Co py rig ht DA SS AUL T S YS TE ME S 1 Aerospace Composites Preliminary Design CATIA Training Foils Version 5 Release 14 September 2004 EDU-CAT-E-CPD-FF-V5R14 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 3 Planning (1/2) DAY 1 MORNING CATIA Options General CPD presentation Live demo AFTERNOON Foils Exercises Foils Exercises Parameters Group of Zones Zones Transition Zones Ex 1 2 3 Connection Generator Impose Thickness Point Stack-Up from Zones Import Laminate Ex 4 - 5 DAY 2 MORNING Foils Exercises Foils Exercises Solids from Zones Plies from Zones Ex 6 7 8 9 Limit Contour with multi-curves selection Support logical combination of zones Ex 10 11 AFTERNOON Foils Exercises Foils Exercises Plies Group Manual plies Cores Ex 12 13 Ply Exploder Ex 14 Co py rig ht DA SS AUL T S YS TE ME S 4 Planning (2/2) DAY 3 MORNING Foils Exercises Foils Exercises Managing the part, Pivot and non-pivot symmetry Ply table Numerical Analysis, Core Sampling analysis Ex 15 16 17 Drawing Ex 18 19 AFTERNOON Foils Exercises Foils Exercises Foils Exercises Manufacturing data Shell Swapping Ex 20 21 22 Edges Of Part Material Excess Ex 23 24 3D multi-splice operator Ex 25 - 26 DAY 4 MORNING Foils Exercises Foils Exercises Producibility Analysis Darts Flattening Ex 27 28 Export Ex 29 30 AFTERNOON Exercises Overview exercise Full definition of composites part with Manufacturing preparation Ex 31 Questions Tapers) 5- Select the Zones Group Co py rig ht DA SS AUL T S YS TE ME S 42 Storing the Connection Generator Feature 1- Click on the OK button Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 46 Modifying ITP 2- Change the value 3- Click OK for validation 1- Double click on the ITP attribute or onto the 3D ITP Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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) Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 51 Modifying a Stack-up File (2/5) Rename sequences/plies Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 53 Modifying a Stack-up File (4/5) Change logical zones combinations Will require Plies creation from Zones with Staggering value Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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. Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 57 Solid and Top Surface from Zones You will become familiar with the Solid from Zones option Defining Solid Defining Top Surface Co py rig ht DA SS AUL T S YS TE ME S 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. Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 64 Composites Preliminary Design Product Engineering Detail Design Tools Co py rig ht DA SS AUL T S YS TE ME S 65 Limit contour You will become familiar with the Limit Contour command Relimiting Plies Geometry Limit contour on Plies from Zones with Staggering Value Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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. Co py rig ht DA SS AUL T S YS TE ME S 69 Plies Group You will become familiar with the Plies Group option Creating Plies Group Automatically Creating Plies Group Manually Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 72 Manual Plies Creation You will become familiar with the Manual Plies option Defining Geometry Defining Attributes Co py rig ht DA SS AUL T S YS TE ME S 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) Co py rig ht DA SS AUL T S YS TE ME S 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 Co py rig ht DA SS AUL T S YS TE ME S 75 Core You will become familiar with the Core Creation option Defining Core Modifying Core Co py rig ht DA SS AUL T S YS TE ME S 76 Defining Core 4- Select the Material 3- Select the Geometry 7- Click OK for creation 1- Click the Core icon 2- Select a Sequence , a Ply or a Core 5- Select the Direction 6- Select the Rosette Co py rig ht DA SS AUL T S YS TE ME S 77 1- Double click on the Core attribute in the tree 3- Click OK for validation 2- Modify the Core parameters Modifying Core Co py rig ht DA SS AUL T S YS TE ME S 78 Ply Exploder You will become familiar with the Ply Exploder option Exploding Plies into Surfaces Cross-Sectioning with DMU Co py rig ht DA SS AUL T S YS TE ME S 79 Exploding Plies into Surfaces 3- Select the scale value 1- Click the Ply Exploder