17 solutions available for body engineering.pdf

8/10/2019 17 Solutions Available For Body Engineering.pdf

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Copyright ESI Group, 2011. All rights reserved.


Solutions Available for Body Engineering -Summary

Virtual Manufacturing

1


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Task: Functional Design in a Multi-

Material Mix that Fulfills Specification

2

Sheet Aluminum

Cast Aluminum

Aluminum Sections

Hot Formed Steel

Cold Formed Steel

http://boronextrication.com/2011/08/2012-audi-a6-body-structure/


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General Trends in the

Automotive Manufacturing Industry

3

Light weight

Mixed materials for functional design (Steel, Al, Mg, CarbonFiber), New Joining and Multi-Domain Optimization to validateperformance.


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Market Trends in Steel

www.carbodydesign.com

4

HS Steel

Standard Steels

UHS Steel

Hot Formed Steel


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Trends for Forming Processes of

Light Metals

5

Krajewski,

GM, Body &

Assembly

Congress

Troy 2011


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Market Trends in Aluminum

6

http://boronextrication.com/tag/body-structure/

Cast aluminum 44%

Aluminum sheet metal 28%

Aluminum sections 17%

Steel 8%

Other materials 3%


7/95Copyright ESI Group, 2011. All rights reserved.

Advancement in VehicleStructures & Safety

Materials Optimization for BodyEngineering

Body EngineeringDigital

Optimization

Manufacturing Engineering

Those are the Engineering Disciplines

Behind

7


8/95Copyright ESI Group, 2011. All rights reserved. 8

This is the Job to be Done

Virtual Prototyping means reducing tests and

physical prototypes with virtual test and prototypes.

This saves the cost for the physical try-out. Also

the time it takes to do the try-out is eliminated

The mandatory condition is the ability to deliver results good enough to

reliably replace the physical tests, in a time frame significantly shorter than

physical try-out would be



About ESI

9

Provider of Virtual Prototyping for the Industrial World

ESI is a world leading software editor for the numerical simulation of prototype

and manufacturing process engineering in applied mechanics

9





Body EngineeringDigital

Optimization


ESI Covers Most Aspects of Body &

Assembly

10


11/95Copyright ESI Group, 2011. All rights reserved. 11

Crash &

Safety

Stiffness &

Strength

NVH &

DurabilityAcoustics

Drivability

Comfort

ESI Virtual Prototyping

Multi-Domain performance engineering solutions

Including the coupling effects between domains andmechanical impact of manufacturing processes

Supported by a unified Visual Environment Platform, designed

to enable multi-task automation and support Engineering

Workflow management and collaborative Engineering.

Stamping Assembly

Virtual Manufacturing



PAM-STAMP 2G:Full chain simulation with hemming assembly

PAM-DIEMAKER

for CATIA V5

Tool design

Virtual

Performance

SolutionCrash, Strength,

NVH, Durability

AssemblyForming Restrike Flanging HemmingSpringback Springback Springback Springback

Less hardware prototypes,

optimized safety marginOptimized production time

& tooling costs

Tool milling

Requirements on:

- Geometry?

-Cosmetic Defect?

Requirements on:

-Material, thickness?

End-to-End Virtual Prototyping

of a Stamped Component

12

Full chain simulation under Visual-Environment,

in early design phase

Requirements on:

- Geometry?

-Cosmetic Defect?

-Material, Thickness?




of a Hot Formed B-pillar

Full chain simulation under Visual-Environment,

in early design phase

Tool milling

PAM-STAMP 2G

Fast Hotformingwith metallurgy

PAM-DIEMAKER

for CATIA v5Quick tool design

Material

Thk, ,

% of Martensite

VPSCrash (including

spot welds rupture),

Strength, NVH, Durability

13




of a Composite B-pillar

14

Draping and RTM simulation withPAM-RTM

Lay-up

+ material

Lay-up strategy definedIn CATIA CPD or SIEMENS FiberSim

E/E0=AE*exp(BE/x)

Draping and

Porosity

affect

Mechanicalproperties

s/s0=AT*exp(BT/x)

