2014-05
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Page 1 Siemens PLM Software
Introduction to the Siemens PLM End to
End Solution for Composites
Restricted © Siemens AG 2013 All rights reserved.
2014-05Page 1 Siemens PLM Software
2014-05
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Page 2 Siemens PLM Software
Siemens PLM is Dedicated to the Future of
Lightweight Engineering
Investing in Leading Technologies
Bringing
intelligence
to the entire
lightweight
product
development
& production
process
2014-05
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Page 3 Siemens PLM Software
Key Market Trends and Industry Challenges
Program excellence
Time-to-market
Weight reduction
Lifecycle costs
Globalization
Quality
Emission standards
Lightweighting
Volume production rate
Time-to-market
Lifecycle costs
Performance
Performance & Safety
Fuel economy
Capacity
Speed
Failure Rate
Lifecycle Costs
Larger & Lighter
Weight reduction
Manufacturing quality
Time-to-market
Production costs
Lifecycle costs
2014-05
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Page 4 Siemens PLM Software
Key Initiatives by Aerostructure Manufacturers are
Driving the Development of Today's Products
Higher rate, lower risk production to achieve lower
cost
Optimization for excellence in fuel economy, range,
and operation
Globalized supply chain for aerostructure
development
Competitive differentiation through design and
quality of aircraft
2014-05
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Page 6 Siemens PLM Software
Often, Designs are not Optimized for the Use of
Composites Materials
"Overdesign to address
uncertainty negates the
advantages of composites"
"Overdesigned composites
cannot compete with lower-
cost, established material
systems."
"The relative inexperience with
composite materials compared to
their metallic counterparts often
necessitates either overdesign
of components or more frequent
inspections and monitoring."
A&D Industry Observations 6
OV
ER
DE
SIG
N
2014-05
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Page 7 Siemens PLM Software
New mixed material cars must satisfy stringent
competitive cost and time to market criteria
The automotive industry must drastically rethink the
way vehicles are engineered and manufactured
New lighter cars must meet the consumer demand
for differentiated branding and better performance
Environmental challenges and world urbanization
are forcing a new level of lighter car innovation
Market Pressures Driving Automotive Mixed
Materials Lightweighting
2014-05
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Page 8 Siemens PLM Software
And the Survey Says6 Expect Big Changes For
Automotive
TOP PRESSURES
DRIVING CHANGE
Automotive companies
report fuel efficiency and
emissions regulations
are the # 1 pressure
THE SOLUTION:
NEW MATERIALS
New material strategies
show results of producing
vehicles at least 40% lighter
January, 2014, Aberdeen Group, Inc.
TIME IS
RUNNING OUT
Automotive companies
respond by planning
lightweighting strategies
now!
Recognize lightweightingas a top strategy to meetimpending regulations
Identify reducing vehicleweight as the top challengefor meeting fuel efficiencyand emission standards
Have or will developnew material strategies
Plan to use mixed materials, including composites, to produce lightweight vehicles
2014-05
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Page 9 Siemens PLM Software
Mixed Material LightweightingBringing the Biggest Changes in 50+ Years
Vehicle PackagingVehicle Packaging
Part ManufacturingPart Manufacturing
Factory DesignFactory Design
Supply ChainSupply Chain
Repair ProcessRepair ProcessSafety
(Crash)
Strength & Strength &
DurabilityNoise, Vibration,
Harshness (NVH)
Fundamental Changes
to how Vehicles are
Designed and Built
Joining MethodsJoining Methods
2014-05
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Page 11 Siemens PLM Software
Analysis & Simulation
Accurate data for FEA
composites models!
Maximized Strength &
Durability performance!
Best-in-class NVH &
Acoustics performance!
Integrated simulation &
test based engineering!
Balanced multi attribute
integration!
Key Challenges of Innovative Lightweighting
Engineering
Design & Manufacturing
Must design producible
composite parts!
Need to design the
composite material!
Requires a predictive
manufacturing simulation!
Close the loop from
manufacturing to design!
Enable a seamless link to
the manufacturing floor!
Concurrent Engineering
Rapid materials &
process selection!
A flexible optimization
process!
Faster & frequent design
& analysis iterations!
Include early cost
estimation!
