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CATIA Composite Design, Analysis, and Manufacturing

Success Story: Terrafugia and the Transition Roadable Light Sport Aircraft

(Date)

J ason Curtis, Inceptra

Rani Richardson, Dassault Systemes

1

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Inceptra Helping engineering and manufacturingcom anies solve mission critical businesschallenges since 1986.

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The Portfolio of PLM Solutions

VirtualProduction

Virtual

Testing

VirtualProduct

PLM

Collaboration

LifelikeExperience

3D

MCAD

3

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Aerospace Customers

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Non Aerospace Customers

Consulting Research

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Inceptra Composite Customers

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Introduction to Composites, Design

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Composites

WhyuseComposites?ReducedWeight

Hi h stiffness and hi h stren th

WhatisaComposite?Twoormoreengineeredmaterialsas

a matrix and reinforcement can

Highthermalresistance

Highcorrosionresistance

Goodfatiguelife

includeplywoodandconcrete)

Thermoset (Irreversiblechemical

reaction)

ermop ast c can eme te y eat

andcoolanynumberoftimes)

ReinforcementfibersContinuous/longfibers

OrganicMatrixCompositesMetallic

Matrix

Composites

(MMC)

Ceramic

Matrix

Composites

(CMC)

Wood

Polymer MatrixComposites(PMC)

aka.FiberReinforcedPlastics(FRP)

Thermoset

Resin

Thermoplastic

Resin

ContinuousFibers ShortFibers Particles

Shortfibers

Sprayedfibers

Robotic Compression

Processes Molding

Spray

Layup

Wet

Layup

Hand

Layup

Prep

Layup

RTM

VARTM

RFI

(ResinFilm

Infusion)

RIM

SCRIMPPultrusion

Robotic

Preforming

SMC

BMC

Hot

Draping

Tape

Laying

Fiber

Placement

Filament

Winding

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Typical Composites Challenges

Long cycle time

Documentation/Plybooks

are time consuming

Lots of data to manage

Cost (Raw Materials, Affordability)

Lack of ConcurrentEngineering

Trial-and-Error inthe Shop Floor

Lots of tediousgeometrical tasks

Lack of Mock-upIntegration

No integration between

Analysis and DesignNo Integration with highly

specialized manufacturing

Lack of ability to predict

manufacturing issues upfront

behavior of the Part Environmental Issues ( Regulations,

Biodegradability, Recyclabil ity, etc)

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Basic CATIA Composite Design Concepts

4itemsingeneraldescribetheCompositeDesign

1. Materials,alongwithneutralfiberdirection

2. LayupSurface,

along

with

direction,

therefore

AssociatedRosette

3. PlyBoundary

4. PlyStackup

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Material properties of a ply

NCF

NONCRIMPEDFABRIC

NON

STRUCTURAL

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

Uncured thickness CATIA V5 Material Properties(beforepolymerization)

Materialwidth

Curedthickness

(Finishedproduct)

(Duringdrapingoperations)

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Group of plies

TheRosette(oraxissystem)givesthe

. .

CATIA V5 Plies Group

DrapingDirectionindicateswhich

directiontheplieswillbestacked

Apliesgroupisusedtoorganizea

groupofplieslogically

PliesGroup3

PliesGroup1

PliesGroup2

CoreGroup

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Sequence (Ply bookkeeping)

Whencreatingaply(nextstep)inaplygroup,a

sequenceisautomaticallycreated.

Themeaningofasequenceisthemanufacturing

sequence.Itcontainsthepliesthatcanbelaidonthe

moldduring

the

same

sequence

in

the

process.

SEQ4,ply4and Ply5SEQ5,ply6

SEQ6,ply7

MOLD

SEQ1,ply1SEQ

2,

Ply

2

,

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Ply Boundary

Thecontourcan

be1geometry

Thecontourcanbe

asetofgeometries

Multiplecontours

areallowed

formingaclosed

contour

formingaclosed

contour (witha

tolerance)

CATIA V5 Pl CreationAlltheinformationrelativetotheply

arestoredandvisibleinthe

specificationtree.

