Copyright DASSAULT SYSTEMES,1,Aerospace Composites Preliminary Design,CATIA Training Foils,Version 5 Release 14September 2004 EDU-CAT-E-CPD-FF-V5R14,Copyright DASSAULT SYSTEMES,2,Course Presentation,Objectives of the course In this course you will learn how to generate Composites parts for aerospace from Preliminary Design to Manufacturing Detail Design Targeted audience Composites for Aerospace Designer Prerequisites Part Design Assembly Design Wireframe and Surface Design Drafting,4 days,Copyright DASSAULT SYSTEMES,3,Planning (1/2),Copyright DASSAULT SYSTEMES,4,Planning (2/2),Copyright DASSAULT SYSTEMES,5,Table of Contents (1/8),PRELIMINARY DESIGN CPD Workbench Presentation p. 13 Accessing the Workbench p. 14 General presentation p. 15 CPD Preliminary Design tools p. 16 CPD Engineering Detail Design toolsp. 17 CPD Manufacturing Detail Design toolsp. 18 Composites Catalogp. 20 Defining New Material p. 21 Defining FEA Properties p. 22 Defining Composites Parametersp. 23 Laminate Parameters p. 24 Selectioning Material Catalog p. 25 Defining Directions p. 26 Group of Zones p. 27 Creating Group of Zones p. 28,Copyright DASSAULT SYSTEMES,6,Table of Contents (2/8),Zones Parametersp. 29 Creating Zone contours p. 30 Creating Laminate p. 31 Selecting Rosette p. 32 Modifying Zone contoursp. 33 Modifying Laminatep. 34 Transition Zonesp. 35 Defining Transition Zone p. 36 Modifying Transition Zonep. 37 Refining Transition Zonep. 38 Connection Generator p. 39 Analyzing Structural Zonesp. 40 Analyzing Transition Zonesp. 41 Storing/Checking the Connection Generator Featurep. 42 Updating the Connection Generator Featurep. 43 Impose Thickness Point p. 44 Defining an ITPp. 45 Modifying an ITP p. 46,Copyright DASSAULT SYSTEMES,7,Table of Contents (3/8),Stack-up file from Zones p. 47 Creating an Excel Stack-Up File p. 48 Zone Connections optionp. 49 Modifying Stack-Up Filep. 50 Import Laminatep. 55 Importing Laminatep. 56 Solid and Top Surface from Zones p. 57 Defining Solidp. 58 Defining Top Surfacep. 59 Plies Creation From Zonesp. 60 Creating Plies From Zones with Tapers p. 61 Creating Plies From Zones with Staggering valuep. 62,Copyright DASSAULT SYSTEMES,8,Table of Contents (4/8),ENGINEERING DETAILED DESIGN Limit Contourp. 65 Relimiting Plies Geometry p. 66 Limit contour on Plies from Zones with Staggering Value p. 67 Plies Groupp. 69 Creating Plies Group Automaticallyp. 70 Creating Plies Group Manually p. 71 Manual Plies Creation p. 72 Defining Geometry p. 73 Defining Attributes p. 74 Core p. 75 Defining Core p. 76 Modifying Core p. 77 Ply Exploder p. 78 Exploding Plies into Surfaces p. 79 Cross-Sectioning with DMU p. 80,Copyright DASSAULT SYSTEMES,9,Table of Contents (5/8),Managing the Part p. 83 Reordering the Partp. 84 Replacing Shellp. 85 Renaming a Zonep. 86 Renaming a Taperp. 89 Ply shadingp. 92 Removing Ply Shellsp. 93 Symmetry Creation p. 94 Defining a Symmetry Pivotp. 95 Defining a Symmetry Non Pivotp. 96 Ply Table p. 97 Creating a Complete Excel Ply Table Filep. 98 Creating an Excel Ply Table File per Group of Pliesp. 99 Numerical Analysisp. 100 Defining Numerical Analysisp. 101 Exporting Numerical Analysisp. 102,Copyright DASSAULT SYSTEMES,10,Table of Contents (6/8),Core Sample p. 103 Core Sampling Analysisp. 104 Core Sampling Storagep. 105 Core Sampling Exportp. 106 Drawing p. 107 Drawing Generationp. 108 Defining General Sheet: Solid activep. 109 Defining General Sheet: Explode activep. 111 Defining Sheet for Table Integrationp. 115,Copyright DASSAULT SYSTEMES,11,Table of Contents (7/8),MANUFACTURING DETAILED DESIGN Manufacturing Data Structure p. 118 Defining Manufacturing Data Structurep. 119 Manufacturing Surface Swapping p. 120 Swapping Manufacturing Surfacep. 121 Edge Of Partp. 123 Creating Engineering Edge Of Part (EEOP)p. 124 Creating Manufacturing Edge Of Part (MEOP)p. 125 Material Excess p. 126 Defining Material Excessp. 