Dr. Olivier Guillermin Composite Design Technologies, Inc. Monte Carlo, Monaco June 7-9, 2000

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

2. Composite Design Technologies, Inc. • The world’s 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

3. Analysis Interface Laser Projection Composite Engineering Environment P001 Actual Ideal P002 P002 • Feature-based design • Laminate surface generation • Producibility simulation • Net flat patterns Flat Pattern Export Documentation Fiber Placement Interface Composite Engineering Environment

4. FiberSIM is fully CAD Integrated C A T I A • U G • P R O / E Master Model

5. • ZONE1 • ZONE2 • ZONE4 • ZONE3 • ZONE8 • ZONE6 90 -45 +45 • ZONE9 0 • ZONE12 • ZONE5 • ZONE11 • ZONE10 • ZONE7 Process & Material Selection Structural Sizing Solid Modeling TARGET LAYUP 25/50/25 TARGET LAYUP 40/40/20 Ply Producibility Preliminary Design & Analysis Detailed Design & Analysis Preliminary Design & Analysis Detailed Design & Analysis Manufacturing Manufacturing Documentation FE Analysis Fiber Placement Tape Laying Laser Projection The Composite Engineering Process

6. Plies & Sequences Materials & Processes • Hand Layup • RTM • Fiber Placement • Tape Laying • Prepreg/Dry • Uni/Woven • Preforms • Engineered Fabric 90 135 45 0 Offset Surfaces True Fiber Orientations A Complete Description of the Composite Part

7. Manufacturing Applications • Documentation • Fiber Placement • Tape Laying • Nesting • Automated Cutting • Laser Projection

8. Analysis MSC Software Design FiberSIM Closing the Loop Between Design & Analysis Decreases product development cycle Optimizes designs Detects & quantifies conceptual errors Increases model accuracy & sensitivity Manufactured Part

9. Case Studies Turbine Spinner Sikorsky S-92 Helicopter

10. 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

11. Fiber Paths in Half-Body Ply - Origin at Top

12. Fiber Paths in Half-Body Ply - Origin at Bottom

13. Displacements of Original Design Load Case: Centrifugal Loading About Y Axis

14. Displacements of Revised Design Load Case: Centrifugal Loading About Y Axis

15. 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

16. 0°/90° Ply (Bottom Skin)

17. +/- 45° Front and Back (Bottom Skin)

18. Analysis of initial design based on true fiber orientations

19. Orthotropic Layup (Bottom Skin)

20. Revised Design (+/- 45° Front & 0/90° Back)

21. Quasi-isotropic Layup

22. Analysis of revised design based on true fiber orientations

23. 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

24. 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