Multi-Physics SCAIMapper
Fraunhofer-Institut für Algorithmen und Wissenschaftliches Rechnen SCAI
Industrial Applications
- SCAIMapper
- VDA FAT AK27: Stamping Crash
- Faurecia: Design-Chains for Automotive Seats
- ThyssenKrupp: Forming Analysis
- Volkswagen: Painting Chains
- Daimler: Robust Design
- Audi: Optimization of Light-Weight Stamping Tools
SCAIMapper
Generally, the manufacturing of complex structures involves various processes that yield the final product. Simulation methods are often used to optimize each single process step. When the manufacturing levels involve di fferent physical disciplines usually diverse discretizations have to be used. Hence, if a result of a simulation has an influence on the simulation of the following processing step it needs to be transferred between possibly diff erent domains.
When chaining these process steps together in the simulation, software interfaces become necessary to realize an integrated virtual process chain. Therefore, the Fraunhofer Institute for Algorithms and Scienti c Computing SCAI developed the software tool SCAIMapper dedicated to mapping physically relevant entities in process chain simulation. The SCAIMapper enables the coupling of a wide range of commercially available FEM software codes for metal forming, heat treatment and crash simulations which can be used in a coupled manufacturing process chain. The methods for data interpolation are not limited to these areas and can easily be carried forward to di fferent application fields.
VDA FAT AK27: Stamping Crash
COUPLED FEM CALCULATIONS – A CAE TOOL TO IMPROVE CRASH-RELEVANT AUTOMOTIVE BODY COMPONENTS BY LOCAL HARDENING
Robert Schilling - Ford-Werke GmbH, IWT Bremen, ISD Universität Stuttgart, Tecosim GmbH, GNS mbH, Daimler AG, Faurecia Autositze GmbH, Fraunhofer SCAI at MpCCI UF 2009
In the automotive industry, there is an increasing demand for weight reduction as well as safety requirements. These demands have motivated the use of locally optimized components. This study shows how local rigidity of crash-relevant side rails made of multi-phase steels can be improved by local hardening and thus avoiding an increase of the cross section. At the same time simulation process chains were completed and results validated by experiments. A dedicated software tool for the coupling of a wide range of commercially available FEM software products was developed. Codes for metal forming, heat treatment and crash simulations can now be used in one serial workflow. One major aspect here was the transfer of tensor-like values such as stress or strain states.
The research project 171 N of the Forschungsvereinigung Automobiltechnik e.V. (FAT) and the Arbeitsgemeinschaft Wärmebehandlung und Werkstofftechnik e.V (AWT) was funded by the program „Industriellen Gemeinschafts-förderung (IGF)“ by the Federal Ministry for Economics and Technology through the AiF.
Faurecia: Design-Chains for Automotive Seats
SIMULATION OF LOCAL MATERIAL CHARACTERISTICS AT FAURECIA
The models used by crash simulations do not normally take into account the local differences in geometry and material characteristics resulting from the various manufacturing processes. These traditional models are idealised, and therefore only provide an inexact reflection of reality. In an effort to obtain an accurate picture of reality, Faurecia became the first company to use the SCAIMapper since 2006. The SCAIMapper makes it possible to integrate the results of production simulations into the crash model. This improves the information value of the crash simulations and so assists in the development and manufacture of components.
In Faurecia’s largest division (Automotive Seating, Emissions Control Technologies, Interior Systems and Automotive Exteriors) in terms of sales in 21 countries complete seats, frames, adjustment mechanisms, cushions, seat covers and headrests, armrests and pneumatic comfort systems are produced and every day 100.000 seats assembled.
Faurecia first deployed the ScaiMapper successfully in April 2006 during a project at the company’s German headquarters in Stadthagen. The project was for the Alpha Beta front seat for its customer Volkswagen. In 2007, the company integrated the software throughout the group as a transfer tool in all stages of its seating design process.
Today the software is used for crash simulations when physical forming variables
such as plastic strains or material thicknesses exceed or fall short of certain critical thresholds. In order to fix these thresholds, Faurecia carried out a number of studies into the buckling behaviour of the relevant seat components. The company specified particular criteria, and by comparing this with the real values, was able to determine whether it is possible to influence a component and what results this influence has.
