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Renault F1 Team on Developing Composite Racecars In 6 Months
LWV5 ConferenceOctober 6, 2003
Alex EdwardsVISTAGY, Inc.
F1 Design Challenges
Get It Right the First Time PhilosophyFIA Testing
– Side Impact Tests– Nose Push Off Test– Nose Impact Testing– Rear Impact Testing– Roll Hoop Tests
Reducing WeightMaintaining Desirable Design Characteristics
Composite Design/Manufacturing Timescales
Very short timescales to design and manufacture the car
Composite Parts Use
ChassisRear Wing AssemblyFront Wing AssemblyBodyworkWishbonesBrake DuctsDrivers Seat
Previous Nosebox Composite Design Process Design Challenges
Produce CATIA V4 skin or solid of componentCreate major ply boundaries in 3D spaceCreate 2D viewsProject ply boundaries from 3D to 2DCreate extra 2D geometryAnnotate drawings (ply number, sequence, orientation)Dimension drawingsNO ASSOCIATIVITY OF GEOMETRIC DATA OR PLY DATA
FiberSIM Requirements
Ensure consistent quality of components (especially those previously ratified by the FIA)Fully integrate with CATIA V4 and VPMReduce time for design and manufacturing process as a wholeProvide tailored training solutionOffer superior support package- Staff knowledgeable in composite materials and
processesProvide full associativity of design data with ease of modification
R23 Nosebox Design Requirements
Reduce weightMaintain aerodynamic shape as specified by the Aerodynamics DepartmentEnhance design to improve structural integrity whilst using simpler manufacturing process
CATIA Model Preparation– FiberSIM provided starter model containing drawing
templates and Renault F1 Team defined annotation– Component and pattern surfaces used to create a
skin– All skin non-tangencies must be filleted– Ply boundaries created on skin (use of layers
important)
R23 Nosebox Design Using FiberSIM 3.5
FiberSIM Design Process– Laminate definition – specify tool surface– Rosette definition – specify fibre direction reference– Ply definition – material, fibre direction, boundary,
etc.– Drawing creation – plybooks, cross sections, ply
tables– Producibility assessment and generation of flat
patterns– Data transfer to production – laser projection,
automated cutter– Input to analysis – enables rapid design iterations
R23 Nosebox Design Using FiberSIM 3.5
Curve utilities – curve offset and curve from points (very powerful tools)Design stations – aid in the evaluation of design criteriaPart attribute calculations – weight, c.g., area, costAuto ply dropoff – decrease time to define layupZone utilities – create plies from zonesLaminate mirror – define above core plies in one step
FiberSIM Utilities
Auto-chaining of ply boundaries – no need to create single concatenated curve boundariesSplicing – automatic tools allow rapid ply definitionDarting – 3D dart geometry created/modified quickly3D Cross Sections – allow easy part visualizationManufacturing Trim – automatically defined for rapid transition to productionSkin Swap – allows rapid modification when design changes are required
FiberSIM Utilities
Ply Defined – Initial FiberSIM Producibility
Initial Producibility Results
Initial Flat Pattern for Cutting Machine
Darts Defined to Resolve Manufacturing Issues
Revised Producibility Results
Revised Flat Pattern for Cutting Machine
Laser Data Generation
Ply Book Generation (1)
Ply Book Generation (2)
Effectively manage all composites dataAble to do more work in 3D (created detailed ply boundaries)Automatically created engineering drawings and manufacturing plybooksProvided full associativity of geometric and non-geometric dataFLAT PATTERN AND PRODUCIBILITY DATA PROVIDED FOR FREELASER DATA PROVIDED FOR FREE
Improvements in FiberSIM Process Over Original CATIA Process
Nose 12% lighter than last yearFiberSIM weight prediction was 99% of actualFiberSIM-predicted darts aligned correctly in mould toolPlybook modifications required minimal timeReduction in man hours for design and manufacturing process
Results of Trail (1)
Total process time reduced by eliminating the need to create ply templates
Results of Trail (2)
XXLaser Output
XXDXF Output
XXXXPlybooks
Group 4(e.g., Brake
Ducts)
Group 3(e.g., Chassis)
Group 2(e.g., Front & Rear Wings)
Group 1(e.g., Floor)
FiberSIMProcess
(Full/Partial)
Classification of Parts
60% of F1 teams with CATIA V4 use FiberSIMFiberSIM 3.5.1 has Renault F1 Team-specific enhancements (available to all 3.5.1 users)Composites software is the core of VISTAGY’s business
– FiberSIM has proven track record in aerospace composites market
– Used on 90% of all production programs
– UK support is 30 minutes from Enstone site– Entire support staff has experience in composites
design and manufacturing– Able to provide answers within 24 hours
Renault F1 Team and VISTAGY Partnership
In preparation for designing the 2005 car:Further benchmarking of FiberSIM 4.x to be completed in January 2004Starting complete composite process pilot of CATIA V5 in February 2004All designers are to be trained on V5 in June/July 2004All designers to be trained on FiberSIM 4.x in August 2004Existing FiberSIM 3.5.x data will transfer seamlessly to FiberSIM 4.x
Transition to CATIA V5
FiberSIM 4.0 on CATIA V5Producibility Simulation
FiberSIM 4.0 on CATIA V5Flat Pattern Generation
Partnership between VISTAGY and Renault F1 Team enables Renault to be involved in the development of FiberSIM 4.x
– Resulting tool will be well-suited for handling the challenges of Formula 1 design
– Faster composite development process for automotive applications
Even More Success Expected with FiberSIM 4.x on the 2005 Car