searching for the optimum between practical project expertise and process competence – optimized...
DESCRIPTION
A major challenge of today´s development processes is to find the optimal balance between practical project expertise and process competence. The present MAGNA STEYR paper describes some fundamental aspects on the example of structural durability. In this phase of the development process HyperWorks plays a vital role. To gain a better understanding for the approach chosen by MAGNA STYEYR, we look, first, at the tasks of the Structure & Durability Department, a subdivision of the Complete Vehicle Department. Secondly, we refer to major modules within an efficient process chain and will discuss a number of specific examples.TRANSCRIPT
Searching for the optimum between
practical project expertise and process
competence – optimized component
design in the development process by
using HyperWorks
A. Falkner, G. Kepplinger, F. Schmalhofer
MAGNA STEYR Engineering, Austria
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 2
Outline
• Validated virtual development
Overview simulation methods
General remarks to the CAE-process
Structure & Durability: Technical & process tasks
• Application examples
Stiffness based multi-objective optimization of a car body section
Strength based design of a composite high pressure tank
Damage based shape optimization of a threaded tank valve component
under pulsating pressure
• Summary / Outlook
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 3
Validated Virtual Development / Overview Simulation
Methods
E CC PTO SOP
Virtual development based on a
validated platform vehicle
No prototype vehicles!
Validation of all targets
and homologation with
PTO & PP vehicles
Production at
MAGNA STEYR
since 2010
Multi Body Simulation
Finite Element Method
Statistical Energy Analysis
Computational Aero Acoustics
Computational Fluid Dynamics
Simulation methods
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 4
General remarks to the CAE-process
Multi Body Simulation Finite Element Method Statistical Energy
Analysis
Computational Aero Acoustics
Computational Fluid Dynamics
Interaction of the methods
to describe the NVH
frequency range up to
~ 8 kHz
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 5
General remarks to the CAE-process
Multi Body Simulation Finite Element Method Statistical Energy Analysis
Computational Aero Acoustics
Computational Fluid Dynamics
Top five:
• Common model / data strategy: MBS, one CBIW for SD, NVH and Crash, CFD
• Optimization strategy: One optimization-tool for all methods
• Correlation between simulation and measurement
• Link to the CAD-World via TeamCenter
• Software tools-environment: As simple as possible, as complex as necessary.
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 6
Structure & Durability: Technical & process tasks
Development, optimization and
validation of the durability function
on complete vehicle level
technic
al ta
sks
Pro
cess /
Structural durability
function & load spectra Simulation body
Simulation & methods
complete vehicle
• Load data analysis
• Generation of test-rig
programs
• Target settings &
validation
• Integration team
management
• CAE-body-management
• Support quotation process
• CAD2CAE regarding FEM
• CBIW model build-up for
Crash, NVH & SD
• ODC-coordination
• Product development
FEMSITE
• R&D-tasks
• Simulation & optimization
of the closed body in white
regarding
stiffness
strength
fatigue
• Simulation & optimization
of the complete vehicle
regarding misuse tests,
vibrational fatigue
• Modules: Suspension,
powertrain, battery
system, fuel-system,…
Complete vehicle
System
Component
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 7
Outline
• Validated virtual development
Overview simulation methods
General remarks to the CAE-process
Structure & Durability: Technical & process tasks
• Application examples
Stiffness based multi-objective optimization of a car body section
Strength based design of a composite high pressure tank
Damage based shape optimization of a threaded tank valve component
under pulsating pressure
• Summary / Outlook
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 8
Example 1: Stiffness based multi-objective optimization
of a car body section
Global stiffness,
static & dynamic BIW
Local stiffness,
static BIW
Strength: Body
Fatigue-life
Central questions in every body-in-white development:
• Where is the actual design?
