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Technical perfection, automotive passion.

Marcin Debniak, Faurecia Poland R&D

European HyperWorks Technology Conference

Berlin, GermanyOctober 23-24, 2007

Modern Seat Development Process

in Faurecia supportedby Hyper Works products


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Door panel / Modules

Instrument panel / Cockpit

Front endSeating

Exhaust system

Acoustic package Door panel / Modules

Instrument panel / Cockpit

Front endSeating

Exhaust system

Acoustic package

Faurecia is an expert in 6 major modules

What is Faurecia


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Auburn Hills

Toledo

Troy

USA

3

Pune

Shin-Yokohama

India

JapanShanghai

China

Korea

Shihwa

Magny

Mru

Mouzon

Nogent/Ver.

Seloncourt

Audincourt

Brires

Bavans

Beaulieu

FlersQuartde Poblet

Torsas

Spain

Sweden

Germany

France

Frth

Hagenbach

Ingolstadt

Munich

Peine

Sassenburg

ScheuerfeldStadthagen

Poland

Grojec

Sales: Over 11.6 billion

R&D 5,2% of sales (610M)

Over 4000 engineers

Over 65,000 employeesworld wide

28 R&D centers

Listed on the EuronextParis - Eurolist

Faurecia basic key figures 2006


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Car Seats

One of six modules produced by Faurecia

Very complex structure Up to 99 parts and 16 electrics engines Seat design takes into account numerous factors,

including safety, comfort, and thestandardization of parts that are not visible

and an extreme customization of appearance More and more customers requirements as well as

legal requirements Year by year number of seat features is permanently

increasing Up to 80% of design given by safety issues Comfort becomes more and more important Around 100 test before being assemble in vehicle

New ideas and permanent innovation

What Grojec is focus on


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Why CAE Department in Grojec (Poland)?

Biggest production plant in Poland (over 1500 employees)

Good location, close to main strategic customers (France andGermany) mobility

Great potential good educated young staff

Fast growing market

Low Cost Country

GRJEC

Faurecia R&D GROJEC


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28 Simulation Engineers

Work on complete seats projects as well on single parts modifications and optimization on

following levels:

Meshing Static and quasi-static calculations Dynamic calculations Optimization

Used software: HyperWorks, ABAQUS and PAM-CRASH

Support for Faurecia offices in Germany, France, China and USA

CAE GROJEC activity


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Altair Software used in Grojec:

HyperWorks

HyperMesh pre-processing (meshing and model preparation)

HyperCrash pre-processing (model preparation)

HyperGraph pre-processing + post-processing

HyperView post-processing (model evaluation and results )

RADIOSS explicit solver

CAE GROJEC


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Single parts (wires, tubes, metal parts etc.)

Complete seats

Car environment

Assemblies

Mechanisms (solid meshing)

Meshing HypeMesh

CAE GROJEC HyperMesh support


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Single parts

Complete seats

Car environment

Assemblies

Mechanisms


Welding and spot welds definition (up to 200 points) Pivots, screws , rivets Property definition (thickness, type of elements,materials, etc)

Contact definition


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Single parts

Complete seats

Car environment

Assemblies

Mechanisms



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Single parts

Complete seats

Car environment

Assemblies

Mechanisms


Include files creations Contact managements Occupants

Boundary conditions and loads


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Why HyperMesh? Simple and friendly user interface

User defined applications macros

BOM (Bill Of Material)

Compatible with most of CAD and FEA software CAD (Catia V5, Catia V4, Unigraphics) FEA (RADIOSS, ABAQUS, PAMCRASH, Ls-Dyna)

Smart and powerful algorithm for shell and solid meshing (Batchmesher, HyperMorph)

Very efficient in daily work, stable (especially ver. 7)

Easy managing of big models (include manager, groups etc. )

Good technical support (customization, trainings)



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Why HyperCrash? Software available only for RADIOSS (well suited)

Visually clear, smart and simple functions:

