the value of fibersim for a composite design workflo€¦ · the value of fibersim for a composite...

Realize innovation.Unrestricted © Siemens AG 2017

The Value of Fibersim for a

Composite Design Workflow

PLM Connection Europe 24/10/2017

Boris Vetter, SIEMENS PLM Software

Unrestricted © Siemens AG 2017

2017.10.24 PLM Europe Siemens PLM Software

• Formerly Vistagy, acquired by Siemens PLM Software 2011

• Primary focus on Automotive and Aerospace industries

• Solutions

• Specialized domains

• Industry focused

• End-to-end solutions

• Multi-CAD, open architecture

• 300+ global customers

• Located outside of Boston, Massachusetts, USA

Siemens Specialized Engineering Software



Huge improvements to fuel economy required by 2025!

Past: ~0.5 mpg per year

Future: ~2.0 mpg per year

4X CURRENT RATE

Time to act is NOW!

Fuel Economy & Emissions Reductions Are

Driving Lightweight Design



Audi R8 – Designed with FIBERSIM



Composite Engineering Environment

Template Based Documentation

Analysis Interface

Fiber PlacementResin Transfer Molding

Laser Projection

Flat Pattern

Producibility

Siemens Composite Design Innovations and Composites Growth in

AirframeSiemens Has Pioneered the Major Innovations in Composite Design Software

3D Annotations Cross sections etc.

Grid/Structure Based Design

Variable Offset Surface Technology

Composite Model Based Design

Mockup Solids & Weights

Model Merge

Skin Transfer

20251993 2000 2005

Open XML Standards

Bi-Directional CAE Interfaces

DFM ADD

Next Generation Composite

Development Capabilities

1995

10%

30%

40%

60%

50%

20%

2010 2015 2020

HDF5 Analysis Exchange Format

Multi-Ply Methodology

Structural Weight of Composite

Material in Advanced Airframes

Year

PLM Integration

MES Integration

Boundary Workflows

Next Generation

Aircraft Designs



Engineers may taylor their materials when using advanced composite

materials …

… which adds additional

possibilities

… and additional challenges

besides „just“ defining the shapes Number of plies

Types of fibers / resins

Ply orientations

Shape influence

Reinforments

Sandwich design

Joining technologies

…

+ Material Design



Source: Best Practices in Composite Engineering, VISTAGY, Inc.

Over 75% of companies either replace a metal part or consolidate a minimal number of parts

Composites treated as “black metal”

Only 30% of companies met weight targets

Due to product overdesign and uncertainty – reduced less than 30%

42% saw part cost increase by 20% or more

Due to inefficiencies in design, manufacturing and material waste

Only 9% of companies meet design release schedules

The ones that met design release schedules invested in people and technologies

What’s Happening in the Industry ?



Source: Best Practices in Composite Engineering, VISTAGY, Inc.

Over 75% of companies either replace a metal part or consolidate a minimal number of parts

Composites treated as “black metal”

Only 1/3 of companies met weight targets

Due to product overdesign and uncertainty – reduced less than 30%

42% saw part cost increase by 20% or more

Due to inefficiencies in design, manufacturing and material waste

Only 9% of companies meet design release schedules

The ones that met design release schedules invested in people and technologies

What’s Happening in the Industry ?

How can engineering technology help to improve

performance on composite intensive programs?



• Saving weight

• = Saving material cost !

Uncertainty leads to higher weight and higher costs



SIEMENS PLM Software Solutions to design Lightweight

Structures with Advanced Composite Materials

Designing and manufacturing innovative,

durable and lightweight composite structures

Designing and manufacturing

complex assemblies and large structures

Predict structural behaviour

during manufacturing and operation

SIMCENTER

SYNCROFIT

FIBERSIM



FIBERSIM

Production-proven success

addressing the challenge of

engineering lightweight

structures for 20+ years with

the Fibersim™ portfolio of

software.

Saves over

50% in

design

efforts

Reduces

manufacturing

scrap by 90%

Improves

quality and

reduces risk

Automates

capturing of

design intent

Ensures

accuracy with

design

changes

Supports

NX, CATIA

and Creo

platforms

Works

inside

native CAD

Direct

integration

with PLM

workflow

Bi-

directional

links

to CAE



Fibersim Is a Multi-CAD Solution

FIBERSIM

Same user experience across all CAD platforms

http://magazin.isap.de/wp-content/uploads/2014/04/NX-treatment-CMYK-Stone_300x150.png




