• Preprocessing

– Add ACP (Pre) Component to the project (p. 308)

– Define Engineering Data (p. 309)

– Import or construct Geometry (Units) (p. 312)

– Open the Model and

→ Define Named Selections/Element Sets (p. 312)

→ Generate Mesh

– Open ACP (Pre) (p. 312) and

→ Define Fabric

→ Define Rosettes and Oriented Selection Sets

→ Create Modeling Plies

• Workbench Analysis System

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Example Analyses

– Add Analysis System to the project (p. 313)

– Open the Analysis System and

→ Define Analysis Settings

→ Define Boundary Conditions

– Solve model (update the project)

• Postprocessing

– Postprocess Results in the Mechanical Application (p. 314)

4.1.1. Preprocessing
The steps involved in pre-processing are described in the sections below:
4.1.1.1. Workbench Integration
4.1.1.2. Adding ACP Components to the Project
4.1.1.3. Engineering Data
4.1.1.4. Properties
4.1.1.5. Geometry and Units
4.1.1.6. Named Selections and Elements/Edge Sets
4.1.1.7. Starting and Running ACP

4.1.1.1. Workbench Integration

The Workbench Add-in of ACP installs two additional Component Systems to the Workbench
Toolbox: ACP (Pre) and ACP (Post). These systems allow transferring the composite definitions of
ACP between ACP and Mechanical on the Workbench schematic level. ACP is now fully integrated
in the data structure of Ansys Workbench and the update and refresh logic.

It is important that the user updates (refresh) the upstream data to pass the modifications to the
ACP components. The update symbols can be used to check the up-to-date status of each compon-
ent.

4.1.1.2. Adding ACP Components to the Project

The components ACP (Pre) and ACP (Post) are available in the Toolbox menu.

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 Analysis of a Composite Shell Model

Figure 4.1: ACP Components

These components are handled in the Project Schematic like the other standard components
(drag-and-drop or right mouse-click menu).

4.1.1.3. Engineering Data

With the installation of ACP a new material catalog named Composite Materials is available in the
databank. This catalog contains typical materials used in composite structures like unidirectional
and woven carbon and glass, or core materials. Within the Workbench workflow of ACP, the mater-
ials have to be defined in Engineering Data and not in ACP (Pre).

Figure 4.2: Engineering Data Sources

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Example Analyses

Figure 4.3: Outline of Composite Materials

4.1.1.4. Properties
To fulfill the ACP requirements, the materials in Ansys Workbench have some additional properties
which are highlighted below.

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 Analysis of a Composite Shell Model

Figure 4.4: Material Properties for ACP

The new properties are:

• Ply Type: Physical behavior of the material like core, unidirectional or woven ply.

• Strengths:

– Orthotropic Stress Limits

– Orthotropic Strain Limits

– Isotropic Strain Limits

• Composite Failure Parameters:

– Tsai-Wu Constants

– Puck Constants

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Example Analyses

– LaRc03/04 Constants

– Additional Puck Constants

– Woven Specification for Puck.

More information about the ACP material definitions are described in Section Material Data (p. 74).

4.1.1.5. Geometry and Units

A shell geometry is required for building any composite model in ACP. The geometry can either
be constructed in the Ansys DesignModeler or imported as a CAD file.

The ACP unit system is independent from the unit system in the Mechanical application (user inter-
face or solver). The transfer from the Mechanical application to ACP and vice versa automatically
converts the data. The current unit system is displayed in the status bar of ACP at the bottom of
the screen.

4.1.1.6. Named Selections and Elements/Edge Sets

Named Selections based on bodies, surfaces, and edges defined in the DesignModeler or the
Mechanical application are transferred to ACP as an Element Set and Edge Set, respectively. They
are necessary for building a composite model.

4.1.1.7. Starting and Running ACP

First, an ACP (Pre) component has to be defined in the Workbench project. Double-click Setup to
open ACP (Pre). You can also use the context menu and select Edit, or run a Python script in which
the ACP commands are included, from the context menu. After defining the composite data in ACP
(Pre), you can return to the Workbench project to proceed. The ACP data is saved with Save in the
Workbench project or any other Save Project command in the different components.

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 Analysis of a Composite Shell Model

Figure 4.5: Context Menu of ACP (Pre) Setup

4.1.2. Workbench: Adding an Analysis System to the Project

The ACP components are handled in the Workbench Project Schematic like any other standard
components. The components can be connected by drag-and-drop operations or by using the context
menu. The Mesh, Engineering Data, Named Selections and Coordinate Systems are transferred to the
analysis system.

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Example Analyses

Figure 4.6: Connecting a Static Structural Analysis to ACP (Pre) using a Drag and Drop Operation

4.1.3. Postprocessing
For postprocessing in the Mechanical application, see Postprocessing of a Composite Shell Model in
the Mechanical User's Guide.

4.2. Analysis of a Composite Solid Model

In the case of thick composites, the layered shell theory can cause significant errors in the obtained
results. In some cases, it is necessary to work with 3D models - also referred to as solid models. ACP
has the unique feature that can generate layered solid models based on the shell lay-up definitions.
ACP generates layered solid elements based on the shell mesh and the ACP composite definitions, thus
representing one-to-one the composite part. Drop-offs, staggering and tapering are also considered.
In addition, the solid model extrusion allows you to define extrusion directions and boundary curves.

In this section, the workflow of modeling a composite solid is outlined as it differs to some extent from
shell modeling. Selected steps that differ from shell modeling are explained in more detail below and
highlighted with a link.

• Preprocessing

– Add ACP (Pre) component to the project

– Define Engineering Data

– Import or construct Geometry

– Open the Model and

→ Define Named Selections/Element Sets

→ Generate Mesh

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 Analysis of a Composite Solid Model

– Open ACP (Pre) and

→ Define Fabric

→ Define Rosettes and Oriented Selection Sets

→ Create Modeling Plies

→ Create Solid Model (p. 315)

• Workbench Analysis System

– Choose an Analysis System (WB Mechanical/Mechanical APDL) (p. 316)

– Add Analysis System to the project (p. 317)

– Add other systems (p. 320)

– Open the Analysis System and

→ Define Analysis Settings

→ Define Boundary Conditions

– Solve model

• Postprocessing

– Postprocess Results in the Mechanical Application (p. 320)

4.2.1. Preprocessing

Creating a Solid Model

You can generate a Solid Model by performing a mesh extrusion which converts the shell-based lay-
up definition into a layered, solid-element mesh. The configuration of the extrusion happens in ACP
(Pre) with the Solid Model feature. (For details, see Solid Models (p. 183) in the Usage Reference
chapter.) The options and advanced settings of the Solid Model feature control the extrusion, shape,
and mesh quality. See Guide to Solid Modeling (p. 283) for practical tips and recommendations.

The Export settings for the Sold Model control how it is exported for downstream analysis. For instance,
you can choose between different element types (layered solid185 or solsh190). Within Workbench,
the element and node labels are automatically handled to avoid numbering conflicts. (See the section
on Assembly (p. 50).) If automatic numbering is disabled, then the numbering options can be used
to specify the initial labels.

