Simulation for laying composite material

The result of several years’ collaboration with major aerospace customers, NCSIMUL Machine 9.1 can replicate material laying processes executed by numerical control (NC) machines.

This machining simulation software decodes NC programs, representing the machine environment in 3D to identify and analyze programming errors and collisions. A Composite option enables a dynamic representation of fiber ribbon laying, depicting the 3D form of the carbon fiber. Positioning of each fiber in the ribbon is managed independently.

The software alerts users to issues specific to the way composites are processed and liable to occur in machining. Alerts include fiber steering angle errors, twisting of taut fiber between the head and the position on the spool, fiber tension issues including speed disparities between fibers or sudden changes of direction that can create backwards laying.

Analysis functions can send information to the process planning department and the design office before going live. Analysis can be for the length of the laid material, layer thickness, fiber ribbon intersection angle, and aperture radius. The section-plane function gives insights into layering or possible holes in the material. At any time, the fiber path, or the end result of the material laying generated on the tooling in CAD, can be exported.

The software considers the shape of the initial tooling and the tension applied to the fibers. Fast algorithms enable fiber laying simulation with performances of 300m/min on a conventional CAD workstation.
 

Create, synchronize documentation

The NCdoc add-on is fully integrated into NCSIMUL Machine 9.1, so for the Composite option, technical content publication functions are accessed via a specific ribbon in the software’s MMI. Machining simulation (tool sheets with associated times, tooling assembly sheets, machining results between operations, internal check sheets, etc.) can create documents for the shop floor. The pages can be edited: right-clicking allows a 3D view of the machining to be inserted, and markup functions are accessible before exporting it in PDF or HTML format.

All the functions dedicated to composite technology are grouped together in a ribbon (Office mode) for a fast learning curve.

The software can also link a page in the document set to an NC program block. A project exported in NP3 format now encapsulates the associated document, maintaining the links between pages and blocks. The NC operator viewing the simulation can bring information up on the screen while displaying the simulation.
 

More than 50 new features

Automatic saving of intermediary rough stocks saves time, notably on programs that involve multiple machining operations. Intermediary rough stocks produced during a simulation are saved automatically at each tool, program, or sub-program change. Users can replay the simulation from the latest valid rough stock before the detection of an error or a change, without starting over.

Automatic removal of support lugs from the rough stock at the end of the simulation has been added, which automatically recognizes support lug information in order to keep the simulated part and not the associated scrap. Machine accessories can be positioned automatically by processing the contact with tailstocks, rests, and chucks on the machined rough stock, enabling the job to be set up and built quickly.

To facilitate data exchange, the latest version offers a CAM interface with Alphacam 2013, in addition to the existing CAM interfaces.

SPRING Technologies
www.springplm.com

See the video to experience NC SIMUL Machine in action at http://bit.ly/1fB7ilU.