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Integrated Design and Analysis of Composite Structures using FiberSIM and ANSYS ACP

Olivier Guillermin, PhDDirector of Product and Market StrategyVISTAGY, Inc.

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Leading provider of industry-specific engineering software and servicesEstablished in 1991

Headquartered in Waltham, Massachusetts, USAWell established worldwide business

Nearly 300 customers across the globe

4500+ users

About VISTAGY, Inc.

Aerospace

Automotive

Energy

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The world’s leading companies rely on VISTAGY to help them engineer success

Work how you think Communicate more effectively Make better-informed decisions Reuse engineering data

Help reduce your costs and cycle times, improve your top and bottom line

Support your thought leadership and innovative business strategy

Strategic Partner

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VISTAGY enhances the highest performing 3D platforms by applying domain expertise and specialized process knowledge to efficiently

create error-free, optimized composite structures

The VISTAGY Advantage

DomainExpertise

ProcessKnowledge

3D CADIntegration

Industry-Specifi cSolutions

Deep, synthetic, cross-disciplinary

workfl ows

Deep understandingof your industry

Aero/auto/marine/wind Structures; Composite

Materials Design/Analysis Manufacturing Processes

Native geometric integration with underlying CAD/Viewer

data modelCATIA

Creo Elements/Pro (Pro/ENGINEER)NX

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VISTAGY’s Product Portfolio

for designing and manufacturing innovative, durable and lightweight composite structures

…And more

for designing and manufacturing complex assemblies and large aerostructures

QPEQuality Planning Environment™

for developing plans to assess aerostructure quality

SDESeat Design Environment™

for designing and manufacturing innovative transportation seat systems and interior components

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A Complete Engineering Environmentfor Composite Design

Design methods

ply, zone, grid, blade

Design verification

Producibility

Splicing, core design

Offset surface mockup, mating

Materials & processesCost

modeling

Weight calculations

Design Review

CFD/StructuralLayout

Conceptual part

definition

Interface to analysis

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And a Seamless Link to Manufacturing

Design Review

EngineeringRelease

Generate flat patterns

Create technical

documentation

Generate laserprojection data Generate data for

automated placement

üOn timeüOn budgetüOn spec

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VISTAGY SolutionGrid-based, zone-based and ply-based design methodologies.

Import/export capability for zones and target laminates; interface capability to industry-specifi c concept design software.

Best practices for effi cient modeling, ply-drop-off strategies for weight reduction, parts and materials classifi cation.

ValueAssistance with the technology assessment investigations; selection of new materials and manufacturing processes.

Process development to support future design activities.

Automating geometry creation to reduce modeling time.

Open technology for interfaces with concept design software, layout and sizing tools, materials databases.

VISTAGY Facilitates Optimization of Preliminary Design

Zone- and ply-based iterative design loop

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VISTAGY SolutionFiberSIM Composite Engineering Environment for detailed ply layup defi nition, materials and process producibility assessment.

Best practices for producibility tradeoffs, splicing and drop-off strategies, alignment between simulation and shop fl oor layup techniques.

ValueFiberSIM single source master model drives the entire manufacturing process.

Complete detailed part authoring improves communication, eliminates interpretation of the design intent.

Quickly identifi es manufacturing challenges.

Provides instant feedback regarding design changes.

VISTAGY Design Process Ensures Part Manufacturability

Detailed ply layup

Producibility simulation

Fiber deviations

Offset surface and solid model

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VISTAGY SolutionExport of 2D fl at pattern and 3D laser projection data.

2D/3D documentation including cross-sections and ply books.

Best practices for hand-off between design and manufacturing, linked design and manufacturing model approach.

Partnerships with all major nesting and cutting solution companies.

ValueEnables repurposing of design data for manufacturing.

Automates the generation of fl at patterns for all best-in-class nesting and cutting systems.

Quickly generates laser export formats for all best-in-class laser projection systems.

Automates the generation of manufacturing drawings.

Transition from Manual to Automated Manufacturing

Laser projection

Ply book

Flat pattern generation;Export to nesting and cutting

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FiberSIM Open Architecture Enables Customer Driven Best-in-Class Solutions

Cutting and Nesting Partners

Laser Projection PartnersAutomated Deposition Partners

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Evolution of Composites Engineering

1990 2010

Drapingsoftware

Designenvironment

Seamless linkto manufacturing

CAD / CAEintegration

Advanceddesign

Design and Manufacturing focus Design and Analysis focus

Make it better!Make it!

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The analysis models lack accuracy and completenessFiber orientations are incorrect; not accounting for compound curvature

Zone or ply shapes used in FEA are approximate; limited by the data available

Ply dropoffs and other key design details are missing

The transfer of data between design and analysis is slow and manual

Analysts looking for many more cycles, faster, earlier in the process

Transfer of zone and laminate specs to design done by tables, diagrams

Transfer of ply shapes and fiber orientations to analysis done by drawings

Lengthy paper/verbal process for design changes, analysis changes

The data exchange process is unreliable and incompleteUse of spreadsheets, verbal communications and emails

Time consuming

Errors due to interpretation, inattention

Designers and analysts feel they don’t get complete information from the other parties

The engineering process is too sequentialDelays are incurred

Limits the number of iterations and changes possible

Eventually: there is a disconnect between design, stress and manufacturing

What’s analyzed is not what’s designed and manufactured

Main Pain Points in Composite Design and Analysis Integration

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Toward Resolving the Design and Analysis Communication Problem

Structure LayoutLaminate Specs

Stress Analyst CAD Designer

Structure LayoutLaminate Specs

Domain Abstractions

CAE CAD

Geometry

Clean-up

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Support Abstraction on Multiple Levels

Full scale validation

Aircraft Sections

Stiffened panels

Parts and joints

VCCT, damage models

Composite meso and micro models

Specification

Validation

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Enabling a Concurrent Design and Analysis Workflow

CA

EC

AD

PreliminaryDesign

LayoutDesignDetails

Sizing

ManufacturingDetail

IntegrateSizing

Investigate

IntegrateOptimization

Refine

OptimizationStrategy

Optimize Validate

ZONES ----------------------------------- LAYERS -------------------------------------- PLIES

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FiberSIM Ply Data Export to ANSYS Composite PrePost

FiberSIM

ANSYS ACP

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ANSYS Composite PrePost Ply Data Export to FiberSIM

FiberSIM

ANSYS ACP

Principal stress plot

Deformation plot Thickness plot

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FiberSIM and ACP Interaction (Videos)

Initial Layup Definition in Ansys ACP:

Detailed Layup Definition in FiberSIM:

Final Layup Validation in Ansys ACP:

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The integrated composite design and analysis process is rapidly maturing

- For multiple part types

- In various industries

Only in recent years has the deep integration of design and analysis been considered a critical topic

- In order to further optimize composite parts

Abstraction and open format data exchange is the fastest and most efficient route to powerful design and analysis integration

Together VISTAGY and ANSYS are actively engaged in integration efforts at various levels

- Ply and zone design

- Optimization and validation

Take Away

200 Fifth Avenue ● Waltham, MA 02451 USA+1.781.250.6800

www.vistagy.com