CAD / CAE Leichtbauprozesse entlang der Zulieferkette

Transcription

1 CAD / CAE Leichtbauprozesse entlang der Zulieferkette Roman Reuschke und Manfred Dienes Innovation Intelligence Altair Engineering GmbH Altair, Zulieferer im Automobil Leichtbau - Strategien, Technologien, Disziplinen, Welche Daten sind erforderlich Innovation Intelligence Was hat Altair zu bieten Optimization Center Case Studie Getrag / Truck Inspire 1

2 All Across the Globe 45+ offices in 22 countries on 6 continents with over 2,200 engineers, scientists, developers, designers and creative thinkers We Work with Some of the Best Automotive Aerospace Heavy Equipment Government Electronics/ Life/Earth Sciences Consumer Goods Energy Architecture 5,000 customers worldwide 2

3 Beitrag der Zulieferer zum Leichtbau Zulieferer entwickeln und liefern eine Vielzahl von Fahrzeugkomponenten Gewichtsanteil am Fahrzeug ist entsprechend hoch Zulieferer muessen befaehigt werden die Verantwortung am Leichtbau wahr zu nehmen indem: Techniken zur Optimierung bereit gestellt werden (CAE Software / Support) Alle notwendigen Daten zur Gewichtsoptimierung definiert und zur Verfuegung gestellt werden (OEM) Light Weighting Strategies Advanced Materials High Strength Steels Non-ferrous metals Composites Changing Architecture New structures Mixed materials Different needs Design Process More simulation Optimization Material modeling 3

4 Light Weighting Strategies Advanced Materials High Strength Steels Non-ferrous metals Composites Changing Architecture New structures Mixed materials Different needs Design Process More simulation Optimization Material modeling Put the Right Material in the Right Place Boeing 787 Material Breakdown 4

5 Light Weighting Strategies Advanced Materials High Strength Steels Non-ferrous metals Composites Changing Architecture New structures Mixed materials Different needs Design Process More simulation Optimization Material modeling Automotive next generation BMW i3 5

6 Aerospace next generation Airbus 2050 Vision Light Weighting Strategies Advanced Materials High Strength Steels Non-ferrous metals Composites Changing Architecture New structures Mixed materials Different needs Design Process More simulation Optimization Material modeling 6

7 Are we exploiting the full potential of simulation? Design Performance/Maturity/Details CAD Traditional CAD CAD CAE CAD De-featuring CAE CAD CAE Modeling CAE Results CAE Simulation Driven Previous Design Previous Design Time Are we exploiting the full potential of simulation? Design Performance/Maturity/Details CAD Traditional CAD CAD CAE CAD De-featuring CAE CAD CAE Modeling CAE Results CAD CAE Simulation Driven Previous Design Previous Design Time 7

8 Altair positioning in Light Weighting.. (*) Design change as Facilitator: (*) Leichtbaustrategien für den Automobilbau, Stuttgart 10. und 11. Juni 2012, Müller, Porsche Topology Optimization Process Casting Direction Stiffness Mass F 1 F 2 M 1 Mesh generation, definition of loads and boundary conditions Setup of optimization problem, definition of design constraints Computation Interpretation of results Definition of available package space CAD Design 8

9 Optimierungsdisziplinen Werkzeug zur Bestimmung einer optimalen Materialverteilung innerhalb eines vorgegebenen Bauraums Volumenbauteile Optimierungsdisziplinen Schalenbauteile 9

10 Optimierungsdisziplinen Werkzeug zur Ermittlung von optimalen Sickenmustern für dünnwandige Bauteile Optimierungsdisziplinen Werkzeug zur Formmodifikation bestehender Bauteile 10

11 Optimierungsdisziplinen Werkzeug zur Bestimmung der optimalen Parameter von 2D / 1D Bauteilen und Laminaten Optimization State of the Art Technology Today Calculating weight saving... Calculating weight saving... Calculating weight saving... 15% 23% 20% FE-Based optimization technology topology, topography, sizing, shape, staking, free-shape, multi-disciplinary... 11