Support end-to-end engineering process workflow…

plus a seamless link to manufacturing

CAD surface

Define

Laminate

Design, Producibility,

Analysis Iterations

Open CAE

Architecture

Accurately Solve forStiffness, Strength, Thermal,

NVH, Acoustics, Durability,

Crash…

Bi-Directional

Analysis Interface

Design

Validation

Auto-generate

Drawings and

Documents

Auto-generate Flat

Patterns,

Manufacture DataOptimize

For

Light

Weight



Fibersim Supports an Efficient Workflow between Design and

Analysis at All Stages of the Process

Sim

ce

nte

ro

r

oth

er

CA

EF

ibe

rsim

Direct to Simcenter

or

Open Exchange

Direct to Simcenter

or

Open Exchange

Direct to Simcenter

or

Open Exchange

Preliminary DetailedDesign Evolutions



Fibersim Is Integrated, Open, and Specialized

FIBERSIMAnalysis

Exchange

Many Others …

Open support not

just for CAD, but for

industry standard

CAE tools

Bi-directional

analysis interface

supports efficient

change processes



http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCPb02oSu-sgCFYE6PgodL3kP3A&url=http://www.skywarder.eu/blog/en/2015/01/31/skyward-cooperating-msc-software/&psig=AFQjCNEP9ZfyKptQ_EvBVn_91gKX_O-P_Q&ust=1446849897111898




Fibersim’s Powerful Design Methodologies

Zone BasedPly 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



Producibility

Design Release

Efficient Hand-off

From Design To

Manufacturing

3D Geometry

Tool Surface Ply / Zone

Definition

Detailed Ply

Shape Definition

Manufacturing

DocumentationPlybooks, 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



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



FIBERSIM

Producibility Simulation & Flat Pattern Generation



©2006 C

onfiden

tial

FIBERSIM

Manufacturable Composite Designs



Manufacturing Process Influence on the Fiber Orientations

Simulate the manufacturing process as it is expected to occur



FIBERSIM DFM Splicing Demonstration



Resolving Composite Product Development Complexities –

Manufacturing

Modern airframes employ a high level

of automation in their manufacture

Important to take unique composite

manufacturing constraints into

account during design

Material and machine limitations

can reduce the speed of production

and increase the weight of parts

It is important to maintain a digital

thread for both manual and machine

layup to improve rate and quality



Siemens has the industry's most open machine partnership program to allow maximum flexibility in your machine investments

Creates laminate design features in context of machine characteristics

Machine limitations taken into account to support automation and avoid rework of data

Fibersim Supports Design for Automated Deposition



1 2 3 4 5

Changing technologies in Aerospace

Additive Manufacturing and Robotics

ServicesProduction

execution

Production

engineering

Production

planning

Product

design

Traditional Solution (Portal) Robot with 840D sl

- Faster: 15h 1,75h

(no finishing required)

- More flexibility: higher

reachability of the robot

- Better quality and elimination of

supporting structures



Production Assessment

Machine Limitations

Minimum Course

Across Cut Angle

Minimum Cut Width




Minimum Course Solutions

Special features increase production rate and help manage additional material added for manufacturability

Automated application of a Bird Beak or Bat Ear features ensures maximum rate at minimum weight

Minimum Course

Length




Minimum Weight, Maximum Rate SolutionsAssessing Course Challenges – Example Min. Course Length


Automation in creation of manufacturing

features assures easy updatability of 100s or 1000s of features during design process

Necessary to achieve

an efficient process and high levels of quality



Data Sets for Specialized Composite Manufacturing Processes

Ply

Cutting

Laser

Projection

Automated Deposition

http://www.lap-laser.com/index.html

http://www.lap-laser.com/index.html

http://www.z-laser.com/zlaser_de/home

http://www.z-laser.com/zlaser_de/home



Manufacturing Datasets

• Generate flat patterns, laser

projection, datasets for

ATL/AFP and

documentation

• Revision manage them in

Teamcenter

FIBERSIM for Manufacturing

Teamcenter











SIMCENTER

SYNCROFIT

FIBERSIM



BMW 7 Series 2016 (G11/G12)



Body

Technology

Materials Joining

Methods

Joint

Combinations

Current Steel 1 1 1

All Aluminum 1 3 3

Future

Multi-Material

5+ 10+ 25+

Numerous Joining Options

Challenges of joining Mixed Material

structures



Future predictions in BiW assembly

Source: http://www.repairerdrivennews.com/2017/06/21/car-whitepaper-predicts-future-of-body-materials-everything-but-mild-steel/

http://www.repairerdrivennews.com/2017/06/21/car-whitepaper-predicts-future-of-body-materials-everything-but-mild-steel/



BMW i3

Carbon Fiber

BMW 7 Series

Carbon Fiber

Reinforced Steel

Ford F150

Aluminum

Lightweight design a sweeping change in the automotive industry

Future trend for the

body-in-white (BIW)

consists of a mixed

material approach

including composites

– by 2025, automotive

companies expect

60% of their vehicles

will be comprised of at

least 20% carbon fiber.

