Method and system for modeling and manufacturing composite parts

Abstract

A method for modeling a composite part is provided. The method includes accessing a model in a modeling system, where the model includes a representation of selected layers forming the composite part, and the selected layers include one or more composite fabric material plies. The method includes simulating a manufacturing process for the selected layers based on the model. The method also includes, for each ply in the selected layers, evaluating simulation data from the simulated manufacturing process to quantitatively determine a deviation of the manufactured ply in the selected layers from the model, identifying a set of regions of the ply in the model based on the deviation, and automatically modifying the model based on the identified set of regions prior to manufacturing the composite part.

Description

Technical Field

[0001] This disclosure relates to methods and systems for computer-aided design and manufacturing, and more particularly, to the design and manufacturing of composite components. Background Technology

[0002] Composite components combine sheets of composite fabric material, where the fabric material is selected based on weight, strength, flexibility, or other physical properties. During the manufacturing process, defects can form in the layers of the composite component. These defects can have a variety of causes, including excessive or insufficient tension, folding during manufacturing, or excessive shearing of the material.

[0003] To keep these defects within acceptable limits, modifications can be made to individual fabric sheets or layers. One type of modification involves the manufacturer introducing cuts into the material sheet to break the composite fibers in the defective areas. These cuts (which may be called material-saving cuts) can take the form of a single cut or multiple cuts to remove small areas from the material. This allows the fabric to be applied more easily to the manufacturing surface and to conform more closely to the intended design.

[0004] Determining the shape and location of cuts is crucial for manufacturing-oriented design processes because without these cuts, many designs cannot be created on a three-dimensional surface within the expected tolerances for strength, flexibility, and other physical parameters.

[0005] Current methods for determining the location of notches have many limitations. For example, manufacturers may manually determine the location during manufacturing. Unfortunately, the resulting product may deviate significantly from the designer's original intent, and precise notch placement may not be repeatable. Manual placement relies on the manufacturer's subjective judgment, skill, and experience. Additionally, due to the manual nature of the process, any errors or iterations during notch placement are costly in terms of time, labor, and materials.

[0006] To address some of these drawbacks, designers can use software to simulate what the manufactured part will look like based on their current design before it is sent for manufacturing, including the effects of cuts. However, even with such simulations, designers still need to manually review the initial simulation results, which show how the composite fabric sheet deviates when placed onto the manufacturing surface. Designers then need to determine which areas are unacceptable and decide what cuts to apply, including location, shape, and orientation, to mitigate these unacceptable conditions. Each cut is decided individually, which can make the process both time-consuming and labor-intensive for designers. Therefore, automation is needed for the process of determining how and where to make cuts based on given simulation results. Summary of the Invention

[0007] This embodiment can overcome one or more disadvantages or limitations in related technologies. For example, a method for improving the manufacturability of composite components is provided.

[0008] The above and other objectives are achieved through the features of the independent claims. Further implementations are apparent from the dependent claims, the specification, and the drawings.

[0009] According to a first aspect, a computer-implemented method for modeling a composite component is provided. The method includes accessing a model in a modeling system, the model including representations of selected layers from one or more layers forming the composite component. The selected layers include one or more layups of composite fabric material. The method includes simulating a manufacturing process based on the model for the selected layers. The method includes: for each layup in the selected layers, evaluating simulation data from the manufacturing process simulation to quantitatively determine the deviation between the manufactured layup in the selected layers and the model; identifying a set of regions of the layup in the model based on the deviation; and automatically modifying the model based on the identified set of regions before manufacturing the composite component.

[0010] The method described in the first aspect improves the manufacturability of composite components by simulating the manufacturing process and automatically modifying the component design based on the simulation results. This provides time and cost savings during manufacturing, improves the consistency of the composite component manufacturing process, and reduces the workload for designers and manufacturers.

