5TH ANSA & META INTERNATIONAL CONFERENCE AN INSIGHT TO APPLICATIONS BASED ON ANSA TO THE BMW CAE PROCESSES

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Transcription:

Josef Fürfanger, 5.6.2013 5TH ANSA & META INTERNATIONAL CONFERENCE AN INSIGHT TO APPLICATIONS BASED ON ANSA TO THE BMW CAE PROCESSES

AGENDA 1 History of BMW BETA Cooperation 2 Mapping Deep-Drawing Simulation 3 Convertible Top Lid Kinematics Page 2

BMW starts working with the Software tool BETA Late 1980 s 1995 2005 2007 2008 Page 3

BMW starts working with the Software tool BETA BMW starts using ANSA v5 as a mesher for complete models Late 1980 s 1995 2005 2007 2008 Page 4

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 1995 2005 2007 2008 Page 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 BMW switches all crash projects to work with Abaqus Explicit Late 1980 s 1995 2005 2007 2008 Page 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 AFE Spotwelding with Failure + Postprocessing Late 1980 s 1995 2005 2007 2008 Page 7

Dummy/seat kinematics 2008 2008 2009 2010 2011 Page 8

Dummy/seat kinematics Morphing & Optimization 2008 2008 2009 2010 2011 Page 9

Wet Area Dry Area Acoustic Insulation Dummy/seat kinematics Morphing & Optimization Doorbag Generation Sideimpact 2008 2008 2009 2010 2011 Page 10

Dummy/seat kinematics Morphing & Optimization Doorbag Generation Sideimpact EF Chassis Meshing 2008 2008 2009 2010 2011 Page 11

Dummy/seat kinematics Morphing & Optimization Doorbag Generation Sideimpact EF Chassis Meshing Roof Kinematics 2008 2008 2009 2010 2011 Page 12

Composites Modeling Al-Druckguss Al-Schale / Al-Profil Stahl Schale CFK-Schale / CFK-Profil 2011 2011 2012 Page 13

Composites Modeling Mapping Deep- Drawing Simulation 2011 2011 2012 Page 14

Composites Modeling Mapping Deep- Drawing Simulation CFK Post Processing 2011 2011 2012 Page 15

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

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

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

PROCESS OVERVIEW. ROOF KINEMATICS. Add intelligence to the system Kinematic Tool in CATIA V5 CAD Model Basic CAD Model with Attributes Page 19

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

PROCESS OVERVIEW. ROOF KINEMATICS. Page 21

PROCESS OVERVIEW. ROOF KINEMATICS. Page 22

PROCESS OVERVIEW. ROOF KINEMATICS. Page 23

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 0 1 2 3 4 5 time in weeks Page 24

THANK YOU FOR YOUR ATTENTION! Page 25

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