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CAD: Composites Are DifferentCAD: Composites Are Different

Moving Beyond Yesterday’s CAD Moving Beyond Yesterday’s CAD

Tools to Accelerate Adoption in MassTools to Accelerate Adoption in Mass--

Produced AutosProduced Autos

Rani RichardsonRani Richardson

CATIA Composites Product SpecialistCATIA Composites Product Specialist

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AgendaAgenda

Why Composites for the automotive industry

Current CAD challenges with Composites automotive

components

CAD: Composites are different

No one likes to be the leader

Enabling the automotive market with CAD tools to get

the job done

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8 Ι Why Composites for the automotive industryWhy Composites for the automotive industry

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Composites Enable a More Sustainable World

Composites are strategic for “Eco-friendly” aircrafts Composite technology used in airplanes has increased from 5-10% to 50% in the

recent B787 and A350 aircrafts. The massive adoption of lightweight composites

allows to aggressively lower fuel consumption, reducing carbon dioxide emission.

Composites in mass production cars also reduces emissions Given the pressures to improve fuel economy and lower emissions, engine

technology and alternative power train can only go so far. Making vehicles lighter by

replacing metal with lightweight, impact and corrosion-resistant polymer composites,

is a strategic way to meet market needs for improved performance.

Renewable wind energy enabled by composites As demand on oil reserves and derived fuel price continue to rise, renewable forms of

energy are becoming more cost-effective and profitable. Wind power is the world’s

fastest growing energy source and could provide 20% of electricity by 2030.

Aircraft Fuel Consumption per seat and trip: The B787 and A350 are 20% more efficient than all current quads and twins aircraft

Pervasive use of thermoplastic reinforced polymers in recent mass production cars

Composites projects are aimed at sustaining environmental challenges

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Why Composites in automotive?Why Composites in automotive?

To reduce weight -> Lower fuel consumption, lower emissions

To decrease number of parts -> Design flexibility

For structural robustness -> Safety improvement

For styling innovations -> New aesthetics

For NVH improvements (reducing noise) -> Better comfort

For fatigue resistance, no corrosion -> Improved lifecycle compared to steel

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From “Body in White” to “Body in Black” ChallengesFrom “Body in White” to “Body in Black” Challenges

Steel

BiW

Requirements for the body to be lighter. New Material introduction

Composites material

introduced for body

panels in the

mass market

Now!

Plastic BIW

+

Steel BiW

Composite BiW+

Steel / Alu BiW

Aluminium

BiW 2025+

Full Composites

Body in White

BODY IN

BLACK

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Current CAD challenges with Composites Current CAD challenges with Composites

automotive componentsautomotive components

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From metal to composites: facing new challenges

Current status Tools for design, analysis and manufacturing are in different formats

Lack of collaboration, automation and communication

CAD/CAE tools intended to work with metals

Trial and error on the Shop Floor

Composites materials are costly

Future New tools for end-to end process

Product design ->virtual testing->ensure manufacturability

Unified platform to accelerate collaboration

Concurrent engineering reduces cycle time

Validate manufacturing by simulating what will happen on the Shop Floor

Less expensive Composites materials

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Mastering a complex design process

Factors to take into account:

Material properties

Software tool must be able to handle frequent design changes

Balance between weight and design optimization

Design software must be able to automatically communicate with

and receive feedback from analysis and manufacturing

Manufacturing constraints must be integrated into the design

model

Simulate manufacturing during the design phase to ensure

designed intent and as-built model match

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8 Ι CAD: Composites are differentCAD: Composites are different

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Composites: EndComposites: End--toto--End SolutionEnd Solution

Enable change manageable and concurrent composites planning, programming and execution

WaterJet &Ultra-sonic Cutting, Non Destructive Inspection

Perform Process Planning in DELMIA

Execute Work InstructionsDistribute Machine Code DataOptimize Processes

ATL/AFP Machine/RobotsMetrology, and Reporting

Author Work Instructions

Configuration-managed and effectivity-controlled Product/Process/ResourceInfrastructure