[0011] According to the first aspect, in a first implementation of the method, the simulation data includes data specifying the following: in-plane deformation at each point of the simulation, fiber wrinkling and bridging, deviation from the expected fiber direction, or any combination thereof.

[0012] The first implementation provides data related to defects that occur during the manufacturing of the selected layer, thereby enabling the identification of areas that may require modification.

[0013] In the second implementation, evaluating the simulation data includes deriving error values ​​for each point of the selected layer being manufactured, based on the simulation data.

[0014] In the third implementation, the determined set of regions includes one or more consecutive regions of identified points, wherein for each point in the consecutive regions, the error value exceeds a predefined threshold value.

[0015] The third implementation allows for the identification of areas where the deviation between the manufacturing layer and the intended design exceeds the acceptable tolerance level.

[0016] In the fourth implementation, evaluating the simulation data includes evaluating a predefined set of conditions, each condition in the predefined set of conditions corresponding to one or more data types in the simulation data, and specifying a range of threshold values ​​for each of the one or more data types.

[0017] In the fifth implementation, the determined set of identified regions includes one or more consecutive regions of identified points, wherein for a point in each of the one or more regions, at least one of the predefined conditions is not met.

[0018] The fifth implementation identifies the region where the deviation of one or more measured quantities from the simulation data exceeds the acceptable tolerance level.

[0019] In the sixth implementation, the set of regions in the identification model includes a first region identified by a deviation and a second region that is discontinuous with the first region, a continuous region is formed based on the first region and the second region, and the continuous region is included in the set of regions.

[0020] The method of the sixth implementation connects, for example, discontinuous regions that may be very close together, and treats the resulting connected region as a single continuous region.

[0021] In the seventh implementation, automatically modifying the model before manufacturing the composite part includes: for each of the one or more regions, automatically identifying one or more curves within that region based on a predefined curve identification strategy, and forming cuts based on the one or more curves.

[0022] The seventh implementation automatically determines the location and shape of modifications based on a predefined strategy. This further improves the design and manufacturing process for composite parts.

[0023] In the eighth implementation, the method according to the first aspect further includes iteratively repeating the steps of the method until the allowable deviation condition is met.

[0024] According to the method of the eighth implementation, after applying the modifications, the manufactured layer is re-simulated to determine whether further modifications are needed, and the modifications are continued to be applied until all areas of the layer are within the allowable deviation range.

[0025] In the ninth implementation, each cut is a slit or a V-shaped cut.

[0026] In the tenth implementation, identifying one or more curves also includes translating the identified one or more curves based on the location of cuts in layers adjacent to the selected layer.

[0027] The method according to the tenth implementation improves the structural integrity of the manufactured composite component by taking into account the cuts in adjacent layers when considering the position of the cuts in the selected layer.

[0028] In the eleventh implementation, the method includes applying a manufacturing process to manufacture selected layers of the composite component based on the model.

[0029] These and other aspects of the invention will become apparent from the embodiments described below. Attached Figure Description

[0030] To gain a more complete understanding of this disclosure and its advantages, reference is now made to the following description in conjunction with the accompanying drawings, wherein:

[0031] Figure 1 This is a flowchart illustrating a method for modeling composite components, based on an example.

[0032] Figure 2 A simulated perspective view of the layers in a composite component according to an example is shown;

[0033] Figure 3A The diagram shows Figure 2 High deformation region in simulation;

[0034] Figure 3B The diagram illustrates what is applied to Figure 2 The first example of the simulation method of this disclosure;

[0035] Figure 3C The diagram illustrates what is applied to Figure 2 A second example of the simulation method of this disclosure;

[0036] Figure 3D The diagram illustrates what is applied to Figure 2 A third example of the simulation method of this disclosure;

[0037] Figure 3E The diagram illustrates what is applied to Figure 2 The fourth example of the simulation method of this disclosure;

[0038] Figure 4 Examples of data processing systems in which embodiments of the present disclosure may be implemented, such as CAD systems configured to perform the processes described herein, are illustrated. Detailed Implementation

[0039] Example embodiments are described below in sufficient detail to enable those skilled in the art to implement and carry out the systems and processes described herein. Embodiments may be provided in various alternative forms and should not be construed as limited to the examples set forth herein.

