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    CATIA Composite Design, Analysis, and ManufacturingDriving Innovation in the Automotive IndustryDriving Innovation in the Automotive IndustrySuccess Story: Terrafugia and the Transition Roadable Light Sport Aircraft

    (Date)( )

    Jason Curtis, InceptraRani Richardson, Dassault Systemes

    1

  • Inceptra Helping engineering and manufacturing companies solve mission critical business pchallenges since 1986.

  • The Portfolio of PLM Solutions

    VirtualProduction

    VirtualTesting

    VirtualProduct

    PLMCollaboration

    LifelikeExperience

    3DMCAD

    3

  • Aerospace Customers

  • Non Aerospace CustomersAutomotive ShipbuildingAutomotive Shipbuilding

    Wind

    Consulting Research

    Wind

    Material ProvidersMaterialProviders

  • Inceptra Composite Customers

    CAESCOCAESCO

  • Introduction to Composites, Design

  • Composites

    WhyuseComposites?ReducedWeightHigh stiffness and high strength

    WhatisaComposite?Twoormoreengineeredmaterialsasa matrix and reinforcement (can Highstiffnessandhighstrength

    HighthermalresistanceHighcorrosionresistanceGoodfatiguelife

    amatrixandreinforcement(canincludeplywoodandconcrete)Thermoset (Irreversiblechemicalreaction)Th l ti ( b lt d b h tThermoplastic(canbemeltedbyheatandcoolanynumberoftimes)Reinforcementfibers

    Continuous/longfibers

    OrganicMatrixComposites MetallicMatrix

    Composites(MMC)

    CeramicMatrix

    Composites(CMC)

    Wood

    PolymerMatrixComposites(PMC)aka.FiberReinforcedPlastics(FRP)

    ThermosetResin

    ThermoplasticResin

    ContinuousFibers ShortFibers Particles

    ShortfibersSprayedfibers

    Manual Processes Liquid Molding Processes Robotic Compression Automated PlacementManualProcesses LiquidMoldingProcesses Processes Molding AutomatedPlacement

    SprayLayup

    WetLayup

    HandLayup

    PrepLayup

    RTMVARTM

    RFI(ResinFilmInfusion)

    RIMSCRIMP Pultrusion

    RoboticPreforming

    SMCBMC

    HotDraping

    TapeLaying

    FiberPlacement

    FilamentWinding

  • Typical Composites Challenges

    Long cycle time

    Documentation/Plybooks are time consuming

    Lots of data to manage

    Cost (Raw Materials, Affordability)

    Lack of Concurrent Engineering

    Trial-and-Error in the Shop Floor

    Lots of tedious geometrical tasks

    Lack of Mock-up Integration

    No integration between Analysis and Design

    No Integration with highly specialized manufacturing applications

    Lack of ability to predict manufacturing issues upfront

    Hard to simulate the global applicationsHard to simulate the global behavior of the Part Environmental Issues ( Regulations,

    Biodegradability, Recyclability, etc)

  • Basic CATIA Composite Design Concepts4itemsingeneraldescribetheCompositeDesign

    1. Materials,alongwithneutralfiberdirection

    2. LayupSurface,alongwithdirection,therefore

    AssociatedRosette

    3. PlyBoundary

    4. PlyStackup

  • Material properties of a ply

    NCFNONCRIMPEDFABRIC

    NONSTRUCTURAL

    UNIDIRECTIONAL BIDIRECTIONAL UNDEFINED (Preassemblyofplies) (i.e.Peelplies)

    Uncured thickness

    CATIA V5 Material PropertiesUncuredthickness

    (beforepolymerization)Materialwidth

    Curedthickness(Finishedproduct)

    DEFORMATIONDEFORMATION(Duringdrapingoperations)

  • Group of plies

    TheRosette(oraxissystem)givesthereference for the fibers direction X axis is 0referenceforthefibersdirection.Xaxisis0 .

    CATIA V5 Plies Group

    DrapingDirectionindicateswhichdirectiontheplieswillbestacked

    Apliesgroupisusedtoorganizeagroupofplieslogically

    PliesGroup3

    PliesGroup1

    PliesGroup2

    CoreGroup

  • Sequence (Ply bookkeeping)

    Whencreatingaply(nextstep)inaplygroup,asequenceisautomaticallycreated.

    Themeaningofasequenceisthemanufacturingsequence.Itcontainsthepliesthatcanbelaidonthemoldduringthesamesequenceintheprocess.

    SEQ 3 Ply 3SEQ4,ply4and Ply5SEQ5,ply6SEQ6,ply7

    MOLDSEQ1,ply1SEQ2,Ply2SEQ3,Ply3

  • Ply Boundary

    Thecontourcanbe1geometry

    Thecontourcanbeasetofgeometries

    Multiplecontoursareallowedg y

    formingaclosedcontour

    gformingaclosedcontour(witha

    tolerance)

    CATIA V5 Ply CreationAlltheinformationrelativetotheplyarestoredandvisibleinthespecificationtree.

    y

  • Ply Stackup

    SettheorderoftheSequence/Plies Setthematerialsused Setthemainfibersorientations

    InteractivePlyTable ChangeSequence/PlyNames ChangeSequence/PlyOrder ChangeMaterialDefinition ChangeMaterialDirection