In addition, Element Sets and Edge Sets are transferred from ACP (Pre) to the downstream analysis
system (Mechanical Model) where they appear as Named Selections. This aids the definition of
boundary conditions and contacts, for instance, and makes your model associative. (See the section
on Solid Model Properties (p. 185) for more information.) The figure below shows how Named Selections
of the shell geometry are converted into Named Selections of the solid mesh (geometry). An edge
becomes a wall (edge_1 ⇒ EDGE_1_WALL) and a surface is converted into a bottom and top surface
(face ⇒ FACE_BOT and FACE_TOP) in the solid of the downstream Mechanical system.

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Example Analyses

Figure 4.7: Conversion of the Named Selections in the Solid Model Workflow

4.2.2. Workbench Application Analysis System

Within the Ansys Workbench application, there are two ways to analyze composite solid models: The
analysis can be done in the Workbench Mechanical application, or it can be carried out in the Mech-
anical APDL software (Ansys Classic). While the functionality is identical, the user interface is very
different. As an alternative, composite solid models can be exported from the ACP application for
processing outside of Ansys.

Analysis with Mechanical Application

In the Mechanical application, the composite layered solid element model appears as a meshed body.
Any other bodies in the ACP (Pre) component are not carried forward. You can define loads, boundary
conditions, and connections to other parts in the Mechanical application as usual. An example of
such a solid model workflow is shown below:

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 Analysis of a Composite Solid Model

Figure 4.8: Workbench Software Workflow for Composite Solid Modeling with Mechanical
Application

Analysis with Mechanical APDL Application

A further option is to link solid models to a Mechanical APDL application system where the boundary
conditions and loads are defined. Typically, an APDL script is used to set boundary conditions and
analysis settings for a workflow with the Mechanical APDL application. An example of a solid model
workflow with the Mechanical APDL application is shown below:

Figure 4.9: Workbench Software Workflow for Composite Solid Modeling with Mechanical APDL
Application

Adding an ACP (Pre) Component to the Project

The solid modeling workflow in Ansys enables the assembly of many preprocessing components into
one analysis system. In some cases, it may be desirable to analyze thick-walled composites in isolation
but often it is desirable to see the interaction between multiple bodies. The connection procedure
is explained with the help of two examples for both analysis methods (Workbench Mechanical and
Mechanical APDL applications).

Link with Workbench Mechanical Application

The procedure for building an analysis model is illustrated with a Static Structural Analysis system
as an example. A composite doubly-curved tensile test specimen is held by two metallic grips at its
two ends. Both the composite and the metallic parts are integrated into an assembly model.

A Project Schematic is shown below:

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Example Analyses

Figure 4.10: Analysis of a Composite Doubly-Curved Specimen and Metal Grips Modeled with
Mechanical Application

In this example, the geometry consists of one layered solid specimen and two metal grips. The link
between ACP (Pre) (B5) and Static Structural (C2) only transfers the generated layered solid element
model. The link between the Mechanical Model (D4) and Static Structural (C2) transfers all metallic
parts. The connections, boundary conditions, and all other preprocessing definitions can be defined
in Setup (C3) as usual. The global solution and postprocessing can be determined and analyzed in
the Workbench Mechanical application.

Figure 4.11: One Layered Solid Specimen and Two Metal Grips in Mechanical Model

Link with Mechanical APDL Application

Two composite components — a plate and a t-joint — serve as an example for the workflow procedure
in the Mechanical APDL application. A Project Schematic is shown here:

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 Analysis of a Composite Solid Model

Figure 4.12: Analysis of Composite Plate and T-joint Modeled with the Mechanical APDL
Application

The proper sequence of connecting the system always begins with connecting an ACP (Pre) component
first. In this case, it is not important because both inputs are ACP (Pre) solid models.

In the Mechanical APDL component the boundary conditions, loads and all other preprocessing
definitions can be defined through APDL macros. These macros can be linked with the Mechanical
APDL cell which will be integrated in the automatic update functionality of Workbench. A macro file
can be added to the component through the right-click context menu (see figure below). Add Input
File... appends the APDL running sequence with an additional macro. Check the order of the files of
the Mechanical APDL component. The macros should be listed after the Solid Model Process Setup
file(s).

Figure 4.13: Add Reference File

Figure 4.14: List of Used Files and Their Order in Mechanical APDL

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Example Analyses

Multiple Parts (Adding Other Systems)

It is possible to add multiple components to one analysis system: two composite parts or a composite
part connected to two isotropic parts, for example.

4.2.3. Postprocessing

Global Postprocessing
In general, the global solution of all parts can be viewed in the Workbench Mechanical or Mechanical
APDL applications. Analyzing the results of a multi-part assembly considering solid bodies is also
possible in the Mechanical software. Specifically, the results are accessible directly in the analysis
system, which must be associated with an ACP (Pre) system. The postprocessing functionality for
solid models of ACP enables the mapping of ply-wise results onto the reference surface of the solid
model. This functionality ensures that failures occurring inside the laminate can be observed and in-
vestigated.

Mechanical Application Postprocessing

For postprocessing in the Mechanical application, see Postprocessing of a Composite Solid Model in
the Mechanical User's Guide.

4.3. Analysis Using Variable Material Data

This simple example of a race car nose and wing demonstrates a possible workflow for composite
analyses using variable material data, ACP draping simulation, and temperature dependence. Variable
material data is used to simulate incomplete curing of the composite material in the model. Note that
the wing geometry, composite lay-up, and material data are fictitious and should not be used in any
real world analysis or application.

The following figure shows the Workbench setup. Cell D (External Data) contains the results of a Fluent
analysis which provides the surface pressure distribution on the race car nose and wing. The composite
lay-up, draping, and incomplete curing field are defined in ACP-Pre in cell A. Cell E (External Data)
defines the temperature field. The structural effect of the airflow around the race car nose and wing
are analyzed in cell B (Static Structural), which also contains the failure analysis of the composite
structure.

The model used in this example analysis is available by .

A general overview of using variable material data can be found in Variable Material Data in Composite
Analyses (p. 303).

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 Analysis Using Variable Material Data

Figure 4.15: Race Car Setup in the Workbench Application

4.3.1. Workbench Application Engineering Data: Set-Up Variable Data

Variable data for composite materials are configured in Engineering Data. The following properties
can be functions of up to nine field variables:

• Density

• Elasticity parameters

• Stress limits

• Strain limits

Temperature, Shear Angles and Degradation Factor are predefined field variables. User-defined field
variables can also be created. In this example, the effect of incomplete curing across the parts is
modeled. As a first step, the field variable Incomplete Curing is defined and specified as dimensionless.
A value of 1.0 indicates perfect curing while a value of 0.0 indicates that no curing took place.

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Example Analyses

Figure 4.16: Predefined and User-Defined Field Variables in Engineering Data

In the next step, the field variables are assigned to the material properties. Make the elasticity para-
meters of the Epoxy_Carbon_Woven_230GPa_Prepreg material a function of Temperature, Shear
Angle, and Incomplete Curing. To accomplish this, select the material and then select the Ortho-
tropic Elasticity property. Double-clicking a field variable assigns it to the Orthotropic Elasticity
property. Fill the table for the Orthotropic Elasticity property by manually entering values or by
importing a CSV file.

