FiberSIM 2010 CEE R1

FiberSIM 2010 CEE
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Trademarks
FiberSIM and EnCapta are registered trademarks of VISTAGY, Inc. in the United States and in other countries. All of the following are trademarks of VISTAGY, Inc. in the United States and in other countries: Engineer Success, Composite Engineering Environment, FiberSIM CEE, Advanced Composite Engineering Environment, FiberSIM ACEE, Automated Deposition Design, FiberSIM ADD, FiberSIM Documentation, FiberSIM Analysis Interface, FiberSIM Flat Pattern Export, FiberSIM Laser Projection, FiberSIM Fiber Placement Interface, FiberSIM Tape Laying Interface, Composite Viewer, FiberSIM Applications Programming Interface, FiberSIM API, XML Interface, Pattern Design Environment, Seat Design Environment, Seat Manufacturing Environment, Seat Viewer, Airframe Development Environments, Airframe Design Environment, Airframe Manufacturing Environment, Quality Planning Environment, Characteristics Design Environment, Variable Surface Offset Technology
Copyright
2011 VISTAGY, Inc. All Rights Reserved. Printed in the USA. Reproduction requires written permission from VISTAGY, Inc. This product includes software developed by the Apache Software Foundation: http://www.apache.org 1999-2007 The Apache Software Foundation. All rights reserved. Xalan and Xerces software from Apache Software Foundation is provided AS IS and any expressed or implied warranties, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose are disclaimed. In no event shall the Apache Software Foundation or its contributors be liable for any direct, indirect, incidental, special, exemplary, or consequential damages (including, but not limited to, procurement of substitute goods or services; loss of use, data, or profits; or business interruption) however caused and on any theory of liability, whether in contract, strict liability, or tort (including negligence or otherwise) arising in any way out of the use of this software, even if advised of the possibility of such damage. Restricted Rights Legend Use, duplication, or disclosure by the government is subject to restrictions as set forth in subparagraph (1) (ii) of The Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 or subparagraphs (1) and (2) of Commercial Computer Software Restricted Rights at 48 CFAR 52.227-19, as applicable.
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Table of Contents
Table of Contents
Chapter 1 Introduction to FiberSIM ..................................................1-1 Exercise 1a Orientation to FiberSIM...................................... 1-3 Chapter 2 Model Setup ......................................................................2-1 Exercise 2a Create a Model from an Extended Surface and Planes .............................................................................. 2-3 Exercise 2b Create a Model from a Solid ............................ 2-13 Exercise 2c CATIA Model Setup from Planes and Surface (Optional) ................................................................. 2-23 Chapter 3 CEE Basics........................................................................3-1 Exercise 3a Basic Part with 8 Full-body Plies........................ 3-3 Exercise 3b Reinforcement Plies, Sequencing, and Cutouts........................................................................... 3-13 Exercise 3c Flat Pattern....................................................... 3-27 Exercise 3d Create Basic Part............................................. 3-34 Chapter 4 Producibility......................................................................4-1 Exercise 4a How Geometry Affects Producibility................... 4-3 Exercise 4b How Simulation Options Affect Producibility (Simulation Skin) ................................................................... 4-29 Exercise 4c How Simulation Options Affect Producibility (Two-Stage) .......................................................................... 4-39 Exercise 4d Resolving Producibility Issues ......................... 4-53 Chapter 5 Rosettes ............................................................................5-1 Exercise 5a Translational Rosette ......................................... 5-3 Exercise 5b Radial Rosette ................................................. 5-18 Chapter 6 Utilities...............................................................................6-1 Exercise 6a Symmetric Laminate .......................................... 6-3 Exercise 6b Curve Creation and Ply Drop-off Utilities ......... 6-13 Exercise 6c Fiber Path Curve .............................................. 6-31 Project 1 Monolithic Panel ............................................................. P1-1 Exercise P1 Monolithic Panel ............................................. P1-3 Chapter 7 Core ...................................................................................7-1 Exercise 7a Core Types ........................................................ 7-3 Exercise 7b Modeled Core with Overcore and IML Laminates....................................................................... 7-15 Exercise 7c Core Panel Design from a Solid (Optional) ...... 7-30
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FiberSIM 2010 CEE
Chapter 8 Documentation .................................................................8-1 Exercise 8a 3D Documentation ............................................. 8-3 Exercise 8b Generating a Ply Book and Ply Table .............. 8-14 Chapter 9 Model Interrogation ..........................................................9-1 Exercise 9a Model Interrogation ............................................ 9-3 Project 2 Core Panel ....................................................................... P2-1 Exercise P2 Core Panel...................................................... P2-3
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Chapter 1
Introduction to FiberSIM
This chapter includes:
Exercise 1a: Orientation to FiberSIM
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Exercise 1a
Orientation to FiberSIM
FiberSIM is fully integrated with CATIA and launched from within the CATIA user interface. Engineers define composite parts by creating FiberSIM objects, such as laminates, rosettes, plies, and cores. During definition, engineers associate these FiberSIM objects to their corresponding CAD geometry. In this exercise, you will use the FiberSIM user interface and investigate the FiberSIM objects and their associated CATIA geometry.
Goal
After you complete this exercise, you will be able to:
Launch FiberSIM and display the CEE menu Investigate the User Interface Show Object details in List and Form modes Investigate each Object type and its dependencies Show Net Producibility and Net Flat Pattern
Task 1 - Open FS2010_CEE_INTRODUCTION_A.CATPart. 1. Open FS2010_CEE_INTRODUCTION_A.CATPart. The model displays as shown in Figure 11.
Figure 11 Task 2 - Launch FiberSIM and display the CEE menu.
1. Click
(FiberSIM). The FiberSIM window opens.
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2. Expand the CEE menu to display the object types, such as Laminate, Rosette, and Ply as shown in Figure 12.
Figure 12 Task 3 - Investigate the User Interface. 1. The main menu, main toolbar, and CEE menu of the Application Tree are shown in Figure 13. Main menu Main toolbar CEE menu
Application Tree
Documents Browser
Figure 13
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2. In the FiberSIM drop-down list, select - CEE as shown in Figure 14.
Figure 14 3. Only the CEE menu is now displayed in the Application Tree, as shown in Figure 15.
Figure 15
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4. Select Laminate. The User Interface updates with the Object toolbar and Object Details that are related to the selected Object Type, as shown in Figure 16.
Object toolbar
Object Types
Object Display Window
Figure 16 Task 4 - Show Object Details in List and Form modes. When an object type is selected from the CEE menu, the Object Display window displays a list of all of the objects of the selected object type for the current model. This display is called List mode. When an object is double-clicked, its object details display in Form mode. In this task, you use the List and Form modes. 1. In the CEE menu, select Ply to display the details of all of the plies contained in the current model in List mode, as shown in Figure 17.
Figure 17
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2. Double-click on the P001 ply. The Object Details display in Form mode in a form as shown in Figure 18.
Figure 18 Alternatively, if you select from the CEE menu without clicking you are prompted to save the new or modified objects. 3. Click changes. to return to the ply list without making any
4. In the CEE menu, select Rosette to list all of the rosettes in the current model. 5. Double-click on the ROS001 rosette to display its details in Form mode. 6. Click changes. to return to the rosette list without making any
7. In the CEE menu, select Laminate to list all of the laminates in the current model.
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Task 5 - Investigate the Laminate standard form. A Laminate is the tool surface on which you build your plies. 1. Double-click on the Skin laminate to display its details in Form mode. By default, the Standard tab is selected. The Standard form contains areas for specifying Non-geometric information (such as Name, Sequence, and Step) and Geometric information (such as Layup Surface, Net, and Extended boundaries), as shown in Figure 19. Non-geometric information
Geometric information Figure 19 2. Next to Default Material, click (Link with Database Link Dialog) to open the dialog box containing the available materials. The prepreg material, PPG-PL-3K, is currently set. Select each tab as shown in Figure 110 to view all of the material information.
Figure 110 3. Click changes.

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to return to the form without making any material
4. Switch to the CATIA window and note the green highlight indicating the laminate surface and the layup direction inherited from the CAD surface normal as shown in Figure 111.
Figure 111 Task 6 - Investigate the Laminates dependencies. 1. In the FiberSIMs laminate standard form in the Geometry area, three Geometry references are displayed. Geometry references can be identified by (Link Geometry). The Layup Surface is linked to the Tool Surface CAD feature. Net Boundary is linked to the Net Boundary CAD feature and Extended Boundary to the Extended Boundary CAD feature as shown in Figure 112.
Figure 112 2. Close the FiberSIM window.
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3. In CATIA, in the specification tree under the FiberSIM Geometry geometrical set, note the three CAD features: Tool Surface, Net Boundary, and Extended Boundary. Select each one to display its associated CAD geometry as shown in Figure 113. Net Boundary (inside cyan boundary) Extended Boundary (outside magenta boundary)
Tool Surface
Figure 113 Task 7 - Investigate the Rosette standard form and dependencies.
1. Click
(FiberSIM).
2. In the CEE menu, select Rosette. 3. Double-click on the ROS001 rosette to display its details in Form mode as shown in Figure 114. Note that Skin is the rosettes laminate.
Figure 114
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4. Note the linked geometry indicated by as shown in Figure 115. In the CATIA window the rosette geometry is highlighted in green.
Figure 115 5. Close the FiberSIM window. 6. In CATIA, in the specification tree under the FiberSIM Geometry geometrical set, note the Rosette Origin and Zero Direction CAD features. Select each to display its associated CAD geometry as shown in Figure 116. Zero Direction Rosette Origin
Figure 116 Task 8 - Investigate the Ply standard form and dependencies.
1. Click
(FiberSIM).
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2. In the CEE menu, select Ply. The Material of the ply is inherited from its parent, but can be overridden at any time. 3. Double-click on the P001 ply to display its details in Modify mode as shown in Figure 117. Note that Skin is the plys parent.
Figure 117 4. Note the linked geometry identified by as shown in Figure 118. In this case, ROS001 is linked to the Origin and the Skin laminates Net Boundary is linked to the Boundary of the ply.
Figure 118 Task 9 - Show the Net Producibility. 1. In the ply toolbar, click Figure 119. (Net Producibility) as shown in
Figure 119
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2. Switch to the CATIA window to display the producibility results as shown in Figure 120.
Figure 120 Task 10 - Generate a Net Flat Pattern. 1. In the FiberSIM ply toolbar, click Pattern) as shown in Figure 121. (Generates the Net Flat
Figure 121
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2. Switch to the CATIA window to display the net flat pattern results as shown in Figure 122.
Figure 122 3. Click to save the Net Flat Pattern.
4. Close the FiberSIM window. Flat patterns are CATIA Sketch features and can be edited in the CAD system if necessary. 5. In CATIA, in the specification tree under the FiberSIM Flat Patterns geometrical set, note the new NET_FP_P001 feature. Select NET_FP_P001 to highlight its associated geometry.
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Chapter 2
Model Setup
Exercise 2a: Create a Model from an Extended Surface and Planes Exercise 2b: Create a Model from a Solid Exercise 2c: CATIA Model Setup from Planes and Surface (Optional)
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Model Setup
Exercise 2a
Userguide Reference: 2.1 Introduction 2.2 CEE Organization 2.3 Understanding CEE Data Hierarchy 2.4 Defining Boundaries for CEE Objects 2.6 Laminates 2.7 Rosettes
Create a Model from an Extended Surface and Planes

In this exercise, you will prepare a CATIA model for composite design with FiberSIM from an extended surface and planes. The completed model displays as shown in Figure 21.
Figure 21
Goal
Create Net Boundary geometry Create Extended Boundary geometry Create a Tool Surface Create Rosette geometry
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Task 1 - Open a part. 1. Open FS2010_CEE_MODEL_SETUP_A.CATPart. The model displays as shown in Figure 22.
Figure 22 Task 2 - Verify that the model units are Millimeters. 1. Select Tools > Options > General > Parameters and Measure. Select the Units tab and verify that Length is set to Inch. If the length is not in Inches, expand the Length drop-down list and select Inch (in) as shown in Figure 23. When changing units, the part dimensions are displayed with respect to the new system of units. However, the size of the part remains the same.
Figure 23 2. Click .
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Model Setup
Task 3 - Create Net Boundary geometry.
1. Click opens.
(Intersection). The Intersection Definition dialog box
2. In the specification tree, for the First Element, select Loft Surface. 3. For the Second Element, click and select the first 7 planes in the Master Lines geometrical set (starting with UPPER.1 and ending with FWD) as shown in Figure 24.
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5. Click (Trim). Select the elements in the location and order shown in Figure 25.
Figure 25 6. Click to display the trimmed surface.
7. In the specification tree, collapse the Multi Output.1 (Intersect) branch. 8. In the specification tree, select Trim.1, right-click and select Properties. 9. Select the Feature Properties tab. For the Feature Name, enter [Net Boundary].
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Model Setup
10. Select the Graphic tab. In the Lines and Curves Color drop-down list, select cyan. In the Thickness drop-down list, select 2 as shown in Figure 26.
Figure 26 11. Click . The specification tree updates with the new name and the Net Boundary is displayed in cyan with a thickness of 2, as shown in Figure 27.
Figure 27 Task 4 - Create Extended Boundary geometry. 1. Click (Parallel Curve) to create a parallel curve outside the Net Boundary.
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2. For the Curve, select Net Boundary, for the Support, select Loft Surface, and for the Constant, enter [0.5 in] (12.7 mm). The Parallel Curve Definition dialog box updates as shown in Figure 28.
4. In the specification tree, select Parallel.1, right-click and select Properties. 5. Select the Feature Properties tab. For the Feature Name, enter [Extended Boundary]. 6. Select the Graphic tab. In the Lines and Curves Color drop-down list, select Magenta. In the Thickness drop-down list, select 2 as shown in Figure 29.
Figure 29
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Model Setup
7. Click . The specification tree updates with the new name and the Extended Boundary is displayed in magenta with a thickness of 2, as shown in Figure 210.
Figure 210 Task 5 - Create a Tool Surface. 1. Click (Split).
2. For the Element to cut, select Loft Surface. For the Cutting elements, select Extended Boundary. The Split Definition dialog box updates as shown in Figure 211.
Figure 211
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FiberSIM 2010 CEE
3. Click to ensure that the material outside the Extended Boundary is removed. 4. Click .
5. Select Split.1 and click (Join). FiberSIM uses the tool surface normal to determine the direction of the layup (male or female tool). To ensure the correct normal direction on the tool surface, the recommended practice is to use the Join feature. 6. Click Use a Join feature for easy adjustment of the normal and as a placeholder if the tool surface changes. .
7. Double-click on Join.1 to modify it. Verify that the surface normal is pointing toward the xy plane as shown in Figure 212.
9. In the specification tree, select Join.1, right-click and select Properties. 10. Select the Feature Properties tab. In the Feature Name, enter [Tool Surface].
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Model Setup
11. Select the Graphic tab. In the Fill Color drop-down list, select More Colors... and then select Gray as shown in Figure 213.
Figure 213 12. Click twice.
Task 6 - Create Rosette geometry. 1. Click (Point).
2. In the Point type drop-down list, select On surface. 3. Indicate a placement point in the middle of the Tool Surface. 4. Click 5. Click . (Line).
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6. Select the following: Line type: Point-Direction Point: Point.13 Direction: Right-click and select X Component Start: 0in (0mm) Support: Tool Surface End: 3in (76.2mm)
7. The Line Definition dialog box updates as shown in Figure 214.
9. Rename Line.2 as [Zero Direction]. 10. Rename Point.13 as [Rosette Origin]. 11. In the specification tree, select Master Lines. Right-click and select Hide/Show to hide the Master Lines geometrical set.
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Model Setup
Exercise 2b
Create a Model from a Solid