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Ply Stackup

SettheorderoftheSequence/Plies

Setthematerialsused

Setthemainfibersorientations

InteractivePlyTable

ChangeSequence/PlyNames

ChangeSequence/PlyOrder

ChangeMaterialDefinition

Change

Material

Direction

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Composite Design Downstream Results

Solid creation A Solid Body can be generated from Numerical Analysis on Plies

The Solid can be used for Form andFit Checks

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 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

Cross Sections developed tounderstand Ply Stackup

Drop-offs are shown

Ramp sizes are controlled

Plies Surfaces creation Top of Ply Surfaces can be exploded

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Ply Creation Design Approaches

Surfacedesignandcontourspreperation

TRANSITIONZONE1 ZONE2

Zonescreation

Zonescreation

ZONE

(TAPER)

TransitionzonescreationManualpliescreation

Fullplies

&

ETBS

Stackup

ManualStaggering

(LimitContours)Staggering

Datafile

PlyTable

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Ply Creation Design Approaches

Grid Approach SolidSlicing ApproachExcelSheet Approach

Predesign Detaileddesign

Z1Z2Se

ction

Carbon0 2 2

Kevlar0 2 0

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Introduction to Composites, Analysis

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SIMULIA for composites structures performances

NEW

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Basic CATIA Composite Analysis Concepts

4itemsingeneraldescribetheCompositeAnalysisProcess

1. Mesh,alongwithplyboundaryadherence

2. Materials,along

with

neutral

fiber

direction

3. LoadsandBoundaryconditions

4. SolvingandPostprocessing

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CATIA Analysis / CATIA Composites integration

CPDmodel:surface,plies BuildtheFEMbasedontheCATPart

MeshandpropertiesimportedfromCPD

Load,BC

and

Simulation

os process ng

ModificationontheCPDmodel

UpdateSimulation

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Meshing

Notransferofgeometry:CATIAAnalysisisCATIA!

: ow u w u o

Topology

simplification

for

complex

geometrySemiautomaticmesher withmeshmorphingcapability

CATIA V5 MeshinConstrainthemeshontoCPDentities

Pliescontour

Grid

Panel

or

Zones

contour

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Material Mapping

AssociativeCPDdataimport

PliesandCore

CATIA V5 Material Mapping

Usefulespeciallyforcurvedsurfaceandforbeam(fibersalongseedcurve)

Dedicated

re

rocessin

visualization

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Loads and Boundary Condit ions

Restraints

UsedtofixDegreesofFreedomCATIA V5 Loads

and Boundar

LoadsUsed to a l forces to the model

Conditions

Impose Displacement

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Solver ELFINILinearSolverCATIAElfini simulatesComposites

Assembleorthotropicpropertiesdefinedforeachmaterial

Mechanicalload

Temperaturedistribution

Frequency

Bucklinganalysis

AssemblyofAnalysis

Bondedparts

Com ine staticcases

ForexactsameFEA,resultsarethesameasSIMULIAAbaqus

CATIA V5 Solving

Linear static caseUniform ressure

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Post-Processing

Plyperplyvisualization

u o

MaximumFailure

TsaiHill

o man

TsaiWu

CATIA V5 Post-Processingnve opecase:v sua ze emax mumo a urecr er a ora o ep es

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Abaqus Composite Capabilities Today

EASY composites modeling / meshing

Linear static analysis evaluating ply-by-ply stresses

Customerrequestedcompositecapabilities

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

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 defineddama e modelin

Designer-centric composite modeling

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Abaqus = Realistic Simulation of Composites

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

Draping in Abaqus/CAE

Delamination

omposites rus

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Introduction to CATIA Composites, Manufacturing

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Basic CATIA Composite Manufacturing Concepts

4itemsingeneraldescribetheCompositeManufacturingProcess

1. PreparationofDesignModelforManufacturing

2. Ply

Producibility

and

Flattening

of

Plies

3. ExportofFlattenedPlies

4. Plybook Creation

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Composite Manufacturing Considerations

Whytocreateanewfilefor

manufacturingpreparation?

Forphysicalreasons:

manufactured

plies

are

not

equaltoengineeringplies.

engineeringbetween

engineeringand

manufacturing

preparation.

Springback/Warping

Totaldevelopmentcycletime

Engineering Manufacturing

ExcessofmaterialattheplyEngineering

Noconcurrentengineering

boundariesManufacturing

Concurrentengineering

Timeearned

Manufacturingstrategies

compliance(tapes,darts)

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Ply Producibility

Theproducibilityanalysisisa

s mu a ono e ers e orma onson

themoldedsurfaceduetotheshapeof

thecomposite

part

and

the

draping

process

esee po n sa soca e

strategypoint .Itisthepointwhere

theoperatorbeginstoplacetheply

(thefirst

contact

point

between

the

ply

an emo

Deformed

weft

CATIA V5 Ply Producibility

Deformed

warp

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Ply Flattening

Atthisstep,itis

possibletodisplay

,

andcheckthe

materialwidth.