12 Copyright 2013 solidthinking, Inc. Proprietary and Confidential. All rights reserved. solidthinking Inspire Success Original Design: * Inspire Design Proposal Final Design: - 55% mass! *Source:. Hoepke, S. Breuer (Hrsg.),Nutzfahrzeugtechnik, Vieweg+Teubner, Wiesbaden 2013 Simulation Driven Design key enablers Geometrie, verfügbarer Bauraum, Verbindungstechnik zur Umgebung Lasten, Lastkollektive, Funktionen (das Bauteil kann nur das was vorher definiert wurde das Ziel einer Optimierung) Materialdaten (linear statisch, hoch dynamisch, Lebensdauer) Fertigungsverfahren, Auszugsrichtungen, Montage Einfache Benutzung, Prozesssteuerung, Training 12

13 Fundamental Procedure of Topology Optimization old design design proposal CAD CAE Datenaustausch 13

14 FATXML Durchgängigkeit von Daten im CAE Prozess CAD->Pre(HM)->Solver(OS/Radioss)->Post(HV) Allows Suppliers to better integrate into OEMs processes. Part Names, Part Revision, Creator, Date, Material Name, is kept through the whole process. No loss of information when leaving OEMs PLM environment FATXML is a Standard -> Tool independent. Suppliers can choose their own (only one maybe HM) toolset. FATXML Durchgängigkeit von Daten im CAE Prozess 14

15 CAD CAE Datenaustausch Bi-directional Integration to/from PDM and Material Database Data Persistency throughout Model Build Connection Management MetaData to CAE HyperMesh 5mm Mesh 10mm Mesh Display Material Library Access to corporate material information Guarantee that accurate properties are used in simulations Seamless Integration within HyperWorks Desktop environment 15

16 Material Library Content preview Preview stress-strain curves Overlay and compare curves Import materials from library Access to material library during import process Rough Road Durability Simulation 16

17 Are we exploiting the full potential of simulation? Geometrie, verfügbarer Bauraum, Verbindungstechnik zur Umgebung Lasten, Lastkollektive, Funktionen (das Bauteil kann nur das was vorher definiert wurde das Ziel einer Optimierung) Materialdaten (linear statisch, hoch dynamisch, Lebensdauer) Fertigungsverfahren, Auszugsrichtungen, Montage Einfache Benutzung, Prozesssteuerung, Training Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Strukturfindung & Optimierung bei Altair INSPIRE OptiStruct/ HyperShape Catia HyperStudy System Level Component Level Concept Design Detailed Design 17

18 Optimiztion Centre CAE PFI DESIGN PFI PM OEM Vehicle Programme WEIGHT G3 G4 SOP OEM Line Organisation Back Office Support Worldwide Expertise & Ressourse Automotive OEM Concept Optimization Design Interpretation OEM 18% Mass Reduction Based on Previous Model Equivalent Global Targets Considered Carry Over, Modified Carry Over, New Structure Increased Collaboration between All Stakeholders (Design, CAE, Manufacture) 18

19 Airbus A380 Optimized design achieved a weight saving of over 500kg per aircraft Bombardier Coupler Casting Achieved weight reduction of 24% compared to baseline design 19

20 McLaren Venge Bike Significant weight reduction over the stock frame Topology Optimization for a New Transmission Housing Design 20

21 Modeling Gear set and shifting system are fixed and determining the form of the interior of the housing 41 Modeling Complete Design Space for Housing Design space for clutch housing Design space for transmission housing 42 ~ 3 Mio. elements 21

22 Model Setup Optimization Objective: Minimize mass Boundary Conditions : Max. allowable stresses (depends on material) Max. allowable displacements at the bearing seats Lower limit for 1st eigenfrequency >= 300Hz Load Cases: 1 st gear drive and coast Reverse gear drive and coast Modal Analysis (1st Eigenmode) 43 Getrag 44 22

