Nafems Composites Ply Calculator Handbook

Composite Ply Calculator
This is an Excel spreadsheet used to perform Classical Laminate

Theory calculations in support of the e-learning course and also to
provide a means of completing the homework in some sections
without the use of FEA software.
The calculations have been exposed as much as possible, and can

be investigated in detail. For this reason the number of plies has
been kept to 10 sets.
A version containing Macros is also available to help simplify some

calculations, but the non-macro version does contain all required
functionality.
The calculator is provided ‘as is’ and no warranty is made as to its

accuracy.
NAFEMS. The International Association for the Engineering Analysis Community

FETraining - Your Partner in FEA Training and Consultancy www.fetraining.com
Composite Analysis Ply Calculator V5.0 Page 1
Material Data Input
Material Stiffness and Strength Data is Input in the green cells as shown.
Units are user-defined, so it is up to you to work in consistent units
The label ‘Units’ is just to remind you, along with the description at top right, no
checking is done on units

Loading Data Input
Loading Data is Input in the green cells as shown.
The loading is load/unit length on an infinitesimally small section of layup
The layup datum direction is along the x axis, so a load applied in-plane in x, to a
single 0 degree ply, will be uniaxial, along the fibers.

Ply Data Input
Loading Data is Input in the green cells as shown.
Ten ply variations are available, but the number of plies per ‘layer’ can be varied to
give some versatility
The layup datum direction is 0 degree aligned along the x axis
In this example a [0/90/45/-45/]s layup is used. Each ply is 1e-4 m thick, but ply
1 and 8 have 4 times the number of plies, i.e. a thickness of 4e-4 m each.
Ply 9 and 10 are ignored in the calculation as the number of plies is set to 0.
Total Layer and Layup thickness is checked, don’t overwrite the yellow summary
cells
Calculations – summary output
Total Layup thickness and upper and lower z distance is checked.

The untransformed material stiffness matrix Q is calculated – used in ply Q bar
The material Invariants U1 to U6 are calculated – used in ply Q bar
The total in-plane and bending strains for the whole layup are output in
length/length and percentage strain. These are in global x-y coordinates

Calculations – summary output
Ply local stresses and the ply FI and SR using Tsai-Wu are tabulated. The
calculations for these are all exposed on the backing sheets.
The critical FI and SR is highlighted
The effective, or equivalent, layup stiffness

properties are summarized on the main page

Calculations – ‘calculations’ sheet
The Qbar and A, B, D matrix terms are calculated ply by ply and summed

Calculations – ‘calculations’ sheet
The [A, B, D] matrix is assembled
Its inverse is calculated and the load vector aligned with it

Calculations – ‘stress-strain’ sheet
Ply stresses and strains are calculated in the local ply coordinate system
Results are passed back to the main page

Calculations – ‘FI’ sheet
FI using Tsai Wu is calculated, and the corresponding quadratic roots give the SR,
ply by ply. These values are passed back to the main page.

Calculations – ‘Plots’ sheet
Ply stresses and strains are calculated,

and ply strains are also calculated in the
global xy coordinate system
Plots are produced through thickness

Optional Macro – Force Scaling of applied load
This macro forces the worst SR and FI to be 1.0, by scaling all terms in the
loading vector by 1.0
It is a convenient tool to use with Homework 1, for instance
The macro is invoked by clicking on the button

Optional Macro – Force Percentage of various plies into a layup
This macro forces the a pattern of symmetric plies onto a layup.
It overwrites any existing ply definition
In this example, 30% of 0 degrees, 10 percent of 20 degrees and 60 percent of

a balanced 45/-45 are requested. The total layup thickness is input.
If the percentage does not total 100%, a warning is given. The value t’ is used
to check the thickness contribution either side of the symmetry surface. The
total should be t/2.
The macro is invoked by clicking on the button

Optional Macro – Force Percentage of various plies into a layup
The results of definitions are shown:

Section 1 Homework Review
Using FEA to simulate a test coupon

Section 1 Homework
Use the following material properties to create a single ply FEA test
coupon.
Carbon/Epoxy (AS4/3501‐6)

