Product Lifecycle Management

CATIA

© 2006 IBM Corporation

Composites Part Design
to Manufacturing Process

Technical Overview
Presentation

Tim Greenwood
 Product Lifecycle Management

Usual Challenges of Composites

Cost (Raw Materials, Affordability)
Long cycle time
Lots of data to manage

Lots of tedious Lack of Mock-up Lack of Concurrent Trial-and-Error in

geometrical tasks Integration Engineering the Shop Floor

© 2006 IBM Corporation

No integration between Lack of ability to predict No Integration with highly
Analysis and Design manufacturing issues upfront specialized manufacturing
applications
Hard to simulate the global
behavior of the Part Environmental Issues ( Regulations,
Biodegradability, Recyclability, etc…)
2
 Product Lifecycle Management

CATIA PLM V5 Composites Solutions

End-to-end Composites Solution to address Industry challenges
– Native V5 Composites Solution from Design to Analysis and Manufacturing
– Feature-based, specification-driven, dedicated Solution integrated to CATIA V5

© 2006 IBM Corporation

3
 Product Lifecycle Management

CATIA Composites

Modular and flexible packaging :
– A “all-in-one” CATIA Composites configuration (CD3) including a full mechanical seat plus
the CATIA Composites Part Design to Manufacturing (CPD) product
– To respond to specific roles, two subset Composites products, CATIA Composites
Engineering (CPE) and CATIA Composites Manufacturing (CPM)

© 2006 IBM Corporation

CPD scope: all in one
solution for composite
design

CATIA Composites Engineering 2 dedicated CATIA Composites Design for

to preliminary and engineering detailed design Manufacturing 2 dedicated to
manufacturing preparation

4
 Product Lifecycle Management

CATIA - Composites Engineering (CPE)

Productive process oriented environment dedicated from preliminary to
engineering detailed design of composite parts

Benefits
• Fully integrated in the V5 environment
• Shortened part composite part design time period (up
to ten times faster)
• Fast plies generation from zones (automatic

© 2006 IBM Corporation

management of the ply staggering and stacking rules) Developed in partnership
• Design right first time by taking into account with industry leaders
manufacturing constraints early in the design phase
• Easy concurrent work thanks to true collaborative
composites engineering environment

Capabilities
• Easy to use zone (geometry and laminate) and transition
zones modeling definition
• Powerful ply modeling tools based on 3D features
• Complex geometrical configuration support
• Solid generation from zones and plies (exact solid)
• Complete composites inspection tools (core sample and
numerical analysis, ply table..)
• Best-in-class fiber simulation tools for early
manufacturability assessment
• Easy know-how and composites design features
sharing and merging

5
 Product Lifecycle Management

CATIA - Composites Manufacturing (CPM)

Productive process oriented environment dedicated to manufacturing detailed
design of composite parts

Benefits
• Fully integrated in the V5 environment One system to cover overall composite manufacturing along
• Design right first time by taking into account manufacturing with DS leading partners
constraints early in the design phase

© 2006 IBM Corporation

• Easy collaboration between design and manufacturing
offices enabling concurrent engineering
• Strong manufacturing partnerships ensure that composites
solution can be used by any company, regardless of the
manufacturing process and machine providers

Capabilities
• Dedicated manufacturing part modeling capabilities such
as manufacturing shell swapping, material excess definition
and 3D multi-splice
• Best-in-class fiber simulation and flattening tools for early
assessment of manufacturability
• Effective manufacturing export capabilities and automatic
shop floor documentation
• Powerful synchronization/collaboration mechanisms with
engineering detailed design

6
 Product Lifecycle Management

CATIA PLM V5 Composites Solutions (2)

CAA V5 Market-leading Partners Expertise to complement the V5 Composites
Offering
– Hand Lay-up Solution : Advanced Fiber Modeler (Simulayt), Quickform (ESI), TruLaserView (Magestic), TruNest (Magestic),
Composite Link (Simulayt)
– RTM Solution : PAM-RTM (ESI Group)
– Tape Laying / Fiber Placement Solution : Torlay (Mtorres), Tapelay (CIMPA), iCPS (Ingersoll), ACE V2 (Cincinnati)

