S13-1 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation SECTION 13 MANUFACTURING INTEGRATION

S13-2 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation

S13-3 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation OVERVIEW: INTEGRATION WITH DESIGN AND MANUFACTURING n An integrated process is needed to be efficient in doing work. MSC.Laminate Modeler provides several outputs to aid the design and manufacturing process. u On-screen visualisation of the draping results u Export draped pattern u Export flat pattern u Export mold surface u General analysis data u Export Ply Book n Simulation is rapid, so results can be used to alter ply specification immediately

S13-4 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation EXPORT OF PATTERNS AND SURFACES n Information about the plies, flat patterns, and draped patterns can be exported when creating a Ply Book n A ply book is a reference set of what has been modeled. It can be used both by designers and layup workers. n The ply book is in HTML or postscript format n The ply shapes are exported as separate files

S13-5 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation n The mold shape could be exported n This must be done prior to making the layup. Alternatively the option can be enabled and the layup can be re-created or modified with no actual changes. EXPORT OF PATTERNS AND SURFACES (Cont.)

S13-6 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation n The draped pattern can be exported in IGES or DXF formats n Can then u Import file into a CAD system to form a record of fiber orientations u Use the data for a ply-book as a manufacturing aid u Use the data to project or mark onto mold tools to facilitate initial fabric placement and subsequent forming EXPORT OF DRAPED PATTERN SURFACE

S13-7 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation n The flat pattern can also be exported in IGES or DXF formats n Can then u Plot pattern on paper to use as a guideline for manual cutting using scissors or a knife u Import file it to a CAM system to create plies automatically EXPORT OF FLAT PATTERN SURFACE

S13-8 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation n There is an significant time saving compared with conventional experimental method of flat pattern generation n Average part has 50 plies n Flat pattern generated manually using paper, manually digitized n May take 2 man-days per ply for a complex ply n 100 man-days per component n Target using MSC.Laminate Modeler is 15 minutes/ply n ~ 2 man-days per component n ~ 98% time reduction EXPORT OF FLAT PATTERN SURFACE (Cont.)

S13-9 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation EXPORT OF MOLD SURFACES n The mold surfaces are created based on the layup of plies. The program creates both the top and bottom mold surfaces. n The surfaces are faceted, with each facet generated from an element face

S13-10 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation EXPORT PLYBOOK, CONTINUED n Creates files for use in reporting or manufacture n Draping simulation rerun automatically to generate required data n Layup report can be written in HTML with PNG graphics for use with Web Browsers n Ply data options can be set as required, e.g. to generate flat patterns for each ply

S13-11 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation PLYBOOK IN HTML

S13-12 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation FABRIC THICKENING n When material shears, the fabric typically thickens n This is calculated on the basis of constant volume n Changes fiber volume fraction in standard closed molds, causing fiber breakage or resin starvation n The amount of fabric thickening is stated after a ply is made n Fabric thickening is taken into account when making the mold surfaces

S13-13 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation MODEL COMMUNICATION n Simulation must match manufacturing n MSC.Laminate Modeler creates layup file n File contains all relevant laminate details n Viewed using Laminate Tools Viewer ( n Communicate across departments MSC.Patran MSC.Laminate Modeler Laminate Tools Viewer Layup file Laminate Tools Viewer

S13-14 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation LAMINATE TOOLS VIEWER Tree View Shows relationships between materials, plies and the layup. Summary & Feedback Window Contains comprehensive details of selected entity. Familiar Controls For rotation, display options. Viewport Shows ply and laminate details clearly, and regenerates draping simulation. Multiple models for comparisonPreselection data interrogation Windows Application Familiar to all; cut/paste data to Office applications.

S13-15 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation SPRINGBACK ANALYSIS n A common problem in the composites industry is the high cure temperatures n Thermal effects have two sources. First, the mold tool will expand when heated so there may be an overall increase in component size. Second, when cooling to room temperature, the component experiences deformation due to the anisotropic thermal expansion properties of the composite material. n The solution to this problem is to compensate for the springback in the mold surface shape. This can avoid having costly tooling mistakes or needing to have adjustable mold tools. n MSC.Laminate Modeler is capable of doing springback analysis in order to make a compensated tool.

S13-16 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation ANISOTROPIC THERMAL PROPERTIES n The governing equation when incorporating thermal effects in an orthotropic material looks like u Where T is the current temperature, and T REF is the reference temperature. The thermal expansion coefficients are 1, 2 and 3.

S13-17 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation SPRINGBACK ANALYSIS PROCEDURE n Springback analysis is performed as a linear statics thermal run for the nominal model shape u Reference temperature set to the cure temperature Component temperature set to ambient, e.g. 20° C n Displacements from the analysis are the component springback u Subtract displacements from model to give compensated mold shape n To compensate for mold expansion scale model by

S13-18 PAT325, Section 13, February 2004 Copyright 2004 MSC.Software Corporation n Perform Workshop 8 Springback Analysis of a Jet Engine Cowling in your exercise workbook n Be sure to ask for help on anything you dont understand EXERCISE