[0040] While embodiments may be modified in various ways and take various alternative forms, specific embodiments thereof are shown by way of example in the accompanying drawings and are described in detail below. The invention is not intended to be limited to the specific forms disclosed. Rather, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Throughout the drawings and detailed description, elements of the exemplary embodiments are consistently designated by the same reference numerals where appropriate.

[0041] The terminology used in this document to describe embodiments is not intended to be limiting. The articles “a,” “an,” and “the” are in the singular form because they refer to a single object; however, the use of the singular form in this document should not preclude the possibility that there may be more than one object referred to. In other words, unless the context clearly indicates otherwise, an element referred to in the singular form may be one or more. It will also be understood that the terms “comprise,” “comprising,” “containing,” and / or “having” as used herein specify the presence of the said feature, item, step, operation, element, and / or component, but do not preclude the presence or addition of one or more other features, items, steps, operations, elements, components, and / or groups thereof.

[0042] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall be interpreted in accordance with the conventions of the field. Common terms shall also be interpreted in accordance with the conventions of the relevant field, rather than in an idealized or overly formal sense, unless explicitly defined herein.

[0043] Figure 1 This is a block diagram of a method 100 for modeling composite components. Method 100 can be implemented in a modeling system such as a computer-aided design (CAD) or computer-aided engineering (CAE) system. CAD systems enable the creation, modification, and analysis of designs for manufacturing. CAE systems incorporate simulation tools to test, verify, and optimize designs. CAD and CAE software are used across many industries, including architecture, engineering, manufacturing, and product design. Many CAD and CAE systems include software packages and tools for designing and analyzing advanced composite components.

[0044] In box 110, method 100 includes access to a model that includes a representation of a selected layer from one or more layers forming the composite part. In the example described herein, the layers are formed by layups of one or more composite fabric materials. A layup is a sheet of composite fabric material that can be cut from a larger sheet of fabric material. The composite part can be formed using a lamination process, wherein the layup is laid onto a die or lamination surface in the desired shape of the part. Multiple layups may be required to completely cover the lamination surface. Other layers are built on top of the previous layers in a similar manner to achieve the desired material thickness.

[0045] The model of the selected layer can be retrieved from memory or storage devices on the computing system, or accessed from remote devices or data storage devices. The model of the selected layer can be visualized in a graphical user interface (GUI) on the computing system implementing the CAD / CAE software. Users can interact with the CAD / CAE software through the GUI to select individual elements of the model, manipulate the model, and perform operations using the CAD / CAE software. The model of the selected layer can be a part of a larger model representing a composite component. Users can select different layers through the GUI and access data associated with each layer of the composite component.

[0046] In box 120, method 100 includes simulating a manufacturing process for the selected layers based on the model. Manufacturing processes such as the previously described lamination processes can be simulated using tools available in CAD / CAE. The simulation can provide simulation data for each layup of the simulated manufacturing layers. The simulation data can include data specifying various defects occurring at various points on the layup during the manufacturing process. For example, the simulation data can specify in-plane shear and deformation, fiber wrinkling and bridging, and deviations from the expected fiber orientation.

[0047] Figure 2 A perspective view of a simulated manufacturing layer 200 of a composite component according to an example is shown. Figure 2 In the simulation shown, different regions of the fabrication layer 200 exhibit varying degrees of deformation. For example, regions 210 and 220 represent the areas of maximum deformation for the fabrication layer 200. In contrast, region 230 exhibits a lower degree of deformation.