In this exercise, you will prepare a solid CATIA model for composite design with FiberSIM. The completed model displays as shown in Figure 215.
Figure 215
Goal
Extract a Tool Surface from a Solid Create Net Boundary geometry Extend a Tool Surface to account for manufacturing trim Create Extended Boundary geometry Extract a Ply Edge from a Solid Create Rosette geometry
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Task 1 - Open a part. 1. Open FS2010_CEE_MODEL_SETUP_B.CATPart. The model displays as shown in Figure 216.
Figure 216 2. Select Tools > Options > General > Parameters and Measure. Select the Units tab and verify that Length is set to Inch. 3. Verify that the FiberSIM Geometry geometrical set is active. Task 2 - Extract Tool Surface from Solid. 1. Click (Extract) and extract the rear surface of the solid as shown in Figure 217. For the Propagation type, select Tangent continuity.
Figure 217
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Model Setup
2. Click
3. In the specification tree, select the Extract feature, right-click and select Properties. 4. Rename the extracted surface as [Tool Surface Net] as shown in Figure 218.
Figure 218 5. In the specification tree, select PartBody, right-click and select Hide/Show. Task 3 - Create Net Boundary geometry. 1. Click (Boundary) and select Tool Surface Net to extract its boundary edges as shown in Figure 219.
3. Rename the new Boundary as [Net Boundary].
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Task 4 - Create an Extended Tool Surface. In this task, you will extend the net tool surface to provide a 15mm material excess for the manufacturing trim. 1. Click (Extrapolate) and extend the Tool Surface Net as shown in Figure 220. Use the following parameters: Boundary: Net Boundary Extrapolated: Tool Surface Net Length: 0.6in (15mm) Continuity: Curvature Assemble the result
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Model Setup
3. FiberSIM uses the tool surface normal to determine the direction of the layup (male or female tool). To ensure the correct normal direction on the tool surface, the recommended practice is to use the Join feature. Click (Join) and select Extrapol.1 to create a new Join as shown in Figure 221.
5. Rename Join.1 as [Tool Surface Extended]. 6. In the specification tree, double-click on Tool Surface Extended and verify whether the red arrow (i.e., surface normal) points in the correct layup direction, as shown in Figure 222. If not, select the arrow to flip the direction.
Figure 222
FiberSIM 2010 CEE
7. In the Join Definition dialog box, click 8. Hide Tool Surface Net. Task 5 - Create an Extended Tool Boundary.
1. Following the steps described in Task 3, extract the boundary edges of the Tool Surface Extended. Rename the new boundary as [Extended Boundary]. Task 6 - Change the graphic properties. 1. Change the graphic properties of the created geometry as follows: Tool Surface Extended: Color dark green Net Boundary: Color cyan, Thickness 2 Extended Boundary: Color magenta, Thickness 2
2. The model should display as shown in Figure 223.
Figure 223 Task 7 - Extract a Ply Edge from a Solid. The Extended Boundary curve created in Task 5 provides the dimensions for the full plies. In this task, you will create a curve that will provide dimensions for the shorter plies in the thicker area of the part. 1. Show PartBody (right-click in the specification tree and select Hide/Show).
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Model Setup
2. Click (Multiple Extract) and select two edges of the solid as shown in green in Figure 224. For the Propagation type, select Tangent continuity.
Figure 224 3. Click and hide the PartBody.
4. The extracted ply edge lies on the IML of the part. Therefore, it needs to be projected onto the tool surface. Use (Projection) to project with parameters as shown in Figure 225.
6. Hide Multiple Extract.1. 7. Examine the model. Note that the ends of the projected edge do not reach the extended boundary of the part. You will now extend the edge until it intersects the extended boundary.
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8. Click (Extrapolate). For the Boundary to extend, select either of the two end vertices of the Project.1 curve. For the Extrapolated element (as shown in Figure 226), select Project.1. Set the other parameters as follows: Limit: Up to element Up to: Extended Boundary Continuity: Curvature Assemble the result
10. Click (Extrapolate) and extend the other end of the ply edge as shown in Figure 227.
Figure 227
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Model Setup
11. Click
12. Rename Extrapol.3 as [Ply Edge]. Task 8 - Create a geometrical set for the Rosette geometry. 1. Select Insert > Geometrical Set. 2. In the Name field, enter [Rosette Geometry]. 3. Click . The new geometrical set is created and made active in the specification tree as shown in Figure 228.
Figure 228 Task 9 - Create Rosette geometry. 1. Click (Point).
2. For the Point Type, select On surface. 3. Click in the middle of the tool surface as shown in Figure 229. In the Distance field, enter [0]. (This ensures that the point is in the middle of the surface).
5. Rename the Point feature as [Rosette Origin].
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Task 10 - Create the Rosette zero direction. 1. Click (Line).
2. Make the following selections (as shown in Figure 230): Line type: Point-Direction Point: Rosette Origin Direction: yz plane (aligns the zero direction with the X-axis of the part) Length type: Length Start: 0 in (0mm) End: 3.937in (100mm)
4. Rename the Line feature as [Zero Direction].
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Model Setup
Exercise 2c
CATIA Model Setup from Planes and Surface (Optional)

In this exercise, with minimal instruction, you will prepare a CATIA model for composite design with FiberSIM. The completed model should display as shown in Figure 231.
Figure 231
Goal
Create Net Boundary geometry Create Extended Boundary geometry Create a Tool Surface Create Rosette geometry
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Task 1 - Open a part. 1. Open FS2010_CEE_MODEL_SETUP_C.CATPart.. The model displays as shown in Figure 232.
Figure 232 2. Select Tools > Options > General > Parameters and Measure. Select the Units tab and verify that Length is set to Inch. Task 2 - Create a Net Boundary. 1. Create a Net Boundary by intersecting the Master Surface with the planes LEFT, RIGHT, TOP, and BOTTOM and then trimming the resulting curves to create a closed loop. 2. Modify the graphic properties of the Net Boundary. The resulting model should display as shown in Figure 233.
Figure 233
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Model Setup
Task 3 - Create an Extended Boundary. 1. Create an Extended Boundary by offsetting the Net Boundary by 20mm on the Master Surface (use the Parallel Curve tool). 2. Modify the graphic properties of the Extended Boundary so that the resulting model displays as shown in Figure 234.
Figure 234 Task 4 - Create a Tool Surface. 1. Create a Tool Surface by trimming the Master Surface with the Extended Boundary (use the Split tool). 2. Hide the Master Geometry geometrical set and modify the graphic properties of the Tool Surface as shown in Figure 235.
Figure 235
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Task 5 - Create the Rosette geometry. 1. Create a new geometrical set named [Rosette] and make it active. 2. Create a point in the middle of the Tool Surface and rename it [Rosette Origin]. 3. Create a 3.937in (100mm) line that starts at the Rosette Origin and is aligned with the parts Y-direction. Rename the line as [Zero Direction]. 4. The model is now ready for composite design with FiberSIM and should display as shown in Figure 236.
Figure 236
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Chapter 3
CEE Basics
Exercise 3a: Basic Part with 8 Full-body Plies Exercise 3b: Reinforcement Plies, Sequencing, and Cutouts Exercise 3c: Flat Pattern Exercise 3d: Create Basic Part
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CEE Basics
Exercise 3a
User Guide Reference: 2.6 Laminates 2.7 Rosettes 2.8 Plies B.3.2 Mirror Laminate
Basic Part with 8 Full-body Plies

In this exercise, you will create a FiberSIM model with eight full-body plies. The completed model displays as shown in Figure 31.
Figure 31
Goal
Create a Laminate Create a Rosette Create a single full-body ply Create three full-body plies simultaneously Mirror four plies about the laminate neutral axis
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Task 1 - Create a Laminate. 1. Open FS2010_CEE_BASICS_A.CATPart. The model displays as shown in Figure 32.
Figure 32
2. Click
(FiberSIM).
3. In the CEE menu, select Laminate as shown in Figure 33.
Figure 33
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CEE Basics
Alternatively, you can highlight Laminate, right-click in the main FiberSIM window, and select Create New.
4. Click
(Create New).
5. In the Laminates Standard form, enter the following parameters: Name: Cowl Step: 1 6. Next to Default Material, click to open the FiberSIM - link Material via Default Material dialog box. 7. Click checkbox for PPG-PL-3K and click material to the laminate. Task 2 - Link Geometry to CATIA. 1. Next to the Layup Surface field, click shown in Figure 34. (Link Geometry) as to link the
Figure 34 2. In the CATIA specification tree, select Tool Surface to link the Layup Surface to the CATIA Tool Surface join feature as shown in Figure 35.
Figure 35
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3. The Select Layup Surface window updates as shown in Figure 36.
5. Use the same procedure to link the following geometry: Keep the Enable Curve Auto-Chaining option selected. Net Boundary: Net Boundary Extended Boundary: Extended Boundary 6. The Laminate Standard form updates as shown in Figure 37.
Figure 37 If you need to delete a Laminate, select its name in the list, right-click, and select Delete. 7. Click to complete the laminate creation and return to the list view. Select the Cowl laminate from the list view to display the laminate on the CATIA model as shown in Figure 38. The arrow represents the layup direction, which is inherited from the laminate surface normal.
Figure 38
CEE Basics
Task 3 - Create a Rosette. 1. In the CEE menu, select Rosette as shown in Figure 39.
Figure 39 2. Click (Create New).
3. For the ROS001 rosette, link the following geometry: Origin: Rosette Origin Direction: Zero Direction 4. The Rosette form updates as shown in Figure 310.
Figure 310 5. Click list view. to complete the rosette creation and return to the
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Task 4 - Create a single full-body ply. 1. In the CEE menu, select Ply as shown in Figure 311.
3. For the P001 ply, enter the following parameter: Step: 10 4. Click view. to complete the ply creation and return to the list
Task 5 - Create 3 full-body plies simultaneously. 1. In the CEE menu, select Ply. For the Object Count, enter [3] as shown in Figure 312.
Figure 312
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CEE Basics
2. Click For [20,10], the 20 means that the first newly created ply has the number 20 and the other ply numbers are generated in increments of 10.
(Create New).
3. In the Step field, enter [20,10] as shown in Figure 313.
Figure 313 4. Press <Ctrl> + <T> to toggle to Table mode. The new plies, P002, P003, and P004, display in the table view as shown in Figure 314.
Figure 314 5. In the Specified Orientation field, enter [45], [90], and [-45] as shown in Figure 315.
Figure 315 6. Press <Ctrl> + <T> to return to Form mode.
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7. Click to complete the creation of the three new plies and return to the list view. The four plies P001, P002, P003, and P004, are listed as shown in Figure 316.
Figure 316 Task 6 - Mirror four plies about the laminate neutral axis. 1. In the ply toolbar, click Figure 317. (Mirror Laminate) as shown in
Figure 317 2. The Mirror Laminate dialog box opens as shown in Figure 318.
Figure 318 3. For the Start Component, click shown in Figure 319. (Link with Link Dialog) as
Figure 319
CEE Basics
4. Click checkbox for ply P001 as shown in Figure 320.
6. Link ply P004 to the End Component. The Mirror Laminate form updates as shown in Figure 321.
Figure 321 7. In the New Step field, enter [50] as shown in Figure 322.
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9. The FiberSIM message window opens prompting you that four components were generated successfully as shown in Figure 323.
11. In the Mirror Laminate dialog box, click to complete the mirror operation and return to the list view. The updated list of plies P001 to P008 displays as shown in Figure 324.
Figure 324 12. Close FiberSIM. 13. Save the model.
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Exercise 3b
User Guide Reference: 2.8 Plies B.2.3 Composite Sequence Manager 2.10 Design Stations 2.11 Cutouts
Reinforcement Plies, Sequencing, and Cutouts

In this exercise, you will create reinforcement plies and interleave them using the Composite Sequence Manager. You will also create a cutout and run an analysis comparing the results. The resequenced list of plies is shown in Figure 325.
Figure 325
Goal
Create Reinforcement Plies Use the Composite Sequence Manager to interleave reinforcement plies Rename plies to match the lay-up order Create Design Stations and run a core sample analysis Create a Cutout Run an analysis and verify the results
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Task 1 - Open a part. 1. Select File > Open and select FS2010_CEE_BASICS_B.CATPart. If you completed Exercise 3a, you can continue working with FS2010_CEE_BASICS_A.CATPart instead. The model displays as shown in Figure 326.
Figure 326 Task 2 - Create Reinforcement Plies. 1. In the specification tree, select the Reinforcement Plies geometrical set, right-click, and select Hide/Show. The model displays the reinforcement plies as shown in Figure 327.
Figure 327
2. Click
(FiberSIM).
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CEE Basics
3. In the CEE menu, select Ply. For the Object Count, enter [6] as shown in Figure 328.
Figure 328 4. Click Alternatively, the Net Geometry details can be displayed by selecting the Net Geometry hyperlink or the Net Geometry tab. (Create New).
5. In the Standard form, in the Net Geometry area, click (Link Geometry) for Origin. In the specification tree (under the Reinforcement Plies geometrical set), select LH Reinforcement Origin. 6. Click .
7. For Boundary, click (Link Geometry). In the specification tree, select LH Reinforcement. 8. Click .
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FiberSIM 2010 CEE
9. Press <Ctrl>+ <T> to switch to Table mode. The new plies display as shown Figure 329.
Figure 329 10. In the Specified Orientation field, enter [45], [0], [45], [45], [0], and [45] as shown in Figure 330.
Figure 330 11. Click to display the new plies as shown in Figure 331.
Figure 331
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CEE Basics
Task 3 - Use the Composite Sequence Manager to interleave the reinforcement plies. 1. In the ply toolbar, click (Composite Sequence Manager).
2. Drag and drop the plies to rearrange them in the following order: 1, 9, 2, 10, 3, 11, 4, 5, 12, 6, 13, 7, 14, and 8. The updated list is shown in Figure 332.
Task 4 - Create RH plies using Create Based On. 1. Select the Name column to sort the plies by name and ensure that P001 is at the top as shown in Figure 333.
Figure 333
FiberSIM 2010 CEE
Alternatively, you can select P009, press and hold <Shift> and then select P014 to highlight the range of plies.
2. Select P009 and drag to highlight the plies from P009 to P014. 3. With the six plies highlighted, right-click and select Create Based On as shown in Figure 334.
Figure 334 4. New plies P015 to P020 are created and displayed as shown in Figure 335. Make sure the new plies are shown in Form mode as in Figure 335. You can press <Ctrl> + <T> to switch from Table mode to Form mode.
Figure 335 5. In the Standard form, in the Net Geometry area, click Geometry) for Origin. 6. In the Indicate Origin dialog box, click current origin. (Link
to clear the
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CEE Basics
7. Rotate the model and indicate a location on the surface in approximately the location shown in Figure 336. An X will display after indicating. IndicationPoint.1
Figure 336 8. Click . (Link
9. In the Standard form, in the Net Geometry area, click Geometry) for Boundary. 10. In the Select Net Boundary dialog box, click current boundary. 11. In the specification tree, select RH Reinforcement. 12. Click .
to clear the
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FiberSIM 2010 CEE
13. Click to display the modified plies in the list view as shown in Figure 337.
Figure 337 14. In the Sort drop-down list, select Sequence, Step and Name. The list of plies updates as shown in Figure 338.
Figure 338
CEE Basics
Task 5 - Rename the plies to match the layup order. 1. Highlight one ply in the list, press <Ctrl> + <A> to select all of the plies, right-click, and select Modify. 2. In the Name field, enter [P001,1] and press <Enter>. 3. Click .
Task 6 - Resequence the plies to increments of 1 using the Composite Sequence Manager. 1. Select Tools > Options > FiberSIM Options. 2. Select the Sequence tab. 3. Modify the following parameters: Initial Step: 1 Step Increment: 1 4. Click 5. Click . (Composite Sequence Manager).
6. Select all of the plies and click (Resequence). The Step column updates with increments of 1 as shown in Figure 339.
Figure 339
FiberSIM 2010 CEE
7. Click
Task 7 - Create Design Stations and discuss the various types of core sample analysis. User Guide Reference: 2.10 Design Stations 1. In the CEE menu, select Design Station as shown in Figure 340.
3. In the Design Station Standard form, in the Core Sample Type drop-down list, select All. 4. In the Design Station toolbar, click (Core Sample).
5. A FiberSIM message window opens prompting you that the core sample has completed successfully as shown in Figure 341.
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CEE Basics
7. Double-click on the DS001 line to display the Standard form. Select the Results tab to display the Core Sample Analysis report as shown in Figure 342.
Figure 342
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FiberSIM 2010 CEE
8. Scroll down to display the Detailed Design Station Information as shown in Figure 343.
Figure 343 9. Scroll down further to display the Laminate Rating Analysis as shown in Figure 344.
Figure 344
CEE Basics
10. Click
to close the report and return to the list view.
Task 8 - Create a Cutout. 1. In the CATIA specification tree, select Cutout, right-click, and select Hide/Show. The model displays the cutout geometry as shown in Figure 345.
Figure 345 2. In FiberSIM CEE menu, select Cutout as shown in Figure 346.
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FiberSIM 2010 CEE
4. For the Origin, click (Link Geometry). In the specification tree (under the Cutout geometrical set), select Top Reinforcement Origin. 5. Click .
6. For the Boundary, click (Link Geometry). In the specification tree, select Top Inner Boundary. 7. Click 8. Click . .
Task 9 - Verify the results. 1. In the CEE menu, select Ply. 2. Highlight all of the plies in the list and click (Net Producibility).
3. In the message window indicating that the material width has been exceeded, click .
4. In the CEE menu, select Laminate. Double-click on the Cowl laminate to display its form. 5. Select the Analysis tab if required and click . The results display. Compare the Net results and the with Cutout results as shown in Figure 347.
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CEE Basics
Exercise 3c
User Guide Reference: 2.5 Flat Pattern/Producibility Simulations
Flat Pattern
In this exercise, you will create a flat pattern. The completed model is shown in Figure 348.
Figure 348
Goal
Run Producibility Generate a Flat Pattern Create the Flat Pattern Placement geometry in CATIA Set the Flat Pattern Placement Plane and Orientation Regenerate the Flat Pattern
Task 1 - Open a part. 1. Select File > Open and select FS2010_CEE_BASICS_C.CATPart. If you completed Exercises 3a and 3b, you can continue working with FS2010_CEE_BASICS_A.CATPart or
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FiberSIM 2010 CEE
FS2010_CEE_BASICS_B.CATPart instead. The model displays as shown in Figure 349.
Figure 349
2. Click
(FiberSIM), if required.
3. In the CEE menu, select Ply. 4. Double-click on P002 to display its details in the Standard form. Task 2 - Run Producibility. 1. Click (Net Producibility).
Task 3 - Generate Flat Pattern. 1. Click 2. Click (Generates the Net Flat Pattern). to save P002.
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CEE Basics
3. The Flat Pattern geometry is created on the default XY plane, as shown in Figure 350. Note that it is flipped in the opposite direction of the ply boundary direction.
Figure 350 Task 4 - Create Flat Pattern Placement geometry in CATIA. The default location for flat patterns can easily be changed. FiberSIM will subsequently position all flat patterns directly onto a user-specified plane with a user-specified orientation. In this task, you will create the geometry in CATIA for defining a user-specified plane and orientation to be in the same direction as the ply boundary. 1. Close the FiberSIM window. 2. In CATIA, click (Plane).
3. In the Plane type drop-down list, select Tangent to surface.
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FiberSIM 2010 CEE
4. For the Surface, select Tool Surface. For the Point, select Rosette Origin. The Plane Definition dialog box updates as shown in Figure 351.
Figure 351 5. By dragging the green Move, move the plane to the approximate location shown in Figure 352.
7. In the specification tree, rename the plane as [Net FP Placement Plane]. 8. Click (Point).
9. In the Point type drop-down list, select On surface. 10. For the Surface, select Net FP Placement Plane. 11. Indicate on the middle of the Net FP Placement plane to determine the Distance.
CEE Basics
12. Click 13. Click
. (Line).
14. Select the following: Line type: Point-Direction Point: Point you just created Direction: Zero Direction Start: 0 in (0 mm) Support: Net FP Placement Plane .
15. Click
16. In the specification tree, rename the line as [Net FP Orientation]. Task 5 - Set the Flat Pattern Placement Plane. 1. Launch FiberSIM. 2. In FiberSIM, select Tools > Options > FiberSIM Options. The FiberSIM dialog box opens. Select the Flat Patterns tab if it is not already selected, as shown in Figure 353.
Figure 353 3. In the Net Placement area, next to the Plane field, click Geometry).
(Link
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FiberSIM 2010 CEE
4. In the specification tree, select Net FP Placement Plane. The Select Plane window updates with the selection as shown in Figure 354.
Task 6 - Set the Flat Pattern Orientation. 1. In the Net Placement area, next to the Orientation field, click (Link Geometry). 2. In the specification tree, select Net FP Orientation. The Select Orientation window updates with the selection as shown in Figure 355.
Figure 355 3. Click . .
4. In the FiberSIM Options dialog box, click
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CEE Basics
Task 7 - Regenerate Flat Pattern. 1. Return to the P002 Standard form and click Net Flat Pattern). 2. Click . (Generates the
3. The Flat Pattern updates. as shown in Figure 356. Note that it is now flipped in the correct direction, aligned with the ply boundary direction.
Figure 356
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FiberSIM 2010 CEE
Exercise 3d
User Guide Reference: 2.6 Laminates 2.7 Rosettes 2.8 Plies 2.5 Flat Pattern/Producibility Simulations
Create Basic Part

