CFK-Valley Stade Convention 2015 “Industry 4.0 for … · CFK-Valley Stade Convention 2015 –...

Unrestricted © Siemens AG 2015 Realize innovation.

CFK-Valley Stade Convention

2015 – “Industry 4.0 for

Composites” Delphine Carrella & Boris Vetter, SIEMENS PLM Software

2015-06-16

Unrestricted © Siemens AG 2015. All rights reserved.

Page 2 Siemens PLM Software

Delphine Carrella

Agenda

1. Boris Vetter

1. Challenges in Industry 4.0

Composite Design

2. FIBERSIM

2. Delphine Carrella

1. CAE Solution Portfolio

2. Advanced CAE Methods

3. Summary / Benefits

2015-06-16



Delphine Carrella

The Internet drives mass customization of products

4th Industrial Revolution

2015-06-16



Delphine Carrella

0

5

10

15

20

25

30

1970 1980 1990 2000 2010

SUV

Sports car

Coupés

Luxury class

Medium luxury class

Medium class

Compact class

Sub-Compact class

Example: Audi AG

Source: Wikipedia 2014, Audi AG

Handling

Variants

demands more

flexibility to

manage and

execute

manufacturing

Challenge Number of Automobile Variants

2015-06-16



Delphine Carrella

SOLUTIONS

Product

Requirements

Product

Validation

Product

Structure

Product Design

(CAD, Specialized

Solutions)

Product

Development

Automation

Sensors

& I/O Controllers

& PLCs

HMI Industrial

Communication

Part Planning

Process

Validation

Assembly

Planning

Work

Instruction Quality &

Nonconformance

Management

Process

Planning

Robotics &

Automation

Resource

Management

Data Collection

(Labor, Machine ,

Tool)

Product &

Process

Traceability

Manufacturing

Operations

Management

Order / Route

Management &

Execution

Quality & Non-

conformance

execution

Material & Tool

Calls AGV/SGV

Coordination

PLC, I/O, Sensor

& Controller

Integration

As-built &

Genealogy

Machine / Cell /

Line Monitoring

End-to-End Composites Parts Development

Process Integration

2015-06-16



Delphine Carrella

Product Lifecycle Management

Manufacturing Operations Management

Integrated Production Automation

Siemens is the Only Company Focused on

Optimizing Innovation Within Your Digital Enterprise

2015-06-16



Delphine Carrella

The Composite Engineering Process

Certification of

Design Report

Preliminary Sizing

and Optimization

Design Validation

CAE/

VAL

CAE

PDM

Documentation for

Manufacturing/Production Shape

Definition

Surfacing

Lofting

Layup definition

Zone/Ply

CAD/

SUR

Draping simulation

Splicing/Darting

Manufacturing Process Planning,

Simulation & Optimization Production

Tooling Design,

Machining & Inspection

CAM CAD

CAM

CE/MFG


CAE/

OPT

+45 -45 90

0

TARGET LAYUP

25/50/25 TARGET LAYUP

40/40/20

• ZONE6

• ZONE4

• ZONE5

• ZONE1

• ZONE8

• ZONE2

• ZONE3

• ZONE12

• ZONE10 • ZONE11 • ZONE7

• ZONE9

CE/

PD

CE/

SIM

CAD

CE/

DOC

2015-06-16



Delphine Carrella

Software for designing and manufacturing

innovative, durable and lightweight composite structures

2015-06-16



Delphine Carrella

Producibility

Design Release

Efficient Hand-off

From Design To

Manufacturing

3D Geometry

Tool Surface Ply / Zone

Definition

Detailed Ply

Shape Definition

Manufacturing

Documentation Plybooks, MBD

Metrics

Reporting

Weights, CG, BOM

IML Surfaces Mockup, Mating,

Tooling

As-Built Analysis

A Complete Engineering Environment for

Composite Design …

Design

Verification

Design for

Manufacturing

Producibility

Resolution (ATL / AFP)

Fibersim CAD Integrated Master

Model captures the data need to

engineer a composite laminate

2015-06-16



Delphine Carrella

Release to

Manufacturing

On-time

On-budget

On-spec delivery

Automated

Composite

Layup

Inspection Layup

Cured Laminate

Dimensional

(AS9102)