[0048] In box 130, the method includes: evaluating simulation data from a simulated manufacturing process for each ply in the selected layers to quantitatively determine the deviation of the manufactured ply in the selected layers from the model of the selected layers. In one example, a single error value can be generated for each point in the simulated layer to represent the deviation at that point. The error value can be derived from the simulation data values. A check can then be performed to determine whether the error value is less than a predefined threshold value representing the maximum acceptable deviation from the expected design. In another example, the simulation data values ​​for each point can be checked against a predefined set of conditions, where each condition relates to one or more data types in the simulation data. These conditions can specify threshold values ​​representing the acceptable range for each of the one or more data types.

[0049] In box 140, method 100 includes: for each ply, identifying a set of regions for that ply based on deviation. This set of regions may include consecutive regions within the ply where points do not meet predefined conditions associated with simulation data or where error values ​​exceed predefined threshold values. For example, refer to... Figure 3A It shows the same as Figure 2 For the same simulated fabrication layer 200, due to the high deformation levels of regions 301 and 302, regions 301 and 302 can be identified as continuous regions of the layer that deviate from the intended design. In some cases, if two or more regions of a layup are not connected but are very close to each other, these regions can be merged and treated as a single continuous region.

[0050] In box 150, method 100 includes: automatically modifying the model based on the identified set of regions before manufacturing the composite part. The model can be modified by forming cutouts in each region. The locations of the cutouts can be determined by identifying curves on the layer, the locations of which can be determined using a predefined curve identification strategy. In some examples, different curve identification strategies can be presented to the user, who can apply these strategies via a GUI to a given layer, ply, or ply region. In other cases, the curve identification strategy can be pre-selected for the user.

[0051] Figure 3B It is shown that... Figure 2 The perspective view of the same layer 200 is shown. Figure 3B An example of a curve labeling strategy is illustrated. Figure 3B In this context, points 311 and 312 are the points in regions 301 and 302 that are farthest from the modeling layer boundary 313. Curves 314 and 315 are identified in each region of 301 and 302, extending from points 311 and 312 to points 316 and 317 on the boundary 313. Points 316 and 317 can be the points on the boundary 313 that are closest to points 311 and 312.

[0052] Figure 3C A second example of a curve identification strategy applied to layer 200 is shown. Figure 3C In the diagram, points 321 and 322 correspond to the highest deformation points in regions 301 and 302, respectively. Curves 323 and 324 move away from points 321 and 323, respectively, towards boundary 313 and the points in regions 301 and 302. Figure 3B The points 311 and 312 depicted extend from opposite edges.

[0053] Figure 3D A third example of a curve identification strategy applied to layer 200 is shown. In some cases, the identified curves and corresponding cuts can extend beyond the boundaries of the identified area. Figure 3D In the middle, points 331 and 332 correspond to the closest points on boundary 313. Figure 3C The points 321 and 322 are the points of maximum deformation. Curves 333 and 334 pass through points 331, 332, 321, and 322 and continue to extend beyond the boundaries of regions 301 and 302.

[0054] Figure 3E A fourth example of a curve identification strategy for layer 200 is shown. Figure 3E In the example shown, a point corresponding to the farthest extent of region 302 along boundary 315 is identified, and two curves 341 and 342 are identified. Curves 341 and 342 can be geodesics. The intersection point 343 of curves 341 and 342 is identified, and another curve 344 is determined from point 343 to a point on boundary 315. This point on the boundary can be a point between the points in the farthest extent.

[0055] Examples of curve identification strategies are not limited to Figures 3C to 3E The example shown illustrates this. In some cases, curve marking strategies can be adjusted to take into account factors such as the size, shape, or severity of deformation in the marked area. Curve marking strategies can be adjusted based on cuts already made in adjacent layers below or above the selected layer. For example, designers often do not want cuts in different layers to be aligned, as this can introduce structural weaknesses in composite components. To address this, cuts can be translated by moving them laterally or by staggering them between layers.

[0056] After modifications have been applied to the model, method 100 can be repeated. For example, the manufacturing process can be resimulated in the selected layers, and the simulation data for each layup can be evaluated to check if the layup is within acceptable tolerances. If some areas are still not within acceptable tolerances, further modifications can be applied. This process can be repeated iteratively until the layup meets the design requirements.

