importance of simulation in vehicle lightweighting the ... · design exploration 145,0 150,0 155,0...

© 2017 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Richard Yen, SVP, Automotive and Global Markets Team

25th April, 2017 - GALM Europe

Importance of Simulation in Vehicle Lightweighting – The Innovation Generator


Altair

The Company

Industry’s broadest integrated

Simulation Software Suite

(Model Builders, Solvers,

Optimisers Visualization)

HyperWorks

A global engineering and

design business delivering

innovation to our clients

ProductDesign

Software & Services

Worldwide Leadership in Optimization

120+ Altair Optimization Experts Meeting in Sweden

October 2017


Altair’s Market Position

#1 CAE Platform Provider in Automotive; fastest growing in Aerospace and overall

#1 Design Optimization Technology Developer

#1 Simulation focused consultancy in the world

#1 Technical engineering staffing company in N.A.

Vehicle consulting partner with all OEM’s across AMER/EMEA/APAC

• Including alternative fuel and niche vehicles

Daimler

Ferrari


The synergy between our software and services

organizations keeps Altair close to industry challenges and

uniquely positioned as a valued, long-term partner to

support the dynamic needs of our clients.

Altair Synergy


Increased Requirements on Development Process

Time, costs, flexibility upon market changes, competence,………..

Increased Demands on Performance

Fuel economy, weight, platform complexity, safety, refinement, driving dynamics, driveability, Noise & Vibration…………..

Challenges from Requirements

Innovation in Vehicle Structural Development


Altair’s Solutions to the Challenges

1

2

3

Increase Design Maturity in Concept Phase

Culture of Innovation and Engagement Model

Balance Design for Cost, Weight and Performance Cost

Weight

Performance

Balanced

Design


CAD

CADCAD

CAD

Simulation Driven Design

CADn-1

CADn

Optimization led process

CADn+1

CAE

........Simulation Driven Design is a Solution

CAE

Mod. Res.

CAE

CAEn

Standard Development Approach

CAD

CADCAD

CAD

CADn-1

CADn

CADn+1

CAE CAE

Mod. Res.

CAEn-1

CAE CAE

Mod. Res.


Planned & Reactive Optimization

Altair Vehicle Level Simulation Driven Design Processes

Simulation Driven Concept Design, C123

Multi-Disciplinary Optimization, Altair MDO

Screening

C0 C1 C2 C3

S0 S1 S2 S3 SOP

Feasibility

Product Development

Concept Development

F0 F1

Actively influence Design

Direction and Decisions


Simulation Driven Concept Design, C123


C123 – Vehicle Level Simulation Driven Concept Design Support

Detailed Optimum Sizing of

Manufacturable Sections & Joints

using High Fidelity Models

C3

Identification of Optimum Structural

Layout using Free Form Models

C1

Rapid Optimum Sizing of Idealized

Sections & Joints using Low Fidelity

Models

C2

The strategic and systematic usage of optimization in order to generate:

• design alternatives,

• trade-off information, best balanced designs

• design sensitivities

to actively support the concept development process on daily basis



Size: E

Size: D, Var 1

Size: D, Var 2

Architectural Layout & Load Paths

Identification of Optimum Structural

Layout using Free Form Models

C1

Application of structural loadcase

characterisation and target cascade

process



Cross Section

Dimensioning

W1

W2

W3

W4

W5

X Scale

Y S

cale

Rapid Optimum Sizing of Idealized

Sections & Joints using Low Fidelity

Models

C2

Design Exploration

145,0

150,0

155,0

160,0

165,0

170,0

175,0

180,0

Mass [

kg

]

add

constraints

load path

tunnel

u/d siderail

match package

change gearbox

mounts

change engine

mounts

move batteryalign rear

beam

optimization

setup tweaks

move

crossbeam

reinf.

correct

targetsrelax ODB target

add

battery

basket

add panel in

B-pillar

package

updates

u/d rear undertray

tunnel

reinf.

replace rear

sill material

Ma

ss

Pe

rcen

tag

e

0,82

0,80

0,78

0,76

0,74

0,72

0,70

0,68Extensive interrogation of design

space – rapid design tool



Detailed Optimum Sizing of

Manufacturable Sections & Joints

using High Fidelity Models

C3

Maturing the Structure

+ +

=> =>

Free-Size Gauge Topology Grade Value Eng.

