CATIA Composites 3DEXPERIENCE® R2022x

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Composite Design Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Grid Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Zone Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Plies Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Skin Swapping and Ply Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Solids and Top Surfaces from Plies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Producibility and Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Composites Collaboration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shape Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Composite Manufacturing Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Standard Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Plies Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Skin Swapping and Ply Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Producibility and Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Composites Collaboration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Shape Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Composite Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Preliminary Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Geometry Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Composite Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Manual Ply Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Plies Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Manual Plies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Core Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Review Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Manual Ply Creation Review Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Designing with Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Creating a Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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Composite Grid Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Grid Panel Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Grid Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Virtual Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Plies Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Grid Ramp Support Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Remove Useless Ramp Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Swap Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Reroute Ply Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Local Drop Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
No Drop Off Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Synchronize Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Limit Plies from Panel Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Import-Export Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Composite Grid Design Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Grid Staggering Refinement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Hybrid Composite Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Slicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Slicing Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Plies Creation From Slicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Ply Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Ply Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Importing a Ply Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Stacking Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Creating a Limit Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Symmetric Plies Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Symmetric Plies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Merge Plies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Merge Stackings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Mirroring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Create Mirrored Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Synchronizing a Mirrored Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Creating IML’s & Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Solid From Plies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
IML Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Extended IML Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Create Iso Thickness Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Iso-Thickness Junction Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Iso-Thickness Junction Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Solid From Iso Thickness Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

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Analyzing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
On the Fly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Check Contours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Numerical Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Plies Sectioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Ply Section Beam Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Ply Exploder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Multiple Core Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Rosette Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Rosette Transfer Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Manufacturing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Creating a Manufacturing Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Synchronizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Skin Swapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Defining the Edge of Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Material Excess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Producibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Flattening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Geometry Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Producibility Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Fiber Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Unfold Entity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398

Splicing and Splice Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

Butt Splice Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
No Splice Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Gap Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Splicing with Producibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Splicing Review Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Splicing 2D Review Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

Darting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
Line Darts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
Curve Darts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Darting Review Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452

Exporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Exporting Ply Data as IGES or DXF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
XML Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464

Automated Deposition Design (ADD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467

Adding Material to Plies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Material Addition Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Stagger Origin Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Grid Angle Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
Grid Angle Cut Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
Rounded Corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490

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Drafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
Creating a Ply Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
Problem 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
Problem 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
Problem 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
Problem 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Problem 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
Problem 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
Problem 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
Problem 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
App Preferences - 3D Modeling - Multi Discipline Engineering -
Composites Design - Composites Design . . . . . . . . . . . . . . . . . . . . . . . . . 539
App Preferences - 3D Modeling - Multi Discipline Engineering -
Composite Design - Export Ply Data - DXF Setting . . . . . . . . . . . . . . . . . 541
App Preferences - 3D Modeling - Multi Discipline Engineering -
Composite Design - Export Ply Data - IGES2D Setting . . . . . . . . . . . . . . 543
App Preferences - 3D Modeling - Multi Discipline Engineering -
Composite Design - Export Ply Data - IGES3D Setting . . . . . . . . . . . . . . 544
App Preferences - 3D Modeling - Multi Discipline Engineering -
Composite Design - Laser Projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545

Appendix B - Composite Fiber Modeler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547

Appendix C - Laser Projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567

Additional Geometries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
Stacking Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
Stacking Text on Plies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
Laser Projector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
Laser Projection Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579
Laser Projection File Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587

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Appendix D - Zone Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591

Zone Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
Transition Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598
Imposed Thickness Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Connection Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Zones Bridge Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Solid From Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
New Solid From Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
Importing a Laminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Stack Up File From Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
Stack Up File From Core Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
Plies From Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
Creating a Limit Contour in an Input File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
Transition and Relimitation Review Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
Advanced Relimiting Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641

Appendix E - Drop Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659

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Introduction
CATIA Composites
Upon completion of this course, the student should have a full understanding of the
following topics:

- Defining composite parameters

- Designing with the manual ply method

- Designing with the grid method

- Designing with the zones method

- Designing with the solid slicing method

- Generating solids and IML surfaces based off of zones or plies

- Analyzing and inspecting composite parts

- Creating manufacturing models

- Swapping definition surfaces and ply boundaries for manufacturing

- Splicing and darting plies

- Creating flat patterns

- Exporting ply definitions for ply nesting, cutting and laser projection

- Incorporating manufacturing modifications for automated fiber placement

- Creating ply books

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Composites
This course will cover all of the options found in the Composites Design and Composite
Manufacturing Preparation workbenches. The first portion of the book will focus on the
design options. The second portion of the book will delve into the manufacturing side of
composite parts and how they will be created.