Laser

Guided

Layup

Nesting

Cutting

Automated

Ply

Verification

... and Manufacturing

Fibersim CAD Integrated Master Model can

also be used to automatically generate

manufacturing documentation and data

2015-06-16



Delphine Carrella

FIBERSIM

Producibility Simulation & Flat Pattern Generation

2015-06-16



Delphine Carrella

©2006 C

onfid

entia

l

FIBERSIM

Manufacturable Composite Designs

2015-06-16



Delphine Carrella

Manufacturing Process Influence

Simulate the manufacturing process as it is expected to occur

2015-06-16



Delphine Carrella

FIBERSIM

Advanced Analysis Interface

FEA Preprocessor

Ply Definitions

FiberSIM

2015-06-16



Delphine Carrella

"Time is always of the

essence for us, so

Fibersim’s proven ability to

take us from art to part so

rapidly was a critical

consideration in our decision

to purchase the software."

SPACE-X

“SIEMENS promised

impressive reductions in

product development time for

our composite parts, and they

delivered on their promises.”

LOTUS F1 Team

“We have worked actively to

merge Fibersim with our

engineering software and

processes. Lockheed Martin’s

goal is to integrate the most

productive composites design

and manufacturing tools

available.”

Lockheed Martin Corp.

“"Fibersim enables us to do a

faster conversion from metal to

composites, and minimizes the

risk by verifying information

before it ever gets to the

manufacturing floor."

ThyssenKruppMarineSystems

2015-06-16



Delphine Carrella

Fibersim’s Powerful Design Methodologies

Zone Based Ply Based

• Driven from

mating

specifications

• Automates design

for wings /

fuselages

• Enables

automated

material

deposition

• Allows effective

optimization of

complex designs

• Supports robust

analysis workflows

Structure Based

• Flexible design

method

for hand layup

• Captures all data

and assures

manufacturability

• Automated ply

generation

• Volume based (fill

space between 2

surfaces)

• Zone based

approach

• Each ply with

accurate draping

surface

Volume Based

• Automates ply

based design

• Best of ply and

zone

• Allows late design

modifications

without adding

tedious work

Multi-Ply Based

Restricted © Siemens AG 2015 Realize innovation.

Quantifying the design driven methodologies and Fibersim benefits

• Accelerated overall development time by 60%

• Reduced design time by 20-30% typically

• Reduced layup time by 75% over traditional methods

• Reduced laminate templating time by 80%

• Optimized and verified part performance

• Automatically transferred analysis data to design, increasing speed & providing more analysis

testing cycles

• Verified optimal part performance by sending composite design definitions back to analysis

• Delivered 100% accurate data

• Optimized part strength and weight

• Weight variation of only 1.5%

2015-06-16



Delphine Carrella

Agenda

1. Boris Vetter


Composite Design

2. FIBERSIM





2015-06-16



Delphine Carrella

SIEMENS NX CAE – Selection of Capabilities

Linear

Structures

Multi-CAD

Geometry Editing

Electronics

Systems Cooling

FE Correlation

and Update

Response

Dynamics

Space Systems

Thermal

Laminate

Composites

Assembly

Management

Durability

Knowledge

Automation

Optimization

Nonlinear

Structures

Integrated Data

Management

Advanced

Meshing

Flow

Multi-Solver

Support

Nastran

Ansys

Abaqus

LS-Dyna

Recurdyn

Adams

Motion and

Controls

Thermal

2015-06-16



Delphine Carrella

Combining expertise from different domains …

Materials Geometry Manufacturing Process Testing

Coupon

Component

Subsystem

Aircraft

Validation of

material

models

Model validation on

components and

joint technology

Validation of complex

subsystem modeling

Expertise built-up to full aircraft

simulation/certification

2015-06-16



Delphine Carrella

… gives our customers superior possibilities

2015-06-16



Delphine Carrella

Agenda

1. Boris Vetter


Composite Design

2. FIBERSIM




• Stacking & Fiber orientation

• Springback analysis

• Durability analysis


2015-06-16



Delphine Carrella

Bridge between manufacturing capability and

performance simulation

tregion3_0deg?

