Build Validation Methods for Composite Assemblies Using Simulated Part Form Prediction

摘要

Geometric variability arising from composite part forming or processing conditions can cause problems during assembly as the 'as manufactured' part forms can differ from the geometry used for any computer aided design (CAD) based, simulated build validation. In this paper finite element (FE) simulation methods are integrated with a digital manufacturing framework to illustrate how the current gap between part design and final assembly simulation can be covered for composite components and assemblies. A simple application example based on L shaped stiffeners, demonstrates the limitations of traditional assembly simulation using nominally sized, as designed CAD geometry to represent composite parts and how this can be overcome by enhancing a digital manufacturing simulation platform by using predicted, more realistic part forms. The main benefit of the method presented is that assembly process planning for composite products can be verified before any real part is manufactured thereby minimising the risk of non conformances as the material system, tooling geometry and processing conditions can be tailored to suit the required design geometry. The advantages of both digital manufacturing and advanced composite materials can be exploited using this approach resulting in a reduction in the learning curve as the application of advanced composite materials increases in future transport applications.