Section 1 Homework
The coupon dimensions are 4 inches wide by 20 inches long

(0.102m by 0.508m). Thickness is 0.15 inch (0.00381 m)
The coupon is loaded in the long direction with an axial load of

sufficient value so as to just fail the coupon. (Hint: if your solver has a
SR output option it will be easier to scale the load to failure)
The ply end is held axially, but free to shrink due to Poisson’s effect
The ply orientation is varied from 0 degrees (aligned with the long axis)
to 90 degrees ( aligned with the short axis)
Plot the failing load against ply angle, using the Tsai-Wu criterion
Plot the sigma1, sigma2 and sigma12 stresses against ply angle
Repeat the exercise using the Maximum Stress Criterion

Section 1 Homework
Alternatively use the stress terms given below if you do not have
access to an FEA solver
P
1  cos 2 
A
P
 2  sin 2 
A
P
 12   sin  cos 
A
Another alternative is to use the Ply calculator to calculate stresses,

load and FI terms
Experiment with values of F12 term between 0.5 and -0.5 in the Tsai Wu
criterion, ensuring you normalize the whole term

Section 1 Homework – Answer Using Ply Calculator
Metric Version
Step 1. In ply calculator enter material properties and ply 1 data (theta = 0.0 t
= 0.00381m)
Step2. Enter arbitrary load/width in x

Step2. Investigate SR and scale load by this to get SR 1.0
Step3. First data point
Px total = Load/width* width = 711175 N

Sig1 = 1.830E9 Pa
Sig2 = 0.0 Pa
Sig12= 0.0 Pa
Now repeat for theta = 1,2,3,4,5,10,15,20,25,30,45,75,90

Resultant Loads, Stresses and Tsai-Wu Terms
Dominant terms highlighted

in Tsai-Wu

t1 t2 t3 t4 t5
LAMINATE ANALYSIS – IN PLANE
The terms are tedious to calculate so we will use part of the Ply Calculator
Spread Sheet to evaluate an example from reference [1].
A single dummy ply is input, with the defined Stiffness values

E1 19.981GPa
E2 11.389GPa
G12 3.789 Gpa
 12 0.274
The reduced stiffness matrix is calculated
Note > E1
Note > E2
[1] Introduction to Composite Material Design. Barbero. CRC 1999, page 115
We now want to consider off-axis plies, where the with-fiber angle can be
arbitrary.
The stiffness in the reference directions has to be resolved as shown

The resultant is the transformed reduced stiffness matrix.
 Q11 Q21 Q16 

 
Q   Q12 Q22 Q26 
Q16 Q26 Q66 
 
Note that there can now be coupling terms between in-plane direct and
shear. We will explore this later.
Using the example in Reference [1], by including angle theta -55 degrees:
The Q  matrix is shown for the single ply

Note Q11 is less than E1
For arbitrary coordinates the Stress-Strain relationship for kth ply of a layup are:
 x  Q11 Q21 Q16    x 

 k  Q k  k      
 y   Q12 Q22 Q26    y 
  Q Q Q   xy 
 k 
xy 16 26 66  k  k
Following ref [1] page 125

As an example a 6 ply layup is shown, the ply stack is:
[-55/55/0/0/55/-55] or [-55/55/0]symm
The layup is symmetric and balanced
The A matrix calculations are shown for each ply:

The A matrix summation is shown. Notice that the shear coupling terms go to
zero, as the layup is balanced
An axial loading will show no shear coupling

The ply 1 and 6 angles are changed to remove the balanced condition
The A matrix now shows signs of coupling:
Shear strains are now induced with axial loading

The balance is further altered by changing all plies
The resultant A matrix is shown
And the increased shear strain:

For a balanced symmetric layup an equivalent laminate moduli can be

calculated and used for engineering calculations, sizing etc.
The Moduli represent the stiffness of an equivalent orthotropic plate

under in-plane loading.
The moduli are defined in terms of the A matrix.
A11 A22  A212

Ex 
tA22
A11 A22  A212
Ey 
tA11
A66
Gxy 
t
A
 xy  12
A22
Balanced and symmetric plies used