tregion3_45deg?

tregion3_90deg? Optimal

stacking

sequence

Theoretical optimal orientations

(draping method = simple projection) optimization

2015-06-16



Delphine Carrella



tregion3_0deg?

tregion3_45deg?


stacking

sequence



Ply design Manufacturing

simulation

Design CAE

2015-06-16



Delphine Carrella



tregion3_0deg?

tregion3_45deg?


stacking

sequence



Ply design Manufacturing

simulation

Design CAE

2015-06-16



Delphine Carrella



Design CAE

Zone with

shell finite

elements

Zone with

solid finite

elements

Zone with

cohesive

elements

(delamination)

Use of non linear analysis on the optimal

solution, draped with Fibersim

o Check that delamination will appear

above the nominal loading

2015-06-16



Delphine Carrella

Improve quality and accuracy of (NVH) analysis

models

Dedicated draping

simulation yields:

• as-manufactured fiber

orientations as-

manufactured stiffness and

dynamic response

characteristics

• For plies with unidirectional fiber

orientations:

• simple projection not sufficient

• real draping simulation required

• For plies with woven fibers:

• draping simulation to include both

warp and weft fiber orientation,

• revealing local zones of higher

warp/weft shearing and

corresponding reduced stiffness.

FiberSim

NX CAE

Laminate

Composite

NX Nastran

Samcef

NX CAD / CAE

Moderate to

high

shearing

Limited

shearing

2015-06-16



Delphine Carrella

Agenda

1. Boris Vetter


Composite Design

2. FIBERSIM








2015-06-16



Delphine Carrella



FIBERSIM

(CAD)

• fibers orientation

• geometry

DRAPING MODEL

2015-06-16



Delphine Carrella



FIBERSIM

(CAD)


• geometry

DRAPING MODEL CURING PROCESS

2015-06-16



Delphine Carrella



FIBERSIM

(CAD)


• Matrix properties

• Homogenization

(orthotropic UD)

• Unmolding

• Heat balance

• Cure kinetics

• boundary conditions

• thermal properties

• temperature

• degree of cure

• Tg temperature

• geometry

• residual stresses

• deformed

geometry


• mechanical properties

DRAPING MODEL CURING MODEL

THERMAL ANALYSIS

MECHANICAL ANALYSIS

2015-06-16



Delphine Carrella



FIBERSIM

(CAD)


• Matrix properties

• Homogenization

(orthotropic UD)

• Unmolding

• Heat balance

• Cure kinetics


• thermal properties

• temperature

• degree of cure

• Tg temperature

• geometry

• residual stresses

• deformed

geometry

• stiffness, strength

• damage analysis


• mechanical properties

DRAPING MODEL CURING MODEL STRUCTURAL MODEL

THERMAL ANALYSIS

MECHANICAL ANALYSIS

2015-06-16



Delphine Carrella



o Example: flap (4m long)

Shape distorsion

resulting from the curing

2015-06-16



Delphine Carrella

Agenda

1. Boris Vetter


Composite Design

2. FIBERSIM








2015-06-16



Delphine Carrella

Composite Performance and Durability Analysis

• Failure modes (Strength, durability, crash) much

less predictable

• Many criteria available, none universally

applicable

2015-06-16



Delphine Carrella

Composite Performance and Durability Analysis

Needs addressed:

1. Failure prediction under complex load

2. Damage model for coupon and component

3. Damage tolerance / BVID/VID design approach

4. Fatigue tool

2015-06-16



Delphine Carrella

Challenges • Weight saving requirements instigate adoption of light weight laminated

composite materials in body design

• Use of new materials necessitates the development of new design

performance evaluation methodology

• The reliability & strength behaviour of composites under complex loading is

non-linear

• Need for development of predictive models and related material

characterization procedures for progressive damage analysis and body

performance evaluation

Solution • LMS Samcef Mecano non-linear finite element solver

• LMS Engineering Services for composite damage model identification

Results • Sophisticated material models comprehensively implemented for:

• Progressive ply damage (strength, non-linearities, plasticity, coupling

effects in the matrix)

• Delamination (possibly coupled to damage in the plies)

• Development of the parameter identification procedure, based on a limited

amount of physical tests on coupons

• Predictive damage models at the coupon level and at composite subsystem

design concept level

Honda R&D Co., Ltd.

