An Innovative Vision for Composite Materials: A Platform Connecting Analysis, Design and Manufacturing. Massimiliano Moruzzi Product Manager Autodesk
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1 An Innovative Vision for Composite Materials: A Platform Connecting Analysis, Design and Manufacturing Massimiliano Moruzzi Product Manager Autodesk Copyright 2014 Boeing. All rights reserved. GPDIS_2015.ppt 1
2 Disclaimer We may make statements regarding planned or future development efforts for our existing or new products and services. These statements are not intended to be a promise or guarantee of future delivery of products, services or features but merely reflect our current plans, which may change. Purchasing decisions should not be made based upon reliance on these statements. The Company assumes no obligation to update these forward-looking statements to reflect events that occur or circumstances that exist or change after the date on which they were made. GPDIS_2015.ppt 2
3 Agenda Composite Design State of The Art Our Vision: A Connected Platform How Manufacturing Data drives Design GPDIS_2015.ppt 3
4 Composite Design: State of The Art GPDIS_2015.ppt 4
5 Today s Composite Design Process Flow Engineering Kickoff Inputs: Loft,Initial Surface loads, Materials.. Structural Analysis Producibility (hand layup, ATL/AFP, Forming) IML surfaces It is mainly a Cascade approach Design Rule/Strategies Validation Substructure design (frames, ribs, spar ) Release Documentation ply books, MBD Design Release GPDIS_2015.ppt 5
6 Today s Automotive Design Journey It is mainly a Cascade approach resulting.. GPDIS_2015.ppt 6
7 Composites: Black Metal? How do we exploit the benefits of composites when all Design Software are based on metallic methodology? Is Design in Assembly Context the future for composite? Example Bolted Aluminium Wing Skin CFRP Wing Skin (Prior to bolting) GPDIS_2015.ppt 7
8 Composites: Black Metal? Is Today s Automotive Design flow adequate for composite materials? How Design/Simulation Software can help to improve composite design and manufacturing processes? Example Bolted Aluminium monocoque Composite Automotive monocoque GPDIS_2015.ppt 8
9 Composite design: state of the art The best fiber direction is not always a straight line!!! A Cartesian Design Rosette does not allow to unlock Composite Material benefits!!! Rosette Optimum fiber direction GPDIS_2015.ppt 9
10 Manufacturing is Ahead of Design!!! Source Automated Dynamics GPDIS_2015.ppt 10
11 Our Vision: A Connected Platform GPDIS_2015.ppt 11
12 Autodesk: Composite Vision Innovative Platform based on Holistic Approach for and End-to End Solution Concurrent Engineering Platform Enables Design For Manufacturing Generative Composite Design not black aluminum GPDIS_2015.ppt 12
13 Benefits of collaborating with Autodesk: more than a link between Design and Analysis Highly Skilled Team of Engineers in Composite Applications Highly Reliable Modeling tools to guide and monitor all phases Strong Collaboration with Material Suppliers and Material labs Provide Pilot project to validate Process Flow Material Catalogs Combine Multiple Mfg. Processes Design & Methods Provide Pilot Project GPDIS_2015.ppt 13
14 Universal Platform Open Multi-CAD and Multi-CAE GPDIS_2015.ppt 14
15 Example: SimStudio Flexible, unified, geom-based pre/post for Nastran, CFD, + Explicit Helius CAD connected and cloud-enabled for solving and collaboration Built for optimization and goal driven design Adv thermal Adv / Motion CFD FSI Nastran SimStudio Pre/Post AME Mfg Trad process Additive process geometry tools GPDIS_2015.ppt 15
16 Advanced Materials at Autodesk Design Simulate Make Materials Database GPDIS_2015.ppt 16
17 Portfolio of Solutions Structural Mechanics CFD & Thermal Analysis Molding Processes Composite Design Composite Manufacturing Autodesk Nastran Autodesk Simulation CFD Autodesk Autodesk Simulation Moldflow TruPLAN Autodesk Autodesk Autodesk Simulation TruNEST TruPLAN TruNEST Moldflow TruFIBER TruFIBER Autodesk Composite Suite: From Design to Manufacturing GPDIS_2015.ppt 17
18 How Manufacturing Drives Design GPDIS_2015.ppt 18
19 Autodesk: Deep Investment in Manufacturing Technologies GPDIS_2015.ppt 19
20 TruPLAN: Generative Composite Design GPDIS_2015.ppt 20
21 TRUPLAN: MATERIAL MODELING Bridging Wrinkle GAP/LAP Element Shearing Element Spreading GPDIS_2015.ppt 21
22 Software Testing Tow Steering Trials Tow steering using different: Tow widths (1/4 vs 1/8 ) Resin systems (different level of tackiness) Substrate (bare tool surface or woven ply) Steering radii varied until minimal defects were obtained Results used to define Warn and Limit steering values Gaps Minimal or no tow defects GPDIS_2015.ppt 22
23 TRUPLAN: MATERIAL ANALYSIS KERNEL Fiber Path Material Compaction Analysis Surface Update Material Orientation Analysis GPDIS_2015.ppt 23
24 Capturing Material & Manufacturing Constraints Large Scale Additive Continuous Fiber Test Lab Composite Materials Tested Mfg. Process Parameters GPDIS_2015.ppt 24
25 Composite Materials Layup Tests Test Layup Mould Curvilinear Fiber Path Carbon Fiber Carbon Fiber Interface Carbon Fiber Metal Interface GPDIS_2015.ppt 25
26 Mapping Topology-Material-Manufacturing Correlation Function Material & Manufacturing Knowledge can be Mapped to Voxels describing a discrete Design Volume GPDIS_2015.ppt 26
27 TRUPLAN: EXPERIMENTAL VALIDATION WING SPAR CASE STUDY GPDIS_2015.ppt 27
28 TRUPLAN: EXPERIMENTAL VALIDATION WING SPAR CASE STUDY Steering Results for +45o Ply, Bands a) Fiber placed part exhibiting considerable steering defects (Courses 10-12) b) Simulated part in TruPLAN steering analysis exhibiting considerable steering defects in the same region (courses 10-12) GPDIS_2015.ppt 28
29 TRUPLAN: EXPERIMENTAL VALIDATION WING SPAR CASE STUDY TruPLAN Steering Results a) Fiber placed part with relevant courses/bands (16-17) in the case of - 45o ply b) Simulation from TruFIBER for layup (courses 16-17) c) Simulation from TruPLAN for steering (white line represents center line for course 16). GPDIS_2015.ppt 29
30 Capturing Structural Constraints Analyze As Built From Black Metal to Optimal use of Composite!!! Mapping TRUE Fiber Direction Laminate Reference Element GPDIS_2015.ppt 30
31 Total Manufacturing Process Tracking Freezer Autoclave RFID Bar Code RFID Bar Code Expiration dates for all plies In/Out time for all plies Remaining shelf life for plies Which Roll Each Ply Came From Cutting Layup RFID Bar Code RFID Bar Code GPDIS_2015.ppt 31
32 What is Coming Hand-Layup Advanced Forming Additive Simulation Automated Workcell GPDIS_2015.ppt 32
33 Advanced Materials at Autodesk Design Simulate Make Materials Database GPDIS_2015.ppt 33
34 Contact Info Massimiliano Moruzzi GPDIS_2015.ppt 34
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