In this exercise, with minimal instruction, you will prepare a CATIA model for composite design with FiberSIM. The final flat pattern should display as shown in Figure 357.
Figure 357
Goal
Create a Laminate Create a Rosette Create four full-body plies Run Producibility Generate a Flat Pattern Set the Flat Pattern Placement Plane and Orientation Regenerate a Flat Pattern
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CEE Basics
Task 1 - Open a part. 1. Select File > Open and select FS2010_CEE_BASICS_D.CATPart. The model displays as shown in Figure 358.
Figure 358 Task 2 - Create a Laminate. 1. In FiberSIM, create a Laminate with the following parameters: Name: Skin Step: 1 Material: PPG-PL-3K 2. The Laminates Standard form should display as shown in Figure 359.
Figure 359
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FiberSIM 2010 CEE
Task 3 - Link Geometry to CATIA. 1. Link the following geometry: Layup Surface: Tool Surface Net Boundary: Net Boundary Extended Boundary: Extended Boundary 2. The Laminates Standard form should update as shown in Figure 360.
Figure 360 Task 4 - Create a Rosette. 1. Create a Rosette called [ROS001] and link the following geometry: Origin: Rosette Origin Direction: Zero Direction Task 5 - Create four full-body plies. 1. Create four plies with a Step of [10] and the following orientations: P001: 0 P002: 45 P003: -45 P004: 90
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CEE Basics
Task 6 - Resequence the plies to increments of 1. 1. In the FiberSIM Options menu, modify the following Sequence parameters: Initial Step: 1 Step Increment: 1 2. Run the Composite Sequence Manager to resequence the plies. They should display as shown in Figure 361.
Figure 361 Task 7 - Run Producibility. 1. Run Net Producibility on P001. Task 8 - Generate a Flat Pattern. 1. Using P001, generate the Net Flat Pattern. It should display as shown in Figure 362.
Figure 362
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FiberSIM 2010 CEE
Task 9 - Set the Flat Pattern Placement Plane and Orientation. 1. Change the default Flat Pattern placement by linking the following geometry: Plane: Net FP Placement Plane Orientation: Net FP Orientation Task 10 - Regenerate the Flat Pattern. 2. Generate the Net Flat Pattern again using P001. It should now display as shown in Figure 363.
Figure 363
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Chapter 4
Producibility
Exercise 4a: How Geometry Affects Producibility Exercise 4b: How Simulation Options Affect Producibility (Simulation Skin) Exercise 4c: How Simulation Options Affect Producibility (Two-Stage) Exercise 4d: Resolving Producibility Issues
41
Producibility
Exercise 4a
User Guide Reference: 2.5 Flat Pattern/ Producibility Simulations 2.12 Darting B.3.7 Splice Ply
How Geometry Affects Producibility

In this exercise, you will see how geometry affects producibility by changing ply origins and orientations. You will also create splices and darts to resolve producibility issues.
Goal
Change the ply origin point to observe the impact on producibility and flat pattern Change the ply orientation to observe the impact on producibility and flat pattern Create a Splice to resolve material roll width issues Create Slit darts and V-shape darts to resolve bridging and wrinkling
Task 1 - Open a part. 1. Open FS2010_CEE_PRODUCIBILITY_A.CATPart. The model displays as shown in Figure 41.
Figure 41
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FiberSIM 2010 CEE
Task 2 - Create a Flat Pattern of ply P001.
1. Click
(FiberSIM).
2. In the CEE menu, select Ply to display the ply list view. 3. Double-click on P001 to modify its details in the Standard form. Alternatively, you can click in the Net Geometry area in the Standard tab. 4. Click (Net Producibility) in the Ply toolbar and click in the message box prompting you that the material width has been exceeded. 5. Click 6. Click (Generates the Net Flat Pattern). to save.
7. The P001 producibility results and flat pattern geometry display as shown in Figure 42.
Figure 42 Task 3 - Create P002 from P001 and specify a different origin. In this task you will create a new ply, P002, based on P001 and change its origin. You will then note how the results compare with P001. 1. Show and expand the P002 geometric set. 2. In the ply list, select P001, right-click and select Create Based On. 3. In the Step field, enter [20]. Remember to clear the existing origin first. 4. Link the following geometry: Origin: P002 Origin
44
Producibility
5. Click (Net Producibility) and click in the message box prompting you that the material width has been exceeded. 6. Click (Generates the Net Flat Pattern) to create a Net Flat Pattern of P002. The results display as shown in Figure 43. P001 Producibility is shown for comparison purposes.
P001 Flat Pattern P002 Flat Pattern P002 Producibility
P001 Producibility Figure 43 7. Click to save P002.
Task 4 - Create P003 from P002 and specify a different orientation. In this task you will create a new ply, P003, based on P002 and change its origin. You will then note how the results compare with P002. 1. Show and expand the P003 geometric set. 2. In the ply list, select P002, right-click and select Create Based On. 3. In the Step field, enter [30]. 4. In the Specified Orientation drop-down list, select 45, which changes the value from 0.
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FiberSIM 2010 CEE
5. Click (Net Producibility) and click in the message box prompting you that the material width has been exceeded. 6. Create a Net Flat Pattern of P003. The results display as shown in Figure 44. P002 Producibility is shown for comparison purposes.
P002 Flat Pattern
P003 Flat Pattern
P003 Producibility
P002 Producibility Figure 44 7. Click to save P003.
46
Producibility
8. A comparison between the flat patterns and producibility of the 0 degree P002 ply and the 45 degree P003 ply is shown in Figure 45.
Ply Origins
P003 Flat Pattern 45
P002 Flat Pattern 0
Figure 45 Task 5 - Create P004 from P002 and specify a width offset. In this task, you will create P004 based on P002 and address the exceeded material width issue by specifying a width offset and splicing P004 into two plies: P004A and P004B. 1. In the ply list, select P002, right-click and select Create Based On. 2. In the Step field, enter [40]. For manufacturing purposes, it might be more applicable to run Extended Producibility to allow for the actual width of the bolt of material. 3. Click (Net Producibility) and click in the message box prompting you that the material width has been exceeded.
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FiberSIM 2010 CEE
4. Select the Net Geometry tab and click . The FiberSIM - Material Width Lines dialog box opens as shown in Figure 46. Note that the Material Width Offset is 0.
Figure 46 5. Click . The material width offset with a value of 0 displays in CATIA as shown in Figure 47.
Figure 47
48
Producibility
6. A recommended best practice is to set the material width line to be as centered as possible on the part for strength purposes. In the open FiberSIM - Material Width Lines dialog box, enter [-18] inches (-457.2 mm). Click to display the material width line to the center as shown in Figure 48.
Figure 48 7. Click 8. Click and click to save P004. .
Task 6 - Create a Splice Ply of P004A and P004B. 1. In the CEE menu, select Ply to display the listing of plies as shown in Figure 49.
Figure 49
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FiberSIM 2010 CEE
2. Highlight P004 and click (Splice Ply). The FiberSIM - Splice Ply dialog box opens as shown in Figure 410.
Figure 410 3. Next to the Splice Curves field, click (Link Geometry).
4. Select the material width curve as shown in Figure 411.
Select this curve
Figure 411
410
Producibility
5. Click . The FiberSIM - Splice Ply dialog box updates with the selected curve as shown in Figure 412.
Figure 412 6. Click to perform the splice.
7. The FiberSIM message box opens, prompting you that two plies were spliced successfully as shown in Figure 413.
Figure 413 8. Click twice.
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FiberSIM 2010 CEE
9. The P004 spliced plies display in the ply list as P004-A and P004-B as shown in Figure 414.
Figure 414 10. In the ply list, highlight P004-A and P004-B. The plies are highlighted in blue on the CATIA model. Note that the Splice utility generates origins at the centroid of each ply boundary, as shown in Figure 415. If generated origins are suitable, you can use them. However, in many cases you will have to select a suitable origin that is based on the size of the part, which can limit the access to certain areas. Generated Origins
Figure 415
412
Producibility
Task 7 - Move the origins of P004A and P004B to a new location. In this task, you will move the generated origins created with P004A and P004B to more reliable origins, resulting in a better producibility. 1. Highlight P004-A and P004-B, right-click and select Modify as shown in Figure 416.
Figure 416 2. Press <Ctrl>+ <T> to switch to Table mode. 3. Show and expand the P004A and P004B geometric set. 4. In the Origin column for P004-A, click (Link Geometry).
5. In the specification tree, select P004A Origin. 6. Using the same procedure, link P004-B to the P004B Origin. 7. Click to save the plies.
Task 8 - Compare the Flat Pattern of P002 to the Spliced Result of P004. 1. In the ply list, highlight P004-A and P004-B and click Producibility). 2. Click (Generates the Net Flat Pattern). (Net
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FiberSIM 2010 CEE
3. Click . The Net Flat Patterns of P004-A and P004-B display as shown in Figure 417.
Figure 417 4. A comparison between the flat patterns of the P002 ply and the spliced P004 ply is shown in Figure 418 with the P004A and P004B flat patterns arranged side-by-side. Note the material difference as well.
Ply Origins
P004A-4B Flat Pattern 0
Material Difference P002 Flat Pattern 0
Figure 418
414
Producibility
Task 9 - Create a ply and check the producibility. In this task, you will create P005 based on P002 and check the producibility. 1. Show and expand the P005 geometric set. 2. In the ply list, select P002, right-click and select Create Based On. 3. In the Plys Standard form, enter the following parameters: Name: P005 Step: 50 Specified Orientation: 45 Remember to clear the P002 origin and boundary first. 4. Link the following geometry: Origin: P005 Origin Boundary: P005 Boundary 5. Click (Net Producibility) and click in the message box prompting you that the material width has been exceeded. 6. Click to save P005.
Figure 419
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FiberSIM 2010 CEE
8. To identify material excess and shortage and to characterize deformation regions, observe the red fiber cell behavior in relation to the ply origin. The red fiber cell behavior for Bridging (material shortage) and Wrinkling (material excess) is shown in Figure 420.
BRIDGING SHORTENING ALONG A LINE THROUGH THE PLY ORIGIN
PLY ORIGIN
UNDEFORMED FIBER CELL
WRINKLING LENGTHENING ALONG A LINE THROUGH THE PLY ORIGIN
Figure 420 Task 10 - Create a Slit Dart. In this task you will attempt to address the producibility issue by creating a Slit dart and applying it to P005. 1. In the P005 Standard form, select the Net Geometry tab. 2. Next to the Darts field, click (Link with Link Dialog). The FiberSIM - link Plies via Plies dialog box opens.
416
Producibility
3. In the Darts menu, select Slit Dart as shown in Figure 421.
Figure 421 4. Click (Create New). The Slit Dart form opens as shown in Figure 422.
Figure 422 5. Next to the Base Curve Points field, click (Link Geometry)
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FiberSIM 2010 CEE
6. Indicate twice on the surface at approximately the two points shown in Figure 423. Always indicate dart points in order from the interior of the ply to the boundary. IndicationPoint.1 IndicationPoint.2
Figure 423 7. Click 8. Click Figure 424. . . The Slit Dart form updates as shown in
Figure 424 9. Click 10. Click to save SlitDart001. to return to the P005 form.
418
Producibility
11. The P005 Net Geometry form updates with the dart information as shown in Figure 425.
Figure 425 Task 11 - Run Net Producibility and Generates the Net Flat Pattern. 1. Click (Net Producibility) and click in the message box prompting you that the material width has been exceeded. 2. Click 3. Click (Generates the Net Flat Pattern). to save P005.
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FiberSIM 2010 CEE
4. Switch to the CATIA window to display the producibility and flat pattern results as shown in Figure 426. P005 displays a bridging situation, indicating that there is a material shortage. Note the overlapping flat pattern. The simulation does not complete even though there are no red fibers, this is still a non-producible result.
The flat pattern overlaps itself, indicating that a V-Shape Dart is needed, not a Slit Dart.
Figure 426 Task 12 - Create a V-Shape Dart to resolve bridging. In this task you will address the bridging producibility issue by removing the Slit Dart from P005 and creating a V-Shape or Gap Dart instead. 1. In the ply P005 Net Geometry tab, next to the Darts field, click (Link with Link Dialog). The FiberSIM - link Darts via Darts dialog box opens.
420
Producibility
2. Select the SlitDart001 option to clear the current selection as shown in Figure 427.
Figure 427 3. In the Darts menu, select V-Shape Dart as shown in Figure 428.
Figure 428
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FiberSIM 2010 CEE
4. Click (Create New). The V-Shape Darts form displays as shown in Figure 429.
Figure 429 5. Next to the Base Curve Points field, click (Link Geometry).
6. Indicate twice on the surface at approximately the two points shown in Figure 430. IndicationPoint.1 IndicationPoint.2
Figure 430 7. Click . (Link Geometry).
8. Next to the Second Curve Points field, click
422
Producibility
9. Indicate once on the surface at approximately the point shown in Figure 431. IndicationPoint.1
Figure 431 10. Click 11. Click Figure 432. . . The Slit Dart form updates as shown in
Figure 432 12. Click 13. Click to save VShapeDart001. to return to the P005 form.
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FiberSIM 2010 CEE
Task 13 - Run Net Producibility and Generates the Net Flat Pattern. 1. Click (Net Producibility) and click in the message box prompting you that the material width has been exceeded. 2. Click 3. Click (Generates the Net Flat Pattern). to save P005.
4. Switch to the CATIA window to display the producibility and flat pattern results as shown in Figure 433.
Figure 433 Task 14 - (Optional) Create a Patch Ply. In this task you create a Constant Curve Offset to create a Patch ply to cover the gap. 1. In FiberSIM, select Tools > Curve Creation > Curve Offset. 2. Select the Constant Offset tab. 3. Click (Create New) and link the following geometry:
Curves to Offset: Curve.4, Curve.5 (Dart curves) Skin: Tool Surface

Producibility
Direction Point: Indicate a point outside the Dart curve as shown in Figure 434 Boundary Curves: Net Boundary
Figure 434 4. Enter the following parameters: Number of Curves: 1 Offset Value: 1 in (25.4 mm) Corner Type: Straight 5. Click 6. Click 7. Click . . .
8. Create a ply using the following parameters: Name: P006 Step: 60 Specified Orientation: 0 Net Boundary: Curve.6 (offset curve) Origin: indicate a point within gap as shown in Figure 435
Figure 435
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FiberSIM 2010 CEE
9. Run Net Producibility and create a Net Flat Pattern to display the results as shown in Figure 436. Now a full-coverage ply exists with a 1 inch (25.4 mm) overlap.
Figure 436 10. Click to save P006.
Task 15 - (Optional) Create a P007 Ply, Splice Ply and a Slit Dart. 1. Show and expand the P007A + P007B + P007C geometric set. 2. In the ply list, select P003, right-click and select Create Based On. 3. In the Plys Standard form, enter the following parameters: Name: P007 Step: 70 Specified Orientation: 45 4. Click to save P007. (Splice Ply).
5. Highlight P007 and click
6. Enter the following parameters: Splice Line Curve: Splice Line 1 P007, Splice Line 2 P007 7. Click 8. Click . .
9. Modify the origins of the spliced plies to use the following origins: P007-A: P007A Origin P007-B: P007B Origin
Producibility
P007-C: P007C Origin 10. Click .
11. Run Net Producibility on the spliced plies, P007-A, P007-B, and P007-C. The results display as shown in Figure 437.
Figure 437 12. In the ply list, double-click on P007-C to modify it. 13. Select the Net Geometry tab and next to the Darts field, click (Link with Link Dialog). 14. In the Darts menu, select Slit Dart 15. Click (Create New). (Link Geometry)
16. Next to the Base Curve Points field, click
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FiberSIM 2010 CEE
17. Indicate two points for the slit dart as shown in Figure 438. To indicate points on a surface, curve geometry cannot be selected.
IndicationPoint.1
IndicationPoint.2
Figure 438 18. Click 19. Click 20. Click twice. . .
21. Run Net Producibility on P007-C to display the results as shown in Figure 439.
Figure 439 22. Click 23. Exit FiberSIM. to save.
428
Producibility
Exercise 4b
User Guide Reference: 2.8 Plies 2.5 Flat Pattern/ Producibility 2.5.2 Using Simulation Surfaces
How Simulation Options Affect Producibility (Simulation Skin)