Ford F150 BIW (2015):

5.000 Weld Spots

2.000 FastenersSources: (1) “How Prepared Is the Automotive Industry? Solutions for Meeting Fuel Efficiency and Emissions

Standards” Aberdeen Group, Inc., 2014.

(2) Industry Poll: “Composites to Dominate Automotive R&D for Lightweighting” GALM, April, 2015.

LIGHTWEIGHTING EVOLUTION



Part footprint sizing driven by fastener edge margin rules

Assembly processes driven by Joint definitions (co-curing, bonding)

Composite Specific Design Rules

• Ply positioning

• Drop-off rates

• Material compatibility

• Ply edge to fastener

High-Cost, Long Lead-Time

Diverse manufacturing processes

• AFP Skins

• Formed shear ties and stringers

SYNCROFIT – Manage Assembly and

Fastener Structure Complexities



Optimized mixed material BIW with Syncrofit

Leverage PLM for

the digital thread to

the factory floor

Visualize Fastening

locations and material

stacking data

Validate Design Rules

and interface with CAE

Optimized Mixed Material Vehicle

Define

Assembly

Joints Develop Fastening Patterns

from design rules

Define Joining Details

(Riveting, Gluing, Seam Sealing)











SIMCENTER

SYNCROFIT

FIBERSIM



SIMCENTER 3D

Multi-discipline integration

Best-in-class simulation modeling

Openness and scalability

Leading in system simulation

Leverage industry expertise



SIMCENTER 3D is an OPEN environment to quickly

model & analyse Composites structures

Simcenter 3DDesign

Exchange

CPD

Stacking sequence :

Fiber orientations ; Ply

thickness ; Ply name

Material : name,

properties and units.

Starting point and

direction of draping

Expose ply angle and

rosette

Import core plies

Auto-create group with

unmapped elements

NX Nastran

LMS SamcefFibersim

Design

Exchange





Access to Internal & External FE Solvers

Open Simcenter Laminate Composite FEA-Preprocessor:

Composites Analysis - Supports all common Solvers

Static

Dynamic

Thermal

NVH

Acoustic

Durability

Ply and Zone Definitions Composite Design and Simulation interface

Composite Design Optimization



NX Nastran

Design Optimization

SOL 200

NX Nastran Laminate Optimization

Optimized



NX Nastran Design Optimization

Reduce UncertaintyResults:

Displacement objective:

Initial design Best asymmetric design Best symmetric design

-30

30

90

90

60

-60

1

2

3

4

5

6

-48

13

76

-65

53

-40

-47

47

90

-90

51

-51

8.7 mm

100 %

7.8 mm

90 %

8.4 mm

97 %



Progressive damage simulation

Strength / Stiffness Analysis / Linear Response Buckling and Post Buckling analysis (implicit

solver)

Manufacturing simulation

Simcenter Structure for Composites Analysis

Finite Element solver NX NASTRAN & SAMCEF MECANO

• Displacement

• Stress

• Strain

• Frequencies

•

• Nonlinear with large

displacements/rotations, large

strains & various types of

contact and gluing conditions

• Dedicated algorithm for

buckling, post-buckling

• Classic Failure criteria computed

directly by FE solver

(performance): critical ply, value,

load case

• Progressive damage simulation for

inter- or intra-laminar damage

modeling

• Curing analysis (spring-back)

• Effects on the mechanical

behavior and the tolerance for

assembly.

1 2

3 4











SIMCENTER

SYNCROFIT

FIBERSIM



Fibersim Is the Common Solution to the Complexities Inherent in

Composite Airframe Development

Cross disciplinary workflows to

enhance the development of weight

and rate optimized designs

Common product definition for

accurate and efficient

communication

Specialized capabilities for unique

composite design and

manufacturing challenges



“Without FIBERSIM we wouldn’t be able to keep up with the

production schedule for a program such as the Joint Strike

Fighter.”

Michael Schramko, COO, Quickstep Technology

Unrestricted © Siemens AG 2017 Realize innovation.


2017.10.24 PLM EuropePage 51 Siemens PLM Software

Thank You!


2017.10.24 PLM EuropePage 52 Siemens PLM Software

Contact

Boris Vetter

Senior Consultant

SIEMENS Industry Software GmbH

Digital Factory Division

Product Lifecycle Management

Global Sales & Services

Specialized Engineering Software

Otto-Hahn-Ring 6

81739 München

Germany

Mobile: +49 (174) 7341 606

[email protected]

www.siemens.com/PLM

mailto:[email protected]

http://www.siemens.com/PLM