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The Introduction to Virtual Composite Manufacturing Simulation
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The Introduction to Virtual Composite Manufacturing Simulation 1
THE INTRODUCTION TO VIRTUAL COMPOSITE
MANUFACTURING SIMULATION
Pravin Luthada
Chief Research and Development (R&D) Officer at Addcomposites
The Introduction to Virtual Composite Manufacturing Simulation 2
Abstract
The application of virtual manufacturing simulation tools ensure that composite
manufacturing processes lead to high-quality and cost-effective components. The
simulation tools are used over a wide range of processes to validate the design and
predict material behavior at each step of the processing. A wide gamut of virtual
manufacturing simulations is available for different process simulations.
Keywords: composite manufacturing, virtual simulation.
The Introduction to Virtual Composite Manufacturing Simulation 3
Automation Deposition
Automated depositing of fiber tapes using Automated Fiber Placement (AFP) is
increasingly being adopted by the industry. After the FEA analysis, the main
outcome is fiber orientation and other selective reinforcements. In order to convert
the ply data from the FEA model into an AFP program, the general flow of steps is
outlined below.
Design of tooling
FEA model is exported into a CAD format such as .step or .igs. The CAD model
shape provides the surface geometry of the tool. The tooling will be used for the
layup with compaction force and the curing of parts all occurring on the tool itself.
Typical mold design considerations e.g. sufficient draft angles, complex
geometries, or multi-piece/sacrificial tooling might be required and taken into
consideration. Additionally, tension and part shrinkage can contribute to a
condition known as ‘spring-in’ with cured parts, requiring an angular
compensation in the tool design.
Tooling and mandrels for automated fiber placement and tape-laying processes
typically are designed to provide the appropriate inner-most-loft or outer-most-loft
surface. Tools and mandrels of this type may be designed to index on an automated
machine-bed platform for use with AFP or ATL equipment. Any modern CAD
software can be used to draw the tool CAD model with the above considerations.
The tooling design step from the CAD model is shown in the figure below. The
tool has extended boundaries for the AFP tool runways and vacuum bagging
The Introduction to Virtual Composite Manufacturing Simulation 4
operations. The hole has been filled up to create a continuous surface for runways
within the part. The mounting feature should be considered in the tooling design
e.g. in the example shown below the tooling is mounted on the rotary chuck, so an
extended shaft is added for mounting onto the rotary axis. Depending on the mold
manufacturing method, the rest of the details can be created accordingly.
Figure 1. Part model to tooling design
Programming and simulation of automated placement processes
The tooling CAD model is imported into the offline programming software (OLP)
to create layup definitions in two steps i.e. Planning and Simulation.
Planning
OLP software used for AFP process workflow is presented in the figure below. The
OLP Software takes the tooling CAD models as input. The first step is to define the
layup area and boundary. Next, the processing parameters such as fiber
orientations, runway, approach, clearance, speed, and heating intensity, are input
The Introduction to Virtual Composite Manufacturing Simulation 5
based on your needs. Based on this information, the OLP can create motion paths
for the fiber placement tool with multiple strategies.
Figure 2. Automated fiber placement (AFP) simulation software overview
In addition to the motion paths, there are multiple parameters e.g. tape weight
(GSM), gaps, and staggering, that the engineer can choose from to configure the
motion path. Typical OLP is capable of
● Path Planning: Generate desired fiber orientation paths on 2D & 3D surfaces
(open) automatically
● Custom Path Planning: Import your own fiber paths to create the layup you
require, This is particularly helpful for any custom path trajectories, around
the holes, along with the load direction fiber placement, etc.
● Path modification: Modify generated paths i.e. shorten, suppress, edit motion
frames, edit individual plies, etc. to optimize your placement strategy
● Resource estimator: Estimate material and time utilized to conduct the layup,
optimize process parameters to optimize resource utilization
The Introduction to Virtual Composite Manufacturing Simulation 6
Simulation
The generated paths will be followed by the AFP robot. While the AFP head is
trying to follow the motion paths, there arise possibilities that it might hit the
tooling or pass the robot singularities. In order to visualize these occurrences, robot
motion simulation is evaluated either by automated analysis or by the operator to
eliminate such problems. The key benefit of running the simulation in the virtual
environment is avoiding costly collision and damage to the AFP head, robot, part,
or tooling!
