In this section, PROJECT COMPOSITES CATIA V5, you can evaluate my knowledge of Design and Manufacturing of Composites (CPD & CPM) using Catia V5.
First, I´ve designed an simple example and then I´ve solved it by using the five differents methods existing (Grid Design method, Solid Approach method, Z&T method, Z&ETBS method and Ply by Ply method). This is called CPD (Composites Product Design) and the result is the same in all cases.
Then, I´ve used Manufacturing Tools and Flattening Tools to get the Composite Product Manufactured (CPM). There is only one method to get the final result.
Finally, I´ve used Drafting to get all the draft of every ply as the final product.
First, I´ve designed an simple example and then I´ve solved it by using the five differents methods existing (Grid Design method, Solid Approach method, Z&T method, Z&ETBS method and Ply by Ply method). This is called CPD (Composites Product Design) and the result is the same in all cases.
Then, I´ve used Manufacturing Tools and Flattening Tools to get the Composite Product Manufactured (CPM). There is only one method to get the final result.
Finally, I´ve used Drafting to get all the draft of every ply as the final product.
1.- GRID DESIGN METHOD (CPD)
Grid Design Method is the most powerfull method and in designed for parts in an automatic manufacturing way. We use this method if we need the manufacturing of a certain number of part to design. It´s the method used by important companies as Airbus and other companies of EADS Group.
This method is based on the grid design that will serve to define the limits of each different area and transition zone of the part.
First, I'll add a video which summarizes all the steps in Grid Design Method. I've summarized the Composites Product Design (CPD) of a wing. This complex design has taken me a long time and it's necessary to summarize it. The design is 100% work of my invention, watching other wing's designs. The choice of the different areas and their composition follows a logical order of thickness and mechanical specifications. .
By the way, the song that you can heard during the video is of my group and is sung by me.
Now, I'm going to do the complete exercise of a generic curved part, using the Grid Design Method. Obviously, the number of zones and their compositions are much simpler than the previous exercise as the objective is to show the design method.
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
2.- SOLID APPROACH METHOD (CPD)
Solid Approach method is another powerfull method that is based on design all the differents zones and transition zones to get the solid. Then, we slice the solid to get the Slicing Group. Later, we put the plies on. Finally, we relocate the plies to get the form wanted.
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
3.- ZONES & TRANSITION METHOD (CPD)
Zones & Transition Method is based in the design of the transition zones, so we must chose the most appropiate transition zone in relation with the design that we are searching for.
Then, we must design the zones and transition zones and choose with transition zone belogns each zone. Later, in a exported data file we can change the configuration and order of plies to get the required design. Finally, we´ll get the solid.
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
4.- ZONES & ETBS METHOD (CPD)
Zones & ETBS Method is similar in some ways to the Zones & Transitions. We follow almost the same steps. The most important difference is that in stead of design the transition zones, we export a second data file to define it. Then, as in the previous exercise, we get the solid.
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
5.- PLY BY PLY METHOD (CPD)
Ply by Ply method is the most laborious method because, as their name suggests, we must design ply by ply to get the final design. The conceptual phase is very important in this method as a erroneous decision can make you lose many hours of work.
First, we have to design in GSD, each contour of each ply that we want to designed. Then, we register the ply by defining his boundary ply, material and orientation. This is the most laborious step.
Later, we get the solid. Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
6.- MANUFACTURING COMPOSITES (CPM)
The Composites Product Manufacturing (CPM) is divided in two steps: manufacturing and flattening.
Manufacturing process consists in transforming a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product or MEOP). To achieve it, we incorporate the real mold design, where we'll be positioned plies.
First, we project the plies designs in the real surface or mold to get the Engineering End of Product (EEOP). Then, we apply a material excess to each ply to get the Manufacturing End of Product (MEOP).
Flattening process consists in flatten or stretch the Manufacturing plies (MEOP) on a on a flat surface. Then, we study their producibility and finally, we obtain the final drafts to manufacture the plies.
1.- GRID DESIGN METHOD (CPD)
Grid Design Method is the most powerfull method and in designed for parts in an automatic manufacturing way. We use this method if we need the manufacturing of a certain number of part to design. It´s the method used by important companies as Airbus and other companies of EADS Group.
This method is based on the grid design that will serve to define the limits of each different area and transition zone of the part.
First, I'll add a video which summarizes all the steps in Grid Design Method. I've summarized the Composites Product Design (CPD) of a wing. This complex design has taken me a long time and it's necessary to summarize it. The design is 100% work of my invention, watching other wing's designs. The choice of the different areas and their composition follows a logical order of thickness and mechanical specifications. .
By the way, the song that you can heard during the video is of my group and is sung by me.
Now, I'm going to do the complete exercise of a generic curved part, using the Grid Design Method. Obviously, the number of zones and their compositions are much simpler than the previous exercise as the objective is to show the design method.
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
2.- SOLID APPROACH METHOD (CPD)
Solid Approach method is another powerfull method that is based on design all the differents zones and transition zones to get the solid. Then, we slice the solid to get the Slicing Group. Later, we put the plies on. Finally, we relocate the plies to get the form wanted.
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
3.- ZONES & TRANSITION METHOD (CPD)
Zones & Transition Method is based in the design of the transition zones, so we must chose the most appropiate transition zone in relation with the design that we are searching for.
Then, we must design the zones and transition zones and choose with transition zone belogns each zone. Later, in a exported data file we can change the configuration and order of plies to get the required design. Finally, we´ll get the solid.
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
Then, we must design the zones and transition zones and choose with transition zone belogns each zone. Later, in a exported data file we can change the configuration and order of plies to get the required design. Finally, we´ll get the solid.
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
4.- ZONES & ETBS METHOD (CPD)
Zones & ETBS Method is similar in some ways to the Zones & Transitions. We follow almost the same steps. The most important difference is that in stead of design the transition zones, we export a second data file to define it. Then, as in the previous exercise, we get the solid.
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
5.- PLY BY PLY METHOD (CPD)
Ply by Ply method is the most laborious method because, as their name suggests, we must design ply by ply to get the final design. The conceptual phase is very important in this method as a erroneous decision can make you lose many hours of work.
First, we have to design in GSD, each contour of each ply that we want to designed. Then, we register the ply by defining his boundary ply, material and orientation. This is the most laborious step.
Later, we get the solid. Then, we apply the manufacturing process: manufacturing and flattening. With the manufacturing process we transform a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product). I'll explain in more detail in Manufacturing Composites section, the different stages of Composites Product Manufacturing (CPM).
6.- MANUFACTURING COMPOSITES (CPM)
The Composites Product Manufacturing (CPM) is divided in two steps: manufacturing and flattening.
Manufacturing process consists in transforming a theoretical design of plies (also know as Engineering End of Product or EEOP) in the real plies (also know as Manufacturing End of Product or MEOP). To achieve it, we incorporate the real mold design, where we'll be positioned plies.
First, we project the plies designs in the real surface or mold to get the Engineering End of Product (EEOP). Then, we apply a material excess to each ply to get the Manufacturing End of Product (MEOP).
Flattening process consists in flatten or stretch the Manufacturing plies (MEOP) on a on a flat surface. Then, we study their producibility and finally, we obtain the final drafts to manufacture the plies.