Structural analysis with

Virtual Performance Solution

Part designchange





Body EngineeringDigitalOptimization



Behind

15



Die Face Design & Early feasibility based on geometry

Cold precision forming

Standard processes

Advanced springback for advanced materials

Class A buy-off including all following operations

Cosmetic defects

Hot forming

Casting

Materials Optimization Covers the

Following

16



Parts Covered

17



Time reductionEarly evaluation of manufacturing ability

Reduction in the development times

Reduction of the try-out times

Quick response to needed modifications

Cost reductionCheaper products

Reduction of the die costs

Press down sizing

Increase of reliability

Increase of product qualityOptimal selection of the work piece material

Production of more complicated parts

Know-how accumulation for new materials

Press repeatability

Benefits of Materials Optimization

with Virtual Sheet Metal Forming

Bidding and

Planning

Die Face

Design and

Validation

Precision

Forming

Cold and Hot

Altan 201218



EARLY FEASIBILITY

Sheet Metal Forming

19



Only a few parts will remain mild steel

Complex technology - presented in a simple and accessible manner

From feasibility over precision forming to millingone model based ongeometry

Standard forming operations and compensation will go into early feasibility

Springback / precision needs to be as good as humanly possible

Robustness is interesting in case the major variables are matched

Major Trends in Sheet Metal

Forming

20


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Die Face Design Based on Mesh

22

Die Face Design Next GenerationSwitch from Mesh



Die Face Design Based on

Geometry

23

.to Geometry Approach - Design is Based on Geometry!



New Proposed Work Flow

for Die Design

24

The conventional workflow is shown at the top and the new proposed workflow

based on CATIA V5 / Visual Environment is represented belowclearly

showing the potential time savings


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Die Face Design in CATIA Die

Maker - 15 to 20 Min

25

~ 10 minutesPart preparation Blankholder design ~ 1 minutes

Addendum design ~ 5 minutesExport ~ 1 minutes
http://images.google.nl/imgres?imgurl=http://www.digizelgrafix.com/portfolio/images/lineart/stopwatch-bw.jpg&imgrefurl=http://www.digizelgrafix.com/portfolio/portfolio_lineart.html&usg=__EAiSrEAyFt92ozshRJX8sapHAXk=&h=400&w=325&sz=40&hl=nl&start=50&tbnid=vVzNTYyMALz9IM:&tbnh=124&tbnw=101&prev=/images?q=stopwatch&gbv=2&ndsp=18&hl=nl&sa=N&start=36http://images.google.nl/imgres?imgurl=http://www.digizelgrafix.com/portfolio/images/lineart/stopwatch-bw.jpg&imgrefurl=http://www.digizelgrafix.com/portfolio/portfolio_lineart.html&usg=__EAiSrEAyFt92ozshRJX8sapHAXk=&h=400&w=325&sz=40&hl=nl&start=50&tbnid=vVzNTYyMALz9IM:&tbnh=124&tbnw=101&prev=/images?q=stopwatch&gbv=2&ndsp=18&hl=nl&sa=N&start=36http://images.google.nl/imgres?imgurl=http://www.digizelgrafix.com/portfolio/images/lineart/stopwatch-bw.jpg&imgrefurl=http://www.digizelgrafix.com/portfolio/portfolio_lineart.html&usg=__EAiSrEAyFt92ozshRJX8sapHAXk=&h=400&w=325&sz=40&hl=nl&start=50&tbnid=vVzNTYyMALz9IM:&tbnh=124&tbnw=101&prev=/images?q=stopwatch&gbv=2&ndsp=18&hl=nl&sa=N&start=36


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Part Exchange - Initial Model

and New Model

Different outlines!

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Fully or semi-

automatic replace:Automatic recognition of new

flangesAutomatic definition of symmetry

E.g. recognition of redundant

rolling cylinder curves

Possibility to add new

functionalities (e.g. rolling

cylinders, profiles,..)Recognition of missing input

(flange) surfaces for part on

binder

Automatic or manual re-assigning

start points of floating profiles

Capabilities of Part Exchange

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The Total Time to Target is in this

Example Less then 2 Minutes

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Presented by Daimler AG at

German User Forum 2011

29

The milling result is very good and for a prototyping tool more thansufficient. The programming in TEBIS caused no problems whatsoever.

The Offset-Surfaces could be processed directly in TEBIS without any

problems.

Uwe Fisch er Mercedes -Benz Cars R&D


30/95


Following Operations

Transfer of geometry via IGES

Final forming simulation

Springback compensation

Return of the compensated mesh into

CATPartOverbending of the die set with

DIGITIZED MORPHING

Offset

Generation of solidtooling

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PRECISION FORMING

Summary

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Precision Forming - This is the Task

32

and make sure

material properties are

right for performance

considerations


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Copyright ESI Group, 2011. All rights reserved. 33

Positioning

"Make sure that the panel comes off

successfully in the first shot"

E l I /O St


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Product design

Blank development

Thinningprediction

Forming LimitDiagram (FLD)

Examples: Inverse/One-Step

Simulation


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Applicable to :Progressive dies

Line dies

Transfer dies

Deep draw

Crash forming

Superplastic forming

Sheet & tube hydroforming

Tube bending

Tube and sheet hydroforming

Hot formingIroning

Coining

Stretch forming

Flex forming

Material:Titanium

AluminumStainless

Copper

HSS

Incