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CATIA Composite Design, Analysis, and Manufacturing

Driving Innovation in the Automotive Industry Success Story: Terrafugia and the Transition Roadable Light Sport Aircraft ( (Date) ) Jason Curtis, Inceptra Rani Richardson, Dassault Systemes

Inceptra Helping engineering and manufacturing p solve mission critical business companies challenges since 1986.

The Portfolio of PLM Solutions

3D MCAD Virtual Product Virtual Testing Virtual Production PLM Collaboration Lifelike Experience

Aerospace Customers

Non Aerospace Customers

Automotive Shipbuilding

Wind Consulting Research

MaterialProviders

Inceptra Composite Customers

CAESCO

Introduction to Composites, Design

Composites
WhatisaComposite?
Twoormoreengineeredmaterialsas amatrixandreinforcement(can includeplywoodandconcrete) Thermoset (Irreversiblechemical reaction) Th Thermoplastic l ti ( (canbe b melted lt db byh heat t andcoolanynumberoftimes) Reinforcementfibers
Continuous/longfibers Shortfibers Sprayedfibers
ManualProcesses
Spray Layup Wet Layup Hand Layup Prep Layup

WhyuseComposites?
ReducedWeight Highstiffnessandhighstrength Highthermalresistance Highcorrosionresistance Goodfatiguelife
Wood

OrganicMatrixComposites Metallic Ceramic PolymerMatrixComposites(PMC) Matrix Matrix aka.FiberReinforcedPlastics(FRP) Composites Composites Thermoset Thermoplastic (MMC) (CMC)
Resin Resin

ContinuousFibers

ShortFibers

Particles

LiquidMoldingProcesses
RTM VARTM

Robotic Processes

Compression Molding
SMC BMC Hot Draping

AutomatedPlacement
Tape Fiber Filament Laying Placement Winding

RFI RIM Robotic (ResinFilm Pultrusion SCRIMP Preforming Infusion)

Typical Composites Challenges

Documentation/Plybooks Cost (Raw Materials, Affordability) are time consuming Long cycle time Lots of data to manage Lots of tedious geometrical tasks Lack of Mock-up Integration Lack of Concurrent Engineering Trial-and-Error in the Shop Floor

No integration between Analysis and Design Hard to simulate the global behavior of the Part

Lack of ability to predict manufacturing issues upfront

No Integration with highly specialized manufacturing applications Environmental Issues ( Regulations, Biodegradability, Recyclability, etc)

Basic CATIA Composite Design Concepts

4itemsingeneraldescribetheCompositeDesign 1. Materials,alongwithneutralfiberdirection 2. LayupSurface,alongwithdirection,therefore AssociatedRosette

3. PlyBoundary 4. PlyStackup

Material properties of a ply

UNIDIRECTIONAL

BIDIRECTIONAL

UNDEFINED

NCF NONCRIMPEDFABRIC (Preassemblyofplies)

NON STRUCTURAL (i.e.Peelplies)

CATIA V5 Material Properties

Uncuredthickness (beforepolymerization) Materialwidth

Curedthickness (Finishedproduct) DEFORMATION (Duringdrapingoperations)

Group of plies

TheRosette(oraxissystem)givesthe referenceforthefibersdirection. direction Xaxisis0 0.

CATIA V5 Plies Group

DrapingDirectionindicateswhich directiontheplieswillbestacked Apliesgroupisusedtoorganizea groupofplieslogically
PliesGroup3 PliesGroup2 PliesGroup1 CoreGroup

Sequence (Ply bookkeeping)

Whencreatingaply(nextstep)inaplygroup,a sequenceisautomaticallycreated.

Themeaningofasequenceisthemanufacturing sequence.Itcontainsthepliesthatcanbelaidonthe moldduringthesamesequenceintheprocess.

SEQ6,ply7 SEQ5,ply6 SEQ4,ply4and Ply5 SEQ3 3,Ply3 SEQ2,Ply2 SEQ1,ply1

MOLD

Ply Boundary

Thecontourcan be1g geometry y formingaclosed contour

Thecontourcanbe asetofg geometries formingaclosed contour(witha tolerance)

Multiplecontours areallowed

CATIA V5 Ply y Creation

Alltheinformationrelativetotheply arestoredandvisibleinthe specificationtree.

Ply Stackup
SettheorderoftheSequence/Plies Setthematerialsused Setthemainfibersorientations InteractivePlyTable ChangeSequence/PlyNames ChangeSequence/PlyOrder ChangeMaterialDefinition ChangeMaterialDirection

CATIA V5 Ply Stackup Creation

Composite Design Downstream Results

Solid creation
A Solid Body can be generated from the Composite Design The Solid can be used for Form and Fit Checks

Numerical Analysis on Plies

Center of Gravity Analysis Mass Property Analysis Total Ply area coverage

CATIA V5 Composite Results

Core sample
Core Sampling results in a Ply Table at a location Done on Inspection locations Done on locations of interest

IML Generation
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

Surfacedesignandcontourspreperation Zonescreation Zonescreation i

ZONE1

Manualpliescreation

TRANSITION ZONE (TAPER)

ZONE2

Stackup

Transitionzonescreation Fullplies&ETBS Stackup ManualStaggering (LimitContours) FinalPlies PlyTable Staggering Datafile

Ply Creation Design Approaches

ExcelSheet Approach Grid Approach SolidSlicing Approach

Predesign
Section

Detaileddesign

Z1
Name Carbon0 Kevlar0 Z1 2 2

Z2
Z2 2 0

Introduction to Composites, Analysis

SIMULIA for composites structures performances

NEW

Basic CATIA Composite Analysis Concepts

4itemsingeneraldescribetheCompositeAnalysisProcess 1. Mesh,alongwithplyboundaryadherence 2. Materials,alongwithneutralfiberdirection 3. LoadsandBoundaryconditions 4. SolvingandPostprocessing

CATIA Analysis / CATIA Composites integration

CPDmodel:surface,plies BuildtheFEMbasedontheCATPart MeshandpropertiesimportedfromCPD

Load,BCandSimulation P tprocessing Post i

ModificationontheCPDmodel UpdateSimulation

Meshing
Notransferofgeometry:CATIAAnalysisisCATIA! FMS FMS:PowerfulQUADMesher withmultiplealgorithms
Topologysimplificationforcomplexgeometry Semiautomaticmesher withmeshmorphingcapability

CATIA V5 Meshing g
ConstrainthemeshontoCPDentities
Pliescontour GridPanelorZonescontour

Material Mapping
AssociativeCPDdataimport
PliesandCore Zones

CATIA V5 Material Mapping

Transferproducibility forsimulationwithtruefiberdirection
Usefulespeciallyforcurvedsurfaceandforbeam(fibersalongseedcurve)

Dedicatedp prep processing gvisualization

Loads and Boundary Conditions

Restraints
UsedtofixDegreesofFreedom Clampsfixall6degreesofFreedom

CATIA V5 Loads and Boundary y Conditions

Loads
Used to apply forces to the model Impose Displacement

Solver ELFINI
LinearSolverCATIAElfini simulatesComposites
Assembleorthotropicpropertiesdefinedforeachmaterial Linearstaticanalysis
Mechanicalload Temperaturedistribution

Frequency Buckling ganalysis y

AssemblyofAnalysis
Bondedparts

C bi dstatic Combined i cases

CATIA V5 Solving

ForexactsameFEA,resultsarethesameasSIMULIAAbaqus

Linear static case Uniform pressure p

Post-Processing
Plyperplyvisualization DedicatedFailurecriteriaforplies MaximumFailure TsaiHill H ff Hoffman TsaiWu

CATIA V5 Post-Processing
E l Envelope case:visualize i li the th maximum i of ffailure f il criteria it i for f all llof fthe th plies li

Abaqus Composite Capabilities Today

Customerrequestedcompositecapabilities
EASY composites modeling / meshing Linear static analysis evaluating ply-by-ply stresses 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 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 Designer-centric composite modeling

Abaqus = Realistic Simulation of Composites

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

Draping in Abaqus/CAE Ballistic Impact Delamination

C Composites C Crush h

Introduction to CATIA Composites, Manufacturing

Basic CATIA Composite Manufacturing Concepts

4itemsingeneraldescribetheCompositeManufacturingProcess 1. PreparationofDesignModelforManufacturing 2. PlyProducibilityandFlatteningofPlies 3. ExportofFlattenedPlies 4. Plybook Creation

Composite Manufacturing Considerations

Whytocreateanewfilefor manufacturingpreparation?
Forphysicalreasons: manufacturedpliesarenot equaltoengineeringplies. Itallowsconcurrent engineeringbetween engineeringandmanufacturing preparation.
Totaldevelopmentcycletime

Springback/Warping

Engineering

Manufacturing

Noconcurrentengineering

Engineering

Excessofmaterialattheply boundaries

Manufacturing
Concurrentengineering

Timeearned

Manufacturingstrategies compliance(tapes,darts)

Preparation of Design Model for Mfg., Material Excess

Mainlyduetomanufacturingprocesses, themanufacturingcontoursaredifferentfromtheengineering contours.Thereisacompromisebetweenqualityandraw materialsconsumption.

Boundaries
Design ply p y Manuf. ply p y

Holes
Design ply Manuf. ply

Toavoid deformation,itis bettertocutthe holesaftercuring

Tokeepclean boundaries,itis mandatorytoadd anexcessof material.

CATIA V5 Material Excess

Specificmanufacturingprocess(i.e.tapes)
Manuf. f ply Design ply Manuf. ply

Complexboundaries

Design ply

Toavoid deformation,itis bettertocutafter curing

Toavoid triangulartapes, theboundaryis modified.

Ply Producibility

Theproducibilityanalysisisa simulation i l ti of fthe th fibers fib deformations d f ti on themoldedsurfaceduetotheshapeof thecompositepartandthedraping process Th seed The dpoint i tis i also l called ll d strategypoint .Itisthepointwhere theoperatorbeginstoplacetheply (thefirstcontactpointbetweentheply andthemold)

CATIA V5 Ply Producibility

Deformed weft Deformed warp

Ply Flattening
Atthisstep,itis possibletodisplay theflatpattern, pattern andcheckthe materialwidth.