Figure 4.17: Assigning a Field Variable to Material Property

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 Analysis Using Variable Material Data

Figure 4.18: Populating the Tabular Material using the CSV Interface

During finite element computations and postprocessing, the effective material properties are interpol-
ated from these tables based on the local field variables state. The interpolation scheme can be
controlled when selecting Interpolation Options. When selecting the Material Field Variables property,
the unit, default data, lower, and upper limit can be set. The software suggests program controlled
values for some of the options. The default data defines the assumed state of the field variable, if it
is not specified in the model.

In this way, you can have full material specifications in Engineering Data, but only use a subset of
the specified dependencies during the simulation. For more details, see ACP (Pre): Define Fields for
Shear Angle, Degradation Factor, and User-Defined Field Variables (p. 324).

Figure 4.19: Setting Interpolation Options

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Example Analyses

4.3.2. ACP (Pre): Define Fields for Shear Angle, Degradation Factor, and User-
Defined Field Variables
ACP (Pre) provides the ability to set up fields for Shear Angle (draping), Degradation Factor, and all
user-defined field variables for a complete composite model. The Shear Angle can be defined as a
result of ACP draping simulation or imported via look-up tables (p. 107). Degradation Factor and user-
defined field variables can be defined per shell or solid element as an interpolation result from a
scalar look-up table column. For example, you can define the state of a field variable at various spatial
positions in a .CSV file and import it as a 3D look-up table (p. 107). By creating a Field Definition (p. 165)
object in ACP-Pre, you can assign the imported scalar look-up table column to the field variables
previously specified in Engineering Data and scope them to part of your model, even to single Mod-
eling Plies. See the Element- or Layer-wise Field Definition (p. 303) section.

The application automatically considers the result of the draping simulation when evaluating the ef-
fective material properties in downstream analyses and postprocessing.

Figure 4.20: Draping Results

Use look-up tables to define scalar fields on composite models. The interpolation result from the look-
up tables can be visualized using Scalar Look-up Table plots and the Field Definition objects in turn
can be visualized using Field Definition plots. The following figure shows Curing Degree over the race
car nose and front wing (upside down).

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 Analysis Using Variable Material Data

Figure 4.21: Distribution of the Curing Degree (Scalar Look-Up Table Plot)

To activate a 3D look-up table as the Curing Degree field, you need to assign it in the ACP (Pre) by
setting up a respective Field Definition. Note that you must maintain unit consistency between the
Look-up Table column values and the active unit system in the Mechanical application (units of the
look-up table column are not converted to the active unit system). See the Field Definitions (p. 165)
section for additional details. The following figure shows this process:

Figure 4.22: Activating a Look-Up Table to Define Curing per Modeling Ply (Layer-Wise)

4.3.3. Mechanical, Thermal Loading, and External Data

Thermal loading through the Temperature field variable can be accomplish by:

• Transient Thermal analysis

• External Data analysis component in Workbench

• Setting the environmental or part temperature directly in Mechanical

The resolution of the temperature field is per element node.

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Example Analyses

Figure 4.23: Using External Data to Define Temperature Field

4.3.4. Postprocessing in Mechanical Application: Analysis Effect of Variable

Data
Stress and strain limits can be defined in Engineering Data as a function of field variables. These de-
pendencies are fully reflected in the Mechanical application when evaluating respective failure criteria.

The following figure shows inverse reserve factor plots of combined Maximum Stess, Hashin, Face
Sheet Wrinkling, and Core Failure failure criteria. The structure is viewed from the bottom. On the left
is the result with constant material properties, and on the right the effect of Temperature, Shear
Angle, and Incomplete Curing is shown. The color bar ranges are the same. It is clearly visible that
the IRFs are much higher within the gold square.

Figure 4.24: Inverse Reserve Factor (Constant Material Data on the Left; Variable Material
Properties on the Right)

4.4. Analysis of a Mapped Composite Solid Model

In the case of thick composites, the layered shell theory can cause significant errors in the obtained
results. In some cases, it is necessary to work with 3D models, also referred to as Solid Models. ACP has
the feature to map the ACP Composite Definitions onto external solid meshes.

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 Analysis of a Mapped Composite Solid Model

In this section, the workflow of modeling mapped composite solid meshes is outlined. To a large extent
the workflow is the same as that of a standard solid model (p. 314), except there is one main difference:
The solid mesh is imported via Mechanical Model and not generated in ACP (Pre) itself. See Solid
Modeling (p. 48).

An exemplary complete workflow contains these steps:

1. Preprocessing: Define the Composite Definitions in ACP (Pre) as described in the Analysis of
a Composite Solid Model (p. 314) section.

2. Mapping of the Composite Definitions: Import the external volume mesh and configure the
Imported Solid Model object in ACP (Pre).

3. Analysis: Transfer the solid composite data to a downstream analysis (p. 316) (structural, modal,
etc.).

4. Postprocessing: Run the composite failure analysis for the composite structures in Mechanical.

This example examines how a full cross-section composite spring can be modeled by mapping Composite
Definitions from ACP (Pre) onto an existing mesh.

You can download the Workbench archive for this example here:

Tip:

A video that demonstrates this capability can be found here.

Geometry and the Lay-Up

The geometry and the lay-up of the spring are shown in the figure below. The lay-up can be split into
three sections. The four reinforcement plies at the outer surface consist of a woven fabric, and the total
thickness of this section is 1 mm. The material orientation of the plies is alternating, +/- 45°. The next
ply is a 2 mm thick isotropic core material. And a roving (carbon UD) fills the center section of the spring
where the fibers are along the extrusion direction (helix) of the spring.

Figure 4.25: Geometry and Lay-Up of the Composite Spring

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Example Analyses

4.4.1. Transfer External Solid Mesh to ACP (Pre)

The lay-up mapping feature transfers the lay-up definition of ACP (Pre) onto an external solid mesh
that was generated outside ACP (Pre). This section describes how the solid mesh is transferred to ACP
(Pre), system C. This includes preparing the geometry and meshing as well as linking the Workbench
systems.

4.4.1.1. Geometry
The entire geometry is prepared in SpaceClaim (system E) and contains both the shell reference
surface and the solid. Therefore, the geometry is split into two parts in the subsequent workflow.
The shell surface is used to specify the Composite Definitions in ACP (Pre) and is passed to system
B and later to ACP (Pre), system C. The volume of the spring is required to generate the solid mesh
in the Ansys Mechanical software and is passed to another Mechanical model (system F).

Note:

SpaceClaim is no longer included in the unified installer. Ansys recommends using Dis-
covery Modeling to create geometries, or its alternative DesignModeler.

Figure 4.26: Complete Project Schematic in the Workbench Application

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 Analysis of a Mapped Composite Solid Model

To achieve an accurate FE model of the solid with the correct material assignments, the solid geo-
metry is split into two bodies: the Tube and the Roving. This ensures that, later, the reinforcement
plies and UD roving can be mapped accurately onto their intended region and that the volume
contents of the materials are correct. These bodies are passed to ACP (Pre) (the connection between
system F and C) as Named Selections. The figure below shows the geometry with the two solid
bodies and the Named Selections.

Figure 4.27: Mechanical Application Model F4 with the Bodies Roving and Tube

Also, other Named Selections are added which will be used to apply the boundary conditions in
analysis system D. It is important that all geometries except the solid are suppressed in system F
so that the data transfer from F4 (the Mechanical application model) to C5 (ACP (Pre)) contains only
the solid mesh.