Foam compression tool

Easy and fast dummy positioning

Seat belts generator

Contact interfaces manager

Penetrations and intersections checker

Quality manager

CAE GROJEC HyperCrash support


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Why HyperView? One post processing tool for all codes

Simple and user friendly interface

Easy graph creation

Possibility to compare crash- withcalculation results

Simple and intuitive results visualization

Macros and user defined functions

CAE GROJEC Hyper View support


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FEA explicit calculations using Altair Software - Radioss

CAE GROJEC Radioss solver support


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- Better part of:

-Dynamic tests

-Static and quasi-static testsECE R21Test of the minimum radius

During the test, it is determined whether partswithin the impact zone used for reinforcementmay be displaced or protrude so as to increasethe hazards to passengers or the severity ofinjuries.

ECE R14Dynamic Test95th percentil dummy

Pulse ECE R 16

50km/h

Airbag deactivated

ECE R17Headrestraint M oment Test

Moments:

Mom ent about H-Point = 373 Nm

Headrest = 373 Nm

Dynamic Test(Frontal- and rear impact)

Test without Dummy

Speed = ca. 45 km/hDeceleration = 20 g for 30 ms

ECE R17

ECE R17Load Test (H-Point)

Moment = 530 Nm

Headrestraint Impact Test

Impact Speed = 24,1km/h

Reduced masse = 6,8 kg

max. deceleration = 80 g

max. decelerations time = 3ms

ECE R17

ECE R25ECE R16Dynamic Test

Test with dummy (50%)

Speed = 50km/h

deceleration = 26g - 32g

0

5

10

15

20

2530

35

0 20 40 60 80

A

BC

F

E

D

G H

I

Verzgerungin

g

Zeit in ms

ECE R95Dynamic Test

(Lateral collision)

Test with EUROSID Dummy(50% Dummy)

Speed = 50 km/h

Deceleration = according to the

mobile barrier

ECE R94 Dynamic Test(Protection of the occupants in the event ofa frontal collision into a 40% barrier)

Test with dummy (50%)

Speed = 56km/h

Belt anchorage 3 Point

Loads:

Pelvic = 13500NTorso body block = 13500NAditional: 20 x seat weight (ifat least

1 Anchorage is at the seat)

ECE R14

ECE R17DynamicTest

(Luggage Load Protection)

Two Types of Test BodiesWeight = 18kg and 10kg

Speed = ca. 50km/h

Deceleration: acc. to crash corr.

0

10

20

30

0 20 40 60 80 100 120

28

50 65Zeitinms

Verzgerung

in

g



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Dynamic tests:

- Frontal Collison

- Rear Collision

- Luggage Load Protection



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Static (quasi static) tests:

- Seat Belt AnchorageECE R 14

- ISOFIX testECE R 14

-Static (quasi static) and dynamic customer defined tests, with all requestedconfigurations.



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Acceptable results compared to reality. Convergence 75-90%



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Test calculation convergence: 92%



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Why RADIOSS?

Included in HyperWorks package

Code very stabile regarding unexpected issues

Work very well with big models (include structure, transform cards, C-Nodes, etc.)

Proper material definitions for most of materials (i.e.. Foam)

Able to work in DMP mode

Efficient calculation time

Convergence with real test (75-92%)

Used by our customers (Peugeot, Citroen, Ford, FIAT, etc.)



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CAE GROJEC


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Future view!1. Strong collaboration is expected between Faurecia and Altair2. Radioss explicit evaluation accuracy 90-95%

3. Implementing Radioss as a main calculation code4. Dummy improvements (rigid, deformable)5. Sixth stars and Radioss calculation whiplash methodology6. Implementing Radios implicit as a stabile solution for qusi-static calculation7. Implementation more and more of Optistruct in seat development8. BatchMesher evaluation9. Stabilization of Hyper Works v8 on Linux platform

CAE GROJEC

Technical perfection,

automotive passion.

European HyperWorks Technology Conference


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European HyperWorks Technology Conference,Germany, Berlin 23-24 October

Thank You

For attention !

_debniakfaurecia

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