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CDT 2000 Proprietary

Dr. Olivier Guillermin

Composite Design Technologies, Inc.

Monte Carlo, Monaco

June 7-9, 2000

An Integrated Solution for Advanced Composites Engineering with MSC.Patran

First Southern European Technology ConferenceFirst Southern European Technology Conference

solution partners

CDT 2000 Proprietary

• The world’s leading supplier of composite CAD software

• Focused on providing software solutions for the composite industry

• Software is proven in production

• Staff experienced in composites & CAD/CAM/CAE

• Provide a total solution for your composite design, analysis, and manufacturing needs

Composite Design Technologies, Inc.

solution partners

CDT 2000 Proprietary

Composite Engineering Environment

AnalysisInterface

P002Ideal

Actual

P002

P001

Documentation

Laser Projection

Fiber PlacementInterface

• Feature-based design• Laminate surface generation

• Producibility simulation• Net flat patterns

• Feature-based design• Laminate surface generation

• Producibility simulation• Net flat patterns

Flat Pattern Export

Composite Engineering EnvironmentComposite Engineering Environment

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CDT 2000 Proprietary

C A T I A • U G • P R O / E

Master Model

FiberSIM is fully CAD Integrated

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CDT 2000 Proprietary

Detailed Design& Analysis Manufacturing

Preliminary Design & Analysis

PlyProducibility

Process & MaterialSelection

Solid Modeling Documentation

Laser ProjectionFE Analysis

+45-4590

0

TARGET LAYUP25/50/25

TARGET LAYUP40/40/20

• ZONE6

• ZONE4

• ZONE5

•ZONE1

• ZONE8

•ZONE2

•ZONE3

•ZONE12

•ZONE10 •ZONE11• ZONE7

•ZONE9

StructuralSizing

Fiber PlacementTape Laying

The Composite Engineering Process

Preliminary Design& Analysis

Detailed Design& Analysis

Manufacturing

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CDT 2000 Proprietary

A Complete Description of the Composite Part

Materials & Processes

45135900

Plies & Sequences

Offset Surfaces True Fiber Orientations

• Prepreg/Dry• Uni/Woven• Preforms • Engineered Fabric

• Hand Layup• RTM• Fiber Placement• Tape Laying

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CDT 2000 Proprietary

Manufacturing Applications

• Documentation

• Fiber Placement

• Tape Laying

• Nesting

• Automated Cutting

• Laser Projection

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CDT 2000 Proprietary

Closing the Loop Between Design & Analysis

AnalysisMSC Software

AnalysisMSC Software

DesignFiberSIM

DesignFiberSIM

Increases model accuracy & sensitivity

Optimizes designs

Detects & quantifiesconceptual errors

Decreases productdevelopment cycle

Manufactured

Part

Manufactured

Part

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CDT 2000 Proprietary

Case Studies

Sikorsky S-92 Helicopter

Turbine Spinner

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CDT 2000 Proprietary

Turbine Spinner

CASE DESCRIPTION

PROBLEM STATEMENT:Even though the part was built according to the same manufacturing documentation, a number of parts failed under standard in-service conditions. The failure was caused by uneven circumferential laminate stiffness due to material scissoring that resulted from a change in the manufacturing layup start-point of the plies.

SOLUTION:Only with FiberSIM and MSC.PATRAN working together can you:

• detect such misconceptions in design• control the proper parameters• design the part in its exact and detailed to-be-manufactured state

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CDT 2000 Proprietary

Fiber Paths in Half-Body Ply - Origin at Top

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CDT 2000 Proprietary

Fiber Paths in Half-Body Ply - Origin at Bottom

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CDT 2000 Proprietary

Displacements of Original Design

Load Case: Centrifugal Loading About Y Axis

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CDT 2000 Proprietary

Displacements of Revised Design

Load Case: Centrifugal Loading About Y Axis

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CDT 2000 Proprietary

Sikorsky S-92 Helicopter

CASE DESCRIPTION

PROBLEM STATEMENT:Even though the sandwich part was developed according to the design rules, complex curvature induced non-symmetry in the laminate which caused the part to warp upon curing. The part was ultimately scrapped.

SOLUTION:FiberSIM works with MSC.PATRAN to enable:

• detection of such misconceptions in design• analysts to be involved in the preliminary stages of design• analysis of the part in its exact and detailed to-be-manufactured state

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CDT 2000 Proprietary

0°/90° Ply (Bottom Skin)

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CDT 2000 Proprietary

+/- 45° Front and Back (Bottom Skin)

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CDT 2000 Proprietary

Analysis of initial design based on true fiber orientations

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CDT 2000 Proprietary

Orthotropic Layup (Bottom Skin)

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CDT 2000 Proprietary

Revised Design (+/- 45° Front & 0/90° Back)

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CDT 2000 Proprietary

Quasi-isotropic Layup

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CDT 2000 Proprietary

Analysis of revised design based on true fiber orientations

solution partners

CDT 2000 Proprietary

Customer Quotes

"By sharing design information between our CAD/CAM system and FiberSIM, we are turning the black art of composite engineering into a precise science." Benetton F1 Racing

“Preprogramming the lay-up sequence cut lay-up time by 50%. Exact pattern measurements cut material waste by 25%."The Boeing Company

“FiberSIM assisted the S-92 Helibus Cockpit team in reducing by 27% the flow time required to move the complex Composite Canopy Structure from basic data to completion of production parts. With FiberSIM, our first parts were virtually perfect and we were able to do it right the first time."Sikorsky Aircraft

"After extensive evaluation, FiberSIM was chosen as the design tool of composite components for the next generation of aircraft. FiberSIM takes concurrent engineering to the next level, reduces design time and increases manufacturing efficiency." British Aerospace

"With FiberSIM we experienced average savings of 12 to 1 in the time it takes to develop net flat patterns." DOW-UT

solution partners

CDT 2000 Proprietary

Conclusion

The FiberSIM Composite Engineering Environment provides:• seamless link between CAD master model and PATRAN/NASTRAN• use of a complete and detailed virtual prototype• detection of design misconceptions and inaccurate finite element

modeling

The customer benefits from:• increased confidence • elimination of trial and error• reduced risk • reduced engineering change orders• lowered costs • shortened development time