In this exercise, you will see how simulation options, such as holes and simulation skin, affect producibility. The Net Flat Patterns you will create with each simulation option are displayed in Figure 440.
Before holes
With holes Figure 440
Simulation Skin
Goal
Create a ply using a Fiber Spacing Factor Add holes to the ply and observe the impact on the Flat Pattern Set a Simulation Skin and observe the impact on the Flat Pattern
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FiberSIM 2010 CEE
Task 1 - Open a part. 1. Open FS2010_CEE_PRODUCIBILITY_B.CATPart. The model displays as shown in Figure 441.
Figure 441 Task 2 - Create a Full-body Ply using the Fiber Spacing Factor. In this task you will review the Laminate and Rosette that have already been created and then create a full-body ply using a Fiber Spacing Factor of [0.5]. 1. Click (FiberSIM).
2. In the CEE menu, select Laminate. In the CATIA window, display the associated tool surface and layup direction. 3. In the CEE menu, select Rosette. In the CATIA window, display the associated geometry. 4. In the CEE menu, select Ply. 5. Click (Create New).
6. In the Plys Standard form, enter the following parameters to create a full-body ply: Name: P001 Step: 10 Orientation: 0
430
Producibility
For small features, it is necessary to reduce the Fiber Spacing Factor to conform the simulated fibers to the surface.
7. Click 8. Click .
. For the Fiber Spacing Factor, enter [0.5].
9. Click (Net Producibility) and click in the message box prompting you that the material width has been exceeded. 10. Click (Generates the Net Flat Pattern) to create a Net Flat Pattern of P001. 11. Click to save the ply P001.
Figure 442
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FiberSIM 2010 CEE
Task 3 - Add holes to ply P001. In this task, since the ply material will not be required to cover the enclosed blue boundaries as shown in Figure 443, you will modify ply P001 and add three holes. Ply material will not be required to cover the enclosed blue boundaries
Figure 443 13. In the specification tree, select Hole 1, Hole 2, and Hole 3, right-click and select Hide/Show to show the Hole geometry. 14. In the ply list, double-click on P001 to modify it. 15. Next to the Holes field, click (Link Geometry).
16. Select the three curves: Hole 1, Hole 2, and Hole 3 as shown in Figure 444.
Figure 444
Producibility
17. Click
18. Click (Net Producibility) and click in the message box prompting you that the material width has been exceeded. 19. Click (Generates the Net Flat Pattern) to create a Net Flat Pattern of P001. Note that the outside part of the flat pattern has not changed. 20. Click to save P001.
Figure 445
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FiberSIM 2010 CEE
Task 4 - Set a Simulation Skin. In this task, since a simulation surface must accurately reflect the topology of the tool surface to be covered by material, you will modify ply P001 and set a Simulation Skin that does not include the Boss features as shown in Figure 446. Simulation Skin does not include Boss features.
Figure 446 22. In the specification tree, select Sim_Skin, right-click and select Hide/Show to show the geometry. 23. Select Tool Surface, right-click and select Hide/Show to hide the Tool Surface. Note that the Sim_Skin surface does not include the bosses. Return to the original display with Sim_Skin hidden and the Tool Surface showing. 24. In the ply list, double-click on P001 to modify it. 25. Click box opens. . The FiberSIM - Simulation Options dialog
26. Next to the Simulation Skin field, click 27. In the specification tree, select Sim_Skin.
(Link Geometry).
434
Producibility
28. Click . The FiberSIM - Simulation Options dialog box updates with Sim_Skin as shown in Figure 447.
30. Click (Net Producibility) and click in the message box prompting you that the material width has been exceeded. 31. Click (Generates the Net Flat Pattern) to create the Net Flat Pattern of P001. Compare the flat patterns. 32. Click to save P001.
435
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Figure 448 34. The producibility simulation now follows the Simulation Skin and ignores the bosses in the laminate surface as shown in Figure 449. The new flat pattern is much cleaner because it is not affected by the bosses in the laminate surface.
Figure 449
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Producibility
35. The Producibility and Flat Pattern Comparison for Tasks 2, 3, and 4 is shown in Figure 450.
Before holes
With holes Figure 450
Simulation Skin
Task 5 - (Optional) Create a Splice through a Hole. FiberSIM enables splicing through holes. 1. In the ply list, double-click on P001 to modify it. 2. Generate a Material Width Line using a Material Width Offset of [24] inches (609.6 mm). 3. Splice P001 into two plies, P001-A and P001-B, using the following parameters: Splice Curves: Spline.1 (created material width line) Overlap: Yes Overlap Distance: 1 in (25.4 mm)
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FiberSIM 2010 CEE
4. Run Net Producibility and create a Net Flat Pattern to display the results as shown in Figure 451.
Figure 451 5. Exit FiberSIM.
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Producibility
Exercise 4c
User Guide Reference: 2.5 Flat Pattern/ Producibility Simulations 2.8 Plies 2.5.3 Performing Multi-Stage Simulations 2.12. Darting
How Simulation Options Affect Producibility (Two-Stage)

In this exercise, you will see the ply development using a two stage simulation. The completed standard simulation and two-stage simulation net flat patterns display as shown in Figure 452. Standard simulation (red line) Two-stage simulation (black line)
Figure 452
Goal
Compare the standard simulation to a Biased Geodesic simulation Add a First Stage Region Create V-Shape Darts to alleviate the inside corners Create Slit Darts to alleviate the outside corners
Task 1 - Open a part. 1. Open FS2010_CEE_PRODUCIBILITY_C.CATPart. The model displays as shown in Figure 453.
Figure 453
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FiberSIM 2010 CEE
Task 2 - Create a ply and run the standard simulation. In this task you will review the Laminate and Rosette that have already been created and create a full-body ply. 1. Click (FiberSIM).
2. In the CEE menu, select Laminate. In the CATIA window, display the associated tool surface and layup direction. 3. In the CEE menu, select Rosette. In the CATIA window, display the associated geometry. 4. In the CEE menu, select Ply. 5. Click (Create New).
6. In the Plys Standard form, enter the following parameters to create a full-body ply: Name: P001 Step: 10 Specified Orientation: 45 7. Click 8. Click 9. Click 10. Click . For the Fiber Spacing Factor, enter [0.4]. to close the Simulation Options dialog box. (Net Producibility). to save P001.
Figure 454
Producibility
Task 3 - Run a Biased Geodesic simulation and compare it to the standard simulation. See the User Guide in section 2.8 Plies for more information on Propagation Method and Propagation Direction. 1. In the ply list, double-click on P001 to modify it. 2. Click box opens. . The FiberSIM - Simulation Options dialog
3. Set the following parameters: Propagation Method: Geodesic Propagation Direction: Bias(-WeaveAngle/2) 4. Click 5. Click 6. Click to close the Simulation Options dialog box. (Net Producibility). to save P001.
Figure 455
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FiberSIM 2010 CEE
Task 4 - Add a First Stage Region. In this task you will add a First Stage Region. The First Stage Region is used to define an area of simultaneous material contact (e.g., if material is placed on a flat surface). The simulation solves completely within this region before attempting to conform to the other areas and solving to the defined ply net boundary. The First Stage Boundary in this task is shown in Figure 456. First Stage Boundary
Figure 456 1. In the ply list, double-click on P001 to modify it. 2. Click box opens. . The FiberSIM - Simulation Options dialog
3. Next to the First Stage Region field, click
(Link Geometry).
4. In the specification tree, select First Stage Region. 5. Click 6. Click 7. Click 8. Click . to close the Simulation Options dialog box. (Net Producibility). to save P001.
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Producibility
Figure 457 Task 5 - Create a V-Shape Dart to alleviate the left inside corner. 1. In the ply list, double-click on P001 to modify it. 2. In the P001 Standard form, select the Net Geometry tab. 3. Next to the Darts field, click (Link with Link Dialog). The FiberSIM - link Plies via Plies dialog box opens. 4. In the Darts menu, select V-Shape Dart as shown in Figure 458.
Figure 458 5. Click (Create New). (Link Geometry).
6. Next to the Base Curve Points field, click
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FiberSIM 2010 CEE
7. Zoom in on the left inside corner and indicate on the surface at approximately the two points shown in Figure 459. These will form the first leg of the V that will cut out the red fibers. The first indicated point is the apex of the V-shape. IndicationPoint.1
IndicationPoint.2 Figure 459 8. Click . (Link Geometry).
9. Next to the Second Curve Points field, click
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Producibility
10. Indicate on the surface at approximately the point shown in Figure 460. This will form the second leg of the V.
IndicationPoint.1
Figure 460 11. Click 12. Click 13. Click . . to save VShapeDart001.
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FiberSIM 2010 CEE
14. Switch to the CATIA window to display the completed V-Shape Dart as shown in Figure 461.
Figure 461 Task 6 - Create a V-Shape Dart to alleviate the right inside corner. 1. Use the procedure from Task 5 to create a V-Shape Dart on the right inside corner. The two Base Curve Points are shown in Figure 462 and the Second Curve Point is shown in Figure 463. IndicationPoint.1
IndicationPoint.2 Figure 462
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Producibility
IndicationPoint.1 Figure 463 2. Click 3. Click . to save VShapeDart002.
4. Ensure that both V-Shape darts are linked to the ply as shown in Figure 464.
Figure 464 5. Click 6. Click 7. Click . (Net Producibility). to save P001.
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FiberSIM 2010 CEE
8. Switch to the CATIA window to display the producibility results with the V-Shape darts as shown in Figure 465.
Figure 465 Task 7 - Create Slit Darts to alleviate the outside corners. 1. In the ply list, double-click on P001 to modify it. 2. In the P001 Standard form, select the Net Geometry tab. 3. Next to the Darts field, click (Link with Link Dialog). The FiberSIM - link Plies via Plies dialog box opens. 4. In the Darts menu, select Slit Dart as shown in Figure 466.
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Producibility
6. Select the Curve option as shown in Figure 467.
Figure 467 7. Next to the Base Curve field, click (Link Geometry)
8. In the specification tree, select Slit Darts, right-click and select Hide/Show. 9. In the specification tree, select Slit Dart Right. 10. Click 11. Click 12. Click . . to save SlitDart001.
13. Switch to the CATIA window to display the Slit Dart as shown in Figure 468. The slit dart is a U-shaped curve that will be added to the ply boundary.
Figure 468 14. Repeat Steps 1 to 13 to create a Slit Dart on the left (when looking at the model from the back). In the specification tree, the curve reference for this dart is Slit Dart Left.
FiberSIM 2010 CEE
15. Ensure that both Slit Darts are linked to the ply as shown in Figure 469.
Figure 469 16. Click dialog box. 17. Click to close the FiberSIM - link Slit Dart via Darts
(Net Producibility).
18. Click (Generates the Net Flat Pattern) to create a Net Flat Pattern of P001. 19. Click to save P001.
20. Switch to the CATIA window to display the producibility and net flat pattern results with the darts as shown in Figure 470.
Figure 470
Producibility
Task 8 - Compare the flat pattern to one without a two-stage simulation. 1. In the ply list, select P001, right-click and select Create Based On to create the ply P002. 2. In the Step field, enter [20]. 3. Click . (Link Geometry).
4. Next to the First Stage Region field, click 5. Click 6. Click 7. Click and click .
to close the Simulation Options dialog box. (Net Producibility).
8. Click (Generates the Net Flat Pattern) to create the Net Flat Pattern of P002. 9. Switch to the CATIA window to display the producibility and net flat pattern results as shown in Figure 471.
Figure 471
FiberSIM 2010 CEE
10. Click
to save P002.
11. The two-stage simulation produces a cleaner flat pattern (black) than the standard simulation (red) as shown in Figure 472. Standard simulation (red line) Two-stage simulation (black line)
Figure 472
452
Producibility
Exercise 4d
User Guide Reference: 2.5 Flat Pattern/ Producibility Simulations 2.5.3 Performing Multi-Stage Simulations 2.12. Darting
Resolving Producibility Issues

