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达索复合材料 PLM 解决方案
丁岩CATIA应用工程师达索系统 中国[email protected]
航空产品研发模式的变革
全球协同研发统一的研发环境(OEM、供应商)
多部门不同专业(强度分析、样机、工装、车间)数据协同
并行工程设计/设计实时协同并行,设计/制造同步
数据的全生命周期管理PLM系统管理零部件的整个生命周期
数字化模型支持设计、分析、审核、工艺、制造各个环节
复材零件从设计到制造面临的挑战
Long cycle time
分析和设计环境不能集成,数据单向传递
缺少并行能力
没有与专业应用程序在统一环境下的集成
Cost (Raw Materials, Affordability)
缺少预先发现制造问题的能力
在车间加工阶段才发现问题太多的准备工作(几何元素级别)
难于仿真和优化整个零件的性能Environmental Issues ( Regulations,
Biodegradability, Recyclability, etc…)
要管理很多的数据
难于与样机数据集成
复材已逐渐变成核心业务
好的复材解决方案应该:优化的设计和制造方式和谐的业务流程、方法论、工具OEM和供应商具有统一的工具集覆盖复材的整个流程
要从复材获益需要业务转型
传统复材解决方案不具有高效协同能力不能从下游得到反馈别的专业或团队不能及时参与
面临的多种选择对核心业务/非核心业务进行转型外包/设计制造一体供应商早期介入共同研发
过去• 多个复材流程• 局部的方法论
• 部门专业间缺少集成、沟通和协调
• 许多工具间集成困难• 工具没有实质上工业化
现在和将来• 流程、方法论、工具要协调统一• 集成所有流程的端到端的解决方案• 可靠的集成工具集
复材的大量应用需要一个PLM集成解决方案
只有复材 PLM 集成解决方案才能完全优化整个端到端的流程在一个单一的环境下覆盖设计、分析到制造整个流程集成多个专业以实现并行工程协同的平台同时支持 OEM 和供应商的数据管理
达索是当今唯一一个提供端到端复材PLM解决方案的软件厂商这个解决方案包括用于复材设计的CATIA,验证的 SIMULIA ,虚拟制造的 DELMIA ,管理数据的ENOVIA和基于达索产品开发的一系列第三方软件
这个解决方案使得设计人员虚拟的产品环境下进行设计,从验证和虚拟制造端得到准确的反馈,在复材研发的早期预测到问题的存在,避免错误在现实中发生
进而帮助提供生产效率和质量。在复材研制流程中更多的协同和创新来加速核心业务活动,降低风险和成本
Physical world
IP Capitalization
Hand Lay-Up
RTM, VARTM, VARI
Automated Tape Laying
Automated Fiber Placement
9
达索复材解决方案的创新
Ply modification driven by manufacturing, impacting
assembly context
CPD core product
Assembly context managedin the analysis
Enhanced ply fiberdirection driven by
analysis
Design in Assembly context
Early simulation of manuf process.
Dedicated plymodification features
Design in Manufacturing context
TOO SHORT FIBERS
Design in Analysis context
专用的复材架构、特征和仿真能力,在产品装配环境和分析环境下设计,考虑加工的约束
3 种设计方式
Z1Z2
90 30Carbon 2 2Kevlar 2 0
区域设计
网格设计
实体切片
Z1 Z2 Z3 ... …
90 30Carbon 2 2Kevlar 2 0
TL1
TL1 TL1
TL1
Regular parts Stiffened pannel Monolithic Part managed by a thickness law
12
设计 / 仿真双向迭代
适用于设计员的完全集成的CATIA GPS快速的设计-分析-设计迭代,无数据转换,无信息丢失复材材料特性的自动传输线形热-机械分析集成的后置处理
适用于FE专家的高级分析AbaqusCATIA 网格和CPD 属性通过一个文件倒入ABAQUS CAE ABAQUS 和 CATIA 双向集成设计、分析、可制造性评估间的无缝关联统一环境下全面的复材失效分析Isight 优化纤维方向
为保证重量最轻、成本最低,优化对结构零件的性能起着至关重要的作用
虚拟制造DELMIA解决方案
• 集成解决方案中包括复材得工艺设计、加工仿真、车间指导文档和制造执行系统。
• 直接使用CATIA铺层数据在DELMIA中完成工艺设计和生成车间指导文档。
• 全面的工艺计划生成和管理环境在工艺设计更改时很容易更新指导文档
加工前在虚拟环境中进行可制造性验证是关键的:- 避免后期更改和重复工作- 避免浪费材料
DELMIA 复材工艺设计流程
Auto generate
Process plan based on CATIA ply sequence
Create CATIA Composite Mfg Model
Create
annotation views
and define text
instructions
Engineering in CATIA
Composite Design
Auto Generate
Documentation
Visualize ply build
sequence
由于数据的关联性,更易于更改管理和各环节的并行
WaterJet&Ultra-sonic Cutting, Non Destructive Inspection
Perform Process Planning in DELMIA
Execute Work InstructionsDistribute Machine Code DataOptimize Processes
ATL/AFP Machine/Robots
Metrology, and Reporting
Author Work Instructions
Configuration-managed and effectivity-controlled Product/Process/ResourceInfrastructure
Design in CATIA Composites Part Design (CPM)
Stitching
DELMIA 加工编程和仿真
DS CAA 合作伙伴解决方案
手工铺层TruLASER 激光投影文件生成TruNEST 排版和下料PANOGEN 排版和下料
自动铺带TORRES LAYUP V5
CIMPA TAPE GENERATION & TAPE MANUFACTURING
Tape Laying Advanced CPS Interface
ACE V2 Tape Laying Composite CAA V5 Interface
自动铺丝iCPS for Designer + iCPS for NC ProgrammerACE V2 Fiber Placement Composite CAA V5 InterfaceTORFIBERDES +TORFIBERMANCATFiber Export CAA V5 InterfaceFP Standard Composites Design + FP Virtual ProductionFiberLay + NC Composites Machine Simulation
RTM / VARTM, RFI : Resin Injection Simulation
跟踪树脂流动参数,优化注射时间,验证压力区域在真实加工前优化注射流程
高压水切割、超声波加工
制造执行系统(MES)
与工业界领先企业的合作
DS has worked in partnership with Industry leaders like Boeing and Airbus on major Composites programs.