CATIA V5 Flat Patterns

Theflattenplyiscomputedfromthefibersdeformationanalysis.Itinvolvesaflattencontour ysegments. g gmachine,becausethecutarenotonsmooth madeofmany Badnewsforcutting trajectories.Anautomaticsmoothofthecurvesisproposed. Theplypatternisassociativewithits3Ddefinition.

Export of Flattened Plies

Flatten export to DXF (IGES/XML)

t CATIA V5 DXF E Export

Nesting Software will nest plies to reduce scrap C tti paths Cutting th are developed from nest Labels are printed on cut plies Cut plies are put together in kits for shop floor

Plybook Creation

Tohelptheoperatorplacingthe pliesonthemold, mold adocument called PlyBook iscreated.

CATIA V5 Plybook Creation

Inmanycases,plies boundariesarealso projectedonthemold bylaserprojection.

Manufacturing Documentation with 3DVIA Composer

1. DirectimportofCATIACompositeInformation 2. PlyStackup structuremaintain,plynamingmaintained
3DVIA Composer Player ActiveX

MatureEcosystemofManufacturingSolutions
AutomatedTapeLaying
TORRESLAYUPV5
AIRBUSFrance, F FHI FHI,MHI

V5IntegratedSolution Interface

AIRBUS(UK,Spain,Germany),GKNAEROSPACE,SAAB,EADSMTACASA,SMIC,KAI,KHI,HARBINAVIC122

TAPEGENERATION+TAPEMANUFACTURING TapeLayingAdvancedCPSInterface ACEV2TapeLayingandFiberPlacementCompositeCAAV5Interface

AutomatedFiberPlacement
iCPSforDesigner+iCPSforNCProgrammer
InimplementationphaseatSpiritAerosystems,LockheedMartin,Goodrich,Aircelle

ACEV2TapeLayingandFiberPlacementCompositeCAAV5Interface TORFIBERDES+TORFIBERMAN
IntestatAIRBUSUK,GKNAEROSPACE

CATFiber ExportCAAV5Interface FPStandardCompositesDesign+FPVirtualProduction CompositesStrategyCAAV5based+ FiberLay +NCCompositesMachineSimulation

HandLay yUp p
TruLASERViewComposite+TLVLightViewComposite TruNESTCompositeCAAV5Interface PANOGENNesting SolutionforCompositesPartPrograming

RTM/VARTM,RFI
PAMRTMforCATIAV5

Advanced Fiber Modeler

AdvancedFiberModeler
Over15yearsoffibersimulationexperience FullyintegratedtoCATIAV5CPD

Multiple p MaterialModes
Flatteningalgorithmsandproducability foradvanced materialtypesandscenarios Biaxial,Uniaxial modes Isotropicmodesfor:
NonCrimpFabrics(NCF) ChoppedStrandMat(CSM) KnittedFabrics FoamCores LeatherandVinyl

AdvancedCapacities/Benefits
Geometrybasedproducabiliy independentofmeshsize Flatpatternboundaryresolutionindependentofdraping steplength Simulaterealworldwithseedcurvesandsequential draping(OOD)

TruLASER View Composites

CreateandmodifylaserprojectionprogramsdirectlyformCATIACPD Supportofalllaserprojectormanufacturers(Virtek,LAP,LPT,etc) Dynamicenvironmenttoproduceaccuratelaserprojectionprogramsinposition of fthe h ply l stacking. k Canproject3Dor2Dflatpatterngeometry. Allowsforopengeometry,text,workinstructionsthatmaynotbepartoftheCPD stacking. Extremelyaccurateandcustomizablesothatwhenlaserdataisdeliveredtothe shopitisrightthefirsttime.

CATIA V5 Laser Projection Creation

RTM/VARTM Analysis
1. IntegratedCATIACompositeInformation,nodatatransfer 2. Runswithinexistinganalysistools

Terrafugia, Transition Roadable Light Sport Aircraft Images and testimonial are provided courtesy of Terrafugia

Pic of balsa plane crushed by an FMVSS book

Summary

DS Integrated Solution for Composites innovation

DesigninAnalysiscontext
Assemblycontextmanaged intheanalysis

DesigninAssemblycontext

CPDcoreproduct

Enhancedplyfiber directiondrivenby analysis

Plymodificationdrivenby manufacturing,impacting assemblycontext

DesigninManufacturingcontext

Earlysimulationof manufprocess.

TOOSHORT FIBERS

Dedicatedply modificationfeatures

Mature Ecosystem of Manufacturing Solutions

Adv.Drapingprocesses

Functionaldesign

FiberPlacement

Nesting Cutting

Detaileddesign
LaserProjection System

Manufacturing preparation

TapeLaying

NEW
ManufacturingPlanning Anddocumentation

RTM

hersolvers

On behalf of the entire Inceptra North American Organization Thank You for your time. time
Jason.Curtis@Inceptra.com