In this exercise, with minimal instruction, you will resolve producibility issues. The producibility and flat pattern results for the acceptable solution are shown in Figure 473.
Figure 473
Goal
Set the Fiber Spacing Factor simulation option Compare the standard simulation to a Biased Geodesic simulation Add a First Stage Region Create V-Shape Darts to alleviate the inside corners Create Slit Darts to alleviate the outside corners
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FiberSIM 2010 CEE
Task 1 - Open a part. 1. Open FS2010_CEE_PRODUCIBILITY_D.CATPart. The model displays as shown in Figure 474.
Figure 474 Task 2 - Create a full-body ply. 1. In FiberSIM, review the previously created Laminate and Rosette. 2. Create a full-body ply with the following parameters: Name: P001 Step: 10 Specified Orientation: 0 Task 3 - Run the standard simulation. 1. Set the following simulation option for P001: Fiber Spacing Factor: .2
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Producibility
2. Run Net Producibility on P001. The producibility results should display as shown in Figure 475 and are not acceptable.
Figure 475 Task 4 - Run a Biased Geodesic simulation and compare it to the standard simulation. 1. Set the following simulation options: Propagation Method: Geodesic Propagation Direction: Parallel 2. Run Net Producibility on P001. The producibility results should display as shown in Figure 476. Note that the simulation result has changed slightly but is still not acceptable.
Figure 476
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FiberSIM 2010 CEE
Task 5 - Add a First Stage Region. In this task you will add a First Stage Region. The First Stage Boundary in this task is shown in Figure 477. First Stage Boundary
Figure 477 1. Modify P001 and set the following simulation options: First Stage Region: 1st Stage Region Propagation Method: Standard 2. Run Net Producibility on P001. The producibility results should display as shown in Figure 478. The producibility display has changed but is still not acceptable.
Figure 478
456
Producibility
Task 6 - Develop a Darting Solution. 1. Expand the Ply Geometry geometric set and show the P001 (0 degree) geometry consisting of six darts, as shown in Figure 479.
Figure 479 2. Modify P001 and apply the six Darts as shown in Figure 480. Note that an infinite number of darting solutions are available to solve this manufacturing challenge.
Figure 480
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FiberSIM 2010 CEE
3. The producibility and flat pattern of an acceptable simulation is shown in Figure 481. Note that the interior corners of the channel experienced a bridging situation and patches might need to be created to provide complete material coverage. Figure 481 4. Compare the Net Flat Patterns of the standard simulation and the two-stage simulation as shown in Figure 482. Standard simulation (red line) Two-stage simulation (black line)
Figure 482
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Chapter 5
Rosettes
Exercise 5a: Translational Rosette Exercise 5b: Radial Rosette
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Rosettes
Exercise 5a
User Guide Reference: 2.7.2 Rosette Mapping Types 2.5.1 Simulation Display Types
Translational Rosette
In this exercise, you will learn how and why you use the FiberSIM Translational Rosette.
Goal
Create a Translational Rosette Analyze Producibility for Unidirectional Material Analyze Fiber Deviation
Task 1 - Create a Laminate. 1. Open FS2010_CEE_ROSETTES_A.CATPart. The model displays as shown in Figure 51.
Figure 51
2. Click
(FiberSIM). (Create New).
3. In the CEE menu, select Laminate and click
4. In the Laminates Standard form, enter the following parameters: Name: Cone Step: 1
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FiberSIM 2010 CEE
5. Next to Default Material, click to open the FiberSIM - link Material via Default Material dialog box. T-24-in is a unidirectional tape with fibers running in one direction. 6. Select T-24-in as shown in Figure 52 and click .
Figure 52 Task 2 - Link the geometry to CATIA. 1. In the Geometry area of the form, link the Laminate to the CATIA geometry as shown in Figure 53: Layup Surface: Tool Surface Net Boundary: Net Boundary
Figure 53 2. Click window. to complete the Laminate and return to the main
Task 3 - Create a Standard Rosette. 1. In the CEE menu, select Rosette and click (Create New).
2. Change the rosette name to [Standard Rosette] and link the following geometry: Origin: SR Origin Direction: SR Zero Direction
54
Rosettes
3. Ensure that the Mapping Type is set to Standard as shown in Figure 54.
Figure 54 4. Click view. to complete the rosette and return to the main
Task 4 - Create a full-body ply. 1. In the CEE menu, select Ply and click (Create New).
2. For the P001 ply, enter the following parameter: Step: 10 Note that FiberSIM automatically changes the Simulation Type to Geodesic for unidirectional materials. 3. Click (Net Producibility). The warning message box opens (as shown in Figure 55) because the default Standard producibility method cannot be used for a uni-directional material. Click to close the message box.
Figure 55
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FiberSIM 2010 CEE
4. Click and verify that FiberSIM automatically changed Propagation Method to Geodesic, as shown in Figure 56.
Figure 56 5. Click to exit the Simulation Options form.
6. Click (Net Producibility). (Ignore the warning message box the opens, prompting you about the material width.) 7. Activate the CATIA window. The model should display as shown in Figure 57.
Figure 57 8. Rotate the model and note that the fiber directions in the middle of the part are aligned along the rosettes 0-direction, which in turn, is parallel to the axis of the cone. (The axis of the cone in this exercise is assumed to be the primary strength direction for this particular part. Therefore, it is required that the material fibers be aligned in this direction.)
56
Rosettes
Task 5 - Change the ply origin. 1. Activate the FiberSIM window and click to the Origin field. (Link Geometry) next
2. In the tree or in the model, select the Ply Origin 2 point as shown in Figure 58.
4. Click (Net Producibility) again. The model should now display as shown in Figure 59.
Figure 59
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FiberSIM 2010 CEE
5. Note that the fiber paths (shown with blue lines) are no longer aligned with the part axis in the middle of the surface, where the rosette is located. The observed misalignment is due to the following: The ply Origin point is assumed to be where the fabric first touches the tool surface when laid up on the mold. At this location, for a 0-degree fabric orientation, the warp direction of the fabric roll is aligned with the 0-direction of the rosette. Similarly, for a 45-degree fabric orientation, the warp direction would be aligned with the 45-degree direction of the rosette, etc. However, if the ply origin is selected away from the rosette, the rosettes directions need to be transposed to another location, (the ply origin). This is called rosette mapping. With the Standard mapping method (the default option in FiberSIM), orientation is mapped from the rosette so that it conforms to the part curvature. For example, a simple cube is shown in Figure 510. The arrows on the sides, top, and bottom of the cube indicate the 0-direction mapped to that location.
Figure 510 Since Standard mapping always takes surface normals into account, the result is always intuitively correct. Therefore, Standard mapping should be used on the majority of parts. However, Standard mapping might cause a problem if the same starting 0-direction must be maintained no matter where on the surface you pick the ply origin. For this specific part, that should be the direction along the cone axis. You will learn how to handle this requirement using Translational rosette mapping method in Task 7.
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Rosettes
Task 6 - Analyze the Fiber Deviation. 1. Next to the Origin field, click 2. Click (Link Geometry).
to clear the Origin selection in the form that opens.
3. Click . The ply Origin resets to Standard Rosette as shown in Figure 511.
Figure 511 4. Click . In the Result Display drop-down list, select Deviation as shown in Figure 512.
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FiberSIM 2010 CEE
6. Click (Net Producibility). The model should now display as shown in Figure 513.
Figure 513 Warning (3 deg) and Limit (5 deg) angles can be adjusted in the Deviation area in the Rosette form. 7. The Deviation results display the amount of deviation between the simulated fiber orientations and the rosettes orientation as follows: White fiber paths indicate the difference under 3 degrees. Yellow fiber paths indicate areas where the deviation is between 3 and 5 degrees. Red fiber paths indicate areas where the deviation in direction exceeds 5 degrees. 8. Note that the deviation angles are computed between the fiber paths and the mapped rosette directions. Therefore, it is also important to select the proper type of rosette mapping to correctly assess the fiber deviations. 9. Click to exit the ply form and return to the main view.
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Rosettes
Task 7 - Create a reference Laminate for a Translational Rosette. Translational rosette mapping is a direct point-to-point translation technique, as shown in Figure 514. The 0-direction is directly translated, while the other fiber orientations are calculated by rotating the translated 0-direction around the tool surface normal to the point.
Figure 514 Commonly, point-to-point translation mapping used in surfaces of revolution where you want the 0-direction to always be parallel to an axis. However, Translational mapping does not apply to the majority of parts. For example, the cube shown in Figure 515, uses Translational mapping. Note that point-to-point translation fails on two of the six faces.
Figure 515 Translational Rosette requires the creation of a reference laminate that is only used to determine the Rosettes directions rather than laying up actual plies, etc.
511
FiberSIM 2010 CEE
1. Hide the Standard Rosette geometrical set and unhide the Trans Rosette geometrical set in the CATIA model. The model should display as shown in Figure 516.
Figure 516 2. In the CEE menu, select Laminate. 3. Click (Create New). Ignore any warning messages that open.
4. Rename the new laminate as [TRANS-LAM]. 5. In the Parent drop-down list, select the empty line to clear the default parent laminate, as shown in Figure 517.
Figure 517
512
Rosettes
6. Click (Link Geometry) next to the Layup Surface field and select TR Ref Surface as shown in Figure 518. This surface will be used as a reference surface for the Translational Rosette. The surface must be co-planar to the part axis of rotation.
8. The Laminate form should update as shown in Figure 519.
Figure 519 9. Click view. to complete the Laminate and return to the main
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FiberSIM 2010 CEE
Task 8 - Create a Translational Rosette. 1. In the CEE menu, select Rosette. 2. Click (Create New) and rename the rosette as [Trans Rosette]. 3. In the Laminate drop-down list, select TRANS-LAM as shown in Figure 520.
Figure 520 4. Link the following geometry: Origin: TR Origin Direction: TR Zero Direction 5. Set the Mapping Type to Translational as shown in Figure 521.
Figure 521 6. Click to complete the rosette.
Task 9 - Change the Ply rosette to Translational. 1. In the CEE menu, select Ply. 2. Double-click on P001 to modify the ply.
514
Rosettes
3. In the Rosette drop-down list, select Trans Rosette as shown on Figure 522.
Figure 522 4. Link the ply Origin to the SR Origin. The ply form should update as shown in Figure 523.
Figure 523
515
FiberSIM 2010 CEE
Task 10 - Analyze Fiber Paths 1. Click . In the Result Display drop-down list, select Deformation as shown in Figure 524.
3. Click (Net Producibility). The model should display as shown in Figure 525.
Figure 525 4. Note that all of the fiber paths are oriented along the part axis. 5. You will now change the ply origin. Click to the ply Origin field. (Link Geometry) next
516
Rosettes
6. Clear SR Origin and select Ply Origin 2 in the tree or in the model, as shown in Figure 526.
8. Click (Net Producibility). The model should now display as shown in Figure 527.
Rosettemappedtonewplyorigin
Figure 527 9. Note that the fiber paths are now aligned with the part axis at the new ply origin.
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FiberSIM 2010 CEE
Exercise 5b
User Guide Reference: 2.7.2 Rosette Mapping Types
Radial Rosette
Radial Rosette mapping is a specialized form of translation, used for spherical-shaped parts, such as satellite dishes and dome covers. In Radial mapping, the point-to-point translation takes place with the 0-direction always set in a radial direction from the center of the part as shown in Figure 528. Therefore, the Radial Rosette origin must be always placed in the exact center of the part.
Figure 528 In this exercise, you will create a laminate consisting of four plies butt-spliced onto a model of a satellite dish. The completed model is shown in Figure 529.
Figure 529
518
Rosettes
Goal
Create a Radial Rosette Create butt-spliced plies on multi-domain surfaces Analyze Producibility and Fiber Deviation
Task 1 - Open a part. 1. Select File > Open and select FS2010_CEE_ROSETTES_B.CATPart. The model displays as shown in Figure 530.
Figure 530 Task 2 - Create a Laminate.
1. Click
(FiberSIM). (Create New).
2. In the CEE menu, select Laminate and click
3. In the Laminates Standard form, enter the following parameters: Name: Dish Step: 1 4. Next to Default Material, click to open the FiberSIM - link Material via Default Material dialog box.
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FiberSIM 2010 CEE
5. Select PPG-PL-3K and click
6. In the Geometry area of the form, link the Laminate to the CATIA geometry as shown in Figure 531: Layup Surface: Tool Surface Net Boundary: Net Boundary 1, Net Boundary 2 Extended Boundary: Ext Boundary 1, Ext Boundary 2
Figure 531 7. Click window. to complete the Laminate and return to the main
Task 3 - Create a Radial Rosette. 1. In the CEE menu, select Rosette and click 2. Link the following geometry: Origin: SR Origin Direction: SR Zero Direction (Create New).
520
Rosettes
3. Set the Mapping Type to Radial. The form should display as shown in Figure 532.
Task 4 - Create the first ply. 1. In the CEE menu, select Ply and click (Create New).
2. For the P001 ply, set the Step parameter to [10]. 3. Link the ply Origin to Gore 1 Origin. The ply form should update as shown in Figure 533.
Figure 533
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FiberSIM 2010 CEE
4. Click (Net Producibility). The warning message box opens as shown in Figure 534, because the Net Boundary of the ply consists of two disconnected contours. Click message box. to close the
Figure 534 5. Click (Link Geometry) next to the Boundary field and select the curves Radial 1 and Radial 2, as shown in Figure 535, to re-limit the ply to the first quadrant of the surface.
7. Click (Net Producibility). (Ignore the warning message that opens prompting you about the material width.)
522
Rosettes
8. The model should display as shown in Figure 536.
Figure 536 9. Click view. to complete the P001 ply and return to the main
Task 5 - Create the remaining three plies. 1. Set the Object Count to [3] as shown in Figure 537.
Figure 537 2. In the ply list, select P001, right-click and select Create Based On. 3. Press <Ctrl> + <T> to switch the ply form to the table view and select the Net Geometry tab. The form should display as shown in Figure 538.
Figure 538
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FiberSIM 2010 CEE
4. Note that the Origins and Boundaries (highlighted in Figure 538) of the new plies are incorrect (because they were copied from the first ply). Therefore, they need to be re-linked to the correct CATIA geometry. 5. Link the Origins of the new plies as follows: P002: Gore 2 Origin P003: Gore 3 Origin P004: Gore 4 Origin 6. Link the Boundaries of the new plies as follows: P002: Radial 2, Radial 3 P003: Radial 3, Radial 4 P004: Radial 4, Radial 1 7. The ply form should update as shown in Figure 539.
Figure 539 8. Click to complete the plies and return to the main view.
Task 6 - Analyze the producibility of all of the plies. 1. In the ply list, multi-select P001 through P004 as shown in Figure 540.
Figure 540
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Rosettes
2. Click (Net Producibility). (Ignore the warning message box that opens prompting you about the material width.) 3. Activate the CATIA window. The model should display as shown in Figure 541.
Figure 541 4. Rotate the model and note that the fiber directions in the middle of the quadrants are aligned along the radial direction of the surface, This is done using the Radial Rosette. 5. Close FiberSIM and save and close CATIA model.
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Chapter 6
Utilities
Exercise 6a: Symmetric Laminate Exercise 6b: Curve Creation and Ply Drop-off Utilities Exercise 6c: Fiber Path Curve
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Utilities
Exercise 6a
User Guide Reference: B.4.1 Symmetric Laminate
Symmetric Laminate
In this exercise, you will use the Symmetric Laminate utility to create a second laminate dataset, by copying component data to a symmetric part. The completed model displays as shown in Figure 61.
The Symmetric Laminate utility differs from the Mirror Laminate utility, which mirrors plies about a user-defined step value on the same laminate.
Figure 61
Goal
Create a Symmetric Laminate
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FiberSIM 2010 CEE
Task 1 - Open a part. 1. Open FS2010_CEE_UTILITIES_A.CATPart. The model displays as shown in Figure 62.
Figure 62 Task 2 - Mirror CAD features about a symmetry plane. 1. In CATIA, select Insert > Geometrical Set. For the Name, enter [Sym Lam] as shown in Figure 63.
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Utilities
3. Select Insert > Operations > Symmetry. The Symmetry Definition dialog box opens as shown in Figure 64.
Figure 64 4. Next to the Element field, click .
5. In the specification tree, select the following 5 features in the specified order: Tool Surface Net Boundary Extended Boundary Rosette Origin Zero Direction
6. The Elements dialog box updates as shown in Figure 65.
Figure 65 7. Click to close the Elements dialog box.
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FiberSIM 2010 CEE
8. In the specification tree, for the Reference field, select Sym Plane as shown in Figure 66.
Figure 66 9. Click . The model updates as shown in Figure 67.
Figure 67 Task 3 - Create Symmetric Laminate and Rosette geometry.
1. Click
(FiberSIM).
2. In the CEE menu, select Laminate. 3. Click (Create New).
66
Utilities
4. In Name field, enter [Sym Lam]. 5. Link the following geometry as shown in Figure 68: Layup Surface: select the Symmetry tool surface, Symmetry.1 Net Boundary: select the Symmetry net boundary, Symmetry.2 Extended Boundary: select the Symmetry extended boundary, Symmetry.3
Symmetry Tool Surface (Symmetry.1) Symmetry Net Boundary (Symmetry.2)
Symmetry Extended Boundary (Symmetry.3)
Figure 68 6. Click to save Sym Lam.
7. In the CEE menu, select Rosette. 8. Click (Create New) to create ROS002.
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FiberSIM 2010 CEE
9. Link the following geometry as shown in Figure 69: Origin: select the Symmetry Origin, Symmetry.4 Direction: select the Symmetry Zero Direction, Symmetry.5
Symmetry Origin (Symmetry.4)
Symmetry Zero Direction (Symmetry.5)
Figure 69 10. A message box opens as shown in Figure 610. This issue will be addressed in the following step.
68
Utilities
12. In the Laminate drop-down list, select Sym Lam as shown in Figure 611.
Figure 611 An exact symmetry of ply orientations requires an opposite handed (Left-Hand) rosette. 13. For Hand Direction, select Left as shown in Figure 612.
Figure 612 14. Click to save ROS002.
15. Rename ROS002 as [Sym Ros]. Task 4 - Create a Symmetric Laminate. 1. In the Rosette listing, highlight both ROS001 and ROS002 and select Tools > Derivative Laminates > Symmetric Laminate as shown in Figure 613.
Figure 613 2. In the FiberSIM - list Symmetric Laminate dialog box, click (Create New).
FiberSIM 2010 CEE
3. Specify the following parameters to create the symmetric laminate: Source Laminate: Cowl Source Rosette: ROS001 Symmetry Plane: Sym Plane Symmetric Laminate: Sym Lam Symmetric Rosette: Sym Ros
4. The updated Symmetric Laminate form displays as shown in Figure 614.
Figure 614 5. Click to generate the symmetric laminate.
6. In the message box prompting you that 23 components have generated successfully, click as shown in Figure 615.
Figure 615
610
Utilities
7. Note the Report created on the Symmetric Laminates Standard form as shown in Figure 616.
Figure 616 8. Click 9. Click to complete the Symmetric Laminate creation. to close the window.
Task 5 - Group plies by Parent. 1. In the CEE menu, select Ply. 2. In the Group drop-down list, select Parent to display the plies grouped by their parents as shown in Figure 617.
Figure 617
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FiberSIM 2010 CEE
3. In the Parent ply list, highlight Sym Lam and Cowl, one at a time, to highlight them in the CATIA window as shown in Figure 618.
Figure 618
612
Utilities
Exercise 6b
User Guide References: B.5.2 Curve Creation B.5.5 Curve Offset B.3.6 Ply Drop-Off B.5.4 Boundary Simplification
Curve Creation and Ply Drop-off Utilities

In this exercise, you will use various utilities to create curves and ply drop-offs. The completed model displays as shown in Figure 619.
Figure 619
Goal
Create a curve using Curve Creation Create a Curve Offset - Constant Create a Curve Offset - Directional Use Ply Drop-off Use Boundary Simplification Use Publish the FiberSIM Composite Format
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FiberSIM 2010 CEE
Task 1 - Open a part. 1. Open FS2010_CEE_UTILITIES_B.CATPart. The model displays as shown in Figure 620.
Figure 620 Task 2 - Create a curve using Curve Creation.
1. Click
(FiberSIM).
2. In the CEE menu, select Laminate. In the CATIA window, display the associated tool surface and layup direction. 3. In the CEE menu, select Rosette. In the CATIA window, display the associated geometry. 4. In the CEE menu, select Ply to display the two plies: P001 and P002. 5. Show and expand the Hole Geometry geometrical set. The four points display as shown in Figure 621.
Figure 621
Utilities
6. In FiberSIM, select Tools > Curve Creation > Curve Creation as shown in Figure 622.
Figure 622 7. Next to the Skin field, click Tool Surface. 8. Click . (Link Geometry) and select the
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FiberSIM 2010 CEE
The curve will be created by connecting the selected points in the order of selection.
9. Next to the Points to Connect field, click (Link Geometry) and select the four points: Hole.1, Hole.2, Hole.3, and Hole.4 as shown in Figure 623.
Hole.2
Hole.1
Hole.3 Figure 623 10. Click If Close Curve is not selected, the points will be connected in order without connecting the last point to the first one. .
Hole.4
11. Select the checkbox for the Close Curve option. The FiberSIM Curve Creation window updates as shown in Figure 624.
Figure 624 12. Click

616
.
Utilities
13. Click Figure 625.
The model updates with the curve as shown in
Figure 625 14. In the specification tree, the new FiberSIM Curve From Points geometrical set displays, as shown in Figure 626.
Figure 626
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FiberSIM 2010 CEE
Task 3 - Use Curve to create a Hole. 1. In the ply list, double-click on P002 to modify it. If Enable Curve Auto-Chaining is not selected, each curve must be selected individually. 2. In the Net Geometry area, next to the Holes field, click (Link Geometry) and select the curve you just created as shown in Figure 627.
4. Click in the message box prompting you that the Origin is inside one of the Net Holes and Extended Holes.
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Utilities
5. In the Net Geometry area, next to the Origin field, click (Link Geometry) and indicate a new origin outside the hole boundary as shown in Figure 628. IndicationPoint.1
Figure 628 6. Click 7. Click . to save P002.
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FiberSIM 2010 CEE
Task 4 - Create a Constant Curve Offset. 1. Show and expand the Reinforcement geometric set. The two reinforcement boundaries and two origins display as shown in Figure 629.
Figure 629 2. In FiberSIM, select Tools > Curve Creation > Curve Offset as shown in Figure 630.
Figure 630 3. Select the Constant Offset tab.
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Utilities
The Direction Point determines the side of the selected curves on which the offset curves are created.
4. Click
(Create New) and link the following geometry:
Curves to Offset: RH Reinforcement Boundary Skin: Tool Surface Direction Point: Indicate a point outside the RH Reinforcement Boundary as shown in Figure 631 Boundary Curves: Net Boundary
IndicationPoint.1 Figure 631 5. Enter the following parameters: Number of Curves: 3 Offset Value: 0.25 in (6.35 mm) Corner Type: Fillet 6. Click in the message box as shown in Figure 632.
Figure 632
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FiberSIM 2010 CEE
7. Click
twice to save the curve offset.
8. Switch to the CATIA window to display the constant curve offset as shown in Figure 633.
Figure 633 Task 5 - Change the Constant Offset Curves to be Directional. 1. Select the Directional Offset tab and double-click on CurveOffset001 to modify. The linked rosette determines the 0 and 90 degree offset directions. 2. Enter the following parameters: 0 degree Offset Value: 0.25 in (6.35 mm) 90 degree Offset Value: 0.5 in (12.7 mm) 3. Click .
4. The FiberSIM message window opens, prompting you that the curve offset was generated successfully as shown in Figure 634.
Figure 634 5. Click

