optimized composite design methodologies that enable rapid...
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Optimized Composite Design
Methodologies that Enable Rapid Change
Realize innovation.Unrestricted © Siemens AG 2017
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
• Multi Ply Introduction
• Application
• Rapid Change
Agenda
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
• Acquired by Siemens PLM Software 2011
• Leading composite design solution in Aerospace
and Automotive (300+ global customers)
• Solutions
• Specialized domains
• Industry Focused
• Multi-CAD, open architecture
• Customers include: Boeing, Northrop Grumman,
Lockheed Martin, SpaceX, Spirit Aerosystems,
Ford, Audi, Magna
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Specialized Engineering Software Portfolio
FIBERSIM
Composite structures
development
MASTERTRIM
Seat and interior component
development
SYNCROFIT
Complex assembly
engineering
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
“Fiber-reinforced plastics pose a particular
challenge… these complex processes can only
be mastered with know-how and the right
software technology.”
- Georg Käsmeier, CEO and founding member Roding Automobile GmbH
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Fibersim Has Specialized Composite Design Methods
Only Siemens offers this range of capabilities
▪ Flexible design method for
hand layup
Ply Based Zone Based
Structure Based Multi-Ply Based
▪ Ply geometry is rule-driven
▪ Adapts well to changes
▪ Combines zone method with
ply method, allowing quick
design modifications
▪ Automates design for
wings/fuselages
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
What is Multi-Ply?
Unique Composite Design Methodology
• Easy to understand and implement
• Powerful automation of design definition
and change
• Automated ply geometry creation
3 Reinforcement Plies
3 Reinforcement Plies
4 Full Plies
• Zones are independent
• Material is additive
• Layers can be shuffled
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
What is Multi-Ply?
Initial Stack-up
Schematic
Redefine Sequence
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
What is Multi-Ply?
Ramps for Drop-offs
Create parametric surface
offsets (IML) with ramps from
overlay reinforcements
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Multi-Ply Versus Other Methods
Ply Based Design
+ Flexible
• Define any shape
• Minimal Overhead
• Just geometry and plies
– Manual
• All ply geometry must be
created
• Limited automation
downstream (no IML)
Zone Based Design
– Highly Structured
• Interconnected zones create
initial overhead
+ Powerful
• Ply geometry is rule-driven
• Adapts well to changes
+ Automated
• Minimal geometry creation
• Downstream features easily
created (IML, DFM features,
etc)
Multi-Ply Design
+ Flexible
• Define any shape
• Low Overhead
• Input shapes directly drive
Ply shapes
+ Powerful
• Ply geometry is rule-driven
• Adapts very well to changes
+ Automated
• Minimal geometry creation
• Downstream features easily
created (IML, DFM features)
+ Can be combined with
Zone-Based Design
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Multi-Ply Supports Any Category of Fundamental Part Complexity
Structural• Many plies of differing shapes and materials
• Mating condition / design rule constraints
Shape• Highly curved control surfaces
Process• Manufacturing automation with inherent limitations
• Large or small parts with material handling challenges
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Simple Part
Automotive Panel
Large Airframe
Examples of Part Complexity
Structural complexity Very High
Shape complexity Low
Process complexity Very High
• Zone-based Design/ Multi-Ply Design
• Model Merge
• Automated Deposition Design
• Multi-Ply Design
• CAE Exchange
• Multi-Ply Design
• Parametric Offset Surface
Structural complexity Low
Shape complexity Very High
Process complexity High
Structural complexity Low
Shape complexity Low
Process complexity Low
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Ply-based Workflow
Initial Layup
1. Create Full-body plies
2. Create Pad-ups
1. Generate geometry manually
2. Create plies linked to geometry
3. Generate solid manually
Design Change – new pad-up
1. Create drop-off geometry
2. Create additional plies
3. Re-generate solid manually
+ Flexible
– Manual
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Multi-Ply Workflow
Initial Layup
1. Create full-body area
2. Create pad-up areas
a. Fibersim stacks Lam Specs for you
3. Define drop-off rules
4. Generate layers automatically
5. Generate solid (IML) automatically
Design Change – new pad-up
1. Add new pad-up area
2. Generate layers automatically
3. Regenerate solid (IML) automatically
+ Flexible
+ Powerful
+ Automated
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Zone-based Workflow
Initial Layup
1. Create Zones
2. Define material and drop-off specifications
a. Assign to zones
3. Generate layers automatically
4. Modify individual drop-offs, corners and stacking
a. Automatically modifies layers
5. Generate solid (IML) automatically
Design Change – Add Tear Straps
1. Create tear strap Laminate (more steps!)
2. Create tear strap Zones one with 0 thickness (tricky!)
3. Define material and drop-offs specifications
a. Assign to tear strap zones
4. Generate layers automatically
5. Modify individual drop-offs, corners and stacking
1. Automatically modifies Layers
6. Regenerate solid (IML) automatically
+ Powerful
+ Automated
– Structured
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Zone & Multi-Ply Hybrid Workflow
Initial Layup
1. Create Zones
2. Define material and drop-off specifications
a. Assign to zones
3. Generate layers automatically
4. Modify individual drop-offs, corners and stacking
a. Automatically modifies layers
5. Generate solid (IML) automatically
Design Change – Add Tear Straps
1. Create tear strap Zones (easy!)
2. Define material and drop-offs specifications
a. Assign to tear strap zones
3. Generate layers automatically
4. Regenerate solid (IML) automatically
+ Powerful
+ Automated
= Structured
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Benefits Summary – Multi-ply
• Delivers an open platform supporting NX, CATIA and Creo
• Uses company and program specific rules to drive composite design
• Enables faster and more frequent design/analysis optimization iterations
• Needs minimal geometry to automatically create ply shapes
• Generates downstream features automatically (IML, DFM, etc.)
• Combines best features of zone and ply based methodologies
80% time savings compared to other design methods
• Increase design efficiency
• Minimize geometry creation
• Reduce time to make changes
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Unrestricted © Siemens AG 2017
2017.10.05 Siemens PLM Software
Sean O’Hearn
Portfolio Development Pre-Sales Director
Americas
200 5th Avenue, 5th Floor
Waltham, Massachusetts 02451 USA
Phone: +1 (781) 907-9755
Fax: +1 (781) 907-9880
Mobile: +1 (781) 530-0221
E-mail:
Thank you. Any Questions?
Realize innovation.