Fiber Tool Path Simulation -tool path simulation using UG

1. Fiber Tool Path Simulation-tool path simulation using UG Teresa Chen-Keat GE Global Research Center

2. Fiber Tool Path Simulation-Industry demand Aerospace and Automobile Industries demand more and more composite components

3. Fiber Tool Path Simulation-Manufacture Strategies • Traditional prepreg (pre-impregnated resin in continuous carbon fiber) fiber cutting/laying method • Directly fabricate the component parts using dry preform by fiber placement/winding

4. Fiber Tool Path Simulation-tool path generation • We can’t apply regular CNC tool path approach via UG CAM to generate fiber winding the tool path. Fiber placement/laying/winding machine still in development not as mature as the conventional CNC machine

5. Fiber Tool Path Simulation-tool path generation • Difference in fiber tool path generation vs regular metal removal tool path generation:

6. Fiber Tool Path Simulation-tool path generation using Cadwind • Cadwind: a winding software. Cadwind can generate basic tool path and post process to NC code. What we need is more than just basic winding pattern.

7. Fiber Tool Path Simulation-fiber patterns • Different patterns can be applied in making the same part. Fiber patterns have great impact on the component mechanical property.

8. Fiber Tool Path Simulation-tool path simulation using UG • Why do we need to simulate the tool path generated by Cadwind: • Cadwind doesn’t provide generic tool path simulation capability. • The toolpath used in our process is normally not direct use of Cadwind tool path. • To understand the fiber pattern before fiber being laid.

9. Fiber Tool Path Simulation-tool path simulation using UG A simple case: winding on cylindrical mandrel

10. Fiber Tool Path Simulation-tool path simulation using UG • Steps/Issues: • Read in x,y,z of fiber contact points from an intermediate output file generated by Cadwind. • Generate the curve • Project the curve to the mandrel surface. (PR5955216)

11. Fiber Tool Path Simulation-tool path simulation using UG • Create a line using fiber width as the length. • Create swept feature using the line as section curve and projection curve as guide curve

12. Fiber Tool Path Simulation-tool path simulation using UG • Calculate the angle from start to end position • Use Copy feature to put repeating fiber patterns on the mandrel

13. Fiber Tool Path Simulation-tool path simulation using UG • Visualize combined winding cycle

14. Fiber Tool Path Simulation-future work and application Important for having a reliable way to generate the swept feature. Visualization for asymmetric winding. Visualization for complicated fiber patterns.

15. Fiber Tool Path Simulation-UGS can help • Geometry entity for fiber (spline with width) • Tool path generation capabilty • Post for fiber fabrication machine.