622
twice.
Utilities
6. Click
7. Switch to the CATIA window to display the directional offset curves as shown in Figure 635.
Figure 635 Task 6 - Create Plies from Directional Curve Offsets. 1. In the ply list, for the Object Count, enter [4] as shown in Figure 636.
3. Link the following geometry: Origin: RH Reinforcement Origin 4. Press <Ctrl> + <T> to switch to Table mode.
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FiberSIM 2010 CEE
5. In the Standard tab, select the following for the Specified Orientation column: P003: 0 P004: -45 P005: 90 P006: 45
6. In the Net Geometry tab, for the Boundary column, link the following geometry: P003: RH Reinforcement Boundary P004: Curve.43 P005: Curve.44 P006: Curve.45 to save the plies.
7. Click
Task 7 - Create 4 plies based on existing plies. 1. In the ply list, highlight P003, P004, P005, and P006, right-click and select Create Based On. 2. Press <Ctrl> + <T> to switch to Form mode. 3. Link the following geometry: Origin: LH Reinforcement Origin Boundary: LH Reinforcement Boundary Because they were created based on the RH Reinforcement plies, the LH Reinforcement plies are already sequenced. 4. Click Task 8 - Create a Ply Drop-off. 1. In the ply list, highlight P007, P008, P009, and P010, if they are not already highlighted. You can also find Ply Drop-Off in the main menu by selecting Tools > Operations. 2. In the Ply toolbar, click Figure 637. (Ply Drop-Off) as shown in
Figure 637
624
Utilities
3. Click in Figure 638:
and specify the following parameters as shown
Direction: Outside Offset Distance: 0.25 (6.35 mm) Corner Type: Fillet
5. The FiberSIM message window opens, prompting you that the generation of ply drop-offs is complete as shown in Figure 639.
Figure 639
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FiberSIM 2010 CEE
6. Click In FiberSIM, select P007 through to P010 one at a time to display each ply in CATIA. Note that this Ply Drop-Off result is the same as the Constant Curve Offset.
twice.
7. Switch to the CATIA window to display the new plies as shown in Figure 640.
Figure 640 Task 9 - Show the ply drop-off using a 3D cross-section. You can also find 3D Cross Section in the Documentation menu in the Application Tree. 1. In the Object toolbar, click Figure 641. (3D Cross Section) as shown in
Figure 641 2. Select CrossSection001 and click section). (Generates the 3D cross
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Utilities
3. Zoom and orient the model to display the cross-section details as shown in Figure 642.
Task 10 - Boundary Simplification. 1. In FiberSIM, select Tools > Curve Creation > Boundary Simplification as shown in Figure 643.
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FiberSIM 2010 CEE
3. Next to the Components field, click You can also press <Ctrl> + <L> to link the selected plies.
(Link with Link Dialog).
4. Press <Ctrl> + <A> to select all of the plies, right-click, and select Link to link the selected plies. 5. Click . to display the default options as shown in
Internal Boundary Curves Only will not create closed boundaries, but only the boundary curves that are not shared with the laminate boundary.
Figure 644 7. The form updates as shown in Figure 645.
9. Click in the message box prompting you that the boundary features were generated successfully.
Utilities
10. Click 11. Click
to save BNDSMP001. and exit FiberSIM.
12. In the CATIA window, display the new features by selecting them in the specification tree. Note that P002 includes a Net Holes geometric set. Task 11 - Publish the FiberSIM Composite Format.
1. Click
(FiberSIM).
2. In FiberSIM, select Tools > Custom Utilities > Publish FiberSIM Composite Format as shown in Figure 646.
4. Next to the Laminates field, click (Link with Link Dialog) and select the checkbox for the Hood laminate. 5. Click .
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FiberSIM 2010 CEE
to display the default options as shown in
Figure 647 7. Click 8. Click This feature creates a Model Based Definition (MBD) of the primary components of the composite data stored in FiberSIM. 9. Click to save. and exit FiberSIM. .
10. In the CATIA window, display the new features by selecting them in the specification tree. Note that P002 includes a Net Hole.
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Utilities
Exercise 6c
User Guide Reference: B.5.1 Fiber Path Curve Creation
Fiber Path Curve

In this exercise, you will create two Fiber Path Curves to use for Net Boundary to address deviation producibility issues. The completed model is shown in Figure 648.
Figure 648
Goal
Display Fiber Deviation for a Ply Create a Fiber Path Curve Add Fiber Path Curves to a Net Boundary Create a Net Flat Pattern
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FiberSIM 2010 CEE
Task 1 - Open a part. 1. Open FS2010_CEE_UTILITIES_C.CATPart. The model displays as shown in Figure 649.
Figure 649 Task 2 - Set the Simulation options.
1. Click
(FiberSIM).
2. In the ply list, double-click on P001 to modify it. 3. Click and set the following simulation options as shown in Figure 650: Fiber Spacing: 0.5 Results Display: Deviation
Figure 650
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Utilities
4. Click
Task 3 - Display Fiber Deviation for a Ply. 1. Click 2. Click (Net Producibility). .
3. Switch to the CATIA window and display the producibility results as shown in Figure 651.
Figure 651 For more information on Deviation options, see the Rosettes chapter. The Deviation results display the amount of deviation between the simulated fiber orientations and the rosettes orientation as follows: White fiber paths indicate deviation under 3 degrees. Yellow fiber paths indicate areas where the deviation is between 3 and 5 degrees. Red fiber paths indicate areas where the deviation in direction exceeds 5 degrees.
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FiberSIM 2010 CEE
Task 4 - Create the First Fiber Path Curve. You can also find the Fiber Path Curve Creation utility in the main menu by selecting Tools > Curve Creation. 1. In the ply list, select P001. In the Ply toolbar, click Curve Creation) as shown in Figure 652. (Fiber Path
Figure 652 An indication must be made on the surface, not on the fiber path curve. FiberSIM will not create an indication point unless it is not on the displayed curves. 2. Next to the Fiber Path Position field, click (Link Geometry) and indicate a point on the surface closest to the last full-yellow fiber path as shown in Figure 653.
IndicationPoint.1 Figure 653 3. Click 4. Click . .
5. Click in the message box prompting you that the curve was generated successfully. 6. Click .
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Utilities
Task 5 - Create a Second Fiber Path Curve. 1. Next to the Fiber Path Position field, click (Link Geometry).
2. Create a second fiber path curve by indicating a point on the other side of the surface nearest to the last full-yellow fiber path as shown in Figure 654.
IndicationPoint.1 Figure 654 3. Click 4. Click . .
5. Click in the message box prompting you that the curve was generated successfully. 6. Click .
Task 6 - Modify P001 to use the new Fiber Path Curves. 1. In the ply list, double-click on P001 to modify it. 2. Next to the Boundary field, click (Link Geometry).
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FiberSIM 2010 CEE
3. Clear the existing splines and select the two new fiber path curves, Curve.1 and Curve.2, as shown in Figure 655.
5. Select the Net Geometry tab.
636
Utilities
6. Next to the Markers field, click (Link Geometry) and select the original material width curves as shown in Figure 656.
Figure 656 7. Click 8. Click 9. Click 10. Click . (Net Producibility). (Generates the Net Flat Pattern). to save P001.
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FiberSIM 2010 CEE
11. Switch to the CATIA window to display the producibility and net pattern results. Note that the flat pattern satisfies the fiber deviation limits as shown in Figure 657. Material Width Lines
Figure 657
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Project 1
Monolithic Panel
Exercise P1: Monolithic Panel
P11
Monolithic Panel
Exercise P1
User Guide Reference: 2.8 Plies B.5.2 Curve Creation B.5.5 Curve Offset
Monolithic Panel
In this project, you will use ply based design to complete a layup scenario. The completed model displays as shown in Figure P11.
Figure P11
Goal
After you complete this project, you will be able to:
Create the required CATIA geometry Create ply objects Create a 3D cross-section and confirm layup
Given
The previously created geometry and design details are:
Net and Extended Boundaries have been created Rosette geometry has been created Planes that define the locations of the substructure have been created The substructure is the basis for the ply boundaries
P13
FiberSIM 2010 CEE
Task 1 - Open a part. 1. Open FS2010_CEE_PROJECT1_MONOLITHIC.CATPart. The model displays as shown in Figure P12.
Figure P12 Task 2 - Review FiberSIM geometry. 1. The existing geometry is displayed in the FiberSIM Geometry geometrical set, as shown in Figure P13.
Figure P13
P14
Monolithic Panel
2. The Winglet Tool Surface, Manufacturing (Extended) Boundary, Design (Net) Boundary, Rosette Origin, and Zero Direction are displayed as shown in Figure P14. Manufacturing (Extended) Boundary
Winglet Tool Surface Design (Net) Boundary
Zero Direction
Rosette Origin Figure P14 3. The Substructure geometry is shown in Figure P15. Rib 2 Centerline (Rib 2 CL)
Main Spar Centerline (Main SparCL)
Rib 1 Centerline (Rib 1 CL)
Figure P15
P15
FiberSIM 2010 CEE
Task 3 - Create the required CAD geometry. 1. Create the required CAD geometry for the given plies as shown in Figure P16.
All plies are PPG-PL-3K
90
Drop Offs: 0 = 0.25in (6.35 mm) 90 = 0.5in (12.7 mm)
Aligned to Rib 2 CL
12 Plies
5 in (127 mm)
20 Plies
Aligned to Rib 2 CL
Aligned to Main Spar C
36 Plies
Figure P16
P16
Monolithic Panel
Task 4 - Create ply objects. 1. Create plies, using given quantity, ply drop-off values and orientations as shown in Figure P18 and Figure P18.
Ply Requirements (36 --> 20 Ply Drop)
Figure P17
Ply Requirements (20 --> 12 Ply Drop)
Figure P18
P17
FiberSIM 2010 CEE
Task 5 - Cross-section. 1. Use the Curve Creation Utility to create a curve for a cross-section. Review the 2D Cross Section and confirm that the layup matches the design requirements as shown in Figure P19.
Figure P19
P18
Chapter 7
Core
This chapter introduces:
Exercise 7a: Core Types Exercise 7b: Modeled Core with Overcore and IML Laminates Exercise 7c: Core Panel Design from a Solid (Optional)
71
Core
Exercise 7a
User Guide Reference: 2.9 Cores 5.2 3D Cross Section
Core Types
In this exercise, you will create various types of cores within FiberSIM CEE. (Note that designing the overcore plies/layers has not yet been discussed.) The completed model is shown in Figure 71.
Figure 71 After you complete this exercise, you will be able to:
Create a Virtual Step Core object Create a Virtual Variable Core object Create a Virtual Core object Observe the differences between the different types of core using cross-sections
Task 1 - Open a part. 1. Open FS2010_CEE_CORE_A.CATPart. The model displays as shown in Figure 72.
Figure 72
FiberSIM 2010 CEE
2. Click
(FiberSIM).
3. Review the FiberSIM objects in the model. Note that the model already contains a Laminate, a Rosette, and four full-body plies as shown in Figure 73. The plies are made of the PPG-PL-3K material and are oriented to the 0, -45, 45, and 90 deg directions.
Figure 73 Task 2 - Create a Virtual Step Core. Virtual Step Core is the most commonly used type of core, with the same bevel angle on all sides and a vertical step at the base. 1. In the CEE menu, select Core. 2. Click (Create New). Expand the drop-down list and click
(Virtual Step Core). The Core definition form is displayed as shown in Figure 74 (press <Ctrl> + <T> if the form displays in the Table view).
Figure 74
Core
3. Next to the Material field, click
(Link with Database).
4. Select the checkbox for Honeycomb material as shown in Figure 75.
6. In the Geometry area, next to the Origin field, click Geometry).
7. Indicate a point in the middle of the 1st Core as shown in Figure 76.
Figure 76 8. Click . Close the warning message box if it opens. (Link
9. In the Geometry area, next to the Boundary (1) field, click Geometry).
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FiberSIM 2010 CEE
If required for a given design, a curve inside the core boundary can be used to define the ribbon direction of the core.
10. Select the boundary contour of the 1st Core as shown in Figure 77.
Figure 77 11. Click 12. Enter the following parameters as shown in Figure 78. Thickness: 1.575 in (40 mm) Bevel Angle: 30 Step Height: .095 in (2.413 mm)
Figure 78 13. Click to complete the Core.
76
Core
Task 3 - Create a Virtual Variable Core. Virtual Variable Core requires you to define both the Base Boundary and Top Boundary of the core. The Core bevel angles might be different on all sides and are defined by differences in the geometric shape of the Base Boundary and Top Boundary combined with the core height. 1. In the CEE menu, select Core. 2. Click (Create New). Expand the drop-down list and click (Virtual Variable Core). The Virtual Variable Core definition form is displayed as shown in Figure 79.
Figure 79 3. Next to the Material field, click (Link with Database).
4. Select the checkbox for the Honeycomb material. 5. Click . (Link
6. In the Geometry area, next to the Origin field, click Geometry).
7. Indicate a point in the middle of the 2nd Core as shown in Figure 710.
Figure 710
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FiberSIM 2010 CEE
8. Click
. (Link
9. In the Geometry area, next to the Boundary (1) field, click Geometry).
10. Select the outer contour of the 2nd Core as shown in Figure 711.
12. In the Core Top area, next to the Boundary (4) field, click Geometry).
13. Select the inner contour of the 2nd Core as shown in Figure 712.
78
Core
15. In the Core Top area, in the Thickness (3) field, enter [1.575 in] (40 mm). The form updates as shown in Figure 713.
Figure 713 16. Click to complete the Core.
Task 4 - Create Two Virtual Cores. Virtual Core only requires explicitly defining geometry for the Base Boundary. The cross-sectional shape of the Core is then implicitly defined by specifying numeric values for thickness, bevel angle, etc. 1. In the CEE menu, select Core. 2. In the Object Count field, enter [2] to create two cores simultaneously as shown in Figure 714.
Figure 714
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FiberSIM 2010 CEE
3. Click
(Create New). Expand the drop-down list and click
(Virtual Core). The Virtual Core definition form is displayed as shown in Figure 715.
Figure 715 4. Next to the Material field, click (Link with Database).
5. Select the checkbox for the Honeycomb material. 6. Click .
7. Enter the following parameters in the Core Top area as shown in Figure 716. Thickness: 1 in (25.4 mm) Bevel Angle: 30
Figure 716 8. Press <Ctrl>+ <T> to switch to the Table view. The updated form displays as shown in Figure 717.
Figure 717 9. For the VC001 core, next to the Origin field, click Geometry). (Link
710
Core
10. Indicate a point in the middle of the Core003 curve as shown in Figure 718.
Figure 718 11. Repeat the procedure for the VC002 core, indicating a point in the middle of Core004 curve as shown in Figure 719.
Figure 719 12. Link the Boundary geometry (in the Boundary column) for both Cores as follows: VC001: select the Core003 curve VC002: select the Core004 curve 13. The updated form displays as shown Figure 720.
Figure 720 It is a recommended best practice to return to Form Mode to prevent future confusion. 14. Press <Ctrl> + <T> to return to Form mode. 15. Click to complete both Cores.
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FiberSIM 2010 CEE
Task 5 - Create 3D cross-sections. 1. Show the 3D Cross Section geometric set. 3D Cross Section can also be found in the FiberSIM Documentation menu. 2. In the Core toolbar, click Figure 721. (3D Cross Section) as shown in
4. The cross-section form displays as shown in Figure 722.
Figure 722 5. Next to the Cross Section Curve field, click (Link Geometry).
6. Select the Cross section curve 1 as shown in Figure 723.
Figure 723
712
Core
7. Click
8. Enter the following parameters: Component Type: Ply Style: Draped Ply/Layer Offset Scale: 20 (Note that this parameter is used to exaggerate the offset distances between plies in the cross-section for better visibility.) Core Offset Scale: 1 (Note that this parameter is used to scale the core dimensions. A value of [1] means that the core(s) in the cross-section will be displayed at real size.) 9. Click 10. Click . to complete the cross-section.
11. Switch to the CATIA window. 12. Hide the FiberSIM Geometry geometric set. The model displays as shown in Figure 724.
Figure 724
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FiberSIM 2010 CEE
13. Zoom in to examine the cross-sections of the cores. Note the different bevel angles in the VVC001 core, and the step geometry in VSC001 core as shown in Figure 725. Different bevel angles Step geometry
Figure 725 14. Show the FiberSIM Geometry geometric set. 15. In the 3D Cross Section list, highlight CrossSection001, right-click and select Create Based On to create a 3D Cross Section for Cross section curve 2. 16. Display both cross-sections (multi-select them in the FiberSIM window), and hide the CATIA geometry. The model should display as shown in Figure 726.
Figure 726
714
Core
Exercise 7b
User Guide Reference: 2.9 Cores 9.7 Laminate Tab 2.10 Design Stations
Modeled Core with Overcore and IML Laminates