icon 2- Select the Explode option: Stacking or Plies Groups 4- Click OK for validation Co py rig ht DA SS AUL T S YS TE ME S 80 Cross-Sectioning with DMU (1/3) Accessing the Workbench Co py rig ht DA SS AUL T S YS TE ME S 81 Cross-Sectioning with DMU (2/3) 4- Select the paste option in contextual menu 1- Select the Part1 attribute with the third button of the mouse 2- Select the Copy option in contextual menu 3- Select the Product1 attribute with the third button of the mouse Co py rig ht DA SS AUL T S YS TE ME S 82 Cross-Sectioning with DMU (3/3) 5- Select the section axis position 2- Click the Sectioning icon 4- Select the Surface or Volume option 7- Click OK for validation 1- Put the Engineering Plies Open-Body in No Show 3- Collapse the part 6- Move the plane section position Co py rig ht DA SS AUL T S YS TE ME S 83 Managing the Part You will become familiar with the Part Managing options Reordering the Part Replacing Shell Renaming Zone Renaming Taper Ply Shading Removing Ply Shells Co py rig ht DA SS AUL T S YS TE ME S 84 Reordering the Part 2- Select the Part1 object tab 1- Select the Part tree attribute with the third button of the mouse 3- Select the Reorder Children tab 6- Click OK for validation 4- Select one attribute 5- Reorder the attribute with the arrows Co py rig ht DA SS AUL T S YS TE ME S 85 Replacing Shell 2- Select the Replace tab 4- Click OK for validation 3- Select the New shell 3D view or in the tree 1- Select the Shell-ref tree attribute or 3D view with the third button of the mouse Co py rig ht DA SS AUL T S YS TE ME S 86 Renaming Zone - First Solution (1/2) 2- Select the Properties tab 1- Select the Zone tree attribute or the Zone 3D attribute with the third button of the mouse Co py rig ht DA SS AUL T S YS TE ME S 87 4- Rename the Zone 3- Select the Feature Properties option 5- Click OK for validation Renaming Zone - First Solution (2/2) Co py rig ht DA SS AUL T S YS TE ME S 88 1- Double click on the Zone tree attribute or onto the 3D zone attribute 3- Click OK for confirmation 2- Rename the Zone Renaming Zone - Second Solution Co py rig ht DA SS AUL T S YS TE ME S 89 2- Select the Properties tab 1- Select the Taper tree attribute or the Taper 3D attribute with the third button of the mouse Renaming Taper- First Solution (1/2) Co py rig ht DA SS AUL T S YS TE ME S 90 4- Rename the Taper 3- Select the Feature Properties option 5- Click OK for validation Renaming Taper - First Solution (2/2) Co py rig ht DA SS AUL T S YS TE ME S 91 1- Double click on the Taper tree attribute or onto the 3D Taper attribute 3- Click OK for confirmation 2- Rename the Taper Renaming Taper - Second Solution Co py rig ht DA SS AUL T S YS TE ME S 92 Ply Shading 1- Go to Tools Options General Display Navigation. Make sure the “Highlight faces and edges” option is activated 2- Perform a Numerical Analysis or Core Sample creation on the Ply or group of Plies you want to shade 3- In the stacking tree, select the Ply to shade 4- The corresponding Ply is shaded Ply Shading is only available after a Core Sample creation or Numerical Analysis Co py rig ht DA SS AUL T S YS TE ME S 93 Removing Ply Shells When saving a Numerical Analysis or a Core Sample, surfaces called “Ply Shells” are stored in the Part, enabling a faster computation for the following Numerical Analysis or Core Sample Ply shading These surfaces (one per ply) are not visible, but will be saved with the model, resulting in a potentially bigger model 1- In the contextual menu of the Stacking node, Select Stacking Object 2 Select the Remove Ply Shells option Co py rig ht DA SS AUL T S YS TE ME S 94 Symmetry Creation You will become familiar with the Symmetry option Defining a Symmetry Pivot Defining a Symmetry Non Pivot Co py rig ht DA SS AUL T S YS TE ME S 95 Defining a Symmetry Pivot 4- Press OK 1- Click the Ply Table icon 2- Select Stacking, Plies Group or sequence 3- Select Pivot option Co py rig ht DA SS AUL T S YS TE ME S 96 Defining a Symmetry Non Pivot 4- Press OK 1- Click the Ply Table icon 2- Select Stacking, Plies Group or sequence 3- Select Non Pivot option Co py rig ht DA SS AUL T S YS TE ME S 97 Ply Table You will become familiar with the Ply Table option Creating a Complete Excel Ply Table File Creating an Excel Ply