2014-05
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Page 12 Siemens PLM Software
Composites Part Design
Initial Stack-up
Ply Schematic
Redefine Sequence
Partnering with Siemens PLM to Solve the
Complexity of Structures Lightweighting
Dataset for Manufacturing
Concurrent Design and CAE
Manufacturing Producibility Materials Definition
Strength & Durability
NVH & Acoustics
Thermal Analysis
Composites Optimization
Data Management
Process Integration
CADCAD
AssyFEM
Mesh
FEM
Assy
FEM
Post
• Multi CAD
• Multi CAE
Composites Simulation
2014-05
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Page 13 Siemens PLM Software
Use open CAE Architecture
to third party solutions
Open architecture
Supporting the End-to-End Composites Engineering
Process Workflow
CAD surfaceBegin with CAD surface
based on packaging
requirements
Define laminate, select
material and process
Laminate definition
Meshing and ModelingCreate and mesh composites
simulation models
Solve for Stiffness, Strength,
Thermal, NVH, Acoustics,
Durability6
Performance Analysis
Design Analysis IterationsEfficiently optimize with integrated
design and analysis tools
2014-05
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Page 14 Siemens PLM Software
And Seamless Link to Manufacturing
Design ValidationValidate producibility of design and
generate manufacturing data
Automatically generate engineering drawings, and
data for weight, cost modeling, PLM data feeds
Engineering drawings
Manufacturing DatasetGenerate data for flat patterns,
tooling surfaces, flow modeling
and automated machinery
Fully optimized light
weight structure
2014-05
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Page 15 Siemens PLM Software
Composites Part Design Innovation
Challenge
Designing composites with short time to market
and design cycle that emphasizes weight and
cost reduction
Solution
CAD integrated laminate model definition
Benefits
• Automate design definition and change by
efficiently and accurately capturing the
laminate definition “the way designers think”
• Make design changes transparent, increase
change cycle speed
• Facilitate rapid communication of detailed
design data to suppliers
• Support open, multi platform hybrid IT
environment: NX, CATIA, Creo
Multi-ply laminate definition (auto)
Zone and Structure based design (aero)
Laminate A Laminate A+B Laminate A+B+C
2014-05
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Page 16 Siemens PLM Software
Upfront Manufacturing Producibility Assessment
Challenge
Reducing production cost and reliance
on prototypes
Solution
Accurate simulation of part producibility
for different processes and industries
Benefits
• Identify issues related to manufacturing
process and material to speed transfer of
designs to manufacturing
• Eliminate need for prototypes with
accurate process simulation and design
tools
Accurate producibility assessment for multiple
manufacturing methods
2014-05
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Page 17 Siemens PLM Software
Concurrent Design and CAE
Challenge
Reducing design and analysis cycle time to
enable faster optimization and increased part
performance
Solution
Bi-directional interface between design
and analysis
Benefits
• Speed analysis-to-analysis optimization
loop and shortens design cycle time by
over 50%
• Improve quality and accuracy of analysis
models
• Support open bi-directional data
exchange with major pre/post processors
As-manufactured
fabric properties
Validated
ply layup
Complete
laminate
definition with
as-built fiber
orientations
Strength, NVH,
Acoustics,
Durability, thermal
analysis
2014-05
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Page 18 Siemens PLM Software
Complete CAE Modeling and Performance Analysis
for Composites
Ply and Zone Meshing Assembly Modeling & Meshing
Composites Design Optimization Access to Internal & External FE Solvers
Static
Dynamic
Thermal
NVH
Acoustic
Durability
Crash
2014-05
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Page 19 Siemens PLM Software
Linear and Non-linear Simulation Solutions
First-ply failure, Failure
Indices
Displayed : critical ply,
values, load case
Classical Failure
From Linear Buckling to
Post-Buckling behavior
Buckling, Post Buckling
Progressive Damage
Analysis in Ply and at
the interface
(delamination)
Damage
Linear Methods Non-linear Methods
Stress, Strain,
Thermoelastic,
Frequency and transient
events
Strength & Dynamics
2014-05
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Page 23 Siemens PLM Software
Global Aircraft Structural Analysis and Optimization
Millions of Analyses to Certify an Aircraft
Typical aircraft structure process
Millions of structural analysis to
be performed, validated, checked
= 20% time spend
Aircraft Structure Engineering
= 60% of Non-recurring cost
Optimize topology for best, first
initial design
Automation and
optimization to
produce the best
results for all load
cases
2014-05
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Page 24 Siemens PLM Software
Delivering Unique Value across the Product
Development Process
Materials Geometry Manufacturing Process Testing
Coupon
Component
Subsystem
Assembly
Validation of
material
models
Model validation on
components and
joint technology
Validation of complex
subsystem modeling
Expertise build-up
full vehicle simulation/sign-off
2014-05
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Page 27 Siemens PLM Software
Customer: Airbus Group InnovationsComposites Analysis with LMS Samtech
Business challenges:
• Reduce fuel consumption and emissions
• Increase structural efficiency and
reliability
• Minimize aircraft weight
Keys to success:
• Utilize the full potential of composites
• Identify delamination and damage in
composite structures
• Use nonlinear analysis to determine
adequate safety margins"The LMS Samtech development team is the
cornerstone of these partnerships, contributing to
the dissemination of these new material laws
thanks to the implementation of these advanced
concepts into its LMS Samcef solver."