Please note that some additional environment variables have been activated for the
Composites Design and Composite Manufacturing Preparation workbenches. These
environment variables provide additional functionality and visualizations within the two
workbenches. If these environment variables are not activated in your CATIA load, your
workbenches may look slightly different.

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Review Exercises
This section will review the concepts and operations discussed in the previous sections of
this manual.

Manual Ply Creation Review Exercise

In this section, manual plies will be created to define a composite part. The plies for the
first half of the laminate will be created manually. Next, the user will create the plies for
the top half of the laminate by creating symmetric plies. Finally, the user will rename the
plies using the interactive ply table.

Open the COMP - Manual Ply Review model. The model contains wireframe and
surface geometry for the initial definition of the composite part.

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Select the Composite Parameters icon. The Composites Parameters window

appears.

Select the Add Material button in the Materials tab. A selection window appears.

Select the From Database icon. A selection pane appears.

In the Search field, key in Carbon and select Enter. The results appear.

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Select the checkbox for the Carbon Fiber Cloth core material from the list. You are
returned to the Composites Parameters window. Only one material will be used in this
exercise.

Select the Rosettes tab and select the Add Rosette button. The Rosette Definition window
appears.

Select the axis system from the display to define the Axis system for the rosette. Adjust
the size of the rosette and select OK. The rosette is created.

Select OK to the Composite Parameters window. The parameters are defined.

First a ply group will need to be created to define the location for the plies to be stored.

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Select the Plies Group icon. The Plies Group window appears.

Select the surface from the display to define the Surface option. The draping direction
should be pointing upwards.

Select Rosette.1 to define the Rosette.

Select OK. The plies group is created.

Now the plies will be created for the composite part.

Select the Ply icon and select the Plies Group.1 branch in the specification tree.
The Ply Definition window appears.

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Select the curve in the display to define the contour. A green checkmark should appear
in the window, specifying it is a closed contour.

Select the Attributes tab and set the Material to be Carbon Fiber Cloth and the
Direction to be 0. This will define the first ply.

Select OK. The ply is created.

Right select on Sequence.1 in the specification tree and select Copy from the contextual
menu.

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Right select on Plies Group.1 and select Paste from the contextual menu. A second
sequence and ply has been created.

Notice the name of the ply matches the original ply. This will be fixed eventually. The
new ply will use the same contour and the same attributes as the original. The attributes
will also need to be adjusted eventually.

Create three more copies as shown.

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Select the Limit Contour icon. The Limit Contour window appears.

Select Sequence.5 to define the Entity. This ply will be relimited.

Select the curve as shown to define the Relimiting Curve.

Be sure the arrow is pointing towards the lower portion of the surface and select OK.
This specifies the lower side of the ply will be kept.

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The ply should appear as shown now.

Now the attributes of the plies need to be updated.

Select the Stacking Management icon. It is located in the Review section. The
Stacking Management window appears. You may have to adjust the options in the Column
button to get the window to appear exactly the same.

Modify the Orientation Name for each ply as shown. You will use the Multiple Row
Edition icon or the contextual menu.

Select OK. This defines the bottom half of the laminate.

Now the plies will be symmetried to create the other half of the laminate.

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Select the Symmetric Plies Stacking icon. The Ply Symmetry window appears.

Select the Plies Group.1 to define the Selection for the operation.

Be sure the Non pivot option is selected and select OK. The plies are symmetried as
shown.

Now the names of the plies need to be fixed.

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Select the Stacking Management icon. The Stacking Management window

appears.

Select the Ply option for the Entity Level and select all of the plies in the window. You
will want to use the Shift key.

Right select on the selected plies in the window and select Multiple Row Edition. The
Rows Edition window appears.

In the Rename section, set the Name to be PLY- and the Nb of Digits to be 3 as shown.

Select OK. The plies are renamed as shown.