4.4.1.2. Meshing
The lay-up mapping algorithm in ACP (Pre) is currently designed for structured meshes where de-
generated elements can be filled with an orthotropic material. Therefore, the solid mesh that gets
lay-up data from ACP (Pre) should mainly consist of structured elements (hex) which support layered
section data. In this example, it is the solid Tube.

The mesh of the inner body, the Roving, must meet fewer requirements because the filler option
will be used in ACP (Pre) to assign the UD material to this body. The elements, then, are handled
as homogeneous elements instead of layered elements which relaxes the requirements on the
mesh. The figure below shows the mesh of the solid geometry with a mapped mesh and Sweep
method in the outer region (Tube).

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Example Analyses

Figure 4.28: Detail View of the Final Solid Mesh with Hex Elements only in the Outer Body

4.4.1.3. Linking the Systems in the Workbench Application

The solid mesh is passed to the ACP (Pre) system by transferring F4 to C5. (Simply drag-and-drop
F4 onto C5.) This connection will create an Imported Solid Model object in ACP (Pre) which contains
the solid mesh and Named Selections.

Figure 4.29: Mesh Features and Solid Mesh with the Inflation Layers and Roving Cross Section

4.4.2. Lay-Up Mapping in ACP (Pre)

An Imported Solid Model (p. 208) object is automatically generated in ACP (Pre) as soon as a Mechan-
ical application model is linked to an ACP Setup component. The file format, unit system, and file
path are automatically set and cannot be changed.

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 Analysis of a Mapped Composite Solid Model

Figure 4.30: Imported Solid Model Properties Dialog

The Imported Solid Model object also contains the Named Selections which were generated in the
upstream component. They appear as Mesh Components as shown below. You can see the mesh
of the Imported Solid Model (even before you define any settings for the mapping) by right-clicking
Composite_Spring and selecting Import Initial Mesh from the context menu.

In this example, the lay-up mapping is split into two pieces, one for the Tube and one for the Roving.
So, a Lay-up Mapping Object is generated for each of these regions

The source plies for the region Tube are the woven and core plies which are all defined in the Mod-
eling Group Laminate. The configuration of the Lay-Up Mapping Object is shown below.

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Example Analyses

Figure 4.31: Figure: Lay-up Mapping Definition of the Mesh Component Tube

The filler option is used to assign the UD material to the roving mesh component. The filler option
is activated by passing an empty list of plies and defining a filler material and orientation. In the figure
below, the filler options for the roving are shown– the General options (A) and the Materials options
(B).

Figure 4.32: The Filler Options for the Roving

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 Analysis of a Mapped Composite Solid Model

The mapped plies and generated materials are displayed under the Analysis Plies folder of the Im-
ported Solid Model. You can use these entities to plot ply-wise data such as thickness and fiber direc-
tions.

The figures below show the final solid mesh with mapped plies and UD materials. The first figure
shows the first ply on the solid mesh, its thickness and material orientations.

Figure 4.33: Filler Elements and Fiber Directions

The assignment of the UD material is shown in the next figure. It shows that the orthotropic material
(UD carbon) is perfectly aligned with the extrusion direction of the spring thanks to the selected
Rosettes and Selection Method.

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Example Analyses

Figure 4.34: Using the Filler Option for the Roving

4.4.3. Analysis of A Mapped Composite Model

The Imported Solid Mesh is passed to a structural system to simulate a compression load case until
the surfaces of the helix are in contact. See system D in Figure 4.27: Mechanical Application Model
F4 with the Bodies Roving and Tube (p. 329).

Once the solution is up-to-date, the composite solid model can be postprocessed in the Mechanical
application as shown in the figure below A. Composite Failure Tool is set up to address the different
material types (woven and UD fabrics, and core material). This can be achieved by selecting for example
the Max Stress, Puck, and Core Shear failure criteria.

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 Shear Dependent Materials in Composite Analysis

Figure 4.35: Ply-wise Failure Analysis

4.5. Shear Dependent Materials in Composite Analysis

This example demonstrates a possible workflow for composite analyses using homogenized material
data (with shear dependency) for a woven composite provided by Material Designer. To this end, a

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Example Analyses

simple model consisting of an inflated half-sphere is considered. The effect of draping simulation
combined with shear-dependent material properties in the ACP application will be shown.

The following figure shows the setup in the Workbench application. The material data of a Carbon/Epoxy
woven fabric are computed by the Material Designer software (systems A and B) as illustrated in the
Material Designer Woven Composite Tutorial. The composite lay-up and draping options are defined
in ACP (Pre) (system C). Finally, the structural effect of an internal pressure load is analyzed in system
D (Static Structural).

Figure 4.36: Project Setup in the Workbench Application

If desired, you can the model used in this example analysis and perform the steps yourself.

Homogenized Material Data

Following the Material Designer software's Woven Composite Tutorial, the homogenized material data
for a Carbon/Epoxy woven fabric are generated. In particular, using an RVE whose material directions
are aligned with the yarns bisectors, so that the resulting homogenized material remains orthotropic
in presence of shear (see Fabric Fiber Angle (p. 78) in the Material Designer User's Guide).

Figure 4.37: Woven RVE defined in Material Designer Application

We set up two analyses in the Material Designer software (Cell B in the Workbench project): a constant
material analysis and a variable one with a shear angle between -30° and 30° as parameter. The resulting
materials are then transferred to the Engineering Data component of the ACP system.

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 Shear Dependent Materials in Composite Analysis

Figure 4.38: Materials in the Engineering Data Component of the ACP system

Note that the constant material has a constant Fabric Fiber Angle equal to 45°, while the variable ma-
terial has a shear dependent Fabric Fiber Angle.

Figure 4.39: Shear Dependent Fabric Fiber Angle

Fibers and Material 1 Directions in the ACP Application

In the ACP application, define a ply with a variable woven fabric and a ply angle of 0°.

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Example Analyses

Figure 4.40: Ply Definition

The effect of the Fabric Fiber Angle property can be highlighted by comparing the ply fiber directions
with the material 1 direction.

Figure 4.41: Fiber (Light Green), Transverse (Dark Green) and Material 1 (Red) Directions

The material 1 direction identifies the direction in which the material properties are specified. However,
the fiber direction is still the nominal modeling direction in ACP, that is, the Ply Angle still defines the
orientation of the fibers with respect to the reference direction.

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 Shear Dependent Materials in Composite Analysis

Draping
The Shear Angle can be defined as a result of draping simulation in the ACP application (see Drap-
ing (p. 279)).

You can enable the Internal Draping algorithm in the Draping tab of the Modeling Ply Properties (p. 142)
dialog.

Figure 4.42: Draping Definition

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Example Analyses

Figure 4.43: Draping Mesh in the ACP Application

You can plot the local ply shear value due to draping using an Angle Plot (p. 222) with Draped Shear
Angle as component.

Figure 4.44: Shear Angle Plot

In addition, you can further investigate the shearing effect due to draping by plotting the draped fiber
and transverse directions, as well as the material 1 direction.