© 2006 IBM Corporation

7
 Product Lifecycle Management

Improve Productivity
Composites Design Tasks Composites Manufacturing Tasks

Preliminary design Early Conceptual modeling of Composites Parts
Dedicated Composite Data Structure

Engineering detailed Specification-driven, feature-based Design Solution
design
Automatic plies definition from zones

© 2006 IBM Corporation

Manufacturing Solid and IML generation from zones & plies
preparation
Compliance with MBD and Engineering drawings

Full Associativity for quick Design Change

Downstream
Manufacturing Concurrent engineering between Design & Mfg

Feature-based Manufacturing Solution

Reliable Fiber simulation and flat patterns

Automatic shopfloor documentation

Integration to Shopfloor systems

Productivity Gain

8
 Product Lifecycle Management

Facilitate Innovation

Eliminate basic repetitive design work to focus more on
innovation
– Specification-driven process and feature-based approach
help reduce tedious tasks

– Add knowledge-based engineering to your design to

capitalize on your know-how : Design rules and checks,

© 2006 IBM Corporation

parameters and formulas, Design optimization,…

– Capture your design intent into Automation Templates and

reuse this knowledge across the families of parts or features:
User Defined Features, Powercopy, Part Templates,…

– Benefit from the openness of the Composites architecture

to further customize the process (CAA V5, VB)

9
 Product Lifecycle Management

Ensure Manufacturability, Quality

Eliminate the Trial & Error and costly change orders
– Early incorporation of Manufacturing constraints

– Upfront Simulation of Manufacturing Procedures (Lay-up, Laser Projection, NC, Resin Injection …)

– Direct Integration with the Shop Floor systems

© 2006 IBM Corporation

Optimize Parts Quality
– Full associativity from Design to Manufacturing ensures data consistency

– Integrated FEA properties transfer helps avoid errors and shortens optimization cycles to eliminate overdesign

– Reliable Producibility Analysis and Flat Patterns Generation significantly reduce material waste

10
 Product Lifecycle Management

CATIA - Composites Design (CPE)

Preliminary Design

Key Features :
– Composite Parameters definition : V5 Catalog of Composite materials, Fiber Directions
– Zones definition : Structural Zones Geometry, Laminate Import, Transition Zones definition for
drop-off areas
– Design Checks : Connection Generator
– Solid & Top Surface from Zones

© 2006 IBM Corporation

Key Benefits :
Material
S1454_G900
S1454_G900
Orientation
0
45
Z1-1
3
1
Z2-1
1
1
Z3-1
1
1
Z4-1
1
1
Z5-1
1
1
Z6-1
1
1
Z7-1
1
1
Z8-1
1
0
– Conceptual Definition very early in the lifecycle of the program U174_T900 90 0 0 0 0 0 0 0 0
Adhesive 0 0 1 0 1 0 1 0 0
– IML generation for concurrent Engineering on sub-structures
– Ability to generate intermediate surfaces needed as support for further tasks (ex : core creation for
core stiffened panel)
– Solid generation for DMU, FTA, Drafting purpose
– Link the Composite Design to FEA at the Preliminary Design stage

11
 Product Lifecycle Management

CATIA - Composites Design (CPE)

From Conceptual to Detailed Design

Key Features : Sequence
Sequence 1
Ply
Ply 1
Geo-Lvl
32
Material
GLASS
Zone 1
0
Zone 2
0
– Stack-up file export : Stacking Order optimization, Logical zones combinations Sequence 2 Ply 2 15 GLASS 90 90
Sequence 3 Ply 3 34 GLASS 45 45
– Plies creation from Zones with Tapers : Direct Staggered definition Sequence 4 Ply 4 23 GLASS -45 -45
Sequence 5 Ply 5 14 GLASS 90 90
– Plies with Staggering value : Assisted staggering of Plies, Staggering Report, Dedicated Sequence 6 Ply 6 16 GLASS 0 0
Sequence 7 Ply 7 27 GLASS 45 45
features, Variable drop-off, Plies Crossing Sequence 8 Ply 8 22 GLASS -45 -45
Sequence 9 Ply 9 5 GLASS 0 0
Sequence 10 Ply 10 13 GLASS 90 90
Sequence 11 Ply 11 26 GLASS 45 45