    CATIA V5 Ply Stackup CreationCATIA V5 Ply Stackup Creation

  • Composite Design Downstream Results

    Solid creation A Solid Body can be generated from

    the Composite DesignNumerical Analysis on Plies

    the Composite Design The Solid can be used for Form and

    Fit Checks

    Center of Gravity Analysis Mass Property Analysis Total Ply area coverageCATIA V5 Composite Results

    Core sample Core Sampling results in a Ply

    Table at a location IML Generation

    3D Section

    Done on Inspection locations Done on locations of interest

    Creates a Surface at top of plies Drop-offs and ramps are followed

    3D Section Cross Sections developed to

    understand Ply Stackup Drop-offs are shown Ramp sizes are controlled

    Plies Surfaces creation Top of Ply Surfaces can be exploded

  • Ply Creation Design Approaches

    i

    Surfacedesignandcontourspreperation

    TRANSITIONZONE1 ZONE2

    Zonescreation

    Stackup

    Zonescreation

    ZONE(TAPER)

    TransitionzonescreationManualpliescreation

    Stack up

    Fullplies&ETBS

    Stackup

    Final Plies

    ManualStaggering(LimitContours)

    StaggeringDatafile

    FinalPlies

    PlyTable

  • Ply Creation Design Approaches

    Grid Approach SolidSlicing ApproachExcelSheet Approach

    Predesign Detaileddesign

    Z1Z2

    Name Z1 Z2

    Section

    Name Z1 Z2

    Carbon0 2 2

    Kevlar0 2 0

  • Introduction to Composites, Analysis

  • SIMULIA for composites structures performances

    NEW

  • Basic CATIA Composite Analysis Concepts4itemsingeneraldescribetheCompositeAnalysisProcess

    1. Mesh,alongwithplyboundaryadherence

    2. Materials,alongwithneutralfiberdirection

    3. LoadsandBoundaryconditions

    4. SolvingandPostprocessing

  • CATIA Analysis / CATIA Composites integration

    CPDmodel:surface,plies BuildtheFEMbasedontheCATPartMeshandpropertiesimportedfromCPD

    Load,BCandSimulationP t iPostprocessing

    ModificationontheCPDmodelUpdateSimulation

  • MeshingNotransferofgeometry:CATIAAnalysisisCATIA!

    FMS Powerful QUAD Mesher with multiple algorithmsFMS:PowerfulQUADMesher withmultiplealgorithmsTopologysimplificationforcomplexgeometrySemiautomaticmesher withmeshmorphingcapability

    CATIA V5 MeshingConstrainthemeshontoCPDentities

    PliescontourGridPanelorZonescontour

    g

  • Material MappingAssociativeCPDdataimport

    PliesandCoreZonesZones

    Transfer producibility for simulation with true fiber direction

    CATIA V5 Material MappingTransferproducibility forsimulationwithtruefiberdirection

    Usefulespeciallyforcurvedsurfaceandforbeam(fibersalongseedcurve)

    Dedicatedpreprocessingvisualizationp p g

  • Loads and Boundary ConditionsRestraints

    UsedtofixDegreesofFreedomClamps fix all 6 degrees of Freedom

    CATIA V5 Loadsand BoundaryClampsfixall6degreesofFreedom

    LoadsUsed to apply forces to the model

    yConditions

    Used to apply forces to the modelImpose Displacement

  • Solver ELFINILinearSolverCATIAElfini simulatesComposites

    Assembleorthotropicpropertiesdefinedforeachmaterial

    Linear static analysisLinearstaticanalysisMechanicalloadTemperaturedistribution

    FrequencyBucklinganalysisg y

    AssemblyofAnalysisBondedparts

    C bi d iCombinedstaticcases

    ForexactsameFEA,resultsarethesameasSIMULIAAbaqus

    CATIA V5 Solving

    Linear static caseUniform pressurep

  • Post-ProcessingPlyperplyvisualization

    Dedicated Failure criteria for pliesDedicatedFailurecriteriaforpliesMaximumFailureTsaiHillH ffHoffmanTsaiWu

    E l i li th i f f il it i f ll f th liCATIA V5 Post-Processing

    Envelopecase:visualizethemaximumoffailurecriteriaforalloftheplies

  • Abaqus Composite Capabilities Today

    EASY composites modeling / meshing Linear static analysis evaluating ply-by-ply stresses Fracture / crack growth in composites

    Customerrequestedcompositecapabilities

    Fracture / crack growth in composites Delamination due to thermal loads Calculation of failure theories

    Tsai-Wu, Tsai-Hill, Max Strain, Max Stress VCCT analysis Interlaminar shear predictions Manufacturing simulation Calculation of flat patterns High speed / ballistic impact Draping analysis Draping analysis Buckling and post-buckled performance Macro-modeling capabilities Micro-modeling capabilities Crashworthiness of composites

    / Thru-thickness stress / strain plots BVID (Barely Visible Impact Damage) Visualization of ply stack-ups Interface with EXCEL for layup definitions User defined damage modeling User defined damage modeling Designer-centric composite modeling

  • Abaqus = Realistic Simulation of Composites

    Composites Pre / Post in Abaqus/CAE Crack propagation using VCCTCrack propagation using XFEM

    Draping in Abaqus/CAE

    Ballistic ImpactBallistic Impact

    C C h

    Delamination

    Composites Crush