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 Shear Dependent Materials in Composite Analysis

Figure 4.45: Draped Fiber Direction (Light Blue), Draped Transverse Direction (Blue) and Material
1 Direction (Red)

Plot of Shear Dependent Material Properties

The application automatically considers the result of the draping simulation when evaluating the effective
material properties in downstream analyses and postprocessing. In the ACP application, you can plot
the effective material properties (for example, the Young's modulus) as a function of the Shear Angle
using Material Plot.

Figure 4.46: Shear-Dependent Young's Modulus

Analysis
The composite model is passed to a structural system to analyze the effect of a uniform pressure load.
It is worth comparing the result with the one obtained considering a constant material and no draping:
in the latter case the maximum deformation is underestimated by more than 30%.

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Example Analyses

Figure 4.47: Deformation Plot (variable material on left, constant material on right)

4.6. 3D Ply Workflow – Imported Plies

Many different manufacturing processes are available to build composite structures. Traditional processes
are mainly used to fabricate thin or moderately thick laminated structures which can be modeled based
on a reference surface, also called a mold surface. In ACP (Pre), this is covered by the Oriented Selection
Set (p. 132) and Modeling Ply (p. 142)features.

New and alternative processes, such as 3D printing and winding, can produce thick and complex
structures. In such cases the approach of building the entire laminate on only one reference surface
often proves unfeasible or results in an inaccurate model. The Imported Modeling Ply (p. 160) feature
allows you to model laminated structures independent of a reference surface, where the geometrical
information (ply extent and so on) is imported from an external source. The lay-up mapping capability,
which is part of the Imported Solid Model (p. 208), is then used to map the Imported Modeling Plies (3D
plies) onto a solid mesh. You can employ this workflow in combination with thermal and structural
analyses such as linear, transient, or explicit for example.

4.6.1. Inputs
The 3D Ply Workflow requires two additional inputs, compared to the standard workflow. One is a
finite element mesh of the solid that represents the 3D composite part, and the other is the 3D rep-
resentation of the lay-up. The figure below shows how their data can be transferred to ACP (Pre).

In this example, the solid geometry is meshed in the Ansys SpaceClaim application by using block
meshing (see A3). The solid mesh is then transferred to ACP Pre-Setup by linking the Ansys Mechan-
ical model (the A4-B5 link). Another option is to mesh the solid geometry in the Mechanical software.
You can import meshes from third-party applications (such as HyperMesh) in any supported file format
via the External Model system. For more information on supported file formats, see External Model
in the Workbench User's Guide.

Note:

• SpaceClaim is no longer included in the unified installer. Ansys recommends using Dis-
covery Modeling to create geometries, or its alternative DesignModeler.

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 3D Ply Workflow – Imported Plies

• Named Selections (NS) of the finite element mesh of the solid get transferred to the
downstream systems. These Named Selections can be used to define boundary conditions,
contacts, and so on, to make the model associative.

Figure 4.48: 3D Ply Workflow (Courtesy of 9T Labs)

There are two ways to create the 3D ply representations in ACP (Pre). Option A: By geometry. Or option
B: By loading an HDF5 Composite CAE (p. 245) in ACP (Pre).

Option A: The ply surfaces are represented by CAD faces and are transferred to ACP (Pre) by linking
one or more geometrical components with ACP (Pre) (see D2-B5). All the additional information, such
as fiber directions and material, can be defined in ACP (Pre) using the standard ACP application features
(such as Fabrics, Rosettes, and so on).

Option B: This option allows you to import ply definitions from a third-party application. The HDF5
Composite CAE file includes all the information of a layered composite, so the imported ply objects,
their fiber directions, and their thicknesses are created automatically on import. Currently, many CAE
applications support the HDF5 Composite CAE. Contact your Ansys Support Team for further inform-
ation about this format. The figure below shows you how an HDF5 Composite CAE is loaded using
the context menu of the ACP application's model.

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Example Analyses

Figure 4.49: HDF5 Composite CAE Imported as 3D Plies (Imported Modeling Plies)

4.6.2. Example of Use - HDF5 Composite CAE

The following example has been provided by 9T Labs (https://www.9tlabs.com/) who automates and
digitizes composite manufacturing. It shows how a 3D printed composite structure, designed with
Fibrify, can be imported into Ansys Workbench/ACP for simulation. This workflow allows you to import
a 3D composite lay-up definition and convert it into a solid FE model with minimal effort.

You can download the . You will find the required HDF5 Composite CAE file in the following location:

user_files\200401_Rocker_PA_print_2NEW.hdf5cc

The model is already fully configured, and the description below highlights the most important steps.

Figure 4.50: 3D Printing with Endless Fiber Reinforcement and Final Part (Courtesy of 9T Labs)

The following figure shows the Workbench Project Schematic. The 3D geometry of the printed
composite part (shown above) is loaded into system A (Solid Mesh) and meshed in SpaceClaim. Three
Named Selections are defined in Model A4 which are used to define the forces and supports later in
the analysis system C3. This is important if you want to have an associative model. The material
properties (such as stiffness and strengths) are defined in the Engineering Data component (B2) of
the ACP Pre system. The solid mesh is transferred to ACP Pre by linking Model A4 with ACP Setup B5
which results in an Imported Solid Model in ACP Pre.

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 3D Ply Workflow – Imported Plies

Figure 4.51: Simulation of a 3D Printed Composite (Courtesy of 9T Labs)

At this point, only a few mouse-clicks are needed in ACP Pre to load the 3D plies and to configure
the mapping. You can perform the import using the context menu of the ACP Model as shown above
(Figure 4.49: HDF5 Composite CAE Imported as 3D Plies (Imported Modeling Plies) (p. 344)). The imported
plies are accessible in the object Tree and are displayed when selected. To see the Fiber Directions
and other properties, enable the options in the display’s toolbar. Of course, the input data can be
modified as well if needed.

The solid mesh on which the plies are mapped is already available (mesh transfer from A4-B5). The
mapping algorithm must be switched over to Imported Plies (3D plies) by enabling the Use Imported
Plies option in the Imported Solid Model Property Dialog. By default, all plies are mapped and the
result can be verified by selecting the plies of the solid model. The figure below shows a few plies
which are visualized on the solid mesh. (Enable the Show on Solid option in the display toolbar
and select the plies.)

You can now transfer the solid mesh downstream for many different types of analyses, such as a
static structural analysis as shown in System C in the workflow above ( Figure 4.51: Simulation of a
3D Printed Composite (Courtesy of 9T Labs) (p. 345)). After solving the analysis, you can employ the
Composite Failure Tool to predict the safety margin of the composite part. As an example, the figure

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Example Analyses

below shows the maximum Inverse Reserve Factor per element. Of course, you can easily generate
ply-wise plots for a more detailed assessment.

Figure 4.52: Distribution of the Inverse Reserve Factors in the Mapped Composite Solid Model

4.7. ACP for Workbench LS-DYNA: Bird Strike

An important part of designing composite structures is fulfilling performance and reliability targets
under operational loads. Most structures are subject to quasi-static or transient phenomena where im-
plicit time integration is sufficient. However, when engineers want to understand the structural behavior
under short duration events, explicit time integration methods are necessary. Common scenarios include
assessing passenger safety in a vehicle crash event, predicting the damage state of consumer goods in
a drop scenario, or predicting the effects of a bird strike on an aircraft and the impact on its ability to
land safely.

