CFK-Valley Stade Convention 2015 “Industry 4.0 for … · CFK-Valley Stade Convention 2015 –...
Transcript of 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
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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
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Page 3 Siemens PLM Software
Delphine Carrella
The Internet drives mass customization of products
4th Industrial Revolution
2015-06-16
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Page 4 Siemens PLM Software
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
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Page 5 Siemens PLM Software
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
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Delphine Carrella
Product Lifecycle Management
Manufacturing Operations Management
Integrated Production Automation
Siemens is the Only Company Focused on
Optimizing Innovation Within Your Digital Enterprise
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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
Product Lifecycle Management
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
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Page 9 Siemens PLM Software
Delphine Carrella
Software for designing and manufacturing
innovative, durable and lightweight composite structures
2015-06-16
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Page 10 Siemens PLM Software
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
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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
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Delphine Carrella
FIBERSIM
Producibility Simulation & Flat Pattern Generation
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Delphine Carrella
©2006 C
onfid
entia
l
FIBERSIM
Manufacturable Composite Designs
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Delphine Carrella
Manufacturing Process Influence
Simulate the manufacturing process as it is expected to occur
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Delphine Carrella
FIBERSIM
Advanced Analysis Interface
FEA Preprocessor
Ply Definitions
FiberSIM
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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
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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
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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
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Page 19 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
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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
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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
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Delphine Carrella
… gives our customers superior possibilities
2015-06-16
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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
• Stacking & Fiber orientation
• Springback analysis
• Durability analysis
3. Summary / Benefits
2015-06-16
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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
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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
Ply design Manufacturing
simulation
Design CAE
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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
Ply design Manufacturing
simulation
Design CAE
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Delphine Carrella
Bridge between manufacturing capability and
performance simulation
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
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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
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Page 29 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
• Stacking & Fiber orientation
• Springback analysis
• Durability analysis
3. Summary / Benefits
2015-06-16
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Delphine Carrella
Bridge between manufacturing capability and
performance simulation
FIBERSIM
(CAD)
• fibers orientation
• geometry
DRAPING MODEL
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Delphine Carrella
Bridge between manufacturing capability and
performance simulation
FIBERSIM
(CAD)
• fibers orientation
• geometry
DRAPING MODEL CURING PROCESS
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Delphine Carrella
Bridge between manufacturing capability and
performance simulation
FIBERSIM
(CAD)
• fibers orientation
• 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
• boundary conditions
• mechanical properties
DRAPING MODEL CURING MODEL
THERMAL ANALYSIS
MECHANICAL ANALYSIS
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Delphine Carrella
Bridge between manufacturing capability and
performance simulation
FIBERSIM
(CAD)
• fibers orientation
• 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
• stiffness, strength
• damage analysis
• boundary conditions
• mechanical properties
DRAPING MODEL CURING MODEL STRUCTURAL MODEL
THERMAL ANALYSIS
MECHANICAL ANALYSIS
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Delphine Carrella
Bridge between manufacturing capability and
performance simulation
o Example: flap (4m long)
Shape distorsion
resulting from the curing
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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
• Stacking & Fiber orientation
• Springback analysis
• Durability analysis
3. Summary / Benefits
2015-06-16
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Delphine Carrella
Composite Performance and Durability Analysis
• Failure modes (Strength, durability, crash) much
less predictable
• Many criteria available, none universally
applicable
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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
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Page 38 Siemens PLM Software
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
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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.
Innovative Methodology for Progressive Damage
Analysis in Composite Design
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
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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.
Innovative Methodology for Progressive Damage
Analysis in Composite Design
The stains represent the level of delamination
2015-06-16
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Page 41 Siemens PLM Software
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
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Page 42 Siemens PLM Software
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
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Page 43 Siemens PLM Software
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
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Page 44 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
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Page 45 Siemens PLM Software
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
Airbus Group Innovations
Realizing technological excellence and breakthroughs in
aircraft composite design
Airbus Group Innovations
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Page 46 Siemens PLM Software
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
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Page 47 Siemens PLM Software
Delphine Carrella
Thank You!
2015-06-16
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Page 48 Siemens PLM Software
Delphine Carrella
Questions, Comments, Suggestions?
Contact me:
Boris Vetter
Senior Consultant
SIEMENS Industry Software GmbH & Co. KG
Digital Factory Division
Product Lifecycle Management
Global Sales & Services
Otto-Hahn-Ring 6
81739 München, Germany
Mobile: +49 (174) 7341 606
Smarter decisions, better products.