Turn around time reduction

Transcription

1 Turn around time reduction in early attribute assessments using latest software tools like SFE CONCEPT, Perl and HyperMesh Jörgen Hilmann, Ford of Europe, Basic Design Safety Hans Zimmer, SFE GmbH President & CEO SFE GmbH August 15, 2008

2 Design Requirements A Pillar section Selected Requirements / Constraints Involved Teams Weld Assembly requirement Exterior tool Styling access What is the best balance between the attributes? How to get there? Weld tool Interior access A-pillar visibility Exterior Styling Design studio Glassplanes / Barrels Body Closures Team Interior Styling Vehicle Package Visibility Requirements Vehicle Package & Body Engineering Weld Tool Acccess Manufacturing & Body Engineering Assembly Constraint Manufacturing & Body Engineering Section Properties Attributes & Body Engineering August 15,

3 Separate CAE Attribute Workstreams Old Approach Compatibility Alignment of CAE models and design intent Completeness CAE Level of detail Baseline study CAE Model downsizing Separate Attribute Implication Studies Safety Predecessor Update1 Update 2 Update 3 Update n NVH Durability Pre-decessor Update b Update c Update x Predecessor Update I Update II August 15,

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 August 15,

5 Integrated CAE Attribute Workstream New Approach Compatibility Alignment of CAE models and design intent Completeness CAE Level of detail Baseline study Component studies Re-Use of Models Database Concept development & Iterations Virtual design verification Predecessor New model VCS 1 Level model update VCS 2 level model update VCS 3 Level A B Safety NVH Safety NVH Durability Safety NVH Durability August 15,

6 SFE CONCEPT Features SFE CONCEPT Points / Lines / Sections Geometry Creation & Features Joints / Beams / Freeform Surface Mapping Beads, Stamps, Ribs Penetration-free FE Meshes Automeshing Welds / Adhesives / Bolts Evaluation e.g. sections forces Point area Loading, Etc. Import / Export Iges / VDAFS / Step / CATIA August 15,

7 Mapping (Projections) in SFE CONCEPT Before Mapping (Projection) After Mapping (Projection) Change in Map Target Change in Map Object Change in Map Target Change in Map Target August 15,

8 Rigid Elements in SFE CONCEPT SFE CONCEPT Geometry FE Mesh with Rigids SFE CONCEPT Geometry - Modified Variable size FE Mesh with automatic update of Rigids August 15,

9 Patches for Automated assembly Geometry based connection types (Rigids, Mass, Trace surface, etc.) Easy model assembly for crash & NVH Parameric attachments Rigid Spiders for NASTRAN SFE CONCEPT Patches for RADIOSS/LS-DYNA August 15,

10 Adhesives / Bonding Adhesives as CHEXA-CPENTA SFE CONCEPT Geometry Adhesives as CHEXA-CPENTA-RBE3 August 15,

11 Section Force definition on Geometry Define cutting plane by: User Defined Grid And Plane Normal Direction Select SFE CONCEPT objects to be cut Select PIDs to exclude from cutting (optional) August 15,

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,

13 Automated model built Different PID Same PID Reflected part receives new PID Reflected part needs merge keeps original PID symmetrical parts un-symmetrical parts To be merged in vehicle centre line Final INCLUDE File & Master Welding File in all formats Application Perl HyperMesh Task 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) Merge in vehicle centre line part by part Update element types Renumber and group nodes, elements August 15,

14 Pre Processing attribute models Load connection file realize spot welds check results For RADIOSS Node Application HyperMesh Task Read master welding file and realize spotwelds Different options available: witout failure characteristic with failure characteristic dependent to the material properties and panel thickness Spring Node August 15,

15 Modular Model Built Combination of detailed correlated predecessor parts and SFE CONCEPT derived parts August 15,

16 Conclusion & Prospect Conclusion 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 Prospect Include the evaluation procedure already in the model built Enhance the module database with design alternatives Jörgen Hilmann Hans Zimmer August 15,

17 Turn around time reduction in early attribute assessments using latest software tools like SFE CONCEPT, Perl and HyperMesh Thank You for Your Attention Jörgen Hilmann, Ford of Europe, Basic Design Safety Hans Zimmer, SFE GmbH, President & CEO SFE GmbH August 15, 2008