23 Implementation of the Results Design Suggestion Realized Design 45 Support of Cabin Development Process at truck OEM Stiffness / NVH Crash design space load cases topology result load case Day cab Sleeper cab 1 side crash X X 2 roof crash X X 3 A pillar crash X X 4 back wall crash X X 5 driver seat pull X X 6 passeng. seat pull X 7 durability X X 8 torsion X X 9 brake application X 1 shear X (X) 0 1 bunk pull X 1 1 upper bunk pull X 2 1 front mount stiffn. X 3 verify and refine Cabin passed or exceeded all the punishing U.S. and European crash tests. But that wasn t enough, so we made sure it passed the A-Pillar impact test, the roof crush test, and the seat- and bunk-pull tests. This is the strongest cab we ve ever built, thanks to the stiff, rounded cab design. derived design (hardware) 23

24 Consolidate Information and Create Design Concept Post Calculation Normal Modes Stiffness Crash (e.g roof load > 20 to. instead of required 15 to.) Durability Weight: Required Mass Reduction Fulfilled Winners of the EUROPEAN ALUMINIUM AWARD 2010 Company: Farsund Aluminium Casting / Porsche Country: Norway / Germany Product Name: Porsche Panamera Rear Subframe Category Industrial Products Automotive & Transport Light-weight car subframe for safety functional application with high requirements in strength and stiffness. Cast as one piece in hollow design using only one sand core. With a size of 1200 by 710 by 335 mm and wall thickness down to 3,5 mm it expands the dimensions of usual aluminium castings for chassis application. The concept substitutes usual multi-part solutions and allows a high degree of functional integration. The true value of the Porsche Panamera rear subframe is that is has expanded the boundaries of what is possible in both casting and automotive design. As an alternative to the traditional welded steel sheet design concept, this ultra light weight hollow core aluminium casting is an all round winner. Its weight of 16 kg has a significantly positive impact on the environment with saving of at least 4 kg per car compared to steel. The one-piece concept with a high degree of functional integration also means less efforts during axle assembly as well as the reduction of investments. From the Jury To produce a complex thin-walled shape with no defects requires a fully controlled casting process including feeding and thermal control. 24

25 26 OUTPUT SIGNALS 26 25

26 solidthinking Inspire 2014 solidthinking Inspire

27 solidthinking Inspire 2014 Copyright 2014 solidthinking, Inc. Proprietary and Confidential. All rights reserved. Start with original CAD design 27

28 Copyright 2014 solidthinking, Inc. Proprietary and Confidential. All rights reserved. Create Package Space and Load Cases Copyright 2014 solidthinking, Inc. Proprietary and Confidential. All rights reserved. Inspire Concept Shape 28

29 Copyright 2014 solidthinking, Inc. Proprietary and Confidential. All rights reserved. Explore Different Designs / Shapes Copyright 2014 solidthinking, Inc. Proprietary and Confidential. All rights reserved. Validate Inspire Concept Shape / Proposal 29

30 Copyright 2014 solidthinking, Inc. Proprietary and Confidential. All rights reserved. Inspire Results back into CAD Copyright 2014 solidthinking, Inc. Proprietary and Confidential. All rights reserved. Original Design vs. Inspire Design New Design: 25% Lighter 30

31 Simulation Driven Design key enablers Geometrie, verfügbarer Bauraum, Verbindungstechnik zur Umgebung Lasten, Lastkollektive, Funktionen (das Bauteil kann nur das was vorher definiert wurde das Ziel einer Optimierung) Materialdaten (linear statisch, hoch dynamisch, Lebensdauer) Fertigungsverfahren, Auszugsrichtungen, Montage Einfache Benutzung, Prozesssteuerung, Training Copyright 2013 solidthinking, Inc. Proprietary and Confidential. All rights reserved. solidthinking Inspire Success * *Source:. Hoepke, S. Breuer (Hrsg.),Nutzfahrzeugtechnik, Vieweg+Teubner, Wiesbaden