In this exercise, you will create a Modeled Core object and create overcore and IML laminates. This will demonstrate the process of defining a core panel, display the results on producibility, and indicate why multiple laminates must be used. After you complete this exercise, you will be able to:
Create a Modeled Core object Create an Overcore Laminate Re-sequence the overcore plies to reflect the overcore topology Create an IML laminate with a descending sequence order Interrogate the model using three Design Stations
Task 1 - Open a part. 1. Open FS2010_CEE_CORE_B.CATPart. The model displays as shown in Figure 727.
Figure 727 Task 2 - Create a Modeled Core object.
1. Click
(FiberSIM).
2. In the CEE menu, select Core.
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FiberSIM 2010 CEE
3. Click
(Create New). (Modeled Core) as shown in
4. In the drop-down list, click Figure 728.
Figure 728 5. Enter the following parameters as shown in Figure 729: Click if you are prompted with the messages: The Extended Boundary is invalid or Could not get the Extended Boundary. Parent: OML Step: 50 Material: Honeycomb Thickness: 0.5 in (12.7 mm) Origin: OML Ply Origin Boundary: Core Boundary
Figure 729 6. Click to save MC001.
716
Core
7. Click (Composite Sequence Manager) to review the component stack as shown in Figure 730.
Task 3 - Create an Overcore Laminate. 1. Hide the OML Geometry geometric set. 2. Show and expand the OverCore Geometry geometric set. 3. Click (FiberSIM).
4. In the CEE menu, select Laminate. 5. Click (Create New).
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FiberSIM 2010 CEE
A different alphabetically ordered Sequence letter is assigned to each laminate (Sequence A = OML; Sequence B = Overcore).
6. Enter the following parameters as shown in Figure 731: Name: Overcore Parent: OML Sequence: B Step: 100 Layup Surface: Overcore Net Boundary: Net Boundary Extended Boundary: Extended Boundary
Figure 731 7. Click to save the Overcore.
Task 4 - Turn on Sequence Based Projection. In this task, you will activate Sequence Based Projection. This will automatically project ply geometry for plies that are sequenced after an Overcore or IML laminate. 1. Select Tools > Options > FiberSIM Options. 2. Select the Laminate tab.
718
Core
3. Select the Sequence Based Projection option as shown in Figure 732.
Task 5 - Use the Composite Sequence Manager to move the plies. 1. Click (Composite Sequence Manager).
2. Select P005, press <Shift> and select P008 to multi-select plies P005, P006, P007, and P008 as shown in Figure 733.
Figure 733
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FiberSIM 2010 CEE
3. With the four plies selected, drag and drop them below the Overcore laminate as shown in Figure 734. Note that the Sequence and Step values have been updated automatically to create the required layup order.
Figure 734 4. Click to save.
5. In the CEE menu, select Ply to display the ply list. Note that displays in the Projected column, indicating that P005 to P008 have been projected as shown in Figure 735.
Figure 735
720
Core
6. For reference, the component sequence and steps are shown in Figure 736.
Figure 736 Task 6 - Run Net Producibility and generate Net Flat Patterns. In this task, the Fiber Spacing Factor is reduced for plies (P005 to P008) to ensure that the simulation follows the core ramps accurately. The simulation results should closely conform to the topological changes in the simulation surface (default laminate surface). Changing the Fiber Spacing Factor in this situation will result in a more accurate flat pattern for the plies covering the core object as shown in Figure 737.
1.0 Fiber Spacing
Non-optimized results
0.3 Fiber Spacing
Desirable results
Figure 737
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FiberSIM 2010 CEE
1. Highlight plies P005 to P008, right-click and select Modify as shown in Figure 738.
3. For the Fiber Spacing Factor, enter [.3]. 4. Click 5. Click to close the Simulation Options dialog box. (Net Producibility) to run Net Producibility.
6. Click (Generates the Net Flat Pattern) to create a Net Flat Pattern of P005, P006, P007, and P008. 7. Click to save.
8. Close the FiberSIM window.
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Core
9. Switch to the CATIA window. In the specification tree, highlight NET_FP_P001 to NET_FP_P008 to display the net flat pattern results. Note the bulges in the updated flat patterns due to the different topology of the Overcore surface as shown in Figure 739.
Red FP Tool Ply
Black FP Overcore Ply Figure 739 Task 7 - Create an IML laminate with a descending sequence order. For a layup that progresses in opposite directions (closed mold or caul plate with bag side loading operations), as shown in Figure 740, the Sequence-Step order of the second laminate is typically defined as Descending. In this task you will change the Overcore laminate to be an IML laminate with a descending sequence order.
SKIN NORMAL DOWN
IML
CORE001
IML
SKIN NORMAL UP
OML
Figure 740 1. Hide and collapse the Overcore Geometry geometric set. 2. Show and expand the IML Geometry geometric set.
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FiberSIM 2010 CEE
3. In the Laminate list, double-click on Overcore. Modify the following parameters as shown in Figure 741: Name: IML Sequence Order: Descending Layup Surface: IML Net Boundary: Net Boundary (under IML Geometry) Extended Boundary: Extended Boundary (under IML Geometry)
Figure 741 4. Click to save the IML laminate.
Task 8 - Update the P005 to P008 Flat Patterns. 1. In the Ply listing, highlight plies P005 to P008, right-click and select Modify. 2. Click (Net Producibility).
3. Click (Generates the Net Flat Pattern) to create a Net Flat Pattern of P005, P006, P007, and P008.
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Core
4. Switch to the CATIA window to display the net flat pattern results as shown in Figure 742.
Figure 742 Task 9 - Interrogate the model using three Design Stations. 1. In the CEE menu, select Design Station as shown in Figure 743.
Figure 743 2. Click (Create New with Geometry Selection).
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FiberSIM 2010 CEE
3. Show and expand the Design Stations geometric set as shown in Figure 744.
Figure 744 4. Select DS001 Origin, DS002 Origin, and DS0003 Origin. The FiberSIM Select Origin dialog box updates as shown in Figure 745.
6. In Design Stations, in the Standard tab next to the Laminate field, click (Link with Link Dialog).
7. Select the OML option as shown in Figure 746.
726
Core
9. In the Design Station Standard form, expand the Core Sample Type drop-down list and select Summary if it is not already selected. 10. Click (Core Sample). The FiberSIM message box opens prompting you that the core samples have completed successfully as shown in Figure 747.
12. In the Design Station list, double-click on DS001. 13. Select the Results tab to display the results of the core sample for DS001. The measured thickness of the core is less than the (specified thickness), as shown in Figure 748, because the origin point lies on a core ramp.
Figure 748
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FiberSIM 2010 CEE
14. Click
15. The Design Station locations are shown in Figure 749. DS001 DS002 DS003
Figure 749 16. In the Design Station listing, double-click on DS002 to display the DS002 core sample results as shown in Figure 750. The measured thickness of the core is equal to the (specified thickness) because the origin point lies within the constant thickness region.
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Core
18. In the Design Station listing, double-click on DS003 to display the DS003 core sample results as shown in Figure 751.
A core is not present at this Design Station
Figure 751
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FiberSIM 2010 CEE
Exercise 7c
User Guide Reference: 2.9 Cores 5.2 3D Cross Section 2.10 Design Stations
Core Panel Design from a Solid (Optional)

In this exercise you will design a multi-laminate composite part with a core, starting from a solid CATIA model with minimal guidance. The solid model of the part is shown in Figure 752. The part consists of 16 full-body plies made of PPG-PL-3K pre-preg fabric [cured thickness 0.0075in (0.1905mm)], and a 0.394in (10mm) thick core made of foam. Eight plies are laid underneath the core, and another eight plies are placed over the core. Therefore, the total thickness of the part is 0.514in (13.048mm) in the core area and 0.12in (3.048mm) in all other areas.
Figure 752 After you complete this exercise, you will be able to:
Create an OML Laminate Create a Modeled Core Create an Overcore Laminate Review the design-in-progress with Design Station and 3D Cross Sections Analyze producibility and obtain Flat Patterns for OML and Overcore plies
730
Core
Task 1 - Open the part. 1. Open FS2010_CEE_CORE_C.CATPart. The model displays as shown in Figure 753.
Figure 753 2. Ensure that the units are set to inches. 3. In the specification tree, hide Measure. Task 2 - Review the part. The model is already prepared for composite design with FiberSIM, with all of the necessary surfaces and curves extracted, etc. In this task, you will review the prepared geometry. 1. Hide PartBody, show the FiberSIM Geometry geometric set, and expand the Tool Laminate geometric set as shown in Figure 754.
Figure 754
731
FiberSIM 2010 CEE
The Tool Laminate geometric set contains the geometry required to create the undercore plies: Tool Surface: Surface extracted from bottom of solid model. Tool Net Boundary: Boundary edges of Tool Surface. Tool Rosette: Geometric set containing origin and 0-direction of rosette. 2. Hide the Tool Laminate geometric set and show and expand the Overcore Laminate geometric set as shown in Figure 755.
Figure 755 The Overcore Laminate geometric set contains the geometry required to create the overcore plies: Overcore Surface: Surface extracted from top of solid and offset by 0.06in (1.524mm), the total thickness of the overcore plies. Overcore Net Boundary: Boundary edges of Overcore Surface. Overcore Rosette: Geometric set containing origin and 0-direction of rosette.
732
Core
3. Hide the Overcore Laminate geometric set, and show both the Tool Laminate and Core geometric sets as shown in Figure 756. Note that the Core set contains the Core Boundary curve (extracted from the solid edges and projected onto the Tool Surface).
Figure 756 Task 3 - Create the OML Laminate. 1. In FiberSIM, create a laminate with the following parameters: Name: OML Laminate Sequence: A Step: 1 Default Material: PPG-PL-3K Layup Surface: Tool Surface Net Boundary: Tool Net Boundary
2. The laminate form is shown in Figure 757.
Figure 757 3. Create a new Rosette with the following parameters: Name: OML Rosette Origin: Origin (under Tool Rosette) Direction: 0 Direction (under Tool Rosette)
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FiberSIM 2010 CEE
4. Create eight full-body plies with the following parameters: Name: Accept the default Sequence: A Step: 10,10 Orientations (P001 to P008): 0, 45, 90, -45, 45, 90, -45, 0
5. The plies are shown in Figure 758.
Figure 758 6. Create a Design Station (DS001) and run a core sample to verify that the total thickness of the OML Laminate is currently 0.06in (1.524mm) (8 plies with 0.0075in (0.1905mm) each cured thickness). Task 4 - Create a Modeled Core. Note: Unhide the Core geometric set to locate the Boundary. 1. Create a new core with the following parameters: Name: MC001 Type: Modeled Core Parent: OML Laminate Sequence: A Step: 90 Material: Foam-3.1 Origin: Origin (under Tool Rosette) Boundary: Core Boundary Thickness: 0.394" (10 mm)
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Core
Task 5 - Create an Overcore Laminate. 1. Create a laminate with the following parameters: Name: Overcore Laminate Sequence: B Step: 1 Sequence order: Ascending Default Material: PPG-PL-3K Layup Surface: Overcore Surface Net Boundary: Overcore Net Boundary
2. The laminate form is shown in Figure 759.
Figure 759 3. Create a new Rosette with the following parameters: Name: Overcore Rosette Laminate: Overcore Laminate Origin: Origin (under Overcore Rosette) Direction: 0 Direction (under Overcore Rosette)
4. Create eight new full-body plies, with the following parameters (ignore the warning messages regarding the invalid Net Boundary type): Name: Accept the default names Parent: Overcore Laminate Rosette: Overcore Rosette Sequence: B Step: 100,10 Orientations (P009 to P016): 90, 45, 0, -45, 45, 90, -45, 0
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FiberSIM 2010 CEE
5. The plies are shown in Figure 760.
Figure 760 6. Create a new Design Station (DS002) and verify that the thickness of the Overcore Laminate is 0.06in (1.524mm) (eight plies, each with 0.0075in (0.1905mm) cured thickness). Task 6 - Create 3D Cross Sections. 1. Create a new 3D Cross Section with the following parameters: Name: CrossSection OML Laminate: OML Laminate Cross Section Curve: OML Curve (under Cross Section Curves) Ply/Layer Offset Scale: 10 Core Offset Scale: 1 2. Create another 3D Cross Section with the following parameters: Name: CrossSection Overcore Laminate: Overcore Laminate Cross Section Curve: Overcore Curve (under Cross Section Curves) Ply/Layer Offset Scale: 10 Core Offset Scale: 1
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Core
3. Multi-select both 3D Cross Sections within FiberSIM, hide the FiberSIM Geometry geometric set, and show the PartBody. The model displays as shown in Figure 761.
Figure 761 4. Zoom in on the cross-section and verify whether the laminate thickness, etc., matches the original solid model as shown in Figure 762.
Figure 762 Task 7 - Create flat patterns for the undercore and overcore plies. 1. Run Net Producibility (set the Fiber Spacing Factor as [0.2]) and create a Net Flat Pattern for the P001 ply. 2. Run Net Producibility (set the Fiber Spacing Factor as [0.2]) and create a Net Flat Pattern for the P009 ply.
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FiberSIM 2010 CEE
3. In the FiberSIM window, highlight plies P001 and P009. Examine the differences in the flat patterns for the undercore (P001) and overcore (P009) plies as shown in Figure 763. NET_FP_P001 NET_FP_P009
Figure 763 4. Close FiberSIM and save the CATIA model.
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Chapter 8
Documentation
This chapter introduces:
Exercise 8a: 3D Documentation Exercise 8b: Generating a Ply Book and Ply Table
81
Documentation
Exercise 8a
User Guide Reference: 1.5 Documentation 5.1 Introduction 5.2 3D Cross Section 5.3 Explode Laminate 5.5 3D Text Annotations
3D Documentation
In this exercise, you will use the Documentation tools available in FiberSIM to create 3D cross-sections and annotations, and to generate an exploded view of the ply stack-up. The completed model displays as shown in Figure 81.
Figure 81
Goal
Generate and update 3D cross-sections Explode the ply stack-up of a selected laminate using the Explode Laminate tool Create a core sample annotation Create a ply table annotation Create a ply callout Create a material table
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FiberSIM 2010 CEE
Task 1 - Review the model. 1. Open FS2010_CEE_DESIGN_AND_DOC_A.CATPart. The model displays as shown in Figure 82. The model and much of the FiberSIM data have already been completed. This exercise will focus on the documentation tools of FiberSIM.
Figure 82 2. Show the Cross Section Curves and Core Geometry geometric sets, as shown in Figure 83. These curves determine where on the Tool Surface the cross-section will be created. The curves have been created on the Tool Surface. The Tool Surface is the skin for the Hood laminate on which the cross-section will be generated.
Figure 83 3. Hide the Cross Section Curves geometric set.
84
Documentation
Task 2 - Generate 3D Cross Section. In this task, you will create two 3D cross-sections. 3D cross-sections enable you to visually inspect the laminate stack and help in the manufacturing of the composite part. 1. Click (FiberSIM).
2. In the Documentation menu, select 3D Cross Section. 3. Click (Create New).
4. Specify the following parameters as shown in Figure 84: The Cross Section Curve determines where on the Tool Surface the cross-section will be created. Laminate: Hood Cross Section Curve: Cross Section 1 (from the Cross Section Curves geometric set) Ply/Layer Offset Scale: 10
Figure 84 5. Click (Generates the 3D cross section) and click .
6. Review the 3D Cross Section curves generated on the model. The Cross Section tool adds color to the cross-section curves based on ply orientations for each material. 7. Click (Create New).
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FiberSIM 2010 CEE
8. Create a second cross-section using the following parameters: Laminate: Hood Cross Section Curve: Cross Section 2 Ply/Layer Offset Scale: 10 Boundary Type: Extended Profile Type: Rectangle (Generates the 3D cross section) and click .
9. Click
10. Review the 3D Cross Section curves generated on the model, as shown in Figure 85.
Figure 85 In this task, you created the cross-section as display geometry. To display the cross-section you must select it in FiberSIM. If you want to create the cross-sections as actual CAD Geometry, select the Create Cross Section Geometry option in the create 3D Cross Section dialog box. Task 3 - Re-sequence the plies in the Hood laminate and update 3D cross sections. 1. In the CEE menu, select Ply. 2. Click (Composite Sequence Manager).
3. In the Laminate drop-down list, select Hood.
86
Documentation
4. In the list of objects, select P009 and drag it under Overcore 2, as shown in Figure 86.
Figure 86 5. Drag and drop the plies as described in 5. and shown in Figure 87:
Ply P013 P010 P014 P011 P015 P012 P016 Place after: P009 P005 P010 P006 P011 P007 P012
Table 81
Figure 87
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FiberSIM 2010 CEE
6. Click
7. In the Documentation menu, select 3D Cross Section. Both Cross Sections are Out-of-date. 8. Press <Ctrl> and select both CrossSection002 and CrossSection001. The out-of-date cross-sections display on the model. 9. Zoom in on the cross-section at the location shown in Figure 88. Zoom in to this area so that you can see the Ply names for the blue curves
Figure 88 10. Activate the FiberSIM window. 11. Move the FiberSIM window so that the highlighted cross-section displays in the CAD window. 12. With both cross-sections highlighted, click (Generates the 3D cross section). The cross-sections update to reflect the changes made to the stackup. 13. Close the FiberSIM window. Task 4 - Create a Core Sample annotation. In this task you will create a core sample annotation. Core Sample annotations enable you to display design station results in a 3D text object. Since Design Stations have not been created in the model, you will also need to create one on-the-fly. The model used in this exercise already contains annotations. To create a FiberSIM annotation, you must first create an annotation in the 3D model to be populated with the FiberSIM data.
88
Documentation
1. Hide the FiberSIM Exploded Laminate and Core Geometry geometric sets. 2. In the FiberSIM Geometry geometric set, show the Design Station Origin. 3. Show Annotation Set.1, as shown in Figure 89.
Figure 89
4. Click
(FiberSIM).
5. In the Documentation > Annotations menu, select Core Sample. 6. Click (Create New).
7. Next to the Design Station field, click (Link with Link Dialog) to open the FiberSIM - link Design Station via Design Station dialog box. 8. In the CEE menu, select Design Station. You can also right-click in the main FiberSIM window and select Create New with Geometry selection. 9. Click (Create New with Geometry Selection). .
10. Select Design Station Origin and click
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FiberSIM 2010 CEE
11. In the Laminate drop-down list, select Hood. 12. In the Rosette drop-down list, select ROS001. 13. Click (Core Sample). In the message window, click . 14. Click to save the Design Station definition.
15. Ensure that the DS001 design station that was just created is linked and click An annotation must already be created in the model. to link this station to the Core Sample. (Link Geometry).
16. Next to the Annotation Leader* field, click
17. In the specification tree, select the Core Sample note and click . 18. The FiberSIM window re-activates. Mouse over the CATIA window again to update the note, as shown in Figure 810.
Figure 810 19. Click to save the Core Sample note.
20. Close the FiberSIM application. 21. If necessary, resize and reposition the note in the CATIA model to better format the text.
810
Documentation
Task 5 - Create a Ply Table annotation. In this task, you will create an annotation that will display ply and core information on the Hood laminate in a pre-existing 3D text annotation. 1. Click (FiberSIM).
2. In the Documentation > Annotations menu, select Ply Table. 3. Click (Create New).
4. In the Laminate drop-down list, select Hood. 5. Link the Annotation Leader* to the Ply Table annotation. The model updates as shown in Figure 811. If the Status of the Ply Table is Out-of-date, click (Generates the ply table).
Figure 811 6. Click to save the Ply Table annotation.
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FiberSIM 2010 CEE
Task 6 - Create a Ply Callout annotation. In this task, you will create an annotation that will display all of the ply and core objects at a specified point on the Hood laminate. 1. Activate the model. 2. In the FiberSIM Geometry geometric set, show the Ply Callout Origin. 3. Activate FiberSIM. 4. In the Documentation > Annotations menu, select Ply Callout. 5. Click (Create New).
6. In the Laminate drop-down list, select Hood. The callout point and annotation leader must already exist in the model. 7. Link the following geometry: Annotation Leader: Ply Callout Callout Point: Ply Callout Origin 8. Click (Generates the callout). In the message window, click . The model updates as shown in Figure 812.
Figure 812 9. Click to save the Ply Callout annotation.
Task 7 - Create a Material Table annotation. In this task, you will create an annotation to display all of the materials used in a given laminate(s). 1. Ensure that FiberSIM is active.
812
Documentation
2. In the Documentation > Annotations menu, select Material Table. 3. Click (Create New).
4. Next to the Laminates field, click (Link with Link Dialog) to open the FiberSIM - link Laminate via Laminates dialog box. 5. Press <Ctrl> + <A> to select all three laminates. You can also right-click on one of the highlighted laminates and select Link or press <Ctrl> + <L>. 6. Click 7. Click (Link). .
8. Link the Annotation Leader* to the Material Table annotation. The model updates as shown in Figure 813.
Figure 813 9. Click 10. Close FiberSIM. 11. Save the model. to save the Material Table annotation.
813
FiberSIM 2010 CEE
Exercise 8b
User Guide Reference: 5.4 Flat Pattern Layout 5.6.1 Ply Book 5.6.2 Ply Table
Generating a Ply Book and Ply Table

In this exercise, you will generate a 2D drawing of a composite part. 2D drawings are useful as a method of passing on the necessary information for the manufacturing the part. A sheet from the ply book that is generated in the drawing is shown in Figure 814.
Figure 814
Goal
Generate a Flat Pattern Layout Create a Ply Book Create a Ply Table
Task 1 - Open a part. 1. Select File > Open and select FS2010_CEE_DESIGN_AND_ DOC_B.CATPart.
814
Documentation
If you completed Exercise 8a, you can continue working with FS2010_CEE_DESIGN_AND_DOC_A.CATPart instead. The model displays as shown in Figure 815.
Figure 815 2. For Clarity, hide Annotation Set.1. Task 2 - Create a Flat Pattern layout. In this task, you will use the flat pattern layout utility to manipulate how the flat patterns display in the CAD window. 1. Click (FiberSIM).
2. In the CEE menu, select Ply. 3. Press <Ctrl> + <A> to select all of the plies. You can also right-click on one of the highlighted plies and select Modify or press <Enter>. 4. Click 5. Click (Modify). . .
6. In the Fiber Spacing Factor field, enter [0.3], and click 7. Click (Net Producibility). In the message window, click . 8. Click
(Generates the Net Flat Pattern).