127 Multi Splice Creation p. 128 Defining a Multi Splicep. 129 Producibility Analysisp. 132 Defining Producibility Analysisp. 133 Storing Producibility Analysisp. 134,Copyright DASSAULT SYSTEMES,12,Table of Contents (8/8),Darts p. 135 Defining dartsp. 136 Flattening p. 138 Defining Flatten with Rotated optionp. 139 Defining Flatten without Rotated optionp. 140 Export p. 141 Exporting Plies : 2D and 3D entitiesp. 142,Copyright DASSAULT SYSTEMES,13,CPD Workbench Presentation,You will become familiar with Aerospace Composites Preliminary Design main features Accessing the Workbench General presentation CPD Preliminary Design tools CPD Engineering Detail Design tools CPD Manufacturing Detail Design tools,Copyright DASSAULT SYSTEMES,14,Accessing the Workbench,Accessing the Workbench Modifying CATIA environment Tools/Option/General General User Interface Style: CATIA P3,Copyright DASSAULT SYSTEMES,15,General presentation,CPD tools,CPD features,Product tree,Standard tools,Copyright DASSAULT SYSTEMES,16,Parameters,Creating Zones : Contours + Laminate,Creating Transition Zone,ITP Creation,Connection Generator,Plies Creation From Zone,Zones Group,Stack-up file from Zones,Solid and Top Surface from Zones Creation,Import Laminate,CPD Preliminary Design tools,Copyright DASSAULT SYSTEMES,17,Core Sample,Core Definition,Stacking Order Modification,Stack-up file from Plies,Group of Plies Definition,Numerical Analysis,Manual Plies: Definition / Modification,CPD Engineering Detail Design tools,Ply Exploder,Symmetry Pivot / Non Pivot,Copyright DASSAULT SYSTEMES,18,IGES/DXF Export,Material Excess,EOP Definition,Producibility Analysis,Create Manufacturing Data,Flatten,Manufacturing Skin Swapping,CPD Manufacturing Detail Design tools,Limit Contour,Multi Splice,Copyright DASSAULT SYSTEMES,19,Composites Preliminary Design Product,Preliminary Design Tools,Copyright DASSAULT SYSTEMES,20,Composites Catalog,You will become familiar with Defining the Composites Catalog Defining New material Defining FEA properties Defining Composites parameters,Copyright DASSAULT SYSTEMES,21,Defining New Material,1- Click Insert the menu toolbar,2- Select New Material option,5- Indicate the New material name,4- Select the Feature Properties option,3- Double click on New Material option,Copyright DASSAULT SYSTEMES,22,Defining FEA Properties,7- Select the Type of material,8- Indicate FEA properties values,5- Select the Analysis option,6- Select the Material option,Copyright DASSAULT SYSTEMES,23,Defining Composites Parameters,9- Select the Composites option,10- Indicate Composites parameters values,11- Press OK for validation,Copyright DASSAULT SYSTEMES,24,Laminate Parameters,You will become familiar with Defining the Laminate Parameters Selectioning Material Catalog Defining Plies Direction,Copyright DASSAULT SYSTEMES,25,Selectioning Material Catalog,1- Click the Parameters icon,2- Select the Material Catalog tab,3- Select the Material Catalog,4- Click Open for selection,Copyright DASSAULT SYSTEMES,26,Defining Directions,5- Create New Direction,8- Click OK for validation,6- Reorder Directions,7- Remove the Unused Directions,Copyright DASSAULT SYSTEMES,27,Group of Zones,You will become familiar with Defining the Group of Zones Creating Group of Zones,Copyright DASSAULT SYSTEMES,28,Creating Group of Zones,1- Click the Zones Group icon,2- Select the Shell Support,3- Select the Draping direction,5- Click OK for validation,4- Select the Rosette,Copyright DASSAULT SYSTEMES,29,Zones parameters,You will become familiar with defining the zone parameters Creating Zone contours Creating Laminate Selecting Rosette Modifying Zone contours Modifying Laminate,Copyright DASSAULT SYSTEMES,30,Creating Zone Contours,1,2,3,4,1- Click the Zone icon,2- Click the Geometry tab,3- Select the Zones Group,4- Select the curves which define the zone contour : Respect a logical order, (1 to 4) or (4 to 