Composite models may exhibit complex lay-up patterns when they involve multiple layers, local rein-
forcements, and different materials and orientations. While defining lay-ups in LS-PrePost is tedious and
prone to errors, ACP provides all the functionality (p. 1) needed to generate parametric composite
models efficiently and accurately. You can use these composite models for both implicit analyses in
Ansys Mechanical APDL and explicit analyses in LS-DYNA.

The example that follows shows how to set up a composite model for a bird strike analysis within Ansys
Composite PrepPost for an explicit simulation within Ansys Workbench LS-DYNA. In principle, the
workflow corresponds to the implicit structural analysis of a composite shell model (p. 307). The modeling
steps that have specific application to the Workbench LS-DYNA analysis are given special attention. For
example:

The Workbench project file can be downloaded here:

Tip:

For general considerations and limitations regarding the ACP-to-Workbench LS-DYNA workflow,
see ACP–LS-DYNA (p. 45).

4.7.1. Workbench Workflow

4.7.2. Engineering Data – Material Model Definition
4.7.3. SpaceClaim – Geometry
4.7.4. Mechanical Model Setup

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 ACP for Workbench LS-DYNA: Bird Strike

4.7.5. ACP - Material Assignment and Lay-Up

4.7.6. Setting Up the LS-DYNA Analysis System
4.7.7. Post-Processing in Workbench LS-DYNA:

4.7.1. Workbench Workflow

The ACP to WB-LSDYNA workflow is similar to a standard implicit Analysis of a Composite Shell
Model (p. 307) using ACP and Ansys Mechanical: The required analysis systems are placed on the
Workbench Project Schematic and connected (p. 313). In the case of a composite analysis with LS-
DYNA, you drag-and-drop an LS-DYNA analysis system onto the Workbench schematic.

Figure 4.53: The Drag-and-Drop Workflow Showing the Transfer of ACP Composite Models to
a Workbench LS-DYNA Analysis System

4.7.2. Engineering Data – Material Model Definition

The material data required for the LS-DYNA model is defined in the Engineering Data. There are two
ways the LS-DYNA material cards are generated from the workflow:

1. Ansys standard material property definitions are automatically converted into the equivalent
LS-DYNA material model.

Once the ACP model is transferred to the LS-DYNA system, you can choose which LS-DYNA
composite material model is used by selecting Composite Damage Model in Composite Controls,
located under Details of Analysis Settings. This converts a basic set of parameters. This is a
global control which defines the entire composite model by one of the two available material
models:

• ENHANCED_COMPOSITE_DAMAGE / *MAT054

• LAMINATED_COMPOSITE_FABRIC / *MAT058

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Example Analyses

Figure 4.54: Setting up an Automatic Conversion of LS-DYNA Material Models

2. You directly define the LS-DYNA material model.

Composite structures are often made of different materials, each exhibiting its own material beha-
viors. This might require using multiple material models. Engineering Data simplifies the task by
giving you access to several LS-DYNA material cards, allowing complete control over stiffness and
damage parameters as well as degradation properties.

The model used in this example contains a unidirectional and a woven material. Each is represented
by a specific LS-DYNA material model:

• UD - *MAT_ENHACED_COMPOSITE_DAMAGE/*MAT054

• Woven - *MAT_LAMINATED_COMPOSITE_FABRIC/*MAT058

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 ACP for Workbench LS-DYNA: Bird Strike

Figure 4.55: Material Definition for LS-DYNA in Engineering Data

4.7.3. SpaceClaim – Geometry

The geometry is generated in SpaceClaim. It includes a solid geometry which represents the bird (A
in the figure below) and the surface geometry of the composite wing structure (B). The distance (C)
between the bird and the wing is set to minimize the time between the beginning of the simulation
and the impact event.

Note:

SpaceClaim is no longer included in the unified installer. Ansys recommends using Discovery
Modeling to create geometries, or its alternative DesignModeler.

Figure 4.56: Geometry Preparation in SpaceClaim

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Example Analyses

4.7.4. Mechanical Model Setup

The geometry is then transferred to the Mechanical model where the following entities must be
defined:

• Geometry Properties

– Reference Frame: The Reference Frame of the bird is set to Particle which allows the mesh
generation method with SPH particles. In contrast, the Reference Frame of the wing geometry
is set to Lagrangian by default.

– Material: For the bird geometry, Water2 is assigned, an equation-of-state material model for
water. For the bodies of the wing geometry, the default material assignment is retained but will
be overwritten by the composite definition in ACP-Pre.

Figure 4.57: Mechanical Model - Assigning Part Properties to the Bird Body

• Mesh

The mesh Physics Preference is set to Explicit. A Particle Method is used for the mesh generation
of the bird. A multizone meshing approach is chosen for the wing geometry which allows the
generation of a suitable structural mesh-type for explicit analysis.

• Named Selections

Named Selections for some part domains are defined. ACP-Pre uses the Named Selections to set
up various functional domains for assigning composite plies.

4.7.5. ACP - Material Assignment and Lay-Up

Material Assignment
Because each LS-DYNA material model in Engineering Data has its own definition, you can assign
specific materials to each individual ply. If a material without an LS-DYNA definition is used, it is
automatically converted to the preset LS-DYNA material card. The workflow for defining Fabrics,
Stackups, and Sub-Laminates in ACP (p. 74) does not differ from standard composite model generation.

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 ACP for Workbench LS-DYNA: Bird Strike

The model in this example uses two different Fabrics, one for the woven and another for the unidirec-
tional material. You must define Fabric Thickness in the Fabric Properties dialog. Additional but
optional controls (p. 84) are available for draping computation and solid model material handling
for degenerated elements.

Figure 4.58: Defining Materials in ACP

Lay-Up
The composite lay-up contains the two different materials previously defined. The stiffeners and the
base lay-up of the skins are made from the unidirectional material. Additional woven materials are
applied to the trailing edge of the wing as a local reinforcement. The ply stacking direction of the
skin points inward as defined through the underlying Oriented Selection Set of the modeling plies.

Figure 4.59: Composite Lay-Up Modeling in ACP

4.7.6. Setting Up the LS-DYNA Analysis System

The composite lay-up from ACP is transferred to LS-DYNA as a shell model where the wing as well
as the bird model is now present with their required model configuration. A Body Interaction object

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Example Analyses

is added by default and includes all bodies present in the model. A Fixed Support is applied to one
of the Stiffeners. A Velocity of 125 m/sec is applied to the bird body as an Initial Condition.

Figure 4.60: : Setting Up the Analysis

The Details View of Analysis Settings provides additional controls for the solver run and output en-
tities:

• End Time is set to 0.01 seconds.

• Under Output Controls, History Variables is set to Yes.

• Under Time History Output Controls, different output entities are specified (for example: Element
Data and Nodal Data).

• Other control entities are available such as for SPH Controls, Processing Type, CPU and Memory
Management, and Solver Precision.

4.7.7. Post-Processing in Workbench LS-DYNA:

In Ansys Mechanical, you can review very basic result entities such as deformations, strains, and
stresses.

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 Workflow with Equivalent Beam Models

You can evaluate the history variable output through a user-defined result. Be aware that the history
variables have a different meaning for each material model (see History Variable Output in the LS-
DYNA User's Guide).

For advanced result analyses, you can open the result files and model input files in LS-PrepPost. Right-
click the Solution object and select Open Solver Files Directory in the context menu.

