Introduction to the Siemens PLM End to End Solution for Composites

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1 Introduction to the Siemens PLM End to End Solution for Composites Restricted Siemens AG All rights reserved. Page 1

2 Siemens PLM is Dedicated to the Future of Lightweight Engineering Bringing intelligence to the entire lightweight product development & production process Investing in Leading Technologies Page 2

3 Key Market Trends and Industry Challenges Program excellence Emission standards Performance & Safety Larger & Lighter Time-to-market Lightweighting Fuel economy Weight reduction Weight reduction Volume production rate Capacity Manufacturing quality Lifecycle costs Time-to-market Speed Time-to-market Globalization Lifecycle costs Failure Rate Production costs Quality Performance Lifecycle Costs Lifecycle costs Page 3

4 Key Initiatives by Aerostructure Manufacturers are Driving the Development of Today's Products Optimization for excellence in fuel economy, range, and operation Higher rate, lower risk production to achieve lower cost Competitive differentiation through design and quality of aircraft Globalized supply chain for aerostructure development Page 4

5 Often, Designs are not Optimized for the Use of Composites Materials A&D Industry Observations 6 "Overdesignedcomposites cannot compete with lowercost, 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." OVERDESIGN "Overdesignto address uncertainty negates the advantages of composites" Page 6

6 Market Pressures Driving Automotive Mixed Materials Lightweighting Environmental challenges and world urbanization are forcing a new level of lighter car innovation New lighter cars must meet the consumer demand for differentiated branding and better performance 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 Page 7

7 And the Survey Says6 Expect Big Changes For Automotive TOP PRESSURES DRIVING CHANGE TIME IS RUNNING OUT THE SOLUTION: NEW MATERIALS Automotive companies report fuel efficiency and emissions regulations are the # 1 pressure Automotive companies respond by planning lightweighting strategies now! New material strategies show results of producing vehicles at least 40% lighter Recognize lightweighting as a top strategy to meet impending regulations Have or will develop new material strategies Page 8 Identify reducing vehicle weight as the top challenge for meeting fuel efficiency and emission standards Plan to use mixed materials, including composites, to produce lightweight vehicles January, 2014, Aberdeen Group, Inc.

8 Mixed Material Lightweighting Bringing the Biggest Changes in 50+ Years Vehicle Packaging Fundamental Changes to how Vehicles are Designed and Built Factory Design Part Manufacturing Supply Chain Joining Methods Strength & Durability Noise, Vibration, Harshness (NVH) Safety (Crash) Repair Process Page 9

9 Key Challenges of Innovative Lightweighting Engineering Design & Manufacturing Concurrent Engineering Analysis & Simulation Must design producible composite parts! Need to design the composite material! Requires a predictive manufacturing simulation! Faster & frequent design & analysis iterations! Rapid materials & process selection! A flexible optimization process! Accurate data for FEA composites models! Maximized Strength & Durability performance! Best-in-class NVH & Acoustics performance! Enable a seamless link to the manufacturing floor! Include early cost estimation! Integrated simulation & test based engineering! Close the loop from manufacturing to design! Balanced multi attribute integration! Page 11

10 Partnering with Siemens PLM to Solve the Complexity of Structures Lightweighting Composites Part Design Ply Schematic Concurrent Design and CAE Composites Simulation Initial Stack-up Redefine Sequence Manufacturing Producibility Materials Definition NVH & Acoustics Composites Optimization Process Integration CAD CAD Assy FEM Mesh FEM Assy Multi CAD Multi CAE FEM Post Strength & Durability Dataset for Manufacturing Data Management Thermal Analysis Page 12

11 Supporting the End-to-End Composites Engineering Process Workflow CAD surface Begin with CAD surface based on packaging requirements Design Analysis Iterations Efficiently optimize with integrated design and analysis tools Meshing and Modeling Create and mesh composites simulation models Define laminate, select material and process Laminate definition Use open CAE Architecture to third party solutions Open architecture Solve for Stiffness, Strength, Thermal, NVH, Acoustics, Durability6 Performance Analysis Page 13

12 And Seamless Link to Manufacturing Design Validation Validate producibility of design and generate manufacturing data Manufacturing Dataset Generate data for flat patterns, tooling surfaces, flow modeling and automated machinery Fully optimized light weight structure Automatically generate engineering drawings, and data for weight, cost modeling, PLM data feeds Engineering drawings Page 14

13 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 Zone and Structure based design (aero) Laminate A Laminate A+B Laminate A+B+C Multi-ply laminate definition (auto) Page 15

14 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 Page 16

15 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 Complete laminate definition with as-built fiber orientations 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 Strength, NVH, Acoustics, Durability, thermal analysis Validated ply layup Page 17

16 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 Page 18

17 Linear and Non-linear Simulation Solutions Strength & Dynamics Classical Failure Buckling, Post Buckling Damage Stress, Strain, Thermoelastic, Frequency and transient events First-ply failure, Failure Indices Displayed : critical ply, values, load case From Linear Buckling to Post-Buckling behavior Progressive Damage Analysis in Ply and at the interface (delamination) Linear Methods Non-linear Methods Page 19

18 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 Page 23

19 Delivering Unique Value across the Product Development Process Materials Geometry Manufacturing Process Testing Assembly Expertise build-up full vehicle simulation/sign-off Coupon Component Subsystem Validation of complex subsystem modeling Model validation on components and joint technology Validation of material models Page 24

20 Customer: Airbus Group Innovations Composites 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 Samtechdevelopment 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 Samcefsolver." Didier Guedra-Desgeorges Vice-President and Head of the Technical Capabilities Center, Structure Engineering, Production & Aeromechanics Page 27

21 Customer: Bombardier Shorts Composites 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 Page 28

22 Customer: SpaceX Composites Design and Manufacturing Time is always of the essence for us so Fibersim'sproven 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. Fibersimimproves 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 Page 29

23 Customer: Magna Exteriors & Interiors High Volume Mixed Materials Applications 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 Plastic-Metal Hybrids & RIW Carriers Load Floors Thermoplastic Liftgates Tubs Page 31

24 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 Page 32 "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

25 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 Page 34

26 Introduction to the Siemens PLM End to End Solution for Composites Torrey Sullivan Business Development - Americas Siemens PLM Specialized Engineering Software Phone: Smarter decisions, better products. Page 35

27 Thank You Restricted Siemens AG All rights reserved. Page 36 20XX-XX-XX

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