The design process is focused on the definition of the components from concept studies to detailed geometry. The layup is modeled according to manufacturing and structural requirements. A ply-by-ply digital solid model of the laminated layered geometry is created. This can be of key importance where B-surface definition is required, for example for RTM matched tooled components or for the correct design of core inserts in sandwich designs. The availability of a virtual Ply Book is also key for generating component cost models. Fully associative and parametric models are generated in order to enable multiple geometry iterations in a rapid development timescale and the use of specific tools for composite materials (Dassault Systemes Catia-CPD Technology) allows an effective definition of the manufacturing instructions (plybooks) with optimal lamination sequence (starting points, cuts,…). Manufacturability analysis is used to define effective directions of fibers in structural behavior simulation. Import-export of draped models trough CAD and FEM environment, is based on dedicated software procedures for the maximum overall efficiency during iterative development and optimization activities.
Layup study, stacking and geometry optimization of the plies and zones in order to obtain a flexible model, adaptable to the future geometrical modifications. Plies definition according to the geometrical features of the model and to the results of the first studies coming out from the FEM.
CAD model of the component containing all the information related to the staking and to the layup. Completely parametric model in order to be rapidly updated according to the releases of new geometries.
DES COMPOSITES can supply documentation containing all the necessary information for the manufacturing of the component including Ply books, critical manufacturing instructions, part design with relevant tooling split lines, part trimming and machining details with geometrical and dimensional tolerances and any other form of technical documentation as required by the specific application. The Ply Book is generated directly from the digital 3D layup model to reduce time to production and to maximize conformity of production. A set of flattened templates in .dxf format is also normally produced automatically to feed directly into the nesting process and achieve 100% alignment between digital models and manufacturing of parts thus eliminating ambiguity or interpretation.
Integration with manufacturability studies is key to avoid costly and time consuming loops of design. The aim is to implement “design for manufacturing” in parallel to the component design as much as possible. DES COMPOSITES will deliver component tooling feasibility analysis (draft, split lines), drapability analysis with optimization of fiber orientation and definition of darts/cuts/drop-off, geometrical and dimensional manufacturing tolerances feasibility analysis, feasibility of assembly, feasibility of CNC trimming or machining.
The rapid and efficient data exchange between FE and geometric modelling is of capital importance to withstand the frequent update of the models during multi-disciplinary design and during the optimization process.
