Session: Designing for Cost Effective Weight Reduction
Engineering Software for Design of Cost Effective Lightweight Mixed Material Vehicles
Edward Bernardon, Vice President Strategic Automotive initiatives, Siemens PLM Software
April 24, 2013
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. Page 2 Siemens PLM Software
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New Member of Siemens PL Specialized Engineering Software - SES
Vistagy acquired by Siemens Dec 2011
Business Segment of Siemens PL
Specialized Domains
Industry Focused
End to End Solutions
300+ Global Customers
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Solutions for Seat Design ! Core Industry: Auto
Solutions for Complex Assemblies ! Core Industry: Aero, and Auto*
Solutions for Composites ! Core Industry: Aero, Auto, and Wind
SDE Seat Design Environment
Siemens SES Product Portfolio
Syncrofit
Fibersim
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High Volume Automotive Composite Engineering Software
• What is market size and timing?
• What is the nature of the product that will provide value ?
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Weight Reduction Spiral
Decreasing Weight Lighter Vehicle
Smaller Engine
Fewer Batteries
Less Braking
Lighter Crash Structures
Lighter Vehicle
Smaller Engine
Fewer Batteries
Less Braking
Lighter Crash Structures
Transportation Technology Adoption Rates
12 years 90% horse, 10% car to
10% Horse, 90% Car
6 Years 80% Open Wood Autobody to
70% Closed Steel Autobody
Winning the Oil End game Amory Lovins 2005
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What is the Nature of Composite Software for High Volume Auto
• Automotive has unique requirements relative to traditional aerospace composite applications
• Current composite engineering software must change for HIGH VOLUME automotive composite applications
In Emerging Markets
What customers want
may not match what they need
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Presentation Outline
1. Unique demands of High Volume Automotive Composite Structure Engineering
2. Design trends in high volume automotive that impact Engineering software • Which industry trends impact the nature of software development
• High volume auto composites must evolve to be cost effective
• Shift to mixed materials at part and assembly level
3. Expected nature of future engineering software for mixed material vehicles
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Designing Composites
• Geometry • Shape, profile, curvature – global and local • Ply boundaries • Thickness
• Material characteristics • Forms • Desired fiber orientations • Compression limits • Steering limits
• Processes limitations • Machine configuration • Achievable fiber orientations • Process variance • Knockdown factors and FOS – material and process
Part Geometry
Material Process Limitations
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Aerospace Composite Configuration and Shape Grid Based Design
Boeing 787
Frame/Skin Assembly
Grid Based Design
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Challenges High Volume Commercial Automotive Composite Applications
Economics • Low to Medium Production (5k-50k parts/yr) • High Production (~100k part/yr)
Design/Manufacturing Processes • Time to market is much less than aerospace • High Production rates, fast cycle times • New Material Forms/Processes • Low cost
Material Compatibility • Process/Material Selection and Modeling • Rapid Forming - 2D to 3D
Performance Criteria - Analysis • Tight coupling CAE/Design/Manufacturing • Predictability with less safety margin
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Requires Tight Integration between Analysis, Design Manufacturing
Efficient communications between design and analysis Accommodate late changes to enable optimization Generate interfaces for mating parts Bring appropriate feedback early
Analysis
Design
Manufacturing
Shorter Time Optimized Structure
Fewer Prototypes
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Material Properties May Vary Over Part Surface
15 degree misalignment results in 75% reduction in strength
• Part Properties impacted by changes in Fiber Orientation"
• Fiber orientation impacted by"• Material"• Process "• Geometric features"• Combination of above and
processing parameters "
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Impact of Initial Forming Contact Point on Fiber Orientation
~15 Deg.
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Automotive Composite Processes Choices
Resin infusion • RTM • RFI
Automated deposition • Braiding • Fiber placement • Tape laying • Winding • Spray Fiber
Forming • Dry Preform • Wet/Infused • Hot TP
Pultrusion ! !"#$%!&'($)**!+,&(*)*!-.+/-)!$(.*0'#+.0*!