CATIA Composites is recognized as a Strategic Solution by the Aerospace community and adopted as such by OEMs and their Supply Chain.
DS extended direct R&D relationship to Key Leaders from Automotive to Wind and Shipbuilding Industries
Airbus / DS Composites Partnership
• Our driver: Pragmatism & Collaboration
• Airbus internal “Plateau” mode
• Multidisciplinary Airbus team (Stress, Design & Manufacturing, PDM, production).
• Dassault Systèmes as part of the team since the GO Decision
• Clear requirements based on Airbus processes
• Concurrent technical specifications & developments
• Regular testing sessions to validate the new solutions
• Convergence phase to reach required solution maturity:
• Several loops for testing/bugs fixing/validation/delivery of improved code
BOEING / DS Composites PartnershipKevin Fowler, VP Systems Integration Processes & Tools, The BOEING Co., at COE 2009:
"V5 has a competitive advantage. Without V5, we wouldn't have done a compositeon the 787. It's a real enabler…““… The V5 suite of tools has enabled a new level of productivity and integrationacross the product lifecycle – a composite commercial airliner would not have beenfeasible without it.”
与复材领域相关团体的沟通融合保证技术上的创新
DS is strongly involved with the Composites communityComposites adoption is mature, not materials and technologiesDS is working with all major actors of the domain to develop next generation’s optimized, high volume, low-cost technologiesQuickly adapt, with a strong and dedicated R&D capacity, to these technology changes and be at the forefront of innovation
Active Corporate MembershipsWith Composites Associations , Industry Groups
Constant Market Exposure
Tradeshows,
Sponsored Webcasts,
Forums
Connection to Research & Academics Connection to
Material Providers
Partnerships with Software& Equipment Providers
Connection to Consulting Companies
CONSULTING
Aerospace Customers
Non Aerospace Customers
Automotive Shipbuilding
Consulting
Material Providers
Research
Wind
Engines
General Electric – AviationCD3+DELMIA
to feed iCPS Ingersoll Machine Tools
ROLLS ROYCERolls Royce UK is a NX account. Acquired 2 CPD seats in 2008
Differentiator : Solid Slicing approach for engine blades
Benchmark still in progress
AIRCELLESAFRAN subsidiary with a strong know-how in Nacelles
Larges Nacelles : Sole integrator for AIRBUS A380
Small Nacelles : key supplier to the world’s largest regional aircraft and business jet manufacturers :
– EMBRAER : ERJ 170/190
– DASSAULT AVIATION : FALCON F7X
Composites Aerostructures across programs for Airbus, Boeing, Dassault, Eurocopter …
GOODRICHCPD + Ingersoll iCPS
SPIRITSPIRIT US using CPD for GULFSTREAM 650 nacelles
Space & Satellites
EADS ASTRIUM Satellites
Space Transportation programs
BOEING IDSMultiple sites phasing out FiberSIM /
Adopting CPD on all new V5 Space &
Defense programs
Across multiple sites : El Segundo, Mesa,
Huntington Beach, St Louis
TSAT (Transformational Satellite
Communications System) Military
Satellite System
ATK Space Systems
选择达索系统作为战略伙伴
市场变化需要业务模式变革
制造商应该从核心业务选择战略上的解决方案提供商
达索系统是复材设计领域的领导者
达索系统提供了当前市场上唯一的复材PLM平台
“Innovation Drives Composites Production”
“Automating Wind Blade Manufacture”
“Composites Wind Turbines Design : Leverage Aerospace Advances”
“The PLM Solution for successfully designing and producing Composites”
Dassault Systèmes Composites ExpertiseIn recent Publications
For more information please contact:
Ding [email protected]
Gong [email protected]
Visit our website at www.3ds.com/composites
Thank you for attending!!