introduction to the siemens plm end to end solution … to end composite solution...introduction to...

2014-05

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Siemens PLM Software

Introduction to the Siemens PLM End to

End Solution for Composites


2014-05Page 1 Siemens PLM Software

2014-05



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



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



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


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



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



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



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



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



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



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



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



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



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



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



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



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



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



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



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



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



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



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



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



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



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.

2014-05



Thank You


20XX-XX-XXPage 36 Siemens PLM Software

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