Method and system for modelling and manufacturing composite parts

Abstract

A method for modelling a composite part is provided. The method includes accessing a model in a modelling system where the model includes a representation of a selected layer forming the composite part and the selected layer includes one or more plies of composite fabric material. The method includes simulating a manufacturing process for the selected layer based on the model. The method also includes, for each ply in the selected layer, evaluating simulation data from simulating the manufacturing process to quantitatively determine a deviation of the ply in the manufactured selected layer 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, before manufacturing the composite part.

Description

METHOD AND SYSTEM FOR MODELLING AND MANUFACTURING COMPOSITE PARTSTECHNICAL FIELD

[0001] The present disclosure relates to methods and systems for computer aided design and manufacturing, and, in particular, the design and manufacture of composite parts.BACKGROUND

[0002] Composite parts combine pieces of composite fabric materials, where the fabric materials are chosen for characteristics weight, strength, flexibility, or other physical properties. During manufacture, defects may form in the layers of the composite part. These defects may have a variety of causes, including excessive or insufficient tension, folding during manufacturing, or excessive shearing of the material, amongst others.

[0003] To bring these defects to within acceptable limits, modifications may be applied to individual fabric pieces or layers. One type of modification has the manufacturer introduce an incision in the piece of material to break the composite fibers in an area where defects occur. These incisions, which may be referred to as darts, may take the form of a single cut or multiple cuts to remove a small area of the material. This allows the fabric to be applied more easily to the manufacturing surface and more closely follow the intended design.

[0004] Determining the shape and location of incisions is important to the design-for- manufacture process, since without the incisions, many designs cannot be created on a three-dimensional surface within the desired tolerance for strength, flexibility, and other physical parameters.

[0005] Current methods for determining the placement of incisions have a number of limitations. For example, it is possible for a manufacturer to manually determine the placement at the time of manufacture. Unfortunately, the resulting product may deviate significantly from the original intent of the designer, and precise incision placement may not be repeatable. Manual placement relies on the subjective judgement, skill, and experience of the manufacturer. Additionally, due to the manual nature of the process, any mistake or iteration in the incision placement process is costly in terms of time, labor, and material.

[0006] To address some of these shortcomings, a designer may employ software tosimulate what the as -manufactured part would look like for their current design, including the impact of incisions, before the design is sent for manufacturing. However, even with such a simulation, the designer is still to manually review an initial simulation result showing how the piece of composite fabric deviates as the piece of composite fabric is placed on the manufacturing surface. The designer would then need to determine which areas the designer considers unacceptable and then decide what sort of incision to apply including location, shape, and direction to alleviate the unacceptable condition. Each incision is decided individually, which may make this both a timeintensive and labor-intensive process for the designer. There is therefore a need to automate the process for deciding how and where incisions are made for a given simulation result.SUMMARY AND DESCRIPTION

[0007] The present embodiments may obviate one or more of the drawbacks or limitations in the related art. For example, a method for improving the manufacturability of composite parts is provided.

[0008] The foregoing and other objects are achieved by the features of the independent claims. Further implementation forms are apparent from the dependent claims, the description and the figures.

[0009] According to a first aspect, a computer-implemented method for modelling a composite part is provided. The method includes accessing a model in a modelling system, the model including a representation of a selected layer of one or more layers forming a composite . The selected layer includes one or more plies of composite fabric material. The method includes simulating a manufacturing process for the selected layer based on the model. The method includes, for each ply in the selected layer, evaluating simulation data from simulating the manufacturing process to quantitatively determine a deviation of the ply in the manufactured selected layer 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, before manufacturing the composite part.

[0010] The method according to the first aspect improves the manufacturability of a composite part by simulating the manufacturing process and automatically modifying the design of the part based on the outcome of the simulation. This provides time and cost savings during manufacturing, improves the consistency of the manufacturingprocess for the composite part, and reduces the workload for the designer and manufacturer.

[0011] In a first implementation form of the method according to the first aspect, the simulation data includes data specifying in-plane deformation, wrinkling, and bridging of fibers, deviation from an intended fiber direction, or any combination thereof at each point of the simulation.

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

[0013] In a second implementation form, evaluating the simulation data includes deriving an error value based on the simulation data for each point of the manufactured selected layer.