Collision detection: Essentially measuring the distances between the AFP Head
and the tooling while moving over the planned motion paths, enables the detection
of collision occurrences i.e. where the AFP head would physically collide or
interfere with the tooling.
Collision avoidance: If a collision is detected, repositioning the mold may be able
to create enough clearance for the tool. Options for repositioning the mold are:
moving the mold horizontally, flipping the motion paths, editing the motion frames
to increase tool angle, or another similar workaround that can be identified and
implemented.
Robot singularities: Using algorithms, the AFP head and robot digitally simulate
the movement over the planned motion paths to detect robot singularities i.e. a
configuration in which the AFP robot becomes blocked in certain directions. The
OLP provides automatic detection of such positions. In order to avoid singularities
repositioning the mold, flipping the motion paths could help.
The Introduction to Virtual Composite Manufacturing Simulation 7
The stages to reach the simulation are shown in the image below. The process of
simulating your layup can be described as follows:
1. Select/define boundary and layup area
2. Define the fiber orientation and stacking sequence
3. Run a simulation to visualize anomalies within the virtual environment.
Figure 3. Path planning stages in offline planning software
Flow Simulation
Based on balance equations of mass, momentum, energy, and species, many
computer models have been developed to simulate the mold-filling process in resin
transfer molding (RTM). All of these models treat the mold-filling process as the
fluid flows through porous media. Darcy’s law is used to describe resin flow
through fiber reinforcements. After the mold and process design such as inlet and
outlet
The Introduction to Virtual Composite Manufacturing Simulation 8
locations, mold and resin temperature, resin flow rates or injection pressure at
inlets, fiber permeability, porosity, and part geometric parameters are inputted,
resin flow fronts, filling time, pressure, temperature, and conversion distributions
are obtained by solving the equations. The below image shows the simulated rules
that were performed and found to be matching the simulated results.
Figure 4. Simulated rules were performed and found to be matching the simulated
results (Han et al. 1999)
Cure Simulation
Transient heat transfer simulation established the temperature responses during
the cure cycle over the surface as well as through the thickness of the panel model.
The degree of cure, viscosity response, and resin modulus variation during the
The Introduction to Virtual Composite Manufacturing Simulation 9
curing cycle were computed using the cure-kinetic models of the resin. Selected
heat transfer boundary conditions on the tooling surfaces allowed for heat
conduction into the prepreg material.
Figure 5. Temperature distribution - (a) on the cross-section of the 2D model, (b)
during the cure cycle of the 2D model, (c) on the surface of the 3D model, (d)
during the cure cycle of the 3D model (Sreekantamurthy et al. 2016)
The Introduction to Virtual Composite Manufacturing Simulation 10
Key Takeaways
● Industry uses a variety of tools for performing manufacturing simulations for
different process steps.
● These tools provide a one-dimensional understanding of the process i.e. once
the design of the part is set and fibers stacked, only then these tools can
provide a feasibility check for optimal production. However, such an
approach does not grant the best structure possible, as the design does not
take into account the manufacturing process input.
● Most of these tools are independent solutions and may not have the
interoperability to provide a unified design environment
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The Introduction to Virtual Composite Manufacturing Simulation 11
About Addcomposites
Addcomposites is the provider of the Automated Fiber Placement (AFP) ecosystem
- including the Fiber Placement System (AFP-XS), 3D Simulation and
Programming Software (AddPath), and Robotic Cells (AddCell). With the leasing
program for the AFP system (AFPnext), composites manufacturers can work with
thermosets, thermoplastics, dry fiber placement, or in combination with 3D
Printers on a monthly basis.
References
Bak, M. 2017. New FEA Tools Tackle Composite Challenges. Machine Design.
Kerang Han; Shunliang Jiang; Chuck Zhang; Ben Wang (2000). Flow modeling
and simulation of SCRIMP for composites manufacturing., 31(1), 0–86.
Thammaiah Sreekantamurthy, Tyler B. Hudson, Tan-Hung Hou, Brian W.
Grimsley. 2016. Composite Cure Process Modeling and Simulations using
COMPRO® and Validation of Residual Strains using Fiber Optics Sensors. NASA.