Figure 4.61: Accessing Input Files and Results Files

Alternatively, you can use the free ACT extension LST_PrePost (available in the Ansys Store) to open
the LS-DYNA solver and results files and seamlessly perform further pre- and post-processing. Addi-
tional pre- and post-processing capabilities in Workbench LS-DYNA will be added in future releases.

4.8. Workflow with Equivalent Beam Models

The two examples in this section demonstrate how to set up an equivalent beam model of a layered
composite shell structure. ACP (Pre) is used to compute the equivalent sectional properties from the
shell-based 3D composite models. This workflow is typically used for slender structures such as wind
turbine blades or helicopter rotor blades to efficiently evaluate their dynamic behavior. In each example,
the results of the beam model are compared with the 3D model. In both cases, the results are very
similar, which shows the accuracy of the workflow.
4.8.1. Constant Composite Cross Section with a Straight Beam
4.8.2. Generic Composite Wind Blade
4.8.3. Conclusion

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Example Analyses

The first example is a composites box with a constant cross section and laminate. The second example
is a generic wind turbine blade where the cross section and the laminate vary along the longitudinal
axis. Both have the same project schematic in the Workbench application as shown in Figure 4.62: Work-
flow of a Model Analysis with an Equivalent Beam Model (p. 354). The top systems are used to configure
the 3D model, which steps include:

• Importing the shell geometry and meshing it in the Mechanical application (A4)

• Defining the layup in ACP (Pre) (A5) and computing the equivalent beam properties

• Preparing the APDL input for the beam model in the Modal: Beam model (C) system

• Running the same analysis with the shell or solid model in the Modal Solid (B) system to compare
the results with the equivalent beam model

The analysis with the equivalent beam model is configured in the Modal: Beam model (C) system. It
contains the beam elements and the computed equivalent section properties from ACP (Pre) (A5)
which are passed to the solver by an APDL Command snippet.

Important:

Use the same unit system in ACP (Pre) (A5) and Modal: Beam model (C) to ensure that the
computed beam properties have proper units.

Figure 4.62: Workflow of a Model Analysis with an Equivalent Beam Model

4.8.1. Constant Composite Cross Section with a Straight Beam

The base to compute the equivalent beam properties is a generic straight box-like composite structure
with constant cross section and constant composite layup along the length. A consequent equivalent

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 Workflow with Equivalent Beam Models

beam model is built, and its frequencies are compared against the 3D model frequencies (SOLID185
elements).

The fully configured Workbench project is contained in a compressed file and can be downloaded
. This configured project requires Release 2024 R2 or more recent versions.

The section is shown in the following figure with the coarse mesh used to access the methodology.
The material properties are listed in the table.

Figure 4.63: Cross Section and Layup of the Box

Table 4.1: Material Properties

Foam Glass Carbon

UD Woven
Ex [Mpa] 70 45000 61340
Ey [Mpa] 70 10000 61340
Ez [Mpa] 70 10000 6900
Gxy [Mpa] 26.92 5000 3300
Gxz [Mpa] 26.92 5000 2700
Gyz [Mpa] 26.92 3846.15 2700
νxy 0.3 0.3 0.04
νxz 0.3 0.3 0.3
νyz 0.3 0.4 0.3
Density 6E-11 2.0E-09 1.42E-09
[t/mm3]

For this example, the reference point considered for the cross section properties is the Origin. The
following shows the calculation result.

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Example Analyses

Figure 4.64: Computation Result of the Equivalent Beam Properties

Figure 4.65: Mesh of the Cross Section and its Principal Properties

A simple straight beam of the desired length is created in SpaceClaim and meshed in the Mechanical
application. The equivalent beam model is built in the Mechanical system Modal: Beam model (C)
by adding an APDL snippet under the Geometry object in the Tree View. The results from the Section
Cut computation in ACP are directly pasted here as shown below. Alternatively, a Python script could
be inserted in ACP which automatically generates the APDL inputs (APDL file). This file can then be

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 Workflow with Equivalent Beam Models

loaded by the Command Snippet object in the Mechanical. The Python script option enables further
automation of the workflow.

Note:

SpaceClaim is no longer included in the unified installer. Ansys recommends using Discovery
Modeling to create geometries, or its alternative DesignModeler.

Figure 4.66: APDL Snippet to Apply the Beam Properties

The beam is fixed on one end and the first six frequencies are calculated. The table below compares
the results of the 3D solid model and equivalent beam model.

Table 4.2: Comparison of the 3D Solid Model and Equivalent Beam Model Results

Frequency 3D Equivalent Diff.

Model Beam %
1 82.574 82.152 -0.511
2 95.958 95.484 -0.494
3 509.19 504.95 -0.833
4 592.73 589.07 -0.617
5 1384.1 1372.7 -0.824
6 1619.6 1610.5 -0.562

The following figure shows a comparison of the mode shapes for the first and fifth frequencies.

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Example Analyses

Figure 4.67: Comparison of Mode Shapes for the First and Fifth Frequencies

You may compare the data of the inertia properties for the 3D solid model and equivalent beam
model using the reports below.

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 Workflow with Equivalent Beam Models

3D Solid Model

Equivalent Beam Model

4.8.2. Generic Composite Wind Blade

This example is based on a generic composite wind blade with variable cross section, realistic sub-
components, materials, and thickness distribution. It is used as the base to compute the equivalent
beam properties. A modal analysis is run on the equivalent beam model and its frequencies are
compared against the 3D Shell model frequencies (SHELL181 elements).

The fully configured Workbench project is contained in a compressed file and can be downloaded
. This configured project requires Release 2025 R1 or more recent versions.

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Example Analyses

The blade has a circular root section that transitions to aerodynamics airfoil. Its structure mimics a
typical wind blade with longitudinal UD spar caps, a shear web, trailing edge UD reinforcement, +/-
45 external skins, and core material in the panels.

Figure 4.68: Geometry of the Generic Wind Turbine Blade

The material properties are listed in the table below.

Table 4.3: Material Properties

Foam Glass
UD
Ex [Mpa] 70 45000
Ey [Mpa] 70 10000
Ez [Mpa] 70 10000
Gxy [Mpa] 26.92 5000
Gxz [Mpa] 26.92 5000
Gyz [Mpa] 26.92 5000
νxy 0.3 0.3
νxz 0.3 0.3
νyz 0.3 0.4
Density 6E-11 2.0E-09
[t/mm3]

The blade is 50.6 m long and, due to the variable cross section and design, the beam model has 101
elements. This means that the sectional properties have to be calculated at 101 locations. Ideally, the
section cuts are in the middle of each section cut.

There are two Python scripts in the ACP model. The first is to generate the section cuts at the right
locations (middle of each beam element). And the second script is to write the results as sectional
properties to an APDL input file. The script is based on the example [Export Section Cut]. The generated
output must be manually copied into the APDL Command snippet or refresh the Command snippet
to load it directly from the generated APDL input file.

