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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
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Inceptra – Helping engineering and manufacturing companies solve mission critical business pchallenges since 1986.
The Portfolio of PLM Solutions
Virtual Production
VirtualTesting
Virtual Product
PLMCollaboration
Lifelike Experience
3DMCAD
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Aerospace Customers
Non Aerospace CustomersAutomotive ShipbuildingAutomotive Shipbuilding
Wind
Consulting Research
Wind
Material ProvidersMaterial Providers
Inceptra Composite Customers
CAESCOCAESCO
Introduction to Composites, Design
Composites
Why use Composites ?Reduced WeightHigh stiffness and high strength
What is a Composite ?Two or more engineered materials as a matrix and reinforcement (can High stiffness and high strength
High thermal resistanceHigh corrosion resistanceGood fatigue life
a matrix and reinforcement (can include plywood and concrete)Thermoset (Irreversible chemical reaction)Th l ti ( b lt d b h tThermoplastic (can be melted by heat and cool any number of times)Reinforcement fibers
Continuous/long fibers
Organic Matrix Composites Metallic Matrix
Composites (MMC)
Ceramic Matrix
Composites (CMC)
Wood
Polymer Matrix Composites (PMC) aka. Fiber Reinforced Plastics (FRP)
Thermoset Resin
Thermoplastic Resin
Continuous Fibers Short Fibers Particles
Short fibersSprayed fibers
Manual Processes Liquid Molding Processes Robotic Compression Automated PlacementManual Processes Liquid Molding Processes Processes Molding Automated Placement
Spray Lay‐up
Wet Layup
HandLayup
Prep Layup
RTMVARTM
RFI(Resin Film Infusion)
RIMSCRIMP Pultrusion Robotic
PreformingSMCBMC
Hot Draping
Tape Laying
Fiber Placement
Filament Winding
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 Concepts4 items in general describe the Composite Design
1. Materials, along with neutral fiber direction
2. Layup Surface, along with direction, therefore
• Associated Rosette
3. Ply Boundary
4. Ply Stackup
Material properties of a ply
NCFNON CRIMPED FABRIC
NON STRUCTURAL
UNI DIRECTIONAL BI DIRECTIONAL UNDEFINED (Pre‐assembly of plies) (i.e. Peel plies)
Uncured thickness
CATIA V5 Material PropertiesUncured thickness
(before polymerization)Material width
Cured thickness(Finished product)
DEFORMATIONDEFORMATION(During draping operations)
Group of plies
‐ The Rosette (or axis system) gives the reference for the fibers direction X axis is 0°reference for the fibers direction. X axis is 0 .
CATIA V5 Plies Group
Draping Direction indicates which direction the plies will be stacked
A plies group is used to organize a group of plies logically
Plies Group 3
Plies Group 1
Plies Group 2
Core Group
Sequence (Ply bookkeeping)
When creating a ply (next step) in a ply group, a sequence is automatically created.
The meaning of a sequence is the manufacturing sequence. It contains the plies that can be laid on the mold during the same sequence in the process.
SEQ 3 Ply 3SEQ 4, ply 4 and Ply 5SEQ 5, ply 6SEQ 6, ply 7
MOLDSEQ 1, ply 1SEQ 2, Ply 2SEQ 3, Ply 3
Ply Boundary
The contour can be 1 geometry
The contour can be a set of geometries
Multiple contours are allowedg y
forming a closed contour
gforming a closed contour (with a
tolerance)
CATIA V5 Ply CreationAll the information relative to the ply are stored and visible in the specification tree.
y
Ply Stackup
‐ Set the order of the Sequence/Plies‐ Set the materials used‐ Set the main fibers orientations
Interactive Ply Table‐ Change Sequence/Ply Names‐ Change Sequence/Ply Order‐ Change Material Definition‐ Change Material Direction
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
Surface design and contours preperation
TRANSITIONZONE 1 ZONE 2
Zones creation
Stack‐up
Zones creation
ZONE(TAPER)
Transition zones creationManual plies creation
Stack up
Full plies & ETBS
Stack‐up
Final Plies
Manual Staggering(Limit Contours)
StaggeringData file
Final Plies
Ply Table
Ply Creation Design Approaches
Grid Approach Solid Slicing ApproachExcel Sheet Approach
Pre‐design Detailed design
Z1Z2
Name Z1 Z2
Section
Name Z1 Z2
Carbon 0° 2 2
Kevlar 0° 2 0
Introduction to Composites, Analysis
SIMULIA for composites structures performances
NEW
Basic CATIA Composite Analysis Concepts4 items in general describe the Composite Analysis Process
1. Mesh, along with ply boundary adherence
2. Materials, along with neutral fiber direction
3. Loads and Boundary conditions
4. Solving and Post‐processing
CATIA Analysis / CATIA Composites integration
CPD model: surface, plies… Build the FEM based on the CATPartMesh and properties imported from CPD
Load, BC and Simulation P t iPost processing
Modification on the CPD modelUpdate Simulation
MeshingNo transfer of geometry : CATIA Analysis is CATIA !
