Optimizing Composite Material Design and Manufacturing with KTex Family Software
Technology Category
- Analytics & Modeling - Digital Twin / Simulation
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Life Sciences
- Plastics
Use Cases
- Manufacturing Process Simulation
- Virtual Reality
Services
- System Integration
About The Customer
The customer in this case study is not explicitly mentioned. However, it can be inferred that the customers are companies involved in the design and manufacturing of composite materials. These could include companies in the aerospace, automotive, and other industries that require complex composite materials for their products. These companies need to accurately represent and model the behavior of composite materials, generate realistic finite element models of wound parts, perform global simulations that include refined areas at a lower scale, and simulate the lay-up manufacturing process of complex composite parts to predict the orientation of fibers and fiber volume fraction.
The Challenge
The case study presents several challenges faced by companies in the field of composite material design and manufacturing. The first challenge is to accurately represent the behavior of composite material and choose the best option from many possibilities. The second challenge is to generate a realistic finite element model of a wound part. The third challenge is to perform a global simulation that includes refined areas at a lower scale. The fourth challenge is to simulate the lay-up manufacturing process of a complex composite part to predict the orientation of its fibers and its fiber volume fraction. The final challenge is to simulate the lay-up manufacturing process of an aeronautic radome, predict the orientation of its fibers, and consider these orientations in predicting the electromagnetic performance.
The Solution
The solutions to these challenges are provided by the KTex Family of software by CEDREM. For the first challenge, KTex Pattern is used to represent the composite material at the scale of the yarns, and KTex WovenProperty is used to calculate the homogenized macroscale mechanical properties of any given weave. For the second challenge, KTex Winding is used to visualize the paths followed by the yarns during the winding process and simulate the winding process considering the mechanical properties of the yarns. For the third challenge, KTex Pattern and KTex LayUp are used for precise simulation of the composite material at the scale of the yarns, refinement of the composite material in the chosen areas, and integration of the updated mechanical properties from the lower scale model to the upper scale global simulation. For the fourth and fifth challenges, KTex Pattern is used to build a mesoscopic FE model of several fabrics inside HyperMesh, and KTex Layup is used to set up a manufacturing process simulation inside HyperMesh and run with RADIOSS solver.
Operational Impact
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