Turn around time reduction…

August 15, 2008

Turn around time reduction…

… in early attribute assessments using latest software tools

like SFE CONCEPT , Perl and HyperMesh

JJöörgen Hilmann, Ford of Europe, rgen Hilmann, Ford of Europe, Basic Design Basic Design SafetySafety

Hans Zimmer, SFE GmbHHans Zimmer, SFE GmbH

President & CEO SFE GmbHPresident & CEO SFE GmbH

EHTC 2008 Strasbourg - Jörgen Hilmann | Hans Zimmer

August 15, 2008 2

Design Requirements – A Pillar section

ExteriorStyling

Exterior Styling

Design studio

Glassplanes / Barrels

Body Closures Team

Interior

Interior Styling

Vehicle Package

A-pillarvisibility

Visibility Requirements

Vehicle Package & Body Engineering

Weldtoolaccess

Weldtool

access

Weld Tool Acccess

Manufacturing & Body Engineering

Section Properties

Attributes & Body Engineering

Selected Requirements / ConstraintsInvolved Teams

What is the best balancebetween the attributes?

How to get there?

Assembly requirement

Assembly Constraint

Manufacturing & Body Engineering


August 15, 2008 3

Update 2

Update 3

Updateb

UpdateI

Separate CAE Attribute Workstreams

Completeness

CAE Level of detail

Update1Pre-decessor

Safety

Pre-decessor

NVH

Pre-decessor

Durability

Update n

Updatec

Updatex

UpdateII

Compatibility

Alignment of CAE models and design intent

Baseline studyCAE Model “downsizing”

Separate Attribute Implication Studies


Old Approach

August 15, 2008 4

Motivation to change the process

�(In-) Compatibility Risk to base assessments on different assumptions

�Update effort Update effort duplicated (seperate for each attribute)

�Information exchange Major information exchange effort

each attribute responsible for change content

�Simplification effort Modeling effort to reduce the pre-decessor CAE model

preparation for paramter studies and architecture changes

�Lack of information Only Sections and 3D CAD of selected areas availalable

Cost, Weight and Manufacturing Estimates

Based on Pre-Decessor Data,

AB Comparison

Vision:Use ONE ALL NEW Geometry model as basis

for attribute and commodity assessments

Vision:Vision:Use ONE ALL NEW Geometry model as basis

for attribute and commodity assessments


August 15, 2008 5

model update

VCS 3 Level

Safety NVH Durability

Baseline study

Component studiesConcept development& Iterations

Virtual design verification

Pre-decessor

Safety NVH

New model

VCS 1 Level

Safety NVH Durability

model update

VCS 2 level

Compatibility

Alignment of CAE models and design intent

Completeness

CAE Level of detail

A B

Re-Use of Models Database


Integrated CAE Attribute Workstream

New Approach

August 15, 2008 6

Points / Lines / Sections

Joints / Beams / Freeform

Welds / Adhesives / Bolts

Penetration-free FE Meshes

Surface Mapping

Point area Loading, Etc.

SFE CONCEPT

SFE CONCEPT – Features

Geom

etr

y

Cre

ation

& F

eatu

res

Auto

-m

eshin

g

Evaluation

e.g. sections forces

Import

/ E

xport Iges / VDAFS / Step / …

CATIA

Beads, Stamps, Ribs


August 15, 2008 7

Before Mapping (Projection) After Mapping (Projection)

Change in Map Target Change in Map Target

Change in Map Target Change in Map Object

Mapping (Projections) in SFE CONCEPT


August 15, 2008 8

SFE CONCEPT Geometry FE Mesh with Rigids

SFE CONCEPT Geometry - Modified

Variable size FE Meshwith automatic update of Rigids

Rigid Elements in SFE CONCEPT


August 15, 2008 9

• Geometry based connection types (Rigids, Mass, Trace surface, etc.)

• Easy model assembly for crash & NVH

SFE CONCEPT

Patches for

RADIOSS/LS-DYNA

Rigid Spiders for

NASTRAN

Parameric

attachments

Patches for Automated assembly


August 15, 2008 10

Adhesives / Bonding

Adhesives as CHEXA-CPENTA

SFE CONCEPT Geometry

Adhesives as CHEXA-CPENTA-RBE3


August 15, 2008 11

Section Force definition on Geometry

Define cutting plane by:

User Defined GridAnd Plane Normal Direction

Select SFE CONCEPT objects to be cut

Select PIDs to exclude from cutting (optional)


August 15, 2008 12

Process Chain input


From SFE CONCEPT

�Finite element model

�For symmetrical parts just a half

�For unsymmetrical parts the complete part

�Adhesives

�Master Welding information

�Rigid body formulations

�Evaluation sections

Incremental user input defined

in the Basic Design CAE BOM

�Material ID

�Panel thickness

�Name

�Mirror information

August 15, 2008 13

Automated model built

Application Task

Perl Duplicate the halfmodel and process RADIOSS PID/PART/SUBSETS, reflect model including sections, rigid bodies, adhesives

Duplicate master welding files under consideration of changed PID (e.g. outer panel)

HyperMesh Merge in vehicle centre line part by part

Update element typesRenumber and group nodes, elements


symmetrical un-symmetrical parts parts

To be merged in vehicle centre line

Final INCLUDE File & Master Welding File in all formats

Reflected partneeds mergekeeps original PID

Reflectedpart

receivesnew PID

Different PID

Same PID

August 15, 2008 14

Pre Processing attribute models


Load connection file realize spot welds check results

Application Task

HyperMesh Read master welding file and realize spotwelds

Different options available: witout failure characteristic

with failure characteristic dependent to the material properties and panel thickness

Node

Spring

Node

For RADIOSS

August 15, 2008 15

Modular Model Built

Combination of

detailed correlatedpredecessor parts

and

SFE CONCEPT derived parts


August 15, 2008 16

Conclusion

ConclusionConclusion

�For major top hat changes th turn around time was compressed from about 5days

work to less than 1 day

�The number of required process steps, tools, and manual interaction was reduced.

�The model built quality and robustness was hereby improved significantly.

�Both Compatibilty and Level of Detail Within the Engineering World Improved

�Up Front process is an Enabler For Early Failure Mode Detection �� Process

estabilshed

ProspectProspect

� Include the evaluation procedure already in the model built

�Enhance the module database with design alternatives

& Prospect

Jörgen Hilmann | Hans Zimmer

August 15, 2008

… in early attribute assessments using latest software tools like SFE CONCEPT , Perl and HyperMesh

Thank You for Your Attention

JJöörgen Hilmann, Ford of Europe, rgen Hilmann, Ford of Europe, Basic Design Basic Design SafetySafety

Hans Zimmer, SFE GmbH, President & CEO SFE GmbHHans Zimmer, SFE GmbH, President & CEO SFE GmbH

Turn around time reduction…

Documents

Turn around time reduction…