solution partners CDT 2000 Proprietary Dr. Olivier Guillermin Composite Design Technologies, Inc. Monte Carlo, Monaco June 7-9, 2000 An Integrated Solution for Advanced Composites Engineering with MSC.Patran First Southern European Technology Conference

solution partners CDT 2000 Proprietary The worlds leading supplier of composite CAD software Focused on providing software solutions for the composite industry Software is proven in production Staff experienced in composites & CAD/CAM/CAE Provide a total solution for your composite design, analysis, and manufacturing needs Composite Design Technologies, Inc.

solution partners CDT 2000 Proprietary Composite Engineering Environment Analysis Interface P002 Ideal Actual P002 P001 Documentation Laser Projection Fiber Placement Interface Feature-based design Laminate surface generation Producibility simulation Net flat patterns Feature-based design Laminate surface generation Producibility simulation Net flat patterns Flat Pattern Export Composite Engineering Environment

solution partners CDT 2000 Proprietary C A T I A U G P R O / E Master Model FiberSIM is fully CAD Integrated

solution partners CDT 2000 Proprietary Detailed Design & Analysis Manufacturing Preliminary Design & Analysis Ply Producibility Process & Material Selection Solid Modeling Documentation Laser Projection FE Analysis TARGET LAYUP 25/50/25 TARGET LAYUP 40/40/20 ZONE6 ZONE4 ZONE5 ZONE1 ZONE8 ZONE2 ZONE3 ZONE12 ZONE10 ZONE11 ZONE7 ZONE9 Structural Sizing Fiber Placement Tape Laying The Composite Engineering Process Preliminary Design & Analysis Detailed Design & Analysis Manufacturing

solution partners CDT 2000 Proprietary A Complete Description of the Composite Part Materials & Processes Plies & Sequences Offset Surfaces True Fiber Orientations Prepreg/Dry Uni/Woven Preforms Engineered Fabric Hand Layup RTM Fiber Placement Tape Laying

solution partners CDT 2000 Proprietary Manufacturing Applications Documentation Fiber Placement Tape Laying Nesting Automated Cutting Laser Projection

solution partners CDT 2000 Proprietary Closing the Loop Between Design & Analysis Analysis MSC Software Analysis MSC Software Design FiberSIM Design FiberSIM Increases model accuracy & sensitivity Optimizes designs Detects & quantifies conceptual errors Decreases product development cycle Manufactured Part Manufactured Part

solution partners CDT 2000 Proprietary Case Studies Sikorsky S-92 Helicopter Turbine Spinner

solution partners CDT 2000 Proprietary Turbine Spinner CASE DESCRIPTION PROBLEM STATEMENT: Even though the part was built according to the same manufacturing documentation, a number of parts failed under standard in- service conditions. The failure was caused by uneven circumferential laminate stiffness due to material scissoring that resulted from a change in the manufacturing layup start-point of the plies. SOLUTION: Only with FiberSIM and MSC.PATRAN working together can you: detect such misconceptions in design control the proper parameters design the part in its exact and detailed to-be-manufactured state

solution partners CDT 2000 Proprietary Fiber Paths in Half-Body Ply - Origin at Top

solution partners CDT 2000 Proprietary Fiber Paths in Half-Body Ply - Origin at Bottom

solution partners CDT 2000 Proprietary Displacements of Original Design Load Case: Centrifugal Loading About Y Axis

solution partners CDT 2000 Proprietary Displacements of Revised Design Load Case: Centrifugal Loading About Y Axis

solution partners CDT 2000 Proprietary Sikorsky S-92 Helicopter CASE DESCRIPTION PROBLEM STATEMENT: Even though the sandwich part was developed according to the design rules, complex curvature induced non-symmetry in the laminate which caused the part to warp upon curing. The part was ultimately scrapped. SOLUTION: FiberSIM works with MSC.PATRAN to enable: detection of such misconceptions in design analysts to be involved in the preliminary stages of design analysis of the part in its exact and detailed to-be-manufactured state

solution partners CDT 2000 Proprietary 0°/90° Ply (Bottom Skin)

solution partners CDT 2000 Proprietary +/- 45° Front and Back (Bottom Skin)

solution partners CDT 2000 Proprietary Analysis of initial design based on true fiber orientations

solution partners CDT 2000 Proprietary Orthotropic Layup (Bottom Skin)

solution partners CDT 2000 Proprietary Revised Design (+/- 45° Front & 0/90° Back)

solution partners CDT 2000 Proprietary Quasi-isotropic Layup

solution partners CDT 2000 Proprietary Analysis of revised design based on true fiber orientations

solution partners CDT 2000 Proprietary Customer Quotes "By sharing design information between our CAD/CAM system and FiberSIM, we are turning the black art of composite engineering into a precise science." Benetton F1 Racing Preprogramming the lay-up sequence cut lay-up time by 50%. Exact pattern measurements cut material waste by 25%." The Boeing Company FiberSIM assisted the S-92 Helibus Cockpit team in reducing by 27% the flow time required to move the complex Composite Canopy Structure from basic data to completion of production parts. With FiberSIM, our first parts were virtually perfect and we were able to do it right the first time." Sikorsky Aircraft "After extensive evaluation, FiberSIM was chosen as the design tool of composite components for the next generation of aircraft. FiberSIM takes concurrent engineering to the next level, reduces design time and increases manufacturing efficiency." British Aerospace "With FiberSIM we experienced average savings of 12 to 1 in the time it takes to develop net flat patterns." DOW-UT

solution partners CDT 2000 Proprietary Conclusion The FiberSIM Composite Engineering Environment provides: seamless link between CAD master model and PATRAN/NASTRAN use of a complete and detailed virtual prototype detection of design misconceptions and inaccurate finite element modeling The customer benefits from: increased confidence elimination of trial and error reduced risk reduced engineering change orders lowered costs shortened development time