JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 35

physical prototypes needed to finalize the design. Powerful design optimization tools also include the ability to swap ply edges, optimize drop-offs, shape plies and re-route sets of plies along a preferred path. Integrating advanced specialized applications into the composite design environment makes it possible to simulate ply behaviour at an early stage and to evaluate fibre deformation. Engineers can visualize the ply stacking and tweak the laminate structure to eliminate wrinkles and other issues like fibre defects, fibre misalignments, broken fibres or missing fibres before the design is sent to manufacturing. It also becomes possible to generate conceptual solids to quickly integrate the composite part in the mock-up, enable concurrent engineering with mating parts, and even provide preliminary inputs for tooling to start working on the mould.
Fig. 2: Plies in minimum crossing mode

feedback on whether the changes have corrected the design problem.

Improved composite blade reliability and durability
To test the blade durability and reliability, the analysis department applies many different loading conditions that simulate various wind conditions. Based on the results, the analyst goes back to the designer and recommends changes to the plies. This is typically a repetitive process involving numerous iterations between the analyst and the designer to reach the adequate level of performance.
Fig. 3: Load simulation in SIMULIA

force generation and failure in defined “crush zones”, and VCCT (Virtual Crack Closure Technique). Engineers can use VCCT to identify the overall load at which a crack initiates and to predict the behaviour of the structure as the crack propagates. It also helps them understand the stability and loadcarrying capacity of the composite structure after failure. Not having the possibility to validate the detailed blade design early in the development process is highly detrimental as it may cause structural damage, surface defects, and thin cracks in bonding areas. As quality assessment becomes more important for larger structures, integrated simulation solutions are there to demonstrate that the performance of the final blade complies with the blade design specifications and with blade manufacturing rules from both an internal (processes/requirements) and an external (regulation) standpoint.

Integration with tooling solutions means the tooling designer can create the mould based on the precise output surface. Rotor blade moulds can consist of several complex systems such as an integrated heating system, a hydraulic closing device and a built-in vacuum system that can be designed within the same environment. The lay-up of the composite plies onto the mould tool is simulated to identify areas where the part geometry will cause fabric distortion. The engineer can then add darts or splices, or make other changes to the ply and receive immediate

Integrating the design information with a finite-element analysis programme helps eliminate these lengthy iterations. Additionally, the ability to transfer accurate fibre angles and ply thicknesses directly from the design to the analysis environment improves simulation accuracy. Transferring updated design information from analysis seamlessly back to design enables designers and analysts to work closely together, ensures the analyzed model matches the final structure, and avoids specifying plies and structures that cannot be manufactured down the road. Analysts need advanced, state-of-the-art solutions to simulate composite behaviour realistically, including delamination and damage. These complex, non-linear effects can be modelled using cohesive elements, CZONE technology for direct implementation of crush-based element

No64 April 2011 / jec composites magazine Securing blade life spans of 20 years and beyond requires highly industrialized production planning and manufacturing processes. Process standardization is essential and requires an integrated planning solution to define standard manufacturing processes and resource libraries. Manufacturing processes can be optimized to minimize investment and production costs. Quality assurance (QA) planning and adequate QA measurements for critical manufacturing steps are integrated in the process plan. Optimizing the workflow and directly deriving the complete manufacturing documentation from the process plan are also important. The process plan and work instructions can be generated automatically by taking advantage of the ply stacking and composite properties from the design model to deliver comprehensive process

Securing high-quality production and reducing manufacturing costs

35

Feature wind energy



JEC COMPOSITES MAGAZINE - Issue #64 - April 2011

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #64 - April 2011

Cover
Edito
Point of view: fast expansion
Contents
Agenda of Events
COMPANY & BUSINESS
In Brief
Reinforcement - Red Composites: a real expertise in carbon fibre
Housing - Housetec: a young company with a background of 40 years’ experience
Asia - Hua Dong Fibreglass, an SME that exports worldwide
APPLICATIONS
Construction - Creative eye-catching design for a new Sheraton hotel
Marine - Multiplast builds the Groupama V070
Awards - ICERP-JEC Innovation Awards Programme 2011: eight companies rewarded
MARKET
Human capital - Latest appointments
Sports and Leisure - Rossignol Group: innovation and performance in winter skis applications
FEATURE WIND ENERGY
Reinforcement - WebCore Technologies: great ambitions in the wind industry
New rovings for wind turbine blade applications
Prepreg spar caps: a solution for today
Software - Industrial software for manufacturing large components such as wind blades
Leveraging an end-to-end solution for composite wind turbine blades
Laser placement - Manufacturing rotor blades with highest precision while reducing costs
Automation - A fully-automated manufacturing process for wind blades
Maintenance - An innovative, certified blade repair system
RESEARCH & DEVELOPMENT
Testing - Using nano-scratch testing to detec composite failure
Mould - Processing technology for the rapid production of advanced composites
TECHNOLOGY & INNOVATIONS
Robot - Robotic fibre placement machine helps reduce energy consumption
Process - A new industrialized construction process for transport infrastructures
Fibre placement - Tape laying and fibre palcement: complementary solutions
NDT - What’s new in non-destructive testing labs?
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Cover
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 2
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Edito
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Point of view: fast expansion
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 5
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Contents
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 7
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - In Brief
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Reinforcement - Red Composites: a real expertise in carbon fibre
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Housing - Housetec: a young company with a background of 40 years’ experience
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Asia - Hua Dong Fibreglass, an SME that exports worldwide
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 13
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Construction - Creative eye-catching design for a new Sheraton hotel
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 15
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Marine - Multiplast builds the Groupama V070
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 17
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Awards - ICERP-JEC Innovation Awards Programme 2011: eight companies rewarded
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 19
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 20
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 21
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 22
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Human capital - Latest appointments
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Sports and Leisure - Rossignol Group: innovation and performance in winter skis applications
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 25
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 26
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 27
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Reinforcement - WebCore Technologies: great ambitions in the wind industry
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 29
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - New rovings for wind turbine blade applications
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Prepreg spar caps: a solution for today
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Software - Industrial software for manufacturing large components such as wind blades
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 33
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Leveraging an end-to-end solution for composite wind turbine blades
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 35
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 36
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 37
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Laser placement - Manufacturing rotor blades with highest precision while reducing costs
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 39
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Automation - A fully-automated manufacturing process for wind blades
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 41
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Maintenance - An innovative, certified blade repair system
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 43
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 44
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Testing - Using nano-scratch testing to detec composite failure
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 46
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 47
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 48
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Mould - Processing technology for the rapid production of advanced composites
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 50
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 51
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 52
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Robot - Robotic fibre placement machine helps reduce energy consumption
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Process - A new industrialized construction process for transport infrastructures
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 55
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Fibre placement - Tape laying and fibre palcement: complementary solutions
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 57
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - NDT - What’s new in non-destructive testing labs?
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 59
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 60
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 61
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 62
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 63
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 64
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 65
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 66
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 67
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 68
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