integrated design and analysis of composite …© 2011 ansys, inc. september 22, 2011 1 integrated...
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© 2011 ANSYS, Inc. September 22, 2011
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Integrated Design and Analysis of Composite Structures using FiberSIM and ANSYS ACP
Olivier Guillermin, PhD
Director of Product and Market Strategy
VISTAGY, Inc.
© 2011 ANSYS, Inc. September 22, 2011
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Leading provider of industry-specific engineering software and services
Established in 1991
Headquartered in Waltham, Massachusetts, USA
Well established worldwide business
Nearly 300 customers across the globe
4500+ users
About VISTAGY, Inc.
Aerospace
Automotive
Energy
© 2011 ANSYS, Inc. September 22, 2011
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The world’s leading companies rely on VISTAGY to help them engineer success
Work how you thinkCommunicate more effectivelyMake better-informed decisionsReuse 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
© 2011 ANSYS, Inc. September 22, 2011
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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-SpecificSolutions
Deep, synthetic, cross-disciplinary
workflows
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
© 2011 ANSYS, Inc. September 22, 2011
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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
© 2011 ANSYS, Inc. September 22, 2011
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A Complete Engineering Environmentfor Composite Design
Design methodsply, zone, grid,
blade
Design verification
Producibility
Splicing, core design
Offset surface mockup, matingMaterials &
processesCost modeling
Weight calculations
Design Review
CFD/StructuralLayout
Conceptual partdefinition
Interface to analysis
© 2011 ANSYS, Inc. September 22, 2011
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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
On timeOn budgetOn spec
© 2011 ANSYS, Inc. September 22, 2011
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FiberSIM Open Architecture Enables Customer Driven Best-in-Class Solutions
Cutting and Nesting Partners
Laser Projection PartnersAutomated Deposition Partners
© 2011 ANSYS, Inc. September 22, 2011
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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!
© 2011 ANSYS, Inc. September 22, 2011
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The analysis models lack accuracy and completenessFiber orientations are incorrect; not accounting for compound curvatureZone or ply shapes used in FEA are approximate; limited by the data availablePly dropoffs and other key design details are missing
The transfer of data between design and analysis is slow and manualAnalysts looking for many more cycles, faster, earlier in the processTransfer of zone and laminate specs to design done by tables, diagramsTransfer of ply shapes and fiber orientations to analysis done by drawingsLengthy paper/verbal process for design changes, analysis changes
The data exchange process is unreliable and incompleteUse of spreadsheets, verbal communications and emailsTime consumingErrors due to interpretation, inattentionDesigners and analysts feel they don’t get complete information from the other parties
The engineering process is too sequentialDelays are incurredLimits the number of iterations and changes possible
Eventually: there is a disconnect between design, stress and manufacturingWhat’s analyzed is not what’s designed and manufactured
Main Pain Points in Composite Design and Analysis Integration
© 2011 ANSYS, Inc. September 22, 2011
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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
© 2011 ANSYS, Inc. September 22, 2011
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Support Abstraction on Multiple Levels
Full scale validation
Aircraft Sections
Stiffened panels
Parts and joints
VCCT, damage models
Composite mesoand micro models
Specification
Validation
© 2011 ANSYS, Inc. September 22, 2011
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Enabling a Concurrent Design and Analysis Workflow
CAE
CAD
PreliminaryDesign
LayoutDesignDetails
Sizing
ManufacturingDetail
IntegrateSizing
Investigate
IntegrateOptimization
Refine
OptimizationStrategy
Optimize Validate
ZONES ----------------------------------- LAYERS -------------------------------------- PLIES
© 2011 ANSYS, Inc. September 22, 2011
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FiberSIM Ply Data Export to ANSYS Composite PrePost
FiberSIM
ANSYS ACP
© 2011 ANSYS, Inc. September 22, 2011
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ANSYS Composite PrePost Ply Data Export to FiberSIM
FiberSIM
ANSYS ACP
Principal stress plot
Deformation plot Thickness plot
© 2011 ANSYS, Inc. September 22, 2011
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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:
© 2011 ANSYS, Inc. September 22, 2011
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In recent years, achieving deeper integration of composites design and analysis has become a key challenge
Need to better and faster optimize composite parts; for weight and cost reduction
Abstractions and open format data exchange is the fastest and most efficient route to powerful integration of design and analysis software
Together VISTAGY and ANSYS are actively engaged in a comprehensive integration effort
Ply and zone design; optimization and validation analysis; for multiple part types; across industries (aero, auto, wind, marine)
Take Away