FMS Powerful QUAD Mesher with multiple algorithmsFMS: Powerful QUAD Mesher with multiple algorithmsTopology simplification for complex geometrySemi‐automatic mesher with mesh morphing capability
CATIA V5 MeshingConstrain the mesh onto CPD entities
Plies contourGrid Panel or Zones contour
g
Material MappingAssociative CPD data import
Plies and CoreZonesZones
Transfer producibility for simulation with true fiber direction
CATIA V5 Material MappingTransfer producibility for simulation with true fiber direction
Useful especially for curved surface and for beam (fibers along seed curve)
Dedicated pre processing visualization p p g
Loads and Boundary ConditionsRestraints
Used to fix Degrees of FreedomClamps fix all 6 degrees of Freedom
CATIA V5 Loadsand BoundaryClamps fix all 6 degrees of Freedom
LoadsUsed to apply forces to the model
yConditions
Used to apply forces to the modelImpose Displacement
Solver ELFINILinear Solver CATIA Elfini simulates Composites
Assemble orthotropic properties defined for each material
Linear static analysisLinear static analysis Mechanical loadTemperature distribution
FrequencyBuckling analysisg y
Assembly of AnalysisBonded parts
C bi d iCombined static cases
For exact same FEA, results are the same as SIMULIA Abaqus
CATIA V5 Solving
Linear static caseUniform pressurep
Post-ProcessingPly per ply visualization
Dedicated Failure criteria for pliesDedicated Failure criteria for pliesMaximum FailureTsai‐HillH ffHoffmanTsai‐Wu
E l i li th i f f il it i f ll f th liCATIA V5 Post-Processing
Envelope case: visualize the maximum of failure criteria for all of the plies
Abaqus Composite Capabilities Today
EASY composites modeling / meshing Linear static analysis evaluating ply-by-ply stresses Fracture / crack growth in composites
• Customer requested composite capabilities
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
Introduction to CATIA Composites, Manufacturing
Basic CATIA Composite Manufacturing Concepts4 items in general describe the Composite Manufacturing Process
1. Preparation of Design Model for Manufacturing
2. Ply Producibility and Flattening of Plies
3. Export of Flattened Plies
4. Plybook Creation
Composite Manufacturing Considerations
Why to create a new file for manufacturing preparation?
It allows concurrentFor physical reasons: manufactured plies are not equal to engineering plies.
It allows concurrent engineering between engineering and manufacturing preparation.
Spring back/Warping
Total development cycle time
Engineering Manufacturing
Excess of material at the ply Engineering
No concurrent engineering
boundaries Manufacturing
Concurrent engineering
Time earned
Manufacturing strategies compliance (tapes, darts…)
Preparation of Design Model for Mfg., Material ExcessBoundariesMainly due to manufacturing processes,
the manufacturing contours are different from the engineering contours . There is a compromise between quality and raw materials consumption.
Designply
Manuf.ply
Holes
To keep clean Designply
Manuf.ply
p y p y
To avoid deformation, it is better to cut the
boundaries, it is mandatory to add an excess of material.
CATIA V5 Material ExcessComplex boundariesholes after curing
Specific manufacturing process (i.e. tapes)
f
CATIA V5 Material Excess
Designply
Designply
Manuf.ply
Manuf.ply
To avoid triangular tapes, the boundary is modified.
To avoid deformation, it is better to cut after curing
Ply Producibility
The “producibility” analysis is a i l ti f th fib d f tisimulation of the fibers deformations on the molded surface due to the shape of the composite part and the draping process
Th d i t i l ll dThe seed point is also called « strategy point ». It is the point where the operator begins to place the ply (the first contact point between the ply and the mold)and the mold)
Deformed weft
CATIA V5 Ply Producibility
Deformedwarp
Ply Flattening
At this step, it is possible to display the flat patternthe flat pattern, and check the material width.
CATIA V5 Flat Patterns
The flatten ply is computed from the fibers deformation analysis. It involves a flatten contour made of many segments. Bad news for cutting machine, because the cut are not on smooth y g gtrajectories. An automatic smooth of the curves is proposed.