[0057] Figure 4 An example of a data processing system in which embodiments of the present disclosure may be implemented (e.g., a CAD or CAE application configured to perform the methods of embodiments of the invention described herein) is illustrated. The data processing system 400 includes a processor 410 connected to a local system bus 420. The local system bus connects the processor to main memory 430 and a graphics display adapter 440, which may be connected to a display 450. The data processing system may communicate with other systems via a wireless user interface adapter connected to the local system bus 420 or via a wired network (e.g., a wired network to a local area network). Additional memory 460 may also be connected via the local system bus 420.

[0058] Appropriate adapters (such as a wireless user interface adapter 470) for other peripheral devices (such as a keyboard 480 and a mouse 490 or other pointing devices) allow the user to provide input to the data processing system. Other peripheral devices may include one or more I / O controllers, such as a USB controller, a Bluetooth controller, and / or a dedicated audio controller (e.g., connected to a speaker and / or microphone). Various peripheral devices can be connected to the USB controller (e.g., via various USB ports), including input devices (e.g., keyboard, mouse, touchscreen, trackball, camera, microphone, scanner), output devices (e.g., printer, speaker), or any other type of device operable to provide input to or receive output from the data processing system.

[0059] Many devices, referred to as input or output devices, can both provide input and receive output in communication with the data processing system. Other peripheral hardware connected to the I / O controller can include any type of device, machine, or component configured to communicate with the data processing system.

[0060] The operating system included in the data processing system enables the output from the system to be displayed on a monitor to the user and allows the user to interact with the system. Examples of operating systems that can be used in data processing systems include Microsoft Windows™, Linux™, UNIX™, iOS™, and Android™.

[0061] Furthermore, the data processing system 400 can be implemented in a networked environment, a distributed system environment, a virtual machine architecture, and / or a cloud environment. For example, the processor and associated components may correspond to a virtual machine running in a virtual machine environment on one or more servers. Examples of virtual machine architectures include VMware ESXi, Microsoft Hyper-V, Xen, and KVM.

[0062] Those skilled in the art will understand that the hardware depicted for the data processing system 400 can vary depending on the specific implementation. For example, the data processing system 400 in this example may correspond to a computer, workstation, and / or server. However, alternative embodiments of the data processing system may be configured with corresponding or alternative components, such as in the form of a mobile phone, tablet, controller board, or any other system operable to process data and perform the functions and features described herein associated with the operation of the data processing system, computer, processor, and / or controller discussed herein. The examples depicted are provided for illustrative purposes only and are not intended to impose architectural limitations on this disclosure.

[0063] Data processing system 400 may be connected to a network (not part of data processing system 400), which may be any public or private data processing system network or combination of networks known to those skilled in the art, including the Internet. Data processing system 400 may communicate with one or more other data processing systems (such as servers, also not part of data processing system 400) via the network. However, alternative data processing systems may correspond to multiple data processing systems implemented as part of a distributed system, wherein processors associated with multiple data processing systems may communicate via one or more network connections and may collectively perform tasks described as being performed by a single data processing system. Therefore, it should be understood that, when referring to a data processing system, such a system may be implemented across multiple data processing systems organized as a distributed system and communicating with each other via a network.

[0064] Data processing system 400 is configured to perform methods according to embodiments described herein. For example, keyboard 480 and mouse 490 may be used as user input devices for receiving information from a user, processor 410 may be configured to perform the steps of the method, and display 450 may be configured to display a specific view to the user. A computer product including instructions may be provided that, when run on a computer (such as data processing system 400), cause the computer to perform the steps of the methods of embodiments of the invention outlined above.

