5TH ANSA & META INTERNATIONAL CONFERENCE AN INSIGHT TO APPLICATIONS BASED ON ANSA TO THE BMW CAE PROCESSES
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1 Josef Fürfanger, TH ANSA & META INTERNATIONAL CONFERENCE AN INSIGHT TO APPLICATIONS BASED ON ANSA TO THE BMW CAE PROCESSES
2 AGENDA 1 History of BMW BETA Cooperation 2 Mapping Deep-Drawing Simulation 3 Convertible Top Lid Kinematics Page 2
3 BMW starts working with the Software tool BETA Late 1980 s Page 3
4 BMW starts working with the Software tool BETA BMW starts using ANSA v5 as a mesher for complete models Late 1980 s Page 4
5 BMW starts working with the Software tool BETA BMW starts using ANSA v5 as a mesher for complete models Start of intensive Abaqus Explicit Support in ANSA Late 1980 s Page 5
6 BMW starts working with the Software tool BETA BMW starts using ANSA v5 as a mesher for complete models Start of intensive Abaqus Explicit Support in ANSA BMW switches all crash projects to work with Abaqus Explicit Late 1980 s Page 6
7 BMW starts working with the Software tool BETA BMW starts using ANSA v5 as a mesher for complete models Start of intensive Abaqus Explicit Support in ANSA BMW switches all crash projects to work with Abaqus Explicit AFE Spotwelding with Failure + Postprocessing Late 1980 s Page 7
8 Dummy/seat kinematics Page 8
9 Dummy/seat kinematics Morphing & Optimization Page 9
10 Wet Area Dry Area Acoustic Insulation Dummy/seat kinematics Morphing & Optimization Doorbag Generation Sideimpact Page 10
11 Dummy/seat kinematics Morphing & Optimization Doorbag Generation Sideimpact EF Chassis Meshing Page 11
12 Dummy/seat kinematics Morphing & Optimization Doorbag Generation Sideimpact EF Chassis Meshing Roof Kinematics Page 12
13 Composites Modeling Al-Druckguss Al-Schale / Al-Profil Stahl Schale CFK-Schale / CFK-Profil Page 13
14 Composites Modeling Mapping Deep- Drawing Simulation Page 14
15 Composites Modeling Mapping Deep- Drawing Simulation CFK Post Processing Page 15
16 MAPPING DEEP-DRAWING SIMULATION THICKNESS AND HARDENING RESULTS Influences on crash simulation Using the deformation history of the material as input in a crashsimulation, provides significantly better simulation results (deformation and cracks) and helps to reduce material consumption and to optimize the weight of the part Stamping-Simulation (mesh and results) thickness distribution is displayed Crash-Simulation (mesh and results) mapped thickness distribution Crash-Simulation (body with stamping results) degree of hardening is displayed Page 16
17 END-TO-END CAE PROCESSES FOR COMPOSITE CRASH, DRAPING, FILLING AND WARPAGE MODELS Geometry Layup Draping Simulation Filling Simulation Warpage Simulation Preform feasibility RTM-Tool Design Transformation from tool cavities to parts Mapping fiber orientation Thickness distribution after preforming, RTM Calculation of permeability for RTM Fiber volume content Laminate properties Crash Simulation Page 17
18 translate APPLICATIONS BASED ON ANSA TO THE BMW CAE PROCESSES PROCESS OVERVIEW. ROOF KINEMATICS. CAD Model (CATIA V5) Disadvantages Convertible hood only consists of independent parts (Dead GEO) Connections are not converted (CAE) acceptably CAE starts again right from the beginning Every modeling step by hand FE Model (ABAQUS) NVH Stiffness Acoustics virtual dimensioning KINETMATIC STRENGTH CRASH Opening process Closing process Dimensioning Conv. parts Joint loads High Speed Crash (Front, Side, Rear) Page 18
19 PROCESS OVERVIEW. ROOF KINEMATICS. Add intelligence to the system Kinematic Tool in CATIA V5 CAD Model Basic CAD Model with Attributes Page 19
20 PROCESS OVERVIEW. ROOF KINEMATICS. Add intelligence to the system Kinematic Tool in CATIA V5 CAD Model Basic CAD Model with Attributes - PreProcessing FE Model (ABAQUS) Batch Mesher Cleaned Geometry Page 20
21 PROCESS OVERVIEW. ROOF KINEMATICS. Page 21
22 PROCESS OVERVIEW. ROOF KINEMATICS. Page 22
23 PROCESS OVERVIEW. ROOF KINEMATICS. Page 23
24 PROCESS OVERVIEW. ROOF KINEMATICS. Model Meshing 2 days 3,5 weeks Old Process New Process Add Kinematics 2,5 weeks 1 d Start of Simulation 1 d 4 days Total Time 4 days ca. 5,5 weeks time in weeks Page 24
25 THANK YOU FOR YOUR ATTENTION! Page 25
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