1),Copyright DASSAULT SYSTEMES,31,Creating Laminate,8- Indicate the Number of plies per orientation and material,7- Select the Material,5- Click the Laminate tab,6- Click on Material tab,Copyright DASSAULT SYSTEMES,32,Selecting Rosette,9- Click the Rosette tab,10- Select the Rosette,11- Click OK for validation,Copyright DASSAULT SYSTEMES,33,Modifying Zone Contours,1- Double click on the Contour attribute or onto the 3D identifier to modify,2- Remove the old curves and Select the new curves: Respect the logical order,3- Click OK for validation,Copyright DASSAULT SYSTEMES,34,Modifying Laminate,1- Double click on the Laminate attribute or the 3D Zone Identifier to modify,4- Select the new material,6- Click OK for validation,2- Select the material to modify with the third button of the mouse,3- Click the Change Material option,5- Modify the Laminate,Copyright DASSAULT SYSTEMES,35,Transition Zones,You will become familiar with creating a Transition Zone Defining Transition Zone Modifying Transition Zone Refining Transition Zone,Copyright DASSAULT SYSTEMES,36,Defining Transition Zone,3- Select the curves which define the Transition Zone contour: Respect a logical order, (1 to 4) or (4 to 1),4- Click OK for validation,1,2,3,4,1- Click the Transition Zone icon,2- Select the Underlying Zone,Copyright DASSAULT SYSTEMES,37,Modifying Transition Zone,1- Double click on the Transition Zone attribute or the 3D identifier to modify,4- Click OK for validation,2- Select the new Underlying Zone,3- Select the curves to remove and the new curves,Copyright DASSAULT SYSTEMES,38,Refining a Taper,1- Double click on the Transition Zone attribute or the 3D identifier to modify,6 Press OK to store these parameters,3a - Select the Refinement Number option,4a Key in the number of intermediate curves to be created,5a Press the Visualize button to see the Refinement curves,3b - Select the Curve Selection option,4b Multiselect user-defined intermediate curves,2- Select the Taper Refinement option,OR,Plies,Copyright DASSAULT SYSTEMES,39,Connection Generator,You will become familiar with the Connection Generator option Analyzing Structural Zones Analyzing Transition Zones Storing/Checking Connection Generator Results,Copyright DASSAULT SYSTEMES,40,Analyzing Structural Zones,4- Click Apply for visualization,3- Select the both Structural Zones options,Number of plies at the upper zone,Name of the both zones (Zx,Zy),Curves : Red color : (Zone,Zone) Yellow color : (external Zone contour),1- Click the Connection Generator icon,2- Select the Zones Group,Copyright DASSAULT SYSTEMES,41,Analyzing Transition Zones,7- Click Apply for visualization,6- Select the both Transition Zones options,Number of plies at the upper zone,Curves : Cyan color : (Taper,Taper) Magenta color : (Zone,Taper) Green color : (Taper) top curve Bleu color : low curve of a taper,Name of the different elements (Zones;Tapers),5- Select the Zones Group,Copyright DASSAULT SYSTEMES,42,Storing the Connection Generator Feature,1- Click on the OK button,Copyright DASSAULT SYSTEMES,43,Updating the Connection Generator Feature,1- Edit the Connection Generator Feature in the tree,2- Click the Apply button to see the updated results,3- Check the design changes,4- Click the OK button to store the updated results,Copyright DASSAULT SYSTEMES,44,Imposed Thickness Point (ITP),You will become familiar with creating ITP Defining an ITP Modifying an ITP,number of plies is defined (by the adjacent zones),number of plies is undefined ITP definition needed,Z1,Z2,T1,Z1,Z2,T1,T2,or,Copyright DASSAULT SYSTEMES,45,Defining ITP,3- Select a point,4- Indicate the number of plies at the selected point,5- Click OK for validation,1- Click the ITP icon,2- Select the Zones Group,Copyright DASSAULT SYSTEMES,46,Modifying ITP,2- Change the value,3- Click OK for validation,1- Double click on the ITP attribute or onto the 3D ITP,Copyright DASSAULT