Project Information

PRECIMOULD+ (High Precision Composite Moulding)

PRECIMOULD+ is a collaboration between Finite Element Analysis Ltd. - developers of the LUSAS finite element software, Advanced Composites Group Ltd. , Bombardier Aerospace, Belfast, and BAE Systems. The aim of the project is to develop and validate a software package to refine the accuracy of the predicted distortion of laminated composites during processing, reverse engineer surfaces and apply the simulation to complex structures. Benefits expected from the developed technology include: design confidence to predict and remove distortion, reduction of scrap and reworking, and reduced assembly costs.

During the cure and post-cure of composites, dimensional changes occur which lead to distortion. Predicting these changes and applying an inverse correction to the tooling will enable large cost savings to be achieved. By integration of the analysis software in a design package competent design engineers will be able to extract master model and tooling surfaces "right first time" which will significantly improve the time to market cycle.

It is estimated that in aircraft airframe applications 50% of the costs associated with composite parts occur during the assembly process. This is mainly due to the distortion of individual components and the time associated with the rework and shimming processes required to accommodate these distortions. Typically in an aircraft assembly up to 200kg of shimming can be used to correct errors due to component distortion.

By employing the proposed PRECIMOULD+ predictive software in the design process it is anticipated that the cost and time required to assemble composite components could be halved. Estimates suggest that this would reduce the cost of using composite components by 25%.

• To develop a software package to accurately predict distortion of laminated composites during processing

• To accurately produce nominal CAD surfaces of master/mould tool

• To validate the software for variety of manufacturing processes (Prepreg, RTM, Infusion)

• To integrate with standard aerospace software systems (Catia, CADS, FibreSim) and aim for use by competent tooling CAD operators

For further information please contact the PRECIMOULD+ Project Coordinator, Dr. David Irving, at info@lusas.com