Design in CATIA Composites Part Design (CPD)

Stitching

Automated Processes: Simulate and Program Machine with DELMIA

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Mastering a complex design process Mastering a complex design process

Shifting to non-isotropic materials means mastering a new design process

4 approaches to preliminary design – zone, grid, solid slicing, and manual

Rapid design changes that reduce the number of prototypes

Collaboration with virtual testing

and manufacturing early in the

lifecycle saves time and

ensures a better quality product

Go to market faster

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8 Ι No one likes to be the leaderNo one likes to be the leader

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Composites as a core business

Best-in-class Composites Products Required Design and manufacture every part in an optimum way

Harmonize processes, methods and tools

Support a single harmonized end-to-end process

with a single toolset at OEM and for its Supply Chain

Traditional Sequential Process No efficient collaboration capability

No ability to get feedback

Limited ability to anticipate

Many Industrial Choices Transformation of core / non core business

In-house or externally subcontracted activity

Earlier Supply Chain involvement

Synergies development

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Applying lessons learned in the aerospace industry

3 main objectives:

o Development lead time reduction

o Go to Market with full maturity

o Increase ramp-up capacity

With the expertise acquired in the Aerospace field,

CAD designers can propose not only technological

solutions but also to help customers accelerate the

learning curve by leveraging scalable practices.

Identify & develop market

Best In Class end to end solutions

Competitive solution development

improving baseline

Best solution on existing platform

Enhancement to reach baseline

Best Practices - Secure Deployment

Competitiveness

Best in Class on the market

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Enabling the automotive market with Enabling the automotive market with

CAD tools to get the job doneCAD tools to get the job done

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Composites challenges require a PLM integrated solution

Mostly all composites structures are designed in CAD solutions not intended for Composites, where Design, Analysis and Manufacturing are not integrated.

A sequential process where the different components interface with no efficient collaboration capability, no ability to get feedback, and limited ability to anticipate

Only a PLM Integrated solution allows to fully optimize the complete process.

Unique ability for the Designer to work in functional context, get accurate feedback from Simulation and Manufacturing and even better, anticipate

and avoid problems early in the process.

Physical world

IP

Capitalization

Hand Lay-Up

RTM, VARTM, VARI

Automated Tape Laying

Automated Fiber Placement

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3D simulation for Composites

Bring FEA to Designer with easy to use integrated tools dedicated to preliminary

analysis during design stage.

Enhance productivity for Analyst Expert: tighter integration to Design:

Allows for quick simulations on complex models

Perform accurate advanced virtual testing:

Non linear Structural and Thermal analysis

Fracture and Debonding analysis

Crush and Impact simulation

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From manual to automated manufacturing processes

Challenge:

- Time consuming and costly trial and error

o Cutting plies, placing them on the mold using manual

measurement

o If they don’t fit, start the process over

- Complex shapes make it hard to predict how material will drape on

the mold

- Not a repeatable or optimized process

Improvements when moving to a PLM platform:

- Output for various shop floor systems for automated fiber placement and tape laying systems

- Simulation capabilities ensure that the detailed design is manufacturable

- Generation of flat patterns to be exported to a ply cutting machine or laser projection systems

- Generate output for RTM machines directly from CAD design software

- Shop floor documentation can be printed, created as a PDF file or an electronic ply book

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SummarySummary

Not all CAD tools are the same

Not all CAD tools are designed for complex materials

such as Composites

Not all CAD tools provide integration with other

disciplines such as CAE and CAM

Not all CAD tools can reduce design and manufacturing

time while increasing time to market

Not all CAD tools can leverage co-design and enable

concurrent engineering

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Composite Automotive CommunicationComposite Automotive Communication

Composites for Mass Produced Vehicles:

Leveraging an End-to-End Solution for

Design, Analysis and Manufacturing http://www.3ds.com/products/catia/resource-

center/collaterals/

Flying Off The line: How Aerospace

Knowledge Can Accelerate the Use of

Composites in Mass Produced Autos http://www.autofieldguide.com/Webinars

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