CATIA V5 Flat Patterns

Theflattenplyiscomputedfromthefibersdeformationanalysis.Itinvolvesaflattencontour

madeofmanysegments.Badnewsforcuttingmachine,becausethecutarenotonsmooth

trajectories.Anautomaticsmoothofthecurvesisproposed.

Theply

pattern

is

associative

with

its

3D

definition.

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Export of Flattened Plies

Flatten export to DXF(IGES/XML)

Nesting Software will nestplies to reduce scrap

CATIA V5 DXF Export

u ng pa s aredeveloped from nest

Labels are printed on cut

Cut plies are put together inkits for shop floor

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Plybook Creation

Tohelptheoperatorplacingthe

,

called PlyBook iscreated.

CATIA V5 Plybook Creation

Inmanycases,plies

boundariesarealso

bylaser

projection.

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Manufacturing Documentation with 3DVIA Composer

1. DirectimportofCATIACompositeInformation

2. PlyStackup structuremaintain,plynamingmaintained3DVIA Composer Player ActiveX

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MatureEcosystemofManufacturingSolutions

AutomatedTapeLaying

TORRESLAYUPV5AIRBUS(UK,Spain,Germany),GKNAEROSPACE,SAAB,EADSMTACASA,SMIC,KAI,KHI,HARBINAVIC122

TAPEGENERATION+TAPEMANUFACTURING

V5IntegratedSolution

Interface

rance, ,

TapeLayingAdvancedCPSInterfaceACEV2TapeLayingandFiberPlacementCompositeCAAV5Interface

iCPSforDesigner+iCPSforNCProgrammerInimplementationphaseatSpiritAerosystems,LockheedMartin,Goodrich,Aircelle

ACEV2TapeLayingandFiberPlacementCompositeCAAV5InterfaceTORFIBERDES+TORFIBERMAN

Intest

at

AIRBUS

UK,

GKN

AEROSPACE

CATFiber ExportCAAV5InterfaceFPStandardCompositesDesign+FPVirtualProduction

CompositesStrategyCAAV5based+ FiberLay +NCCompositesMachineSimulation

HandLa UTruLASERViewComposite+TLVLightViewComposite

TruNESTCompositeCAAV5InterfacePANOGENNesting SolutionforCompositesPartPrograming

RTM/VARTM,RFIPAMRTMforCATIAV5

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Advanced Fiber Modeler

AdvancedFiberModeler

Over15yearsoffibersimulationexperience

FullyintegratedtoCATIAV5CPD

MultipleMaterialModes

Flatteningalgorithmsandproducability foradvancedmaterialtypesandscenarios

Biaxial,Uniaxial modes

Isotropicmodesfor:

NonCrimpFabrics(NCF)

ChoppedStrandMat(CSM)

KnittedFabrics

FoamCores

LeatherandVinyl

Geometrybasedproducabiliy independentofmeshsize

Flatpatternboundaryresolutionindependentofdrapingsteplength

Simulaterealworldwithseedcurvesandsequentialdraping(OOD)

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TruLASER View Composites

CreateandmodifylaserprojectionprogramsdirectlyformCATIACPD

Supportofalllaserprojectormanufacturers(Virtek,LAP,LPT,etc)

Dynamicenvironmenttoproduceaccuratelaserprojectionprogramsinposition

oftheplystacking.

Canproject3Dor2Dflatpatterngeometry.

Allowsforopengeometry,text,workinstructionsthatmaynotbepartoftheCPD

stacking.

Extremelyaccurateandcustomizablesothatwhenlaserdataisdeliveredtothe

shopitisrightthefirsttime.

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RTM/VARTM Analysis

1. IntegratedCATIACompositeInformation,nodatatransfer

2. Runswithinexistinganalysistools

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Terrafugia, Transit ion Roadable Light Sport Aircraft

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Pic of balsa plane crushed by an FMVSS book

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Summary

DS Integrated Solution for Composites innovation

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g p

Assemblycontextmanaged

intheanalysis

DesigninAssemblycontextDesigninAnalysiscontext

CPDcoreproduct

Plymodificationdrivenby

manufacturing,impacting

assemblycontext

Enhancedplyfiber

directiondrivenby

analysis

Designin

Manufacturing

context

Earlysimulation

of

manufprocess.

Dedicated

ply

modificationfeaturesTOOSHORTFIBERS

Mature Ecosystem of Manufacturing Solutions

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y g

Adv.Drapingprocesses

FiberPlacementFunctionaldesign

Nesting

Cutting

LaserProjection

System

TapeLaying

DetaileddesignManufacturing

preparation

RTM

Manufacturing

PlanningAnddocumentation

ersolvers

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On behalf of the entire Inceptra North American

.

Jason.Curtis@Inceptra.com