[0014] In a third implementation, identifying the set of regions based on the determination includes identifying one or more contiguous regions of points, where for each point in a contiguous region, the error value exceeds a predefined threshold value.

[0015] The third implementation form enables the identification of regions where the deviation of the manufactured layer from the expected design is above an acceptable tolerance level.

[0016] In a fourth implementation form, 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 a fifth implementation form, identifying the set of regions based on the determination includes identifying one or more contiguous regions of points, where for points in each of the one or more regions, at least one of the predefined conditions is not met.

[0018] The fifth implementation form identifies regions where the deviation of one or more measured quantities from the simulation data is above an acceptable tolerance level.

[0019] In a sixth implementation form, identify ing a set of regions of the ply in the model includes identifying a first region and a second region non-contiguous with the first region, based on the deviation, forming a contiguous region from the first region and the second region, and including the contiguous region in the set of regions.

[0020] The method according to the sixth implementation form connects disconnectedregions that, for example, may be in close proximity, and treats the resulting connected region as a single contiguous region.

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

[0022] The seventh implementation form automatically determines the locations and shapes of modifications based on a predefined strategy. This further improves the design and manufacturing process for the composite part.

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

[0024] The method according to the eighth implementation form re-simulates the manufactured layer after modifications have been applied to determine if further modifications are required, and continues to apply modifications until all regions of the layer are within tolerance.

[0025] In a ninth implementation form, each incision is a cut or a v-shaped incision.

[0026] In a tenth implementation form, identifying the one or more curves further includes translating the one or more identified curves based on positions of incisions in layers adjacent to the selected layer.

[0027] The method according to the tenth implementation form improves the structural integrity of the manufactured composite part by providing that the positions of incisions in the selected layer take into account incisions in adjacent layers.

[0028] In an eleventh implementation form, the method includes applying the manufacturing process to manufacture the selected layer of the composite part based on the model.

[0029] These and other aspects of the invention will be apparent from the embodiments described below.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] For a more complete understanding of the present disclosure, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

[0031] Figure 1 is a flow diagram of a method for modelling a composite part,according to an example;

[0032] Figure 2 shows a perspective illustration of a simulation of a layer in a composite part, according to an example;

[0033] Figure 3 A illustrates regions of high deformation in the simulation of Figure 2;

[0034] Figure 3B illustrates a first example of the method of the present disclosure applied to the simulation of Figure 2;

[0035] Figure 3C illustrates a second example of the method of the present disclosure applied to the simulation of Figure 2;

[0036] Figure 3D illustrates a third example of the method of the present disclosure applied to the simulation of Figure 2;

[0037] Figure 3E illustrates a fourth example of the method of the present disclosure applied to the simulation of Figure 2;

[0038] Figure 4 illustrates an example of a data processing system in which embodiments of the present disclosure may be implemented, such as a CAD system configured to perform processes as described herein.DETAILED DESCRIPTION

[0039] Example embodiments are described below in sufficient detail to enable those of ordinary skill in the art to embody and implement the systems and processes herein described. Embodiments may be provided in many alternate 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 on various alternative forms, specific embodiments thereof are shown in the drawings and described in detail below as examples. There is no intent to limit to the particular forms disclosed. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Elements of the example embodiments are consistently denoted by the same reference numerals throughout the drawings and detailed description where appropriate.

[0041] The terminology used herein to describe embodiments is not intended to limit the scope. The articles '‘a,” “an,” and “the” are singular in that they have a single referent; however, the use of the singular form in the present document should not preclude the presence of more than one referent. In other words, elements referred to in the singular may number one or more unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising.” “includes.” and / or“including,” when used herein, specify the presence of stated features, items, steps, operations, elements, and / or components, 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 including technical and scientific terms used herein are to be interpreted as is customary in the art. Terms in common usage should also be interpreted as is customary in the relevant art and not in an idealized or overly formal sense unless expressly so defined herein.