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Composite Processing Choices
2D Broadgoods Woven, NCF
Weaving Warp Knitting
Tow
2D Braiding
3D Braiding
Pultrusion
Tubes Overbraid
Robotic or Manual 2D Stackup
2D Preform Forming
(Matched Metal, Diaprhagm, w/ or w/o progressive tooling,
constraints...)
Selective Binding
Stitching
3D Preform Tailored
Fiber Placement
3D Hand Layup
Injection (RTM, VARI, SRIM....)
Finished Part
Thermoplastic Resin
TP Broadgoods
TP Forming
Thermoset Resin
Thermoplastic Prepregging
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Composites Eliminated in Frame
Tesla Evolution of Frame Structures
Model S Aluminum BIW (bonded, riveted, weld) Aluminum Panels
Roadster Aluminum Frame (bonded) Carbon Panels
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BMW i3 All Composite Passenger Compartment City Car
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Edison 2 Space Frame w/Composite Skin
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T27 - Composite Reinforced Space Frame
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Composite Reinforced Space Frame Panel
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Design Optimization (TFP) Cost Competitive Composites
IFB Institute of Aircraft Design, Stuttgart, Germany
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Design Optimization (TFP) Costly Hi-Performance Material Only Where Needed
F F
!"#"$"%&'(#)*+,-)".'
F
/0+.1+#-$'230455'(#)*+,-)".' 6+.-$'!6/'/-03'745+%.'
IFB Institute of Aircraft Design, Stuttgart, Germany
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Hybrid Part Examples
Injection Molded
Eggcrate Stiffener
Metal Insert Carbon Fiber
Laminate
SMC
Random Mat
Etc…..
Select Area woven, directional fibers
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! Tradeoff assembly vs. part complexity for mixed metal, plastic composite structures ! Many simple shaped parts (many joints) ! Few complex shaped parts (less joints) ! How to assess tradeoff of assembly or part complexity
! Representation of various Joint Types ! Bonded Joints ! Hybrid metallic/composite joints ! Other fasteners, rivets, bolts…
! Provide tools to tradeoff ! Performance ! Cost ! Producibility
Composite and Hybrid Assemblies/Joints
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Designing the Joint
Resistance Welding Laser Welding
Brazing
Adhesive Bonding Clinch Joining Riveting, Screws
Shielded Arc Welding Arc Splash Welding
Hybrid Joining
Hemming
Punch Elements
Process and Product Related
Joint characteristics ! Fastening requirements ! Adhesive type ! Torque specifications ! Welding processes
! Cure time ! Hold pressure ! Surface area ! Adhesive application method
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Multi-materials will lead to Multi-Joining Methods
! Different material combinations driven by need to cost-effectively lightweight vehicles
! Potential combinations of materials ! Composites ! High strength steel ! Aluminum ! Magnesium ! Plastics
! Avoiding corrosion and thermal deformation issues
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Tradeoff Assembly vs. Part complexity
Red - Issues with Large complex composite part
Issues Eliminate but Joint Added
“T” made of alternate material
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Lightweight Hybrid Structure Design Tradeoffs
“Slider Bar”
What will you pay for Performance/Weight ratio
1 10 High cost
uni hand layup (i.e. F1)
Low cost Steel
Performance-Weight / Cost Ratio Find cost optimal combination of materials,
assembly configuration, joining etc…
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DESIGN Cost Analysis is Critical Part
“Engineers make million dollar decisions and don’t know it.”
Steve Luby CEO VISTAGY
Session: Designing for Cost Effective Weight Reduction
Engineering Software for Design of Cost Effective Lightweight Mixed Material Vehicles
Edward Bernardon, Vice President Strategic Automotive initiatives, Siemens PLM Software
April 24, 2013
Siemens AG 2013. All Rights Reserved.
. Page 32 Siemens PLM Software
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Double Diaphragm Former" Pick and Place Machinery"
Past Experience of Siemens SE Personnel in Automotive Composites Technologies
Flexible Forming Tool Design"