ThyssenKrupp: Forming Analysis
About a new evaluation method increasing the analysis quality in sheet
metal forming applications at ThyssenKrupp Steel Europe AG
M. Linnepe, L. Keßler - R&D / Application Technologies ThyssenKrupp Steel Europe AG (TK-SE AG)
High-quality steel is one of the most important materials in industrial production today. In particular in car manufacturing modern steel grades provide the engineers a wide scope of simulation based optimization for car body structures. Due to the stringent requirements with respect to feasibility, stability and crash performance, exact CAE methods and models for the useful estimation of the specific material behaviour are required. One missing component in the validation process is a robust method which enables the comparison of different simulation results or experiments with each other, especially when trying to interpret larger areas of the geometry of a part. The process becomes even more difficult when using different FEM programs or strain analysis methods. This item was the topic of the co-operation between Fraunhofer SCAI and TK-SE AG. The result is the newly developed SCAIMapper with its new features for forming technology post processing. As a result a direct comparison of two or more tests from practise or simulation has become possible. The primary benefit of using SCAIMapper is that the user can obtain information about the deviation of results either in a section or over the whole geometry of a part. The converted extensions of the SCAIMapper enable the press worker, the vehicle and material developer to display the effects of methodical adjustments in the shortest time.
Volkswagen: Painting Chains
End-to-end Virtualization of the Development and Production of Vehicles
Lena Leck, Martin Rambke - Ostfalia – University of Applied Sciences
Birgit Awiszus - Department Virtual Production Engineering, Chemnitz University of Technology
Sebastian Pinner - Technology Management, Volkswagen AG
Jan-Stefan Knick - CADFEM GmbH, Berlin
The automotive industry is characterized by short product lifecycles, complex products and an increasing number of variants. Global competition demands reduction of development costs and prototype manufacturing. Hence, interest in simulation of the overall process chain has risen. Until now data exchange between simulation programs is mostly done by manual transfer. The specific simulation tools do not have any open data exchange formats. The objectives of the publicly supported project, called VIPROF, are to specify the necessary interfaces between simulation programs, to integrate simulation data into product data management systems and to develop reference processes. The influence of the stamping, welding and painting processes on the product properties should be considered during the whole period of product development. This can be achieved by a virtual validation of the feasibility of the manufacturing processes. The paper shows how to connect the simulations of forming, welding, painting and crash for an automotive reference part.
Daimler: Robust Design
PROCESS CHAIN FORMING TO CRASH: EFFICIENT STOCHASTCIC ANALYSIS
Tanja Clees – Fraunhofer Institute SCAI, Fraunhofer IWM, Daimler
at 7th LS-DYNA European Conference 2009
During the fabrication of products, important material and process parameters, geometry and also external influences (e.g. room temperature) can vary considerably. It is known that they can have a substantial, even critical influence on the quality of the resulting products. Therefore, software tools and strategies supporting an efficient and thorough analysis of sensitivity, stability and robustness aspects as well as a multi-objective robust design-parameter optimization are necessary. This is especially true for parts of a car with a potentially critical influence in crashes as, for instance, the Bpillar which consists of several formed and connected blanks.
We propose a new strategy, built upon several software tools as well as new material models, supporting an analysis of variations for the process chain forming to crash. The strategy roughly consists of the following parts and software too
- forming simulation (LS-DYNA)
- parameter sensitivity analysis (DesParO)
- reduction/compression of input and output (DesParO)
- mapping (SCAImapper)
- crash simulation (LS-DYNA)
- stability analysis (DIFF-CRASH)
- sensitivity analysis (DesParO)
- reduction/compression of input and output (DesParO)
- multi-objective robust design-parameter optimization (DesParO)
- comparisons with physical experiments (as far as available)
Efficient, novel methods are proposed and employed for sensitivity analysis of simulation results on fine grids depending on parameter variations, for a reduction of the design space and the simulation results as well as for mapping an appropriately constructed data base of most influencing trends, not only comprised of thicknesses and strains, but also damage information. Including the latter turns out to be a crucial point. Results are shown, in particular, for a ZStE340 metal blank of a B-pillar. Comparisons to experiments demonstrate the abilities of the strategy proposed.
Audi: Optimization of Light-Weight Stamping Tools
Description will follow soon
Rechnergestützte Einbindung von Prozesslasten in die Entwicklung von Gestaltungsansätzen zur Strukturoptimierung von Umformwerkzeugen
Dipl.-Ing. E. Oswald, Prof. Dr.-Ing. M. Liewald MBA - Universität Stuttgart – Institut für Umformtechnik (IFU)
Dipl.-Ing. O. Stephan - Audi AG
Simulia User Meeting 2011 in Bamberg
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