• Balancing between targets cT, cB,…. and BIW-mass
• List of wall-thickness of each BIW-part
Hierarchical approach
body development
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 9
Example 1: Stiffness based multi-objective optimization
of a car body section
• Task / Boundaries
BIW fulfills / exceeds the stiffness targets
The mass of the BIW should be minimized and still fulfill the stiffness targets
Design variables: All wall thicknesses of BIW upper body (approx. 50kg),
65 discrete design variables
Show the trade-off between benefit (stiffness) and effort (mass) Pareto
• Approach
DOE (FE-runs)
Approximations / fit
Multi-objective optimization
Minimize mass
Maximize torsional stiffness
Maximize bending stiffness
Converged solution
Initial
design
mass
sta
tic b
endin
g s
tiffness
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 10
Example 1: Stiffness based multi-objective optimization
of a car body section
• Results
9.75 kg mass reduction eq.
to 65% of the mass potential
Stiffness targets still fulfilled
• Advantages of this approach
Fast results after changing boundaries (no rerun of FE-simulation)
Easy to understand results
Global optimization methods applicable
Mass potential Mass reduction
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 11
• Task
Minimization of composite mass of type IV pressure vessels (plastic liner with wounded
composite shell) for fuel systems
Load case: Burst pressure
Parameterized fast 3d section model for optimization
Automatic generation FEM model according liner
geometry & parameter setting of design variables
→ layer thickness, winding angle end of layer
Thickness increase dome area considered
Winding angle change in dome area
Contact FRP-layup / boss
• Approach
DOE: Search design space:
> 4000 FE runs, starting point for local optimization
Gradient based optimization for layup
Design verification with detailed simulation: Interaction FRP-layup and boss
Example 2: Strength based design of a composite
high pressure tank
burs
t pre
ssure
mass
Target
starting point for local optimization
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 12
Example 2: Strength based design of a composite
high pressure tank
fib
er
str
ain
bu
rst p
ressu
re
Benchmark Optimized
• Results:
Compared to benchmark vessel
15% composite mass reduction
Same burst pressure performance
Same tank volume
Hardware validation Composite tank
Simulation
Testing
cylindrical part dome area boss area
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 13
Example 3: Damage based shape optimization of a
threaded tank valve component under pulsating pressure
• Task: Increase the lifetime of Shut Off Valve (SOV) in pressure cycle test
• Simulation tools:
Abaqus non-linear simulation (contact, material)
FEMSITE nonlinear lifetime estimation
• Questions:
How much tightening torque?
Is re-tightening useful / necessary?
Optimal radius? Notch effect vs. thickness
Test scenario:
1. Pretension
2. End-of-line Test (105 MPa)
3. Unload pressure (0 MPa)
4. Re-tightening only if necessary (cost)
5. Pressure cycle test: 30.000 cycles 2 – 87,5 MPa
plastification
t
R
R
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 14
Example 3: Damage based shape optimization of a
threaded tank valve component under pulsating pressure
• Results: Parameter study A bigger radius is better, but at about 2mm
no significant recognizable improvement
Re-tightening is recommended at low tightening
torques (<100Nm)
A low damage value can be found
without re-tightening, but requires higher
tightening torques
Find optimum tightening torque at a
radius of 2mm and without re-tightening
• Optimization
Optimum including re-tightening
Optimum without re-tightening
Radius: 1 – 2.2mm
Hexa
go
n h
ea
d fa
ils
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 15
Outline
• Validated virtual development
Overview simulation methods
General remarks to the CAE-process
Structure & Durability: Technical & process tasks
• Application examples
Stiffness based multi-objective optimization of a car body section
Strength based design of a composite high pressure tank
Damage based shape optimization of a threaded tank valve component
under pulsating pressure
• Summary / Outlook
June 2014 Falkner, Kepplinger, Schmalhofer MSE_AUT Disclosure or duplication without consent is prohibited 16
Success-story – Validated virtual development
time
com
ple
xity
Pushing the limits
-6 Months*
* faster time to market
-4 Months*
-6 Months*
-5 Months*
-4 Months*