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Faurecia started to use Altair product years ago mainly for the support of the main crash solvers (RADIOSS, LS-Dyna, Pam Crash, Abaqus). This is a key strength as Faurecia has to deal with all those solvers in order to deliver seat models in car makers format. In order to increase its simulations quality and efficiency, Faurecia decided in 2008 to switch all its FEA Operations to LS-Dyna. That leads to increase drastically the exigency level for Ls-Dyna support inside Altair products. A two years closed collaboration between the two companies started in 2012 focusing first on HyperMesh : main challenge was its capacity to handle (open, edit,save) complex Dyna models build up with a lot of include files. HyperMesh and HyperView being generalist pre and post processor software, Faurecia has in addition developed several customizations throught Tcl/Tk scripting language. This presentation will give a global overview of all efficiency tools developed focusing on the pre & post tasks for parts connections (screws and laser welding lines).
Citation preview
7th E-ATC • Munich 24 June 2014
Matthieu Debray
Efficient Pre/Post operations at Faurecia Seating
with Hyperworks products
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Agenda
Faurecia
FEA @ Faurecia automotive seating
Faurecia / Altair cooperation
Customization Basic examples
Customization Advanced examples
FEA reports
Q&A
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Faurecia
Faurecia is Tier1 automotive supplier split in 4 business groups:
Padding
Headrest
Cover
Mechanism
s
Frames
97,500 employees
320 sites
34 countries
30 R&D centers
500 patents filed in
2012
2013 Key figures
Complete exhaust lines
Mufflers
Catalytic converters
Manifolds
Diesel particulate filter
Commercial vehicles
Cockpits
Acoustic
modules
Door
panels
Instrument
panels
Decoration
Center
consoles • Front End Modules (FEM)
• Front End Carriers / GOR
• Engine cooling systems
(ECS)
• Bumpers
• Trims & rocker panels
• Outside body panels
• A-class
• Semi-structural (closure)
• Structural
FAS FIS FECT FAE
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Simulation & Testing in Seating Division
One worldwide Team:
Test and FEA managed by the
same engineer
Standard tests methods WW
Standard FEA methods WW
FEA / Test lab FEA Test lab
Simulation Portfolio:
Mainly Safety & Regulations
~20 loadcases per project
>20 000 single iteration per year
worldwide
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Department Target
What we want:
Right @ 1st physical test FEA vs Tests > 85%
High Confidence in FEA Models
FEA roadmap to improve model quality
More & more detailed in models
Huge numbers of iterations
Fast parts replacement including connections
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Our métier
Seat versions
FEA iterations
Seat adjustment
Testing
configurations
Constraint : 20 loads cases per project
Safety
Test Dummy Position
Front Impact
R BFR 56 HIII 95 Mid/Mid
R BFR 56 HIII 95 Rm/Lm -> Rm/Mid
R BFR 56 HIII 50 Mid/Mid
N 56km/h HIII 95 Mid :: Mid/Lm F GR114627 F GR114496 F GR115460 F GR114897 F GR114890 F GR115470
N 56km/h HIII 50 Mid :: Mid/Lm F GR114625 F GR114708 F GR115462 F GR114900 F GR114941 F GR115475
Rear Impact
R ADAC HIII 95 Rm :: Mid/Rm
R ADAC HIII 50
N PHEV (32g) HIII 95 F GR115461 F GR115264 F GR115467 F GR115644 F GR115477
N PHEV HIII 50 F GR115641 F GR115643 F GR115480
Luggage Retention
DIN 75410 Part2 Rm -1 notch / Lm
Side Impact
Corridor 1
Corridor 3
Corridor 4 F GR114756 F GR114764 F GR114873 F GR114885 F GR114874
Corridor 5 F GR114759 F GR114772
Corridor 6
Regulation
Anch. Resistance
FMVSS/ECE curve Rm/Lm F GR115524 GR115713 F GR115722 F GR115525 F GR115900 F GR115720
FMVSS/ECE curve Fm/Um
FMVSS/ECE curve Mid/Mid F GR114750 GR115810 GR115811
M M
4W 6W 4W 6W
- - - --
- - - --
Manual / Power
Version
Easy Entry
Tablefold
4W 4W
P P
Memo
M P
- - - -
-
-
- -
-ODS ODS ODS- -
Design & Validate Seats fulfilling OEMS & Regulations Specs
Deliver Seat FEA Models to OEMS for Complete Vehicule Synthesis
Constraint : deliver in OEM Solver format
Since 2008 : One internal solver for all Operations + Conversions
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A nightmare for every pre-processor 7
FEA models architecture
2 levels of includes files
Each file can be called several time