815
FiberSIM 2010 CEE
to save the plies. The model displays as shown in
Figure 816 Flat patterns need to be created before the flat pattern layout utility is used. You can also find Flat Pattern Layout in the Documentation menu in the Application Tree. 10. In the ply list, highlight all of the plies by pressing <Ctrl> + <A>. 11. In the ply toolbar, click (Flat Pattern Layout).
12. Enter the following parameters, as shown in Figure 817: Grid Origin Y: -25 in (-635 mm) Cell Width: 50 in (1270 mm) Cell Height: 50 in (1270 mm) Row Direction: -Y Column Direction: X

816
.
Documentation
14. Click
. The model displays as shown in Figure 818.
Figure 818 Task 3 - Prepare a drawing for ply book insertion. In this task, you will add two views to an existing drawing. These views will be associated with the flat pattern and boundary diagrams in FiberSIM in the next task. In the drawing, the tables, frame, and title block have already been created. 1. Open FS2010_CEE_DESIGN_AND_DOC_B_ANSI.CATDrawing. 2. Ensure that the Plybook Template sheet is active. 3. Click (New View).
817
FiberSIM 2010 CEE
4. Place the view as shown in Figure 819.
Figure 819 5. Right-click on the border of the view and select Properties. 6. In the Scale field, enter [1:10], and click 7. Click (Isometric View). .
8. Orient the Isometric view as shown in Figure 820, and select any planar surface on the model.
Figure 820 9. Click in the drawing to place the view.
818
Documentation
10. Change the scale of the Isometric view to [1:10] and place the view as shown in Figure 821.
Figure 821 Task 4 - Generate the Ply Book.
1. Click
(FiberSIM).
2. In the Documentation > Drawing Sheets menu, select Ply Book. To create a new Ply Book you must have activated FiberSIM from the drawing. 3. Click (Create New).
4. In the Laminate drop-down list, select Hood. 5. Next to Source Objects field, click (Link with Link Dialog).
6. Press <Ctrl> + <A> to select everything. You can also right-click on one of the highlighted laminates and select Link. 7. Click 8. Click (Link). . (Link Geometry).
9. Next to the Template Sheet field, click
819
FiberSIM 2010 CEE
10. Select the border of the Plybook Template sheet in the drawing, as shown in Figure 822, and click .
Figure 822 11. Select the Text Setup tab. 12. In the dialog box, in the Text Associations area, click New with Geometry Selection). (Create
13. Select the following text in the drawing, as shown in Figure 823: a. b. c. d. e. f. g. A 10 P001 000 PPG-8H-3K FIBERSIM 123-456-ABC
f g
b c d e Figure 823
820
Documentation
14. Click
15. In the Text.Seq row, expand the Source Member drop-down list and select Sequence, as shown in Figure 824.
Figure 824 16. Enter the remaining Text Links as shown in Figure 825: Text.Step: Step Text.Name: Name Text.Orient: Orientation Text.Material: Material Plybook_Text_Description: Laminate Name Plybook_Text_PartNumber: Laminate Part Number
Figure 825 17. Select the Diagram Setup tab.
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FiberSIM 2010 CEE
18. In the Flat Pattern Views window, select the Ply Book object type as shown in Figure 826.
Figure 826 19. Click (Create New with Geometry Selection) and select Flat Pattern Diagram. 20. In the drawing, select the Front view and click 21. Click . .
22. In the Boundary Views window, select the Ply Book object type. 23. Click (Create New with Geometry Selection) and select Boundary Diagram. Multiple flat pattern views can be created on one page if required. In this case, all ply boundaries will display in one boundary view. 24. In the drawing, select the Isometric view and click 25. Click Figure 827. .
. The Diagram Setup tab displays as shown in
Figure 827
822
Documentation
26. Click
(Generates the sheets for the ply book).
27. Click . When you generate the Ply book, some of the sheets generate an error. These sheets are views of the core. Since cores do not have a flat pattern associated with them, the flat pattern view cannot be generated. 28. Click .
29. Close FiberSIM, activate the Drawing window, and review the drawing sheets. Task 5 - Create a Ply Table. 1. Select the Ply Table template sheet in the drawing. 2. Click (FiberSIM).
3. In the Documentation > Drawing Sheets menu, select Ply Table. 4. Click (Create New).
5. In the Laminate drop-down list, select Hood. 6. Next to Source Objects field, click (Link with Link Dialog).
7. Press <Ctrl> + <A> to select everything. You can also right-click on one of the highlighted laminates and select Link. 8. Click 9. Click (Link). . (Link Geometry).
10. Next to the Template Sheet field, click
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FiberSIM 2010 CEE
11. Activate the Ply Table Template sheet of the drawing and select the border of the drawing, as shown in Figure 828.
13. Select the Table Setup tab. 14. In the Table Associations area as shown in Figure 829, click (Create New with Geometry Selection).
Click icon in the Table Associations area in the dialog box
Figure 829
824
Documentation
15. In the Ply Table Template sheet of the drawing, select the table as shown in Figure 830, and click .
Select this table
Figure 830 16. In the Table.1 row, click as shown in Figure 831.
Figure 831 17. Double-click on the PLY # row to modify it. 18. In the Data Field drop-down list, select Name and click . 19. Repeat Steps 17 and 18 for each of the other rows, as shown in Figure 832.
Figure 832
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FiberSIM 2010 CEE
20. Click to close the FiberSIM - link Table Column via Define Columns dialog box. 21. Click 22. Click 23. Click . (Updates or generates the sheets). in the message window.
24. Activate the drawing. The last sheet of the drawing contains the Ply Table that was created, as shown in Figure 833.
Figure 833 25. Close FiberSIM. 26. Save and close the drawing and model.
826
Chapter 9
Model Interrogation
This class includes:
Exercise 9a: Model Interrogation
91
Model Interrogation
Exercise 9a
User Guide Reference: B.2.1 Design Checker
Model Interrogation
CEE provides you with the capability of customizing your display by adding columns and by grouping, sorting, and highlighting. After you complete this exercise, you will be able to:
Goal
Add, Sort, and Move Columns Use Find to filter a list Select a default Group and create a Group Select a default Sort and create a Sort Investigate a Highlight Type Reset display settings Run Design Checker - Geometry Check Run Design Checker - Design Check Use Ply Table - HTML to create a Composite Part Ply Table
Task 1 - Open Part. 1. Open FS2010_CEE_ADVANCED_TECHNIQUES_B.CATPart. The model displays as shown in Figure 91.
Figure 91
93
FiberSIM 2010 CEE
Task 2 - Add, Sort, and Move Columns.
1. Click
(FiberSIM).
2. In the CEE menu, select Ply as shown in Figure 92.
Figure 92 3. Select the Step column heading to sort the column in ascending order as shown in Figure 93.
Figure 93
94
Model Interrogation
By default, the Origin details are displayed when you select the Net Geometry tab.
4. Right-click on any column heading and select Origin to display the Origin details, as shown in Figure 94. The Origin column is inserted as the furthest right column and displays within the Standard tab.
Figure 94 5. Drag the Origin column next to the Step column as shown in Figure 95.
Figure 95
95
FiberSIM 2010 CEE
6. Select the Origin column to sort the column in ascending order as shown in Figure 96.
Figure 96 Task 3 - Use Find to filter a list. 7. In the Find field, enter [P010] as shown in Figure 97.
Figure 97 You can also click (Find) to execute the command. 8. Press <Enter> to execute the command. 9. The find results for P010 display as shown in Figure 98.
Figure 98 The Find operation works on the current list of objects. 10. In the bottom right corner of window, the status indicates the number of objects that are selected, shown, and available as shown in Figure 99.
Figure 99
96
Model Interrogation
11. In the Object Details panel, right-click and select Show Available as shown in Figure 910.
Figure 910 12. All 10 plies reappear and the display status updates as shown in Figure 911.
Figure 911 Task 4 - Select a default Group and create a Group. 1. In the Group drop-down list, select Parent as shown in Figure 912.
Figure 912
97
FiberSIM 2010 CEE
2. The display updates with the two parent laminates, each with a total quantity of plies as shown in Figure 913.
Figure 913 3. In the Group drop-down list, select None to clear the grouping. 4. Click (Edit Groups). (Create Group).
5. In the Group field, enter [Function] and click
6. In the 1st Member drop-down list, select Function as shown in Figure 914.
8. Select the Details tab in which the Function column is located.
98
Model Interrogation
9. In the Group field, expand the drop-down list and select Function as shown in Figure 915.
Figure 915 10. The results of the new group are displayed as shown in Figure 916.
Figure 916 11. Select the Standard tab. In the Group drop-down list, select None to clear the grouping.
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FiberSIM 2010 CEE
Task 5 - Select a default Sort and create a Sort. 1. In the Sort pull-down list, select Sequence, Step and Name. 2. The display updates with the compound sort as shown in Figure 917.
Figure 917 3. Click (Edit Sorts). (Create
4. In the Sort field, enter [Function, Name], and click Sort).
5. In the 1st Member drop-down list, select Function and in the 2nd Member drop-down list, select Name as shown in Figure 918.
Figure 918
910
Model Interrogation
6. Click
7. In the Sort drop-down list, select Function, Name as shown in Figure 919.
Figure 919 8. The sort results display as shown in Figure 920. P005 and P006 are at the top because they have a function of Pad-Up. The other plies are defined as Structural. Confirm by selecting the Details tab in which the Function details are located.
Figure 920 9. In the Sort drop-down list, select None to clear the sorting. Task 6 - Investigate the Highlight Type. List only displays the highlighting that is available for the current object. 1. Select P005 and click (Highlight Type - Net Boundary).
2. Note the selected Net Boundary option as shown in Figure 921.
Figure 921
FiberSIM 2010 CEE
3. Note that this current option also displays in the Highlight Type tooltip description as shown in Figure 922.
Figure 922 4. Switch to the CATIA window and note that the Net Boundary is highlighted in red as shown in Figure 923.
Figure 923 5. Click (Net Producibility).
6. Click (Highlight Type - Net Boundary) and note that Net Simulation has automatically been selected. The display updates with the Net Boundary highlighted in red and the Net Simulation displayed as shown in Figure 924.
Figure 924
912
Model Interrogation
Each object type has its own set of highlight types. For example, only the ply object has the simulation displays.
7. Click (Highlight Type - Net Boundary - Net Simulation) and select the Net Shading option. The display updates as shown in Figure 925.
Figure 925 8. Set the Highlight Type back to Net Boundary only. Task 7 - Reset display settings back to default. In this task, you will reset your display settings back to the default settings. 1. Select Tools > Options > EnCapta Options as shown in Figure 926.
Figure 926 2. Select the Appearance tab. 3. Click .
913
FiberSIM 2010 CEE
4. Click You will need to restart CATIA and FiberSIM for the default settings to take effect. 5. Click .
when prompted to delete all user settings.
Task 8 - Run Design Checker - Geometry Check. 1. Click (Design Checker).
2. The FiberSIM - Design Checker dialog box opens as shown in Figure 926.
Figure 927 3. Ensure that the Geometry tab is selected and click .
914
Model Interrogation
4. A window opens prompting you that problems have been detected as shown in Figure 928.
6. The Geometry Report displays as shown in Figure 929.
Figure 929
915
FiberSIM 2010 CEE
Task 9 - Fix Geometry Check Errors. 1. In the Geometry Report, in the P006 area, select the Net Boundary link to open the P006 ply details in a new window as shown in Figure 930.
Figure 930 2. Note the Boundary link to Curve.43. On investigation, you find that Curve.43 is not on the Layup surface as Design Checker stated and that OC1 LH Reinforcement Boundary is the correct boundary. Link OC1 LH Reinforcement Boundary to Boundary and click to save the changes. 3. Click again and display the Geometry Report that no longer indicates a problem with P006. 4. For the issue with P005, in the specification tree, display Project.5 and note that a curve displays as shown in Figure 931. This will require further investigation.
Figure 931 5. Click FiberSIM. in the FiberSIM Design Checker window and exit
916
Model Interrogation
6. On investigation of the Definition of Project.5 you see that it is a projection of Sketch.17 as shown in Figure 932.
Figure 932 7. Edit Sketch.17 and delete the extra curve as shown in Figure 933. Delete this line
Figure 933
8. Click
(FiberSIM).
917
FiberSIM 2010 CEE
9. Click (Design Checker) and click again to open the message window prompting you that no problems were detected as shown in Figure 934.
Task 10 - Run Design Checker - Design Check. 1. Select the Design tab. 2. Click . A window displays prompting you that problems were detected and to display the Design Report. Click .
918
Model Interrogation
3. The Design Report opens as shown in Figure 935.
Figure 935 4. Note the Flat Pattern out-of-date messages for P005, P006, P008, and P009. There are also two material width exceeded messages for P007 and P010. 5. Click .
6. To address the Flat Pattern message, highlight plies P005, P006, P008, and P009 and click 7. Click (Net Flat Pattern). (Net Producibility).
8. Click (Design Checker) and click to open the message window prompting you that there are still two material width exceeded messages for P007 and P010 but there are no longer any Flat Pattern out-of-date messages.
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FiberSIM 2010 CEE
9. You decide that the material width exceeded messages can be handled by creating splices. However, for the purposes of this exercise, this step is optional and can be performed if sufficient time is available. Task 11 - Use Ply Table - HTML to create a Composite Part Ply Table. 1. Select Action > Ply Table - HTML as shown in Figure 936.
Figure 936 2. The HTML Composite Part Ply Table displays as shown in Figure 937.
Figure 937
920
Project 2
Core Panel
Exercise P2: Core Panel
P21
Core Panel
Exercise P2
User Guide Reference: 2.9 Cores 2.5 Flat Pattern/ Producibility Simulation B.3.7 Splice Ply
Core Panel
In this project, you will use both plies and modeled cores to complete a layup scenario. The completed model displaying the four cores is shown in Figure P21.
Core 3
Core 4 (in behind)
Core 1
Core 2
Figure P21
Goal
After you complete this project, you will be able to:
Create Ply and Modeled Core objects Define the Overcore laminate Run Net Producibility Splice plies to address material width producibility problem Create a Net Flat Pattern
P23
FiberSIM 2010 CEE
Given
The existing geometry and design details are:
Net and Extended Boundaries have been created OML laminate has been created Rosette geometry has been created Core CAD geometry has been created Overcore CAD geometry has been created
Task 1 - Open a part. 1. Open FS2010_CEE_PROJECT2_CORE.CATPart. The model displays as shown in Figure P22.
Figure P22
P24
Core Panel
Task 2 - Review the FiberSIM geometry. 1. The existing OML and Overcore geometry is displayed in the FiberSIM Geometry geometric set, as shown in Figure P23.
Figure P23 Task 3 - Create Ply and Core objects 1. The ply details on the OML surface are: Four full plies with a material of PPG-PL-3K Two adhesif plies with a material of Film-Adhsv 2. The Core material details are: Core 1: Honeycomb Core 2: Foam-3.1 Core 3: Honeycomb Core 4: Foam-3.1
P25
FiberSIM 2010 CEE
Task 4 - Cross section details 1. The cross section for Core 1 is shown in Figure P24.
Figure P24 2. The cross section for Core 2 and 4 is shown in Figure P25.
Figure P25 3. The cross section for Core 3 is shown in Figure P26.
Figure P26
P26 2011 VISTAGY, Inc. - Engineer Success
Core Panel
Task 5 - Define the Overcore laminate. Create the Overcore laminate using the Overcore CAD geometry. Task 6 - Create four plies on the Overcore surface. Create two adhesif plies and four full plies on the Overcore surface. Task 7 - Confirm layup. Create cross sections using the provided CAD geometry to confirm that the layup matches the design requirements. Task 8 - Run Net Producibility. Run Net Producibility on all of the plies and address any material width issues by splicing. Task 9 - Run Net Producibility and create Net Flat Pattern. When there are no longer any producibility issues, create the Net Flat Pattern.
P27

FiberSIM 2010 CEE R1

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FiberSIM 2010 CEE R1

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