Table File per Group of Plies Co py rig ht DA SS AUL T S YS TE ME S 98 Creating a Complete Excel Ply Table File 6- Click OK for creation 1- Click the Ply Table icon 3- Select the File address 2- Select Complete Stacking option 4- Rename the File 5- Click Open for File name confirmation Co py rig ht DA SS AUL T S YS TE ME S 99 Creating an Excel Ply Table File per Group of Plies 7- Click OK for creation 1- Click the Ply Table icon 6- Click Open for File name confirmation 4- Select the File address 2- Select Complete Stacking option 3- Select the Plies Group 5- Rename the File Co py rig ht DA SS AUL T S YS TE ME S 100 Numerical Analysis You will become familiar with the Numerical Analysis option Defining Numerical Analysis Exporting Numerical Analysis Co py rig ht DA SS AUL T S YS TE ME S 101 Defining Numerical Analysis 4- Click OK for creation 1- Click the Numerical Analysis icon 2- Select the Stacking , a Plies Group, a Sequence, a Ply Remark: a filter by material is available for the stacking in order to create the bill of material. 3- Click Persistent tab if you want to store the analysis Co py rig ht DA SS AUL T S YS TE ME S 102 Exporting Numerical Analysis 6- Click OK for confirmation 1- Select the File address 3- Click Open for File name confirmation 2- Rename the File 5- Press Export for creation 4- Select Open file after creation option Co py rig ht DA SS AUL T S YS TE ME S 103 Core Sample You will become familiar with the Core Sample option Core Sampling Analysis Core Sampling Storage Core Sampling Export Co py rig ht DA SS AUL T S YS TE ME S 104 Core Sampling Analysis 4- Click Apply for creation 1- Click the Core Sampling icon 2- Select a Point 3- Move the extremity points for the thickness to analyze Co py rig ht DA SS AUL T S YS TE ME S 105 5- Click OK for store Core Sampling Storage Co py rig ht DA SS AUL T S YS TE ME S 106 4- Select the File address 6- Click Open for File name confirmation 5- Rename the File 7- Select Open file after creation option Core Sampling Export 2- Select the Core Sample Group tab 1- Select the Core samples attribute with the third button of the mouse 3- Select the Export Core Samples tab 5- Click OK for creation Co py rig ht DA SS AUL T S YS TE ME S 107 Drawing You will become familiar with the Drawing option Drawing generation Defining general sheet (solid active) Defining sheet for section (explode active) Defining sheet for table integration Co py rig ht DA SS AUL T S YS TE ME S 108 Drawing Generation Accessing the Workbench Co py rig ht DA SS AUL T S YS TE ME S 109 Defining General Sheet: Solid active (1/2) Sheet.1 creation 4- Click OK for validation 3- Select Modify tab if you want to change the standard 5- Click OK for creation 2- Click the automatic layout view 1- In the Model.CATPart, Put the ExplodedPlySurfaces OpenBody in NoShow Co py rig ht DA SS AUL T S YS TE ME S 110 Defining General Sheet: Solid active (2/2) Defining annotations 1- Use the V5 Drafting tools for the annotations definition Co py rig ht DA SS AUL T S YS TE ME S 111 Defining General Sheet: Explode active (1/4) Sheet.2 creation 2- Select the New Sheet icon 1- In the Model.CATPart, Put the ExplodedPlySurfaces OpenBody in NoShow Co py rig ht DA SS AUL T S YS TE ME S 112 Defining General Sheet: Explode active (2/4) View and Section creation 1- Select the Front View icon 2- Select the ExplodedPlySurfaces geometrical set, the Insert partbody and a Reference plane on a 3D geometry 3- Select the Offset Section Cut icon 4- Indicate the Section extremities Co py rig ht DA SS AUL T S YS TE ME S 113 Defining General Sheet: Explode active (3/4) Annotation definition with Text Template (Plies only) 3- Select a 2D ply representation 1- Select the Text Template icon 4- Select the Annotation attribute 2- Select the Annotations catalog 5- Press Close Co py rig ht DA SS AUL T S YS TE ME S 114 Defining General Sheet: Explode active (4/4) Annotation definition with Text Leader 1- Zoom on the Section View 3- Select a 2D ply representation 2- Select the Text with Leader icon 4- Indicate the Annotation Location 5- In the contextual menu, select the Attribute Link option 6- Select the Attribute element 7- Press OK for validation Co py rig ht DA SS AUL T S YS TE ME S 115 Defining Sheet for Table Inte