Composites General Process
The Composites process group provides three alternative processes that model the process of laying up plies onto a mold:
• Hand layup (default layup process): plies are laid up by one or more operators. For some parts, one or more cores are placed between ply layers. Multiple layers are laid up, and debulking (using a vacuum bag) is performed periodically, between layers. Setup options allow you to control when the first debulking occurs and how often subsequent debulks occur.
In addition to layup and debulking costs, the model for this process also includes costs for a vacuum drop test and for attaching thermocouples in preparation for autoclave curing.
The model calculates layup times from area-based layup rates that take into account the complexity of each ply. For parts with cores, the model includes potting costs for core regions that contain fastener holes. A setup option allows you to specify the number of fastener holes in the part (0, by default). The model also includes costs for core splicing, if necessary. A setup option allows you to specify the total length of the joints formed by core splicing for the part (also 0, by default).
• Automated Fiber Placement (AFP): plies are laid up by a machine that uses spools of relatively narrow ply material (1/8”-1/2”). The cost model assumes that cores are not used with AFP. In addition to layup costs, the model for this process also includes programming costs, as well as costs for a vacuum drop test and for attaching thermocouples in preparation for autoclave curing.
The model calculates layup times from area-based layup rates that take into account the complexity of each ply. Layup times are also driven by the number of active machine spools. Setup options allow you to specify programming cost, as well as to override the calculated number of active spools.
• Automated Tape Layup (ATL): plies are laid up by a machine that uses spools of relatively wide ply material (6”-12”). The cost model assumes that cores are not used with ATL. In addition to layup costs, the model for this process also includes programming costs, as well as costs for a vacuum drop test and for attaching thermocouples in preparation for autoclave curing.
The model calculates layup times from area-based layup rates that take into account the complexity of each ply.
Hand layup is included by default in the routing for a Composites part. Users can manually include AFP or ATL instead. All three layup processes take into account tooling and materials costs—see
Tooling for Composites and
Materials for Composites.
Note: In the Composites interface and in this documentation, “mold” and “tool” generally refer to the same thing: the mold onto which plies are laid.
The process group also provides processes that model cutting plies from a roll (prior to hand layup), cleaning and preparing the mold, curing the part, removing the part from the mold, and inspecting the part:
• Ultrasonic Cut: accounts for costs associated with unrolling, cutting, and splicing (if necessary) material in order to assemble ply kits for hand layup. It also accounts for identing and unloading plies.
Cutting time calculations are perimeter based. Cutting rate is taken from a machine property or setup option. Plies are assumed to be cut one at a time, by default, but a setup option allows you to specify the number of plies stacked up in order to be cut all at once. Cutting rate is adjusted when plies are stacked.
• Tool Clean: accounts for costs associated with manual, laser, or cryogenic cleaning of the mold. For manual cleaning, the cost model also accounts for the cost of cleaning agent. The clean time calculation is area based.
• Mold Preparation: accounts for costs associated with applying and curing some number of coats of mold release material, as well as costs associated with applying and curing tack. A setup option allows you to specify the number of mold-release coats. You can manually exclude tackifier application and curing.
Times are calculated based on mold area, as are consumable material costs for mold release and tackifier.
• Autoclave Cure: accounts for costs associated with attaching and detaching thermocouples, loading and unloading the part, and curing the part with heat and pressure in an autoclave. A setup option allows you to specify that multiple parts cannot share the autoclave machine during a cycle, which affects overhead calculations. Multiple parts are assumed, by default, if they can fit in the machine.
• Bench Operation: Tool Breakdown: accounts for costs associated with moving the part and tooling into the work cell, removing the vacuum bag, removing the part from the tool, and moving the empty tooling out of the work cell.
Moving and part-removal times are based on part and tool dimensions. A setup option allows you to override the calculated part removal time. Vacuum bag removal time is based on part perimeter.
• Bench Operation: Final Inspection: accounts for costs associated with visually inspecting the finished part. Times are calculated based on part surface area.
These processes are followed by secondary processes, including Milling (on a 5-Axis Mill), Ultrasonic Scanning (C-Scan or A-Scan), and Manual Paint.