Select OK. The laminate is finished. Now we will take a quick look at the cross section.

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Select the Plies Section icon. The Plies Section window appears.

Select the Complete Stacking option.

Select the Cross Section Plane from Geometrical Set.1 to define the Sectioning planes or
curves.

Select the Realistic and Surfacic types.

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Set the Scale factor to be 2 and select OK. The cross section should appear as shown.

Notice the laminate is completely symmetric. This provides an easy method for creating a
very simple layup of plies without having to use an advanced design method. Keep in mind
that if you wanted to have any staggering in the plies that are dropped off, you would have
to create wireframe curves to be able to manually select the shape of each ply. For this
reason, this method only works well for pretty simple laminates.

Save and close the document.

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Composite Grid Design Review
This exercise will review the grid design method in more of a process based manner.

Open the COMP - Grid Design Review document. The model contains a surface and
wireframe elements.

Select the Composites Parameters icon. The Composites Parameters window

appears.

Define Graphite Unitape for the material.

Create a rosette using the axis system in the display.

Select OK to finalize the parameters.

Select the Grid Panel icon and define the Surface option with the surface in the
display. Select Rosette.1 for the Rosette. Be sure the Draping direction is pointing
upward.

Next, the reference elements will be defined with the necessary default offsets and
staggering.

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The following picture explains how the plies should eventually drop off. Three different
drop off values will be used: 0.25in, 0.375in and 0.5in. In this case, a default drop off will
be set to begin with for all reference elements and then eventually the individual reference
elements will be modified to obtain the correct drop offs at each location.

Select all of the curves from the display as shown to define the first reference element
group. The curves could be split into multiple reference element groups if necessary. In
this case, only one group will be used.

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Edit the group and create a new ramp definition with the Offset set to 0 and the Step
set to 0.25 for both the positive and negative directions. This will not work for all of the
ply drops, but since it is the most common for this model, it will be used as the default. The
other drops will be individually modified later. The window should appear as shown.

Select OK. The grid panel definition is completed.

Select the Grid icon. The Grid Definition window appears. The computed cells
should appear in the display as well. Keep in mind the cell names may be different based
on the order the reference elements were selected in. This shouldn’t matter.

First, the cells that will be a common thickness will be merged together to simplify the
panel definition. Keep in mind this is typically not recommended. Leaving the cells in
their default definition will yield more robustness to the design.

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Merge the cells together as shown to define the three constant thickness areas. Keep in
mind that your cell names may not match.

Select the cell as shown and select the Edit button. The name and stacking sequence for
the cell will be modified.

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The Cell Definition window appears.

Change the Cell name to be 9 Ply Zone and select the New button for the Laminate
option. The Laminate window appears.

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Change the Name to be LAM001 and select the Stacking sequence option.

Set the Material drop down to be Graphite Unitape and the Orientation to be 0 and
select the Add button. The first ply will be a 0 degree ply.

Change the Orientation to be 45 and select the Add button again. The second ply is
defined.

Define three more plies as shown. This will complete half of the laminate.

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Set the Symmetry option to be Pivot. The final 0 degree ply will be the center of the
laminate. The stacking should appear as shown.

Select OK. This defines the thickness law as well as the actual order of the stacking for
constant area. The Cell Definition should appear as shown.

Select OK.

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The cell should appear as shown.

Select the center cell and select the Edit button. The Cell Definition window appears.

Change the Cell name to be 7 Ply Zone.

Create a new laminate called LAM002 with the following stackup.

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Select OK. The cell should appear as shown.

Set the name of the final cell to be 5 Ply Zone with a new laminate called LAM003
with the following stackup.

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Set the 3D text labels to display the Cells name and Thickness law. The panel should
appear as shown.

Select the Reference option under Import/Export Management and select the Browse
icon for the Export to file option. A File Selection window appears.

Browse to your area, key in SS Export for the File name and select Open. This will
define where to create the spreadsheet.

Select the Export button. The file is created.

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Open the file from your area. It should appear as shown.

This is the format for using the stacking sequence option rather than the thickness law. In
this case, the full stacking sequence definition was defined in CATIA so the spreadsheet
may not really be necessary. However, the spreadsheet could be used to make changes in
the future.