In-plane and bending coupling terms are zero

Balanced, but not symmetric, in plane decoupled

Not balanced, or symmetric, full coupling

Buckling in Composites
Typical plate simply supported on all edges
Layup is 0/90/90/0
Ply thickness = 0.0001m = 0.1 mm
Plate length = .0125m = 12.5 mm
Plate width = .01m = 10 mm

Nominal load = 10 N EigenValue = 21.38 Pcr = 213.8 N
365 N
214 N
668 N
Hand Calculation

 D22 2 D11  b 
2 2
D  2 D 1 a 
2
N x cr  m   2
12 66
 2  
b  D22  a 
2
D22 m  b  
N x cr Load per unit width
N x cr  288N
This assumes one half wave as per the FEA, but is quite innacurate
However relative buckling loads are acceptable, based on D11, D22, D66,D12
estimates


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Composite Ply Calculator

This is an Excel spreadsheet used to perform Classical Laminate

The calculations have been exposed as much as possible, and can

A version containing Macros is also available to help simplify some

The calculator is provided ‘as is’ and no warranty is made as to its

NAFEMS. The International Association for the Engineering Analysis Community

Units are user-defined, so it is up to you to work in consistent units

NAFEMS. The International Association for the Engineering Analysis Community

Loading Data is Input in the green cells as shown.

Units are user-defined, so it is up to you to work in consistent units

The loading is load/unit length on an infinitesimally small section of layup

NAFEMS. The International Association for the Engineering Analysis Community

Loading Data is Input in the green cells as shown.

Units are user-defined, so it is up to you to work in consistent units

The layup datum direction is 0 degree aligned along the x axis

Total Layup thickness and upper and lower z distance is checked.

NAFEMS. The International Association for the Engineering Analysis Community

The critical FI and SR is highlighted

The effective, or equivalent, layup stiffness

NAFEMS. The International Association for the Engineering Analysis Community

NAFEMS. The International Association for the Engineering Analysis Community

The [A, B, D] matrix is assembled

Its inverse is calculated and the load vector aligned with it

NAFEMS. The International Association for the Engineering Analysis Community

NAFEMS. The International Association for the Engineering Analysis Community

NAFEMS. The International Association for the Engineering Analysis Community

Ply stresses and strains are calculated,

Plots are produced through thickness

NAFEMS. The International Association for the Engineering Analysis Community

It is a convenient tool to use with Homework 1, for instance

The macro is invoked by clicking on the button

NAFEMS. The International Association for the Engineering Analysis Community

This macro forces the a pattern of symmetric plies onto a layup.

It overwrites any existing ply definition

In this example, 30% of 0 degrees, 10 percent of 20 degrees and 60 percent of

The macro is invoked by clicking on the button

The results of definitions are shown:

NAFEMS. The International Association for the Engineering Analysis Community

Using FEA to simulate a test coupon

NAFEMS. The International Association for the Engineering Analysis Community

NAFEMS. The International Association for the Engineering Analysis Community

The coupon dimensions are 4 inches wide by 20 inches long

The coupon is loaded in the long direction with an axial load of

Repeat the exercise using the Maximum Stress Criterion

NAFEMS. The International Association for the Engineering Analysis Community

Another alternative is to use the Ply calculator to calculate stresses,

NAFEMS. The International Association for the Engineering Analysis Community

Step2. Enter arbitrary load/width in x

NAFEMS. The International Association for the Engineering Analysis Community

Step3. First data point

Px total = Load/width* width = 711175 N

Now repeat for theta = 1,2,3,4,5,10,15,20,25,30,45,75,90

Dominant terms highlighted

NAFEMS. The International Association for the Engineering Analysis Community

A single dummy ply is input, with the defined Stiffness values

The reduced stiffness matrix is calculated

The stiffness in the reference directions has to be resolved as shown

NAFEMS. The International Association for the Engineering Analysis Community

The resultant is the transformed reduced stiffness matrix.

 Q11 Q21 Q16 

The Q  matrix is shown for the single ply

 x  Q11 Q21 Q16    x 

Following ref [1] page 125