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 Workflow with Equivalent Beam Models

Figure 4.69: Wind Turbine Blade with the 101 Cross Sections

Figure 4.70: Two Meshes of Different Cross Sections and the Corresponding Shear, Elastic, and
Center of Gravity

For this example, the reference point considered for the cross section properties is the Origin. The
Mesh (nodes and elements) for the beam model is created conveniently in Mechanical APDL to place
the nodes at the desired location along the span of the blade. Then, this model is imported into the
Workbench application via an external model (.cdb) and can be opened in the Mechanical application,

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Example Analyses

where using an APDL snippet, each element property is reassigned according to the calculated values
for each cross section (these values were saved through the ACP Python script into a .cdb file)

Figure 4.71: APDL Snippet with the Generated Output from ACP

The blade is fixed on one hand and the first five frequencies are calculated. The table below compares
the results of the 3D shell model and equivalent beam model.

Table 4.4: Comparison of the 3D Shell Model and Equivalent Beam Model Results

Shell Equivalent Mode Diff.

Beam Shape %
0.66264 0.67738 First flap 2.2%
0.69092 0.70684 First edge 2.3%
2.3553 2.3932 Second 1.6%
flap
3.2611 3.32467 Second 1.9%
edge
5.3698 5.472 Third flap 1.9%

The following figure shows a comparison of the mode shapes for the first and fourth frequencies.

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 Workflow with Equivalent Beam Models

You may compare the data of the inertia properties for the 3D solid model and equivalent beam
model using the reports below.

Shell Model

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Example Analyses

Equivalent Beam Model

4.8.3. Conclusion
These two examples show that equivalent beam models, based on the ACP section cut computation,
provide accurate results and significantly improve performance. The modal analysis of the beam
model runs in a fraction of the time if compared with a 3D shell or solid model. This approach can
also be used for other types of analysis such as transient analyses.

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Chapter 5: Guide for ACP Terminology
The following terms and concepts appear in composite analyses.

Classical laminate theory (CLT) analysis

For a given sampling point, the laminate properties and stiffness/compliance matrices are evaluated
based on the lay-up on the shell mesh. Also, laminate forces are calculated when a sampling point
is used on a solved model where nodal displacement results are available. For more information,
see Classical Laminate Theory.

Coupling effect

Coupling effects describe the relationship between laminate forces and bending moments of a
composite structure caused by imbalanced laminates. Classical laminate theory (CLT), by default,
uses the coupling effect to calculate the polar properties and laminate engineering constants from
the laminate compliance matrix. For more information, see Analysis Options.

Cut-off selection rule

Acts as a cutting operation on the composite lay-up and can be defined by a geometry or a tapered
edge.

Edge set

A named selection of connected edges in Mechanical are transferred to ACP as an edge set, which
stores the node labels of an edge and is, therefore, not associated with the geometry. You can also
define an edge set manually in ACP (Pre). For more information, see Edge Sets (p. 96).

Element set

A named selection of connected faces/connected elements in Mechanical are transferred to ACP as

an element set, which stores the element label and is, therefore, not associated with the geometry.
For more information, see Element Sets (p. 95).

Fabric

Associates a material with a ply, defines its thickness and optionally the fabrics cost. For more in-
formation, see Fabric (p. 84).

Failure criteria

Is used to evaluate the strength of a composite structure with respect to the different composite
failure modes. A failure plot displays the critical margin to failure (reserve factors, inverse reserve
factors, and margin of safety) to the first ply failure for a given failure criteria definition. For more
information, see Guide to Composite Failure Criteria (p. 301).

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Guide for ACP Terminology

Failure plot

Displays the margin to failure for the first ply failure of a pre-defined failure criteria definition.

Fiber direction

Describes the material 1 direction of a ply material and can be visualized on the composite model.
For more information, see Fiber Directions (p. 28).

Geometry

The virtual 3D shape, and the derived subshapes, imported into ACP (Pre) to build complex laminates.
For more information, see Geometry (p. 97).

Global ply number

Defines a ply’s global position in the ply-ordering sequence. The global ply number represents the
order of the plies in the modeling group. For more information, see Modeling Ply Properties (p. 142).

Inverse reserve factor (IRF)

A result type that measures the margin to failure of a composite material. For more information,
see Failure Mode Measures.

Lay-up

The stack of plies and their sequence in ACP. For more information, see Lay-Up Plots (p. 222).

Modeling ply (MP)

The MP is internal to ACP and is the most basic definition of a ply. The production ply (PP) and
analysis ply (AP) are built automatically from information placed on this level. For instance, a sub
laminate is an MP and each of their materials (either fabric or stackup) displays as a PP. For more
information, see Modeling Ply Properties (p. 142).

Reference direction of an oriented selection set (OSS)

Specifies the reference direction (0°) to which all MP ply angles are relative. For more information,
see Oriented Selection Sets (OSS) (p. 132).

Orthotropic elasticity

A mechanical property for linear elastic materials with direction-dependency. For more information,
see Orthotropic Elasticity.

Puck failure

Composite failure criterion that evaluates the strength of a reinforced material. This criterion is
available in ACP. For more information, see Puck Failure Criteria and Failure Criteria vs. Ply Type
Table.

Sampling point

Used in pre- and post-processing to access detailed properties and results of a layup in a specific
location. ACP samples through the specific element near the given coordinates to run detailed

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 analyses (lay-up plots, through-the-thickness plots, and laminate engineering constants). For more
information, see Sampling Points (p. 168).

Script

Instructions in Python code that allow for more complex model definition, parametrization, and
automation in ACP. Scripts are marked for execution whenever a parameter or the script itself
changes. For more information, see Scripts (p. 71).

Selection rule

Enables you to define specific lay-up areas or ply boundaries without depending on the mesh and
the geometry of the model. The selection can be combined with OSSs or MPs to define plies of ar-
bitrary shapes. For more information, see Selection Rules (p. 115).

Stackup

A multiaxial stack of fabrics consisting of several plies. Typically, these layers are then stitch-bonded
to form a fabric, also called a non-crimp fabric. For more information, see Stackup (p. 88).

Tapering

The process of progressively narrowing the thickness of an individual ply or laminate in a composite
structure.

Thickness type

Determines the thickness definition when defining an MP.

T-joint

A t-joint connects two parts at right angles. It is omnipresent in composite structures.

Tsai-wu

Composite failure criterion to evaluate the strength of reinforced materials. This criterion is available
in ACP. For more information, see Tsai-Wu Failure Criterion and Failure Criteria vs. Ply Type Table.

Tube selection rule

A selection rule that is defined by a constant inner and outer radius along an edge. The longitudinal
direction is defined by an edge set and the radii define the diameters of the inner and outer cylinder.
Enabling Include Rule Type selects all elements between the tube's inner and outer radii. Otherwise,
the elements outside the tube will be selected. For more information, see Selection Rules (p. 115).

Virtual geometry

Enables you to select and group specific regions or bodies of the imported CAD geometry and use
them for subsequent modeling operations. All geometry-based operations are based on virtual
geometries. Virtual geometries act as a reference to one or more faces or bodies of one CAD geo-
metry. For more information, see Virtual Geometries (p. 101).

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Guide for ACP Terminology

Warping limit

When ACP performs shape checking for element quality, solid elements with a warping factor above
this user-adjustable limit are removed from the solid model. For more information, see Element
Quality (p. 188).

Woven fabric

Woven fabrics consisting of fiber strands that have been woven together in two directions, also re-
ferred to as warp and weft. For more information, see Woven Composite.

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370 of ANSYS, Inc. and its subsidiaries and affiliates.