Innovative Methodology for Progressive Damage

Analysis in Composite Design

Composite Delamination

Progressive ply damage

2015-06-16



Delphine Carrella

Exploitation of the methodology

• Validation of damage models at coupon level Starting from identified material parameters, the damage model is used to predict

the mechanical behavior at the coupon level for evaluation of the behaviour for

other stacking sequences and hence replacing physical tests.

• Application of damage models for predictive

delamination behavior at component level The damage models are supporting the prediction of the progressive damage

and delamination inside the plies and at their interface at component level

Honda R&D Co., Ltd.



Progressive ply damage

Progressive delamination

Source : “Strength Calculation of Composite Material considering multiple progress of failure by

Ladaveze model”, Y.Urushiyama, T. Naito, JSAE Spring Conference, 2014 52 05

2015-06-16



Delphine Carrella

• Application of damage tolerant approach for composite design • Barely visible impact damage

• Damage induced by a low energy impact

• Delamination appears at the interfaces between the plies

• Agreement between simulation and C-scan test results

Honda R&D Co., Ltd.



The stains represent the level of delamination

2015-06-16



Delphine Carrella

Industrial references

Airbus Helicopters

Airbus Group Innovations

Damage mesomodel

Elastic behaviour

Challenges

• Reliable solution procedure for damage

analysis at the component level

• Developmet of predictive damage

models

• Specific case of a pre-craked helicopter

blade

Solution

• LMS Samtech Samcef non-linear finite element

solver

Results

• Validation at the component level of the predictive

damage models of LMS Samtech Samcef

2015-06-16



Delphine Carrella

Composites fatigue

Engineering challenges and solutions

Challenges -

Fatigue

Solutions

• Short Fiber

Fatigue • Open interface to 3rd

party solution

• Continuous Fibers • Unique solution

combining

• Complex loads

• Stiffness

Reduction

Added value

• Take

advantage of

good fatigue

properties of

composites

• Make light

weight really

light

2015-06-16



Delphine Carrella

Increased Durability Based on Progressive Stiffness

Degradation Modeling

Fatigue behaviour of Metals

& Composites

Exploit full advantage of

the gradual stiffness

degradation characteristics

of composite in design

Include dynamic loading in the

design process

Complex cyclic loading

scenarios

FE Composite

Modelling

Technology for

composite durability

evaluation based on

progressive stiffness

degradation model

Fiber orientation & Ply

stacking

Efficiency Accuracy

Fatigue material

properties at ply level

2015-06-16



Delphine Carrella

Agenda

1. Boris Vetter


Composite Design

2. FIBERSIM





2015-06-16



Delphine Carrella

"The LMS Samtech development team

is the cornerstone of these

partnerships, contributing to the

dissemination of these new material

laws thanks to the implementation of

these advanced concepts into its LMS

Samcef solver."

Didier Guedra-

Desgeorges

VP and Head of theTechnical

Capabilities Center

Structure Engineering, Production &

Aeromechanics


Realizing technological excellence and breakthroughs in

aircraft composite design


2015-06-16



Delphine Carrella

Composites Part Design

Initial Stack-up

Ply Schematic

Redefine Sequence

SIEMENS – We provide solutions to the challenges of

industrializing advanced composite materials

Dataset for Manufacturing

Concurrent Design and CAE

Manufacturing Producibility Materials Definition

Strength & Durability

NVH & Acoustics

Thermal Analysis

Composites Simulation

Composites Optimization

Data Management

Process Integration

CAD CAD

Assy FEM

Mesh

FEM

Assy

FEM

Post

• Multi CAD

• Multi CAE

2015-06-16



Delphine Carrella

Thank You!

2015-06-16



Delphine Carrella

Questions, Comments, Suggestions?

Contact me:

Boris Vetter

Senior Consultant

SIEMENS Industry Software GmbH & Co. KG

Digital Factory Division


Global Sales & Services

Otto-Hahn-Ring 6

81739 München, Germany

Mobile: +49 (174) 7341 606

[email protected]

Smarter decisions, better products.

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