[0043] Figure 1 is a block diagram of a method 100 for modelling a composite part. The method 100 may be implemented in a modelling system such as a Computer-Aided Design (CAD) or Computer Aided Engineer (CAE) system. CAD systems enable the creation, modification, and analysis of a design of an object for manufacture. CAE systems incorporate simulation tools to enable testing, validation, and optimization of designs. CAD and CAE software is used across many industries, including architecture, engineering, manufacturing, and product design. Many CAD and CAE sy stems include software packages and tools that enable the design and analysis of advanced composite parts.

[0044] At block 110, the method 100 includes accessing a model including a representation of a selected layer of one or more layers forming a composite part. In examples described herein, a layer is formed of one or more plies of composite fabric material. A ply is a piece of composite fabric material that may be cut from a larger piece of fabric material. The composite part may be formed using a layup process in which plies are layered on to a mold or layup surface in the shape of the desired part. Multiple plies may be required to completely cover the layup surface. Further layers are built up in a similar fashion on top of previous layers to achieve a desired material thickness.

[0045] The model of the selected layer may be retrieved from memory’ or storage on a computing system or accessed from a remote device or data storage. The model of the selected layer may be visualized in a graphical user interface (GUI) on the computing system implementing CAD / CAE software. A user may be able to 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 may be part of a larger model representing the composite part. A user may be able to select different layers and access data associated with thelayers of the composite part through the GUI.

[0046] At block 120, the method 100 includes simulating a manufacturing process for the selected layer, based on the model. A manufacturing process such as the layup process previously described, may be simulated using tools provided in CAD / CAE. The simulation may provide simulation data for each ply of the simulated manufactured layer. This simulation data may include data specifying various defects that arise during manufacturing at each point of the ply. For example, the simulation data may specify inplane shearing and deformation, wrinkling, and bridging of fibers, and deviation from an intended fiber direction.

[0047] Figure 2 shows a perspective illustration of a simulated manufactured layer 200 of a composite part, according to an example. In the simulation shown in Figure 2. different regions of the manufactured layer 200 show varying levels of deformation. For example, the regions 210, 220 represent areas of maximal deformation for the manufactured layer 200. In contrast, the region 230 has a lower level of deformation.

[0048] At block 130, the method includes evaluating simulation data from simulating the manufacturing process, for each ply in the selected layer, to quantitatively determine a deviation of the ply in the manufactured selected layer from the model of the selected layer. In one example, a single error value may be generated for each point of the simulated layer, to represent the deviation at the point. The error value may be derived from simulation data values. A check may then be carried out to determine whether the error value is less than a pre-defined threshold value that represents a maximum acceptable deviation from the intended design. In another example, the simulation data values for each point may be checked against a pre-defined set of conditions, where each condition relates to one or more data types in the simulation data. The conditions may specify threshold values representing acceptable ranges for each of the one or more data types.

[0049] At block 140, the method 100 includes identifying, for each ply, a set of regions of the ply, based on the deviation. The set of regions may include contiguous regions of points of the ply where predefined conditions relating to simulation data are not met or where an error value exceeds a predefined threshold value. For example, referring to Figure 3A, which shows the same simulated manufactured layer 200 as Figure 2, the regions 301, 302 may be identified as contiguous regions of points where the layer deviates from the intended design, due to the high level of deformation in these regions. In some cases, where two or more regions of the ply are disjointed, but are within closeproximity to each other, the regions may be merged and treated as a single contiguous region.

[0050] At block 150, the method 100 includes automatically modifying the model based on the identified set of regions, before manufacturing the composite part. The model may be modified by forming incisions in each of the regions. The locations for forming incisions may be determined by identify ing curves on the layer, the positions of which may be determined using a predefined curve identification strategy. In some examples, a user may be presented with different curve identification strategies that the user may apply in a given layer, ply, or region of a ply through the GUI. In other cases, the curve identification strategy may be pre-selected for the user.

[0051] Figure 3B is a perspective illustration showing the same layer 200 as shown in Figure 2. Figure 3B illustrates an example of a curve identification strategy. In Figure 3B, the points 31 1, 312 are the points in regions 301, 302 located at the greatest distance from the boundary 313 of the modelled layer. Curves 314, 315 are identified in each of regions 301, 302 extending from the points 311, 312 to points 316, 317 on the boundary 313. The points 316, 317 may be the points on the boundary 313 that are closest to the points 311, 312.