The ply pattern is associative with its 3D definition.
Export of Flattened Plies
Flatten export to DXF (IGES/XML)
CATIA V5 DXF E t• Nesting Software will nest
plies to reduce scrapC tti th
CATIA V5 DXF Export
• Cutting paths are developed from nest
• Labels are printed on cut pliesplies
• Cut plies are put together in kits for shop floor
Plybook Creation
To help the operator placing the plies on the mold a documentplies on the mold, a document called « Ply Book » is created.
CATIA V5 Plybook Creation
In many cases, plies boundaries are also projected on the moldprojected on the mold by laser projection.
Manufacturing Documentation with 3DVIA Composer
1. Direct import of CATIA Composite Information
2. Ply Stackup structure maintain, ply naming maintained3DVIA Composer Player ActiveX
Mature Ecosystem of Manufacturing Solutions
Automated Tape LayingTORRES LAYUP V5
AIRBUS (UK, Spain, Germany), GKN AEROSPACE, SAAB, EADS MTA CASA, SMIC, KAI, KHI, HARBIN AVIC 122
TAPE GENERATION+TAPE MANUFACTURINGAIRBUS F FHI MHI
V5 Integrated Solution Interface
AIRBUS France, FHI, MHI
Tape Laying Advanced CPS Interface
ACE V2 Tape Laying and Fiber Placement Composite CAA V5 Interface
Automated Fiber PlacementAutomated Fiber PlacementiCPS for Designer + iCPS for NC Programmer
In implementation phase at Spirit Aerosystems, Lockheed Martin, Goodrich, Aircelle
ACE V2 Tape Laying and Fiber Placement Composite CAA V5 InterfaceTORFIBERDES +TORFIBERMAN
In test at AIRBUS UK, GKN AEROSPACE
CATFiber Export CAA V5 InterfaceFP Standard Composites Design + FP Virtual ProductionComposites Strategy CAA V5 based + FiberLay + NC Composites Machine Simulation
Hand Lay‐Upy pTruLASER View Composite + TLV Light View CompositeTruNEST Composite CAA V5 InterfacePANOGEN Nesting Solution for Composites Part Programing
RTM / VARTM, RFIPAM‐RTM for CATIA V5
Advanced Fiber ModelerAdvanced Fiber Modeler
Over 15 years of fiber simulation experienceFully integrated to CATIA V5 CPD
Multiple Material ModespFlattening algorithms and producability for advanced
material types and scenariosBiaxial, Uniaxial modesIsotropic modes for:
Non‐Crimp Fabrics (NCF)Chopped Strand Mat (CSM)Knitted FabricsFoam CoresLeather and Vinyl
Advanced Capacities / BenefitsAdvanced Capacities / BenefitsGeometry based producabiliy independent of mesh sizeFlat pattern boundary resolution independent of draping
step lengthSimulate real‐world with seed curves and sequential
draping (OOD)
TruLASER View Composites
Create and modify laser projection programs directly form CATIA CPD
Support of all laser projector manufacturers (Virtek, LAP, LPT, etc)
Dynamic environment to produce accurate laser projection programs “in position” f h l kof the ply stacking.
Can project 3D or 2D flat pattern geometry.
Allows for open geometry, text, work instructions that may not be part of the CPD stacking. CATIA V5 Laser Projection Creation
Extremely accurate and customizable so that when laser data is delivered to the shop it is right the first time.
CATIA V5 Laser Projection Creation
RTM/VARTM Analysis 1. Integrated CATIA Composite Information, no data transfer2. Runs within existing analysis tools
Terrafugia, Transition® Roadable Light Sport AircraftImages and testimonial are provided courtesy of TerrafugiaImages and testimonial are provided courtesy of Terrafugia
Pic of balsa plane crushed by an FMVSS book
Summary
DS Integrated Solution for Composites innovation
Assembly context managed in the analysis
Design in Assembly contextDesign in Analysis context
CPD core product
Ply modification driven by manufacturing, impacting
assembly context
Enhanced ply fiber direction driven by
analysis
Design in Manufacturing context
Early simulation of manuf process.
Dedicated ply modification featuresTOO SHORT
FIBERS
Mature Ecosystem of Manufacturing SolutionsAdv. Draping processes
FiberPlacementFunctional design
Nesting Cutting
Laser ProjectionSystem
Tape Laying Detailed design
Manufacturingpreparation
NEW
RTM
Manufacturing PlanningAnd documentation
NEW
her solvers
On behalf of the entire Inceptra North American Organization – Thank You for your timeOrganization – Thank You for your time.