[0065] This disclosure is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus, and systems according to examples of this disclosure. Although the flowcharts above show a specific order of execution, the order of execution may differ from the order depicted. Boxes described in one flowchart may be combined with boxes from another flowchart. In some examples, some boxes in the flowcharts may not be required, and / or additional boxes may be added.

[0066] This invention can be embodied in other specific devices and / or methods. The described embodiments should be considered illustrative rather than restrictive in all respects. In particular, the scope of the invention is indicated by the appended claims rather than by the description and drawings herein. All variations falling within the equivalent meaning and scope of the claims should be included within their scope.

[0067] The elements and features recited in the appended claims can be combined in different ways to produce new claims that also fall within the scope of this invention. Therefore, although the dependent claims appended below depend on only a single independent or dependent claim, it should be understood that these dependent claims may alternatively depend on any preceding or subsequent claim, whether independent or dependent. Such new combinations should be understood to form part of this specification.

[0068] While the invention has been described above with reference to various embodiments, it should be understood that many changes and modifications can be made to the described embodiments. Therefore, the foregoing description is intended to be illustrative rather than restrictive, and it should be understood that all equivalents and / or combinations of the embodiments are intended to be included in this specification.

Claims

1. A method for modeling composite components, the method being computer-implemented, the method comprising: Access the model in the modeling system, the model including a representation of a selected layer of one or more layers forming the composite component, the selected layer including one or more composite fabric material layups; Based on the model, the manufacturing process is simulated for the selected layer; as well as For each of the one or more plies in the selected layer: Quantitatively determine the deviation of the corresponding layup in the selected layer of the manufactured product from the model, the quantitative determination including: evaluating simulation data from simulating the manufacturing process; Based on the aforementioned deviation, the corresponding region set of the ply in the model is identified; and Before manufacturing the composite component, the model is automatically modified based on the identified set of regions.

2. The method of claim 1, wherein the simulation data includes data specifying the following: in-plane deformation at each point of the simulation, fiber wrinkling and bridging, deviation from the expected fiber direction, or a combination thereof.

3. The method of claim 1 or 2, wherein evaluating the simulation data comprises: Based on the simulation data, an error value is derived for each point of the selected layer in the fabrication process.

4. The method of claim 4, wherein identifying the region set based on the deviation comprises: One or more consecutive regions of the identified points, wherein for each point in a consecutive region of the one or more consecutive regions, the error value exceeds a predefined threshold value.

5. The method according to claim 1 or 2, wherein evaluating the simulation data comprises: Evaluate a predefined set of conditions, each condition in the predefined set of conditions corresponding to one or more data types in the simulation data, and specify a range of threshold values ​​for each of the one or more data types.

6. The method of claim 5, wherein identifying the region set based on the deviation comprises: One or more consecutive regions of the identifier point, wherein for a point in each of the one or more regions, at least one of the predefined conditions is not met.

7. The method of claim 1, wherein identifying the set of regions corresponding to the ply in the model comprises: Based on the deviation, a first region and a second region that is discontinuous with the first region are identified; A continuous region is formed based on the first region and the second region; as well as The continuous region is included in the region set.

8. The method of claim 1, wherein automatically modifying the model prior to manufacturing the composite component comprises: For each region in the region set: Automatically identify one or more curves based on a predefined curve identification strategy; as well as Cuts are formed based on one or more of the curves.

9. The method of claim 1, further comprising: The access, the simulation, and the quantitative determination, the identification, and the automatic modification are repeated iteratively for each of the one or more plies in the selected layer until the tolerance condition is met.

10. The method of claim 8, wherein each cut is a slit or a V-shaped cut.

11. The method of claim 8, wherein automatically identifying the one or more curves comprises: Based on the location of the cut in the layer adjacent to the selected layer, translate the identified one or more curves.

12. The method according to claim 1, further comprising: The manufacturing process described herein is applied to manufacture the selected layer of the composite component based on the model.

13. A computer-readable storage medium comprising instructions that, when executed by a processor, cause the processor to perform the steps of the method according to claim 1.

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