[0052] Figure 3C shows a second example of a curve identification strategy applied to the layer 200. In Figure 3C, the points 321, 322 correspond to points of highest deformation for regions 301. 302. The curves 323, 324 extend away from points 321, 323, to the boundary 313 and the opposite edges of the regions 301, 302 to the points 311, 312 depicted in F igure 3B .

[0053] Figure 3D shows a third example of a cun e identification strategy7applied to the layer 200. In some cases, the identified curves, and corresponding incisions, may extend beyond the limit of an identified region. In Figure 3D. points 331. 332 correspond to the points on the boundary 313 that are closest to the points of maximum deformation 321, 322 depicted in Figure 3C. The curves 333, 334 pass through points 331, 332, 321, 322 and continue beyond the limits of regions 301, 302.

[0054] Figure 3E shows a fourth example of a curve identification strategy for the layer 200. In the example shown in Figure 3E, points corresponding to the furthest extent of the region 302 along boundary 315 are determined, and two curves 341, 342 are identified. The curves 341, 342 may be geodesic curves. An intersection point 343 of the curves 341, 342 is identified, and a further curve 344 is determined from the point 343 to a point on the boundary 315. The point on the boundary may be the pointbetween the points of furthest extent.

[0055] Examples of curve identification strategies are not limited to the examples shown in Figures 3C - 3E. In some cases, the curve identification strategy may be adjusted to account for factors such as size, shape, or severity of deformation in the identified regions. The curve identification strategy may be adapted based on incisions that have been made in adjacent layers that are either below or above the selected layer. For example, designers will often not want the incisions in different layers to line up. as this may introduce structural weakness in the composite part. To resolve this, incisions may be translated by shifting the incision laterally or staggering the incisions between layers.

[0056] The method 100 may be repeated after modifications have been applied to the model. For example, the manufacturing process may be re-simulated in the selected layer, and the simulation data for each ply may be evaluated to check if the ply is within acceptable tolerances. If some regions are still not within acceptable tolerances, further modifications may be applied. This process may be repeated iteratively until the ply- meets the design requirements.

[0057] Figure 4 illustrates an example of a data processing system in which an embodiment of the present disclosure may be implemented (e.g., a CAD or CAE application configured to perform the methods of the embodiments of the present invention as described herein). The data processing system 400 includes a processor 410 connected to a local system bus 420. The local system bus connects the processor to a main memory 430 and graphics display adaptor 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, for example, to a local area network. Additional memory 460 may also be connected via the local system bus 420.

[0058] A suitable adaptor, such as wireless user interface adapter 470, for other peripheral devices, such as a keyboard 480 and mouse 490, or other pointing device, allows the user to provide input to the data processing system. Other peripheral devices may include one or more I / O controllers such as USB controllers, Bluetooth controllers, and / or dedicated audio controllers (e.g., connected to speakers and / or microphones). Various peripherals may be connected to the USB controller (e.g., via various USB ports) including input devices (e.g., keyboard, mouse, touch screen, trackball, camera, microphone, scanners), output devices (e.g.. printers, speakers), or any other type ofdevice that is operative to provide inputs or receive outputs from the data processing system.

[0059] Many devices referred to as input devices or output devices may both provide inputs and receive outputs of communications with the data processing system. Other peripheral hardware connected to the I / O controllers may include any type of device, machine, or component that is configured to communicate with a data processing system.

[0060] An operating system included in the data processing system enables an output from the system to be displayed to the user on the display and the user to interact with the system. Examples of operating systems that may be used in a data processing system may include Microsoft WindowsTM, LinuxTM. UNIXTM, iOSTM, and AndroidTM operating systems.

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

[0062] Those of ordinary skill in the art will appreciate that the hardware depicted for the data processing system 400 may vary for particular implementations. For example, the data processing system 400 in this example may correspond to a computer, workstation, and / or a server. Alternative embodiments of a data processing system may, however, be configured with corresponding or alternative components such as in the form of a mobile phone, tablet, controller board, or any other system that is operative to process data and carry out functionality and features described herein associated with the operation of a data processing system, computer, processor, and / or a controller discussed herein. The depicted example is provided for the purpose of explanation only and is not meant to imply architectural limitations with respect to the present disclosure.

