Composite Ply Drop Modeling with Draping Analysis
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Solution Overview
Problem
Current computer modeling software for composite components lacks accurate representation of draping information, material properties, and fiber orientation, leading to manufacturing inaccuracies and tool path issues during the production of composite laminates.
Innovation Solution
A computer-implemented method and system that generates a three-dimensional model of composite components by defining ply drop regions, creating surface meshes, and applying node data based on layup table information to analyze angle deviations, incorporating draping data and composite properties for precise simulation and manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If conventional CAD systems are used to model composite components, then basic 3D geometry can be represented, but draping information and material properties cannot be accurately incorporated
Solution Approach 1:
The patent merges multiple information sources including layup tables, material look-up tables, and draping software into a single integrated computer model. This consolidation ensures that draping information, material properties, and geometric data are all captured together, eliminating the information loss that occurs when using separate conventional CAD systems.
Solution Approach 2:
The computer model serves multiple functions simultaneously: it stores geometric information, material properties, draping effects, and manufacturing parameters. This multi-functional approach allows a single system to handle all aspects of composite component representation, rather than requiring separate specialized systems for each type of data.
2Manufacturing precision
If simplified 3D models are used for manufacturing, then processing is easier, but manufacturing precision deteriorates due to inaccurate ply representation
Solution Approach 1:
The patent segments the composite component model into discrete ply layers, with each ply represented as a separate element in the computer model. This segmentation allows for precise representation of ply drop regions and thickness variations, enabling accurate manufacturing guidance while maintaining manageable model complexity through systematic organization.
Solution Approach 2:
The computer model applies different levels of detail and properties to different regions of the component. Specifically, ply drop regions are modeled with enhanced precision including local thickness variations and angle deviations, while other regions use standard representation. This local quality approach ensures manufacturing precision where needed without unnecessarily increasing overall model complexity.
3Measurement precision
If comprehensive draping data is collected and analyzed, then angle deviation accuracy improves, but computational time increases
Solution Approach 1:
The patent performs preliminary analysis of draping data during the modeling stage, calculating angle deviations and identifying critical regions before manufacturing begins. By pre-computing these measurements and storing them in the computer model, the system achieves high measurement precision without requiring time-consuming calculations during actual manufacturing operations.
Data Source
AI summary
A method for generating a computer model of a composite component includes generating a surface mesh based on a ply drop region and a ply curved surface and generating node data including a plurality of node points relative to the ply drop region. The method also includes receiving composite data relating to a plurality of composite plies and generating a three dimensional model based on the composite data. The method further includes receiving layup table information and applying the node data, based on the layup table information, to generate a curve through a center of the surface mesh to define a plurality of element sets. The method also includes receiving composite draping data and determining, based on the draping data, where each element set intersects the three dimensional model. The method also includes analyzing an angle deviation of the plies based on the intersection of the element sets.