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©2010 C
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Merging Analysis with Design and Manufacturing
for Composites
Presented By:
Chuck Higgins
Director, Latin America
VISTAGY, Inc.
2010 ANSYS South America Conference & ESSS User Conference
29 October 2010
Atibaia, SP - Brasil
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The VISTAGY Advantage
Domain
Expertise
Process
Knowledge
3D Integration
Industry-Specific
Solutions
Deep, synthetic,
cross disciplinary workflows
Deep understanding
of the industry
Airframe Structures
Composite Materials
Joints and Fasteners
Airframe Design/Analysis
Composite Manufacturing
Assembly Techniques
First Article Inspection
Native geometric integration
with underlying CAD/Viewer
data model
Catia, Pro/E, NX
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Proven Track Record of Innovation
20111993 2001 2006
CATIA V3
Unigraphics / NX
Pro/ENGINEER
CATIA V5
CATIA V4
CATIA V6
Comanche
B787A350 XWB
V-22
F-22
S-92
JSF Boeing
JSF LMTAS
F-35
CRJ700
GE90
C-Series
G650
MS21
GEnx
Delta
A380
Premier
COMAC 919
Ares / CCM
Mockup Solids & Weights
Analysis
Interface
RTM3D Annotations
Cross sections etc.
Optimized UIComposite
Engineering
Environment
Template Based
Documentation
Fiber
Placement
Laser
ProjectionFlat Pattern
Producibility
Grid/Structure
Based Design
Variable Offset
Surface Technology
Model
Based
Design
Model Merge
Skin Transfer
XML Design
Checking
COS
Quality PE
SimXpert
Integration
DFM ADD Project
Go Deep
Project
Graphite
Project
Take Flight
GamesaCener
Vestas
Sinoma
TPI
Dong Feng
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“A 4 to 1 savings in
production time was
achieved for complex parts
of the first aircraft.”
Bombardier Inc.
“VISTAGY promised
impressive reductions in
product development time for
our composite parts, and they
delivered on their promises.”
Renault 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.
“With FiberSIM, our first parts
were virtually perfect and we
were able to do it right the first
time.”
Sikorsky Aircraft Corp.
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Increased Use of Composites Over Time
1%
747
3%757/767
11%777
50%
787
Source: Boeing
Carbon laminate
Carbon sandwich
Other composites
Alenia Aeronautica
Spirit Wichita
Fuji Heavy Ind.Boeing Seattle
Kawasaki Heavy Ind.
Goodrich Aerospace
Vought Aircraft
Spirit Tulsa
Boeing Winnipeg
Korea Aerospace
Harbin AircraftFACC
Boeing Moscow
Korean Airlines
Aermacchi
DACC
787 - 50%Composites by Weight but almost
All Surfaces and Structure made of Composites
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Industry Specific Solutions….
Quality Planning Environment (QPE)First Article Inspection Planning and
Execution for Parts and Assemblies
– Definition and Manufacturing of Composite Detailed Parts
Airframe Design Environment (ADE)Engineering Definition of
Parts, Assemblies, Joints & Fasteners
Airframe Manufacturing Environment (AME)Manufacturing Planning for Parts, Assemblies, Fasteners
Define Intermediate manufacturing states
Define Conditions of Supply
Industry has a need for considering the entire airframe in the design process!
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XML XML XML
Manufacturing
Where Do VISTAGY Products Fit?
Conceptual Detailed
Installation
Quality
FS - CEE
ADE AME
System
Requirements,
Sizing
QPE
Preliminary
Loft,
Substructure,
Openings,
Sizing
FS-ACEE
Develop Design
in a Robust
Process
Planning for Efficient
and Low Cost
Manufacture
Verified
Requirements
Fabrication
CAPP
ERP
PDM
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Flexible Solutions for Manufacturing
Manufacturing– Nesting software– Cutting systems– Laser projection systems– Path planning software– Fiber placement machines– Tape laying machines– Ply verification systems
Simulation– Materials analysis– Structural analysis– Composites FEA– RTM flow– Failure analysis
Other– Cost estimation– Process planning
•CUTTING MACHINES AND NESTING SOFTWARE
•LASER PROJECTION SYSTEMS
•ANALYSIS AND SIMULATION SOFTWARE (FEA, CFD)
•AUTOMATED DEPOSITION
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Improving the Development Process
Efficient communications between Design, Analysis and
Manufacturing
Accommodate late changes to enable optimization
Bring appropriate feedback directly to design
Analysis
Shorter Development Time
More Optimized Structure
Design Manufacturing
ManufacturingDesign
Manufacturing
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Engineering Starting Point
Geometry
• Loft Surface
• Part Boundary
• System Lines
Stress Data
• Laminate Spec
for “Bays”
Stacking Tables
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FiberSIM Supports the Entire Engineering Process
FiberSIM Results
Loft Surface
Part Boundary
System Lines
Stress Data
Automatic Geometry Creation
Automatic Ply Creation
Automatic Change Updates
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Dynamic Design Changes with
FiberSIM ACEE
Design starts with loft surface and
substructure definition
Zones are created directly from
substructure definition
Ply layup is automatically generated
from zones
Model updates dynamically with
design changes–Stringer and frame spacing
–Zone thickness and laminate stress gage
–Ply drop strategy
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FiberSIM Integrated with FEA
Tools
FEA Tool
CAD/FiberSIM
Design Part
Mesh
Part
Populate
Properties
Run analysisLBC
•®
Fully defined
composite mesh
properties
Shared native
CAD geometry
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Structural Requirements and
Optimization Driving Zone
Changes...
Sizing Specification -
Add Plies
This can be done in
either product
Zone Modification
FEA
Thickness Plot
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... which Result in FiberSIM
Zone/Ply Changes ...
Import Ply and Laminate
changes into FiberSIM
Design rules are
automatically applied
NO MANUAL
INTERACTION
REQUIRED!
®
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... and can be Validated as a Ply-
Based Analysis
Load-cases are run against true Layup
Drop-offs and thickness variations are expressed with fidelity of mesh
FiberSIM Simulation provides true thickness and fiber orientations
FEA
Thickness Plot
45o ?
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Industry Specific Solutions for
Design…
Design
Release
Quickly Release
Designs To
Manufacturing
QPE
Loft
Datums
LoadsSizing Analysis
Structure Based
Skin Design
ProducibilityATL/AFP
Hand LayupForming
IML Surfaces Mockup, Mating,
Tooling
Joint
Definitions
Fast. Layout
Substructure
Design
Detailed
Fastener/Hole
DefinitionsDesign Rule
Validation
Metrics
ReportingWeights, CG, BOM
Release
DocumentationPlybooks, MBD
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... and Manufacturing
Release to
Manufacturing
Condition of
Supply
On-time
On-budget
On-spec delivery
TM
Automated
Drilling and
Fastening
Automated
Composite
LayupInspection
Layup
Cured Laminate
Dimensional
(AS9102)
QPE
QPE
Flat Patterns
Laser
Guided
Layup
200 Fifth Avenue ● Waltham, MA 02451 USA
+1.781.250.6800
www.vistagy.com
Chuck HigginsDirector, Latin America
+1.214.458.1775