Close the spreadsheet. You should be back to the Grid Definition window in CATIA.

Select OK. The grid definition is created.

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Select the Virtual Stacking icon and select Grid.1 from the tree. The Virtual
Stacking Management window appears.

Since the stacking sequences were already defined for the cells, it is not necessary to
rearrange the rows in this window. If any changes were needed, they could be made
though.

Select OK. Now you are ready to create the plies.

Select the Plies From Virtual Stacking icon. The Plies Creation window
appears.

Select the Minimum Crossing & Weight Savings algorithm and the Backslash pattern
and select OK. The plies are created.

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Hide the Grid.1 and Grid Virtual Stacking.1 and show the grid ramp supports in the
tree. The plies should appear as shown.

Most of the drop offs are correct, but a few need to be modified to have the correct
staggering. Fortunately, the original grid panel definition can be modified and the plies will
automatically update.

Double select on Grid Panel.1 from the tree. The Panel Definition window appears.

Select the reference group and select Parallel.7 in the window. It should highlight as
shown in the display.

This curve should have a drop off staggering of 0.375 in the negative X direction instead of
0.25. This will be fixed now.

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Select the Edit button in the Reference elements area. The Reference Element Definition
window appears for the curve.

Turn off the Same on both sides option and create a new ramp definition for the
positive side.

Set the Step to be 0.375 for the new ramp support. It should appear as shown.

Select OK. Notice the representation in the display updates.

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Change the ramp definition for Parallel.6 to use the 0in / 0.375in ramp definition in
both directions. You can simply select the 0in / 0.375in ramp definition from the drop
down to reuse the one you just created.

Select OK. The representation should update in the display.

Select OK.

Select the Update icon. The plies should update. The final ply manipulation will
require a new grid ramp support.

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Select the Ramp Support icon.

Select the curve as shown. The Grid Ramp Support window appears.

Select the Side + option and set the Curves count to be 3. This specifies which side of the
reference element and the number of curves to be created.

Select the Override reference element spec with option and select the New button. The
Ramp Definition appears.

Change the Step to be 0.5 and select OK.

Select OK. The new grid ramp supports are created.

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Use the Swap Edge icon to modify the plies as shown.

This should have all of the ply drops in the correct direction and with the correct staggering.

Hide the ramp supports in the tree. The plies should appear as shown.

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Explode the plies with the Shell Constant Offset option and a Scale of 10. They
should appear as shown. The plies should be symmetric.

Remove the exploded surfaces and save and close the document.

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Now the producibility optimization option will be investigated.

Open the COMP - Producibility Optimization document. It should appear as shown.

Select the Producibility for Hand Layup icon. The Producibilty for Hand Layup
window appears.

Select the first ply in the tree, set the Mesh Step Length to be Scaled with a value of 0.5
and select the Optimize button next to the Seed point definition. The Optimization
window appears.

Variable Specifies whether the seed point locations for the selected plies can vary

Objective Specifies the optimization criteria: Mean Absolute, Weighted or Greatest for
the shearing angle

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Method Specifies the method for distributing points over the ply area

Settings Specifies the number of points to be analyzed over the ply during the
optimization

Select Shearing angle - Weighted in the window, then right select on it. The contextual
menu will appear as shown.

This is how you can edit the various options for the optimization.

Right select under the Settings column and select Edit. The Optimization Settings
window appears. This would allow you to modify the number of points to be included in
the optimization.

Select Cancel.

Select OK. The optimization is run. You may get a Diagnostic List window which you
may close.

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The display should appear as shown.

Notice 50 locations were analyzed for producibility. The location yielding the lowest
maximum shearing angle was selected.

Select the Results tab and turn on the Statistics option. The Producibility Statistics
window appears. Note, the values may differ if you aren’t using CFM Optimized Energy.

Notice the maximum shearing angle for the weighted computation is 23 degrees.

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The values next to the other locations in the display correspond to what the maximum
shearing angle for the weighted computation would be if the seed point were positioned at
each location.

Close the Producibility Statistics window.

Select Preview. The producibility should appear as shown.

Feel free to select any of the other locations and preview their results.

