Offset modeling of shell elements : A study in shell element modeling using Nastran

Abstract: At Saab Aerostructures they are manufacturing a lot of parts for Airbus and Boeing. When these components are investigated using finite element analysis four-node Kirchhoff shell elements and a very fine mesh is often used. In order to make the pre-processing easier Saab would like to offset the shell mid surface from the nodal plane (the modeling surface) rather than to extract mid surfaces for the entire component. This would also make it easier to model a component which needs a thickness change later on, this since the original modeling surface could be used but with an offset of the elements in order to represent the new geometry. When offset is used in Nastran multi point constraints are created between the nodes and the shell mid surface points. All loads, which are applied in the nodal plane, are then transformed to the mid surface where the stiffness matrices, displacements and stresses are calculated. In order to be able to use this method more knowledge about its effects are needed, which is the reason for this thesis work. The offset is studied for two simpler cases, thickness variation and a 90°corner, as well as fora more complicated component called a C-bar. This is a hinge connecting the flaps to the wings of an airplane. The simpler cases are modeled using both mid surface and offset models subject to either a transverse load, an in-plane load or a bending moment. These are compared to a solid model in order to determine which is the most accurate. When mid surface modeling is used fort he thickness variation the surfaces are connected using rigid links. The conclusion made from these simulations is that using offset may give different results if the load is an in-plane load. This kind of load leads to the creation of a bending moment, which is linearly dependent on the amount of offset. The severity of this depends on the overall geometry and how this load is applied.