SYSTEMES,47,Stack-up file from Zones,You will become familiar with the Stack-up file from Zones option Creating an Excel Stack-Up File Zone Connections option Modifying a Stack-Up File,Copyright DASSAULT SYSTEMES,48,Creating an Excel Stack-Up File,5- Click OK for creation,1- Click the Stack Up File From Zones icon,3- Rename the File,4- Click Open for File name confirmation,2- Select the File address,Copyright DASSAULT SYSTEMES,49,“Zones Connections” Option,This matrix provides :the total surface of a zone, the total Length of Free edges of a zone (Zx/Zx) the total Length of Connection between 2 adjacent zones (Zx/Zy),Copyright DASSAULT SYSTEMES,50,Modifying a Stack-up File (1/5),Switch Lines,1- Open the excel Stack-Up File,2- Cut the elements to move,3- Insert the cutting elements to reorder the laminate,4- Save: new File name if necessary,Copyright DASSAULT SYSTEMES,51,Modifying a Stack-up File (2/5),Rename sequences/plies,Copyright DASSAULT SYSTEMES,52,Modifying a Stack-up File (3/5),Geometrical level Theorical Stacking with the plies representation Switch line in Stacking with the plies representation Geometrical Level Modification in Stacking with Plies representation,Plies visualization,Plies visualization,Plies visualization,Copyright DASSAULT SYSTEMES,53,Modifying a Stack-up File (4/5),Change logical zones combinations Will require Plies creation from Zones with Staggering value,Copyright DASSAULT SYSTEMES,54,Manually Modifying a Stack-up File (5/5),2- Modify the Stack-up file: Order, new plies, material, direction,3- Create an Import Laminate file from the Modified Stack-up file,4- Update the zones with the Import Laminate file,1- Create the initial Stack-up file from zones,5- Create the Plies from zones with the Modified Stack-up file,Material or direction modification, plies deletion or addition, might create a loss of consistency with the Zones definition in the Part,Copyright DASSAULT SYSTEMES,55,Import Laminate,You will become familiar with the Import Laminate option Importing Laminate,Activate the “Import Laminate” function to import Zones Laminate data (number of layers for each couple Material/Direction) directly from an Excel spreadsheet instead of providing this information from the Zone creation panel.,Copyright DASSAULT SYSTEMES,56,2- Click on the Import Laminate icon,Importing the Laminate,3- Select the Laminate File,4- Click OK for Import,1- Create a laminate file,5 The laminate definition of the zones is automatically populated from the laminate file,Copyright DASSAULT SYSTEMES,57,Solid and Top Surface from Zones,You will become familiar with the Solid from Zones option Defining Solid Defining Top Surface,Copyright DASSAULT SYSTEMES,58,Defining Solid,4- Click OK for validation,1- Click the Solid from Zones icon,2- Select the Zones Group,3- Select the Solid tab,You can activate the Solid “Update from Plies” capability. The update will be effective only along Taper locations, if design changes in Plies create a difference compared to the initial Zone design along those areas. You can also create a Solid taking only the structural zones into account by activating the “Solid without Transition-Zones” option.,Copyright DASSAULT SYSTEMES,59,Defining Top Surface,4- Click OK for validation,1- Click the Solid from Zones icon,2- Select the Zones Group,3- Select the Top surface tab,Copyright DASSAULT SYSTEMES,60,Plies Creation from Zones,You will become familiar with the Plies Creation from Zones option Creating Plies From Zones with Tapers Creating Plies From Zones with Staggering value,Copyright DASSAULT SYSTEMES,61,Creating Plies From Zones with Tapers,4- Select the Create Plies without staggering and/or Create plies in new group options,2- Select the Zones Group(s),3- Select the Stack-Up File if you have generated it,6- Click OK for creation,1- Click the Plies Creation From Zones icon,3a - Select the Stack-Up