Didier Guedra-Desgeorges
Vice-President and Head of the Technical
Capabilities Center, Structure Engineering,
Production & Aeromechanics
2014-05
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Page 28 Siemens PLM Software
Customer: Bombardier ShortsComposites and Fasteners Solutions for C Series Wing Assembly
Bombardier adopted Siemens PLM solutions
for composite development and fastener
management on the C Series composite wing
assembly.
The original manual process was unable to
accommodate frequent iterations due to
evolving stress requirements. The Siemens
approach led to significant assembly
development cycle time reduction (sample
assembly 24 days to 1.2 days)
“[Siemens'] expertise 5 allows us to capture
and leverage design information more
completely, thereby contributing to efficiency
throughout the entire aircraft development
process.”
- Nick Perkins, Director of Advanced Product Development, Bombardier Aerospace
2014-05
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Page 29 Siemens PLM Software
Customer: SpaceX
Composites Design and Manufacturing
“Time is always of the essence for us
so Fibersim's proven ability to take us
from art to part so rapidly was a critical
consideration in our decision to
purchase the software."
"But it is about more than just speed.
Fibersim improves product quality by
providing accurate engineering
information to the manufacturing floor,
which also helps the repeatability of the
manufacturing process. This assures
that parts fit when they come off the
tool.”
- Chris Thompson, Vice President of
Structures Engineering for SpaceX
2014-05
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Page 31 Siemens PLM Software
Customer: Magna Exteriors & Interiors High Volume Mixed Materials Applications
Tubs
Load Floors
Plastic-Metal
Hybrids & RIW
Carriers
Thermoplastic
Liftgates
Business challenge:
• Light weight parts to reduce overall vehicle energy use
• Deliver same attribute and function at lower mass
• Commercialize high volume composite parts and structures
Keys to success:
• Integrated Fibersim design and analysis environment
• Excellent results with static linear predictions
• Rapid initial baseline model facilitating ease of adjustment
between CAE model and design files
• Development of complex geometry parts and models
Results:
• Accurate representation and analysis of laminate formability
and drapability
• Accelerate exchange of fiber laminate data with CAE tools
• Moving forward with first ply failure prediction and efforts to
model the non-linear behavior and relation to the FPF
• Achieved flat plate plaque correlation, and 3d geometry studies
• Yields a refined laminate model for structural evaluations
2014-05
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Page 32 Siemens PLM Software
Customer: Composites Innovation Centre (CIC)
Composite Materials and Technologies
Business challenge:
• Reduce/eliminate manual rework of analysis models
• Evaluate large number of parameter combinations
• Reduce product development cycle time
• Increase personnel productivity
• Analyze products of complex composite materials
Keys to success:
• Integrated NX design and analysis environment
• Powerful geometry editing & clean up capabilities
• Rapid and automatic updating of analysis models
• Robust laminate composite modeling capabilities
Results:
• Component weight reduction exceeding 40%
• Faster creation of analysis models
• Faster design-analysis iterations
• Evaluation of more design alternatives
• Almost complete elimination of manual rework
• Accurate representation and analysis of laminate composites
• Compliance with federal safety standards
"Previously, we used standalone CAD and FEA
software packages. Whenever we wanted to make
changes to the geometry we would have to make them
in the CAD software, reimport the model into the FEA
software, and then start the analysis from scratch. This
was extremely time-consuming."
Alastair Komus, Principal Engineer
Ground Transportation Sector
2014-05
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Page 34 Siemens PLM Software
Benefits Summary
Siemens PLM Delivers Value across the Product Lightweighting
Process
• Enable a consistent, model based engineering process
• Support accurate simulation based on as-manufactured material
properties
• Provide access to complete range of product performance
solutions
• Enable faster and more frequent design/analysis optimization
iterations
• Make design changes transparent and reduce change cycle times
• Reduce time to create product documentation and digital
manufacturing data
• Support customer with best-in-class multidisciplinary team of
experts
• Facilitate rapid communication of detailed design, analysis and
manufacturing data across the supply chain
2014-05
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Page 35 Siemens PLM Software
Introduction to the Siemens PLM End to End Solution
for Composites
Torrey Sullivan
Business Development - Americas
Siemens PLM
Specialized Engineering Software
Phone: 310-545-8953
E-mail: [email protected]
Smarter decisions, better products.