Select Cancel when you are done. The producibility will be computed and optimized for
all plies now.

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Select the Edit Producibility Table icon. The Edit Producibility Table window
appears.

Select all of the plies in the window. You may use the Shift key.

Select the Producibility for Hand Layup icon in the window. Many of the
columns in the window will populate.

The producibility has been setup for all of the plies according to the last producibility
analysis that you ran.

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Select the Edit button. The Edit Multiple Producibilities - Hand Layup window appears.

Turn on the Optimize option and select the Parameters button. The Optimization
window appears.

Select Cancel. The default optimization settings will be used.

Notice you can also transfer 3D geometry to 2D for a group of plies within this window as
well.

Select OK. The optimization begins and will be computed for each ply. When it is
completed, the Edit Producibility Table will reappear.

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Select Run. The producibilities will be computed for each ply.

Select each ply in the window to view its producibility.

Select OK when finished.

The Optimize option is very useful for determining the best position of the seed point
without manually reviewing the producibility.

Save and close the document.

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Flattening
The Flattening option allows you to generate a flat pattern for each of the plies.

Open the COMP - Flattening document. The producibility has already been computed
for all of the plies.

Select the Flattening icon. The Flattening window appears.

Entities Specifies the plies to flatten

Only consider... Specifies if cut-pieces exist, only they will be used

Plane Specifies the plane to create the flat patterns on

Location Point Specifies the location each flat pattern will be located at on the
flattening plane

Transfer draping... Allows you to flip the flat patterns on the flatten plane

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Flatten type

Material roll Flat patterns are positioned on the flattening plane according
to the fiber directions of the ply and the axis of the plane.
This is typically what will be needed for exporting the dxf
files correctly for a cutting software.

Unfold assembly Flat patterns are positioned according to the 3D positioning of

the ply

Check material... Performs a material width analysis to be sure the ply will fit on the
specified material. If any ply ever fails this analysis, a mask will
appear on the features in the tree as shown. In this case Ply.1 is
failing the material width check.

Create Flatten... Specifies the flat pattern will be created as a sketch rather than a
wireframe curve

Rosette Size Specifies the rosette size in the flat pattern

Smoothing Allows the flat patterns to be smoothed for optimization

Select the Sequence.1 to define the ply to flatten. Select the Flattening Plane from
Geometrical Set.1 and select the point from the Flattening Points geometrical set.

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With the Unfold assembly option selected, select Apply. The flattened ply appears in the
display.

Notice the original point that was selected during the producibility operation is positioned at
the specified point from the flattening operation.

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Select the Material roll option in the Flattening window and select Apply. The flattened
ply is repositioned on the plane.

Select Cancel in the window. Since you want to create a flat pattern for all of the plies,
you will do it all at once.

Select the Flattening icon. The Flattening window appears.

Select Plies Group.1 to define the Entities to flatten.

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Select the same Flattening Plane again and select the rectangular pattern in the
Flattening Points geometrical set to define the Location Point for the operation. The
Flattening window should appear as shown.

Notice there are 9 plies selected and 9 point locations as well. Selecting a pattern will
automatically assign the plies or cut pieces to each point in the pattern.

Select the Multi Selection icon for the Location Point option in the window. The
Location Points window appears.

Notice all of the plies are listed and each ply was assigned a location point. You can
manually specify which ply is assigned to which point from this window if you wanted to.

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Select Close. You are returned to the Flattening window.

Select the Material roll option and select Apply. The flattened plies are created, but are
randomly located at the points. This is typically how you want to export create flat patterns
for export to dxf files.

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Select the Unfold assembly option. Set the Continuity to Threshold and the Tangency
threshold to 10, turn on the Curvature threshold and select OK. The plies are positioned
in a more uniform manner this time. The plies were also smoothed in tangency. Keep in
mind, it is rare that you would want to use Unfold assembly, since the flat patterns are not
oriented based on their orientation to be exported as dxfs.

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Expand the first ply in the tree as shown.

Notice the categories under the Flatten Body allow you to organize the contents of the
flattening. This is important when it comes to exporting the flat patterns. This will be
discussed in more detail in the Exporting section.

Manufacturing Process, Page 388 ©Wichita State University