handle by a Simulation Data Manager
One solver : fine but …
Hypermesh (up to v10) was not able to fully open/save without issues our models
Main root cause:
Load case diversity leads to define a complex architecture to be efficient
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FAS / Altair cooperation
2 years of cooperation with Altair development team to:
Open & save ls-dyna models while preserving include file structure
Develop management of isolated includes files
Improve efficiency : creation, review, modification of entities
This work have impacted / created:
LS-Dyna FAS Keywords support
Femzip support
Transformation manager
IDs manager
Review button
Properties area
Parameter browser
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Replace Part A by Part B : looks simple but …
Leads to update all Part B environment
Screws replacement
Laser welding update
Mapping of stamping process
Renumbering
Checks
…
Is Hypermesh “Core” able to do that in 5 clicks ?
NO !! Strongly linked to Enterprise methods
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Efficiency Tools
Scripting :
Tcl/Tk
XML
skills needed
No limit
Efficiency tools Altair solutions to reach the “5 Clicks” is to
develop métier tools :
Session replay :
TPL
.cmf
no developers skills
Limited possibilities
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Basic tools – HM: Renumber
need to repeat for all entities
Not follow internal rules
HM core FAS customization
All entities are renumbered in one click
Follow internal rules
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Basic tool – HV : LS-Dyna groups
Hyperview core : to display only the seat frame
FAS customization: only
@opening:
Groups per
includes
Groups per
materials
A% retrieved from
our matDB
Colors setup
Show/Hide
function for
groups on
contextual menu
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Advanced tool : Screws
« Old » Since 5 years
Tools:
Connectors feature in HM
Some minutes
1 Screw model =
9 parts , 6 sections & Material
3 entity sets, 2 coordinate system
1 preforce, 2 contacts
Time to put 1 screw manually = 20 min at least
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Advanced tool : Screws
In 2012, a tool has been created by Altair
Replace part use case: screw deletion + screw creation
Take head/nut & matrial
from database
Position the screw
Create washers
Calculate all diameter
and contact gap
Setup contact, sets
Create preforce
Put each parts in the
correct include
Respect the numbering
rules
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From 20 min to <1min
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Advanced tool : Screws
Failure assessment:
HV/HG core : Very boring, several hours of post-treatment
Customization is mandatory script inside HV (internal development)
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Advanced tool : Laser welding line
Previously Today
Row of spotwelds
~3 mm mesh
Tied contact
Hexa elements
1.4 mm mesh
Transition zone
Coincident nodes
Connectors features
Some minutes
Tools:
By hand :
Several additional hours of mesh/pre
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Advanced tool : Laser welding line
Internal development done to automate / assist the FEA pilots
Use case: change the welding line shape
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Advanced tool : Laser welding line
For post processing, tool with user interaction that assist him to
assess the risk of failure.
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Automate FEA reports ?
Now:
Take CAD
Make FEA
Send report
Simulation
Data
Manager
Old approach
Dead document
Service provider
Time consuming
Take CAD
Make FEA
Analyse jobs
Capitalization
Data Mining
Stored automatically in DB
Key results
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Key results in SDM
Example: In rear crash, one of the key criterion is the maximum dynamic backrest angle.
Using customization in HV: the value is automatically stored in the SDM database
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Conclusion
Hypermesh is now a good pre-processor for LS-Dyna
But Core function of HW are “general” ones
Our game field
More & more complex models
Less & Less time to pre & post process them
Customization is mandatory
Tcl/Tk
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Q&A
Thanks for your attention.