DESVAR LABEL DESCRIPTION 30km/h Barrier BOF10 Roof BOF10 Front BOF10 Rear ECER29 Roll Over 90 ECER29 Roll Over1801 PSHELL_37 CROSS MEMBER YES

3 PSHELL_40 VERTICAL MEMBERS FRT

6 PSHELL_81 MEMBER YES

10 PSHELL_168 SIDE PANEL LFT YES YES YES YES YES

11 PSHELL_172 A-PILLAR LFT YES YES YES YES

13 PSHELL_181 REINFORCING PLATE LFT YES

14 PSHELL_197 B-PILLAR LFT YES YES YES YES

15 PSHELL_200 C-PILLAR LFT INR YES YES YES

16 PSHELL_206 SIDE REINFORCEMENT UPR LFT YES YES

17 PSHELL_210 DOOR FRAME LFT YES YES YES YES

18 PSHELL_211 C-PILLAR LFT OTR YES YES

19 PSHELL_225 REINFORCING PLATE RGT YES

21 PSHELL_272 SIDE PANEL RGT YES YES YES

22 PSHELL_279 A-PILLAR RGT YES YES

23 PSHELL_280 C-PILLAR RGT INR YES YES

25 PSHELL_293 B-PILLAR RGT YES YES

26 PSHELL_314 SIDE REINFORCEMENT UPR RGT YES

27 PSHELL_317 C-PILLAR RGT OTR YES

28 PSHELL_318 DOOR FRAME RGT YES YES

30 PSHELL_369 REINFORCEMENT A-PLR RGT YES YES

31 PSHELL_380 REINFORCEMENT A-PLR LFT YES YES

35 PSHELL_5739 PLATE YES

Load Paths Cross Sections Structural Joints

Optimization and Design Exploration

Full suite of optimization and solver

technology


Active management of design balance

Increased concept maturity

More informed design decisions

Adapt to new requirements and adopt new

technology

Rapid interrogation of the design space

Supports the design team actively and

continuously

Benefit of C123


Altair MDO - Optimization in Product Development


Sim

ula

tio

n D

rive

n

Des

ign

Su

pp

ort

C123 – Simulation Driven Concept Design

Simulation Driven Design Support

Frontal ImpactRoof Crush

Side impact

Rear impact

NVH stiffness models NVH acoustic models

Occupant

Des

ign

Dep

art

me

nt C0 C1 C2 C3

S0 S1 S2 S3 SOP

Concept Development

Product Development

Request

Feedback

Request

Feedback

Multidisciplinary Design Optimization (MDO)


Front crash

NVH acoustic

Side crash

Rear crash

NVH global stiffness NVH equivalent static stiffness

Occupant

Target:

Minimize weight

Requirements:

Technical requirements to be met:• Intrusions

• Accelerations

• Fuel system integrity

• VPI “Vehicle Pulse Index”

• Global stiffness

• Local stiffness

• Acoustic limits

MDO Problem Definition


Challenges

100+ Design Variables and ResponsesQuick turn-around to influence design

Dataflow

IT-Integration

Efficient Optimization Strategies


Goals

MDO Set-up < 4hrs

Optimization runs < 5 days

Assessment < 4hrs

Focus on size and shape optimization

Work with multiple CAE models


Sub-Space Response Surface MDO Solution

User interface

Su

b R

eg

ion

s

Global Torsion

Rear ImpactFront Crash

Methods & Technologies

Evaluation

# 1 # 2 # 3


47Structural

Targets

8+2Crash + NVH

Load Cases

103Panel

Thickness

Variables

3.5MCPU Core

Hours

ALLStructural Targets

Achieved

3.5 Days40,000 CPU Cores

7.7kgMass Reduction


Summary


C123 - Simulation Significantly Impact Concept Design


Altair MDO a Key Technology for Balanced Design

16th May 2017Chesford Grange Hotel, Warwickshire, CV8 2LD

www.altair.com/productivity

Free to attend

Presentations from: & more

Productivity Gains through Best in Class Pre & Post Processing Seminar

Business Benefits

Productivity - ’Best in class’ capabilities,

process automation and integration.

Integration - Direct interfaces with a wide

variety of CAD packages & CAE/CFD analysis

solvers supporting your PLM environment.

Support - Fast, responsive customer support

team, continual product development

Return on Investment - Patented licence

HyperWorks Licensing System adding value

since 1999

www.altair.com/productivity

& more…


DESIGN THE DIFFERENCE™

Richard Yen, SVP, Automotive and Global Markets Team

[email protected]

importance of simulation in vehicle lightweighting the ... · design exploration 145,0 150,0 155,0...

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