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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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