File location,5- Select the “Create plies from Zones with Taper” option,Copyright DASSAULT SYSTEMES,62,Creating Plies From Zones with Staggering value (1/2),8- Click OK for creation,See next slide for results,4- Select (or not) the Create plies in new group option,2- Select the Zones Group(s),3- Select the Use Stack-Up File if you have generated it,1- Click the Plies Creation From Zones icon,3a - Select the Stack-Up File location,5- Select the “Create plies from Zones with Taper” option,6- Select the Staggering data File creation location,7- You can activate this option to see theStaggering data File after creation,Copyright DASSAULT SYSTEMES,63,Creating Plies From Zones with Staggering value (2/2),Following the imported stack-up file order, creation of the plies all sharing the Engineering Edge of Part (EEOP),Creation of an open body with all the Edges To Be Staggered (ETBS),Creation of a report with the following data: Shapes Set of zones, direction, number of plies, for each shape Name of the plies for each shape. Set of Edges To Be Staggered (ETBS) for each shape,Copyright DASSAULT SYSTEMES,64,Composites Preliminary Design Product,Engineering Detail Design Tools,Copyright DASSAULT SYSTEMES,65,Limit contour,You will become familiar with the Limit Contour command Relimiting Plies Geometry Limit contour on Plies from Zones with Staggering Value,Copyright DASSAULT SYSTEMES,66,Relimiting Plies Geometry,1- Click the Limit Contour icon,2- Select one or several entities to be relimited (Ply, Sequence, Ply Group or Stacking),4- Define the Relimiting Direction,3- Select one or several Relimiting Curve,5- Define the Staggering Value,6- Define the Staggering Step (if only one ply is selected),8- Click the OK button,7- Choose a relimiting option,Extrapolation,Relimitation,Gap filling,Copyright DASSAULT SYSTEMES,67,Limit contour on Plies from Zones with Staggering Value (1/2),1- Select the Limit Contour icon,Thanks to the staggering data file, the user knows for each Shape which plies have to be staggered, along which ETBS,2- Select the Plies to be staggered,3- Select the ETBS to be used as relimiting curves,Copyright DASSAULT SYSTEMES,68,Limit contour on Plies from Zones with Staggering Value (2/2),5- Define the Relimiting Direction along each ETBS,4- Define the Staggering Value and Staggering Step along each ETBS,6- Choose a Relimiting option,7- Select the OK button,One Limit contour feature is created for each ply.,Copyright DASSAULT SYSTEMES,69,Plies Group,You will become familiar with the Plies Group option Creating Plies Group Automatically Creating Plies Group Manually,Copyright DASSAULT SYSTEMES,70,Creating Plies Group Automatically,3- Select the Create plies in new group option,2- Select the Zones Group(s),4- Click OK for creation,1- Click the Plies Creation From Zones icon,Copyright DASSAULT SYSTEMES,71,Creating Plies Group Manually,3- Select the Draping direction,2- Select the Surface support,6- Click OK for creation,1- Click the Plies Group icon,4- Select the Rosette,5- Select the Plane for Flatten,Copyright DASSAULT SYSTEMES,72,Manual Plies Creation,You will become familiar with the Manual Plies option Defining Geometry Defining Attributes,Copyright DASSAULT SYSTEMES,73,Defining Geometry,4- Select the Shell Support,2- Select the Stacking , a Plies Group, a Sequence, or a Ply,1- Click the Ply icon,3- Click the Geometry tab,2,1,3,4,5- Select the curves which define the ply contour : Respect a logical order, (1 to 4) or (4 to 1),Copyright DASSAULT SYSTEMES,74,Defining Attributes,10- Click OK for creation,6- Click the Attributes tab,9- Select the Rosette,8- Select the Direction,7- Select the Material,Copyright DASSAULT SYSTEMES,75,Core,You will become familiar with the Core Creation option Defining Core Modifying Core,Copyright DASSAULT SYSTEMES,76,Defining Core,4- Select the Material,3- Select the Geometry,7- Click OK for creation,