Composite Applications

Programmation & Logiciel de simulation pour l’automatisation des placements de fibres (AFP) et pour les machines de pose de bandes (ATL)

VERICUT Composite Programming

VERICUT Composite Simulation

VCP lit les surfaces CAO des outils de dépose composite ainsi que les informations de frontières de plis qui définissent les strates ou les couches de plis et crée les parcours de placement de fibres pour rajouter l’épaisseur matière selon les exigences spécifiées par l’utilisateur et les normes de fabrication.

VERICUT Composite Programming (VCP) reads CAD surfaces and ply boundary information and adds material to fill the plies according to user-specified manufacturing standards and requirements. Layup paths are then linked together to form specific layup sequences and output as NC programs for the automated layup machine.

VERICUT Fiber Placement Programming Process:
Reads CATIA, STEP, Siemens NX, Pro E, Creo, SolidWorks, or ACIS surface models

Reads Fibersim, CATIA STEP, or SAT external ply geometry and information
• Boundary geometry
• Ply direction
• Axis or rosette system
• Start points
Creates Geometry within VCP
• Axis systems
• Points, lines, & curves
• Add thickness to form for subsequent sequences
Generates layup paths based on manufacturing engineering specifications
• Rosette projection at specified angles
• Parallel to guiding curve
• Following the natural path of the form’s surface
• Limited material steering
• And more…
Visualizes roller orientation
• Display roller and machine head to avoid collision
• Detect roller collision
• Visualize roller conformance to layup surface
Links paths to create form layup sequences
• Automatically or manually link paths based on shortest distance and form’s topology
• Insert machine-specific commands and actions
• Insert safe start and restart events
• Fully support spinning, stationary, and alternative rotisserie axes
Post-processes linked paths
• Output per machine requirements
• Configurable machine-specific events and feed rate optimizations
• Output safe start and restart sequences
Optimizes the quality process
• Export XML files for laser projectors
– Head paths, ply boundaries
– Safe restarts
– Tow Gaps & More
Calculates & balances material usage
• Keep track of material on each spool
• Alter head paths to re-distribute material
Checks material conformance
• *New* Heat map
• Visualize ply angle deviations, steering violations and roller compression
• Pin point most severe material violations
Analyzes gaps, overlaps, and staggers
• Highlight excessive overlaps, and gaps
• Calculate the sum of gaps and overlaps
• Control and stagger splice locations
• Visualize areas of course convergence

Excerpt from: Roadmap to Automated Composites
By: Charles B. Anderton, André Colvin

Implementing automated composites requires a significant capital investment, alongside a steep learning curve. The expenditure in both cost and time inhibit many manufactures from instituting automation, despite the clear advantages. This paper will define important terminology, provide a business case for adopting automated composites, and point out considerations when deciding upon a machine. By shedding light onto these specific considerations, informed and successful steps can be taken to implement this constantly evolving technology.

Programming and Simulating AFP CNC Machines White PaperPDF

VCS lit les modèles CAO et les programmes ISO soit générés par VCP, soit issus d’une autre application composite et simule les séquences des programmes ISO sur une machine virtuelle. Les plis de fibre de carbone sont appliqués à l’outillage via les instructions du programme CN dans un environnement de simulation CN virtuel. En savoir plus…

VERICUT Composite Simulation (VCS) is a simulated work environment for automated composites manufacturing. Through CAD models and NC programs, VCS simulates the sequence of NC programs on a virtual machine, including head changes, probing, knife cutting, and more. Material is applied to the layup form via NC program instructions in a virtual CNC simulation environment. The simulated material applied to the form can be measured and inspected for stack thickness, ply offset, ply angle, and other manufacturing priorities to ensure the NC program follows manufacturing standards and requirements. A report showing simulation results and statistical information can be automatically created.

Fiber Placement Machine Simulation details:
• Based on industry leading VERICUT Software
• User-configurable machine kinematics and control emulation models for any machine and control
• Reads and simulates ISO (G-Code) NC program file

VERICUT Composite Machine Simulation & Analysis Features:

Reads CAD geometry of the layup form
• Used for collision detection and material application
Uses VERICUT virtual machine and control emulation to simulate the layup machinery
• Can be configured for virtually any CNC syntax and machine kinematics configuration
Reads the NC program and simulates the layup process based on NC program commands
• Validate the actual NC program that will run on the layup equipment
• Add material to the form based on NC program commands
• Material added in discreet layers/sequences, constructing the workpiece exactly like the physical process
Checks the process for compaction roller/form conformance and direction
• Verify roller orientation to path
• Verify path correctness to the form and previously applied sequences/layers of material
• Check roller conformance and compaction axis travel for bridging or excessive compaction
Added material is measurable and can be inspected for manufacturing requirements
• Measure overlap and gap areas
• Interrogate simulated material for thickness
• Detect steering radius violations
• Verify ply stagger
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