[0063] The data processing system 400 may be connected to the network (not a part of data processing system 400), which may be any public or private data processing system network or combination of networks, as known to those of skill in the art, including the Internet. The data processing system 400 may communicate over the network with one or more other data processing systems such as a server (also not partof the data processing system 400). However, an alternative data processing system may correspond to a plurality of data processing systems implemented as part of a distributed system in which processors associated with several data processing systems may be in communication via one or more network connections and may collectively perform tasks described as being performed by a single data processing system. Thus, it is to be understood that when referring to a data processing sy stem, such a system may be implemented across a number of data processing systems organized in a distributed system in communication with each other via a network.

[0064] The data processing system 400 is configured to carry out the methods in accordance with the embodiments described herein. For example, the keyboard 480 and mouse 490 may function as a user input device for receiving information from the user, the processor 410 may be configured to carry out the steps of the method, and the display 450 may be configured to display a particular view to the user. A computer product including instructions that, when run on a computer, such as the data processing system 400, may be provided to cause the computer to execute the steps of the methods of the embodiments of the present invention outlined above.

[0065] The present disclosure is described with reference to flow charts and / or block diagrams of the method, devices, and systems according to examples of the present disclosure. Although the flow diagrams described above show a specific order of execution, the order of execution may differ from that which is depicted. Blocks described in relation to one flow chart may be combined with those of another flow chart. In some examples, some blocks of the flow diagrams may not be necessary, and / or additional blocks may be added.

[0066] The present inventions may be embodied in other specific apparatus and / or methods. The described embodiments are to be considered in all respects as illustrative and not restrictive. In particular, the scope of the invention is indicated by the appended claims rather than by the description and figures herein. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

[0067] The elements and features recited in the appended claims may be combined in different ways to produce new claims that likewise fall within the scope of the present invention. Thus, whereas the dependent claims appended below depend from only a single independent or dependent claim, it is to be understood that these dependent claims may, alternatively, be made to depend in the alternative from any preceding orfollowing claim, whether independent or dependent. Such new combinations are to be understood as forming a part of the present specification.

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

Claims

CLAIMS1. A method for modelling a composite part, the method being computer- implemented and comprising: accessing a model in a modelling system, the model comprising a representation of a selected layer of one or more layers forming the composite part, the selected layer comprising one or more plies of composite fabric material; simulating a manufacturing process for the selected layer based on the model; and for each ply of the one or more plies in the selected layer: quantitatively determining a deviation of the respective ply in the manufactured selected layer from the model, the quantitatively determining comprising evaluating simulation data from the simulating of the manufacturing process; identifying a set of regions of the respective ply in the model, based on the deviation; and automatically modifying the model based on the identified set of regions, before manufacturing the composite part.

2. The method of claim 1, wherein the simulation data comprises data specifying inplane deformation, wrinkling and bridging of fibers, deviation from an intended fiber direction, or a combination thereof at each point of the simulation.

3. The method of claim 1 or 2, wherein evaluating the simulation data comprises deriving an error value based on the simulation data for each point of the manufactured selected layer.

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

5. The method of claim 1 or 2, wherein evaluating the simulation data comprises: 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.

6. The method of claim 5, wherein identifying the set of regions based on the deviation comprises: identifying one or more contiguous regions of points where for points 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 of the respective ply in the model comprises: identifying a first region and a second region non-contiguous with the first region, based on the deviation; forming a contiguous region from the first region and the second region; and including the contiguous region in the set of regions.

8. The method of claim 1, wherein automatically modifying the model before manufacturing the composite part comprises: for each of the set of regions: automatically identifying one or more curves based on a predefined curve identification strategy; and forming an incision based on the one or more curves.

9. The method of claim 1. further comprising iteratively repeating the accessing, the simulating, and for each ply of the one or more plies in the selected layer, the quantitatively determining, the identifying, and the automatically modifying until a tolerance condition is met.

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

11. The method of claim 8, wherein automatically identifying the one or more curves comprises translating the one or more identified curves based on positions of incisions in layers adjacent to the selected layer.

12. The method of claim 1, further comprising applying the manufacturing process to manufacture the selected layer of the composite part based on the model.

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

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