© 2006 IBM Corporation

Key Benefits : Sequence 12
Sequence 13
Sequence 14
Ply 12
Ply 13
Ply 14
24
10
31
GLASS
GLASS
GLASS
-45
90
0
-45
90
0
– Automated plies generation from Zones Sequence 15 Ply 15 35 GLASS 45 45
Sequence 16 Ply 16 33 GLASS 45 45
– Staggered definition of plies using tapers, or user-defined staggering with report and Sequence 17 Ply 17 12 GLASS 90 90
Sequence 18 Ply 18 15 GLASS 45
dedicated features Sequence 19 Ply 19 13 GLASS 90
Sequence 20 Ply 20 11 GLASS -45

12
 Product Lifecycle Management

CATIA - Composites Design (CPE)

Engineering Detailed Design

Key Features :
– Manual Plies Groups, Plies (Adhesive, Bonding strips) and Core
Creation
– Design Checks : Core Sampling, Numerical Analysis, Stacking
Table
– Export to external Files

© 2006 IBM Corporation

– Exact Solid and Smooth IML from Plies
– Exploded Surfaces

Key Benefits :
– Second entry-level in the Composites process for non-structural
entities
– Dedicated Features for Data Integrity and Design Validation
– Refined Solid from Plies for DMU
– Smooth IML for Tooling and Relational Design

13
 Product Lifecycle Management

CATIA – Mechanical Design

Engineering Drawings

Key Features :
– Drawing views and section cuts creation
– Generative View style options to visualize solids, plies boundaries
and/or exploded surfaces, flat patterns and Export to external
Files
– Annotation Templates for Plies and Cut-pieces labelling
– Embedded Sheets for Ply Table, Core samples, Numerical

© 2006 IBM Corporation

Analysis, etc…

Key Benefits :
– Associativity of 2D Composites Drawings with 3D Design
– Dedicated Labeling of Composites entities

14
 Product Lifecycle Management

CATIA – Product Review (DMU)

Enabling Model Based Definition

Key Features :
– Browsing the complete Stacking data structure : List of Plies Groups, Plies,
Cores with associated attributes
– Visualization of all Composites Geometries, Exploded Surfaces, Solids and
IMLs
– 3D Dynamic Sectionning, On Solids and / or Exploded Plies Surfaces
– 3D FTA Annotations

© 2006 IBM Corporation

Key Benefits
– Composites Data can be visualized from a Low-end-Viewer as V5 native
data by without a Composites license.
– Seamless Communication with cross-functional Disciplines such as Stress,
NC or Tooling.

15
 Product Lifecycle Management

CATIA – Structural Analysis (GPS/EST)

Composite Stress Analysis

Key Features :
– Associative Meshing & Pre-processing in CATIA V5
– Composite Properties Import, from Zones or Plies
– Integrated Elfini Solving & Post-processing : Deformation, Displacements, Stress, Strain, etc …
– Create Reports and optimize the Part if needed
– LMS Virtual Lab add-on for Nastran deck creation
– Simulayt Composite Link bridge to Abaqus solver

© 2006 IBM Corporation

Key Benefits :
– Automatic Composites Properties Transfer from the Design model to the mesh, at Zones level for
Pre-dimensionning or at Plies level for Design certification
– Link with Elfini, Nastran and Abaqus solvers

16
 Product Lifecycle Management

CATIA - Composites Manufacturing (CPM)

Manufacturing Preparation

Key Features
– Swapping feature to account for Spring Back
– Material Excess and Extended EOP
– Splicing feature for Material Roll Width with butt-splice and No-splice areas
definition

© 2006 IBM Corporation

Key Benefits
– Early incorporation of Manufacturing constraints
– Split between Engineering & Manufacturing Parts provides easier Data
Management
– Concurrent Engineering between teams improves Productivity

17
 Product Lifecycle Management

CATIA - Composites Manufacturing (CPM)

Producibility and Flattening

Key Features
– Dedicated Producibility Analysis capability
– Several display modes : Shear Deformation and Fiber Deviation/Rotation
– Several Propagation types : minimum distortion and symmetry
– Thickness Update accounts for draping sequence
– User Defined Darting features
– Inspection Tool
– Plies Flattening
– 2D/3D and 3D/2D Geometry Transfer

© 2006 IBM Corporation

Key Benefits
– Early assessment of Fiber Deformations and Deviations inside
plies
– Reliable Flat Patterns generation eliminates trial and error in the shop
floor

18
 Product Lifecycle Management

CATIA - Composites Manufacturing

Key partnerships for Fiber Simulation / Flattening

Advanced Fiber Modeler (AFM)
– Key Features :

Seed Curve and Order of Drape specification

Optimized propagation types

Instant flat patterns display

© 2006 IBM Corporation

Accounts for surface topology, draping sequence and darts
– Key Benefits :

Cutting-edge add-on for advanced Producibility
and Flattening, fully integrated to CATIA V5

Simulates fabric draping on complex surfaces

Pam-Quickform
– Key Features :

Unique Unidirectional Simulation with control
of maximum shearing angle and spreading

Seed Curve specification

Instant flat patterns display
– Key Benefits :

Dedicated Bidirectional and Unidirectional Fiber Simulation

and Flattening Solution, fully integrated to CATIA V5

19
 Product Lifecycle Management

CATIA - Composites Manufacturing

Downstream Manufacturing for Hand Lay-up

Key Features
– 2D Ply Book
– 3D Dynamic Ply Book to support 3D Master
– Neutral DXF and IGES export of all 2D Flat Patterns and 3D Geometry
– CAA V5 TruNest (Magestic Systems)
– CAA V5 Panogen (CIMPA)
– CAA V5 TruLaserView (Magestic Systems)

© 2006 IBM Corporation

Key Benefits
– Automatic 2D and 3D Shopfloor documentation
– Neutral Export to the Shop floor systems
– Dedicated CAA V5 Partner applications for Nesting/Cutting and Laser
Projection to address major production systems

20
 Product Lifecycle Management

CATIA - Composites Manufacturing

Downstream Manufacturing for Automated Processes

Key Features
– CAA V5 PAM-RTM (ESI Group) to predict the filling of a mold during RTM
process and control injection parameters such as time, pressure or temperature.
– Dedicated Solutions to address the main Tape Laying and Fiber Placement
machines Providers :

Integrated CAA V5 Pan-PRT Solution (CIMPA) for

© 2006 IBM Corporation

Tapes Design & Manufacturing

Integrated CAA V5 TORLAY (MTorres)

Integrated CAA V5 iCPS (Ingersoll)

CAA V5 ACE V2 Interface (Cincinnati)

Key Benefits
– V5 Integrated Resin Injection Simulation Solution
– Integration with highly specialized Manufacturing Applications to address
Automated Composites Processes

21
 Product Lifecycle Management

CATIA - Manufacturing
Tooling, NC Machining & Digital Simulation

Key Features
– CATIA V5 Tooling Solutions
– CATIA V5 NC programming and Machining from 2 to 5 axis for Trimming,
Drilling, Cutting operations
– DELMIA V5 Digital Simulation of processes

Assembly Process Simulation

Laser Projection Simulation

© 2006 IBM Corporation

Tape Laying / Fiber Placement simulation

Key Benefits
– Unified Platform from Design to Tooling and NC Machining
– Composites Process optimization in context of Product Definition and Resources
– Digital Simulation of all Composites Processes

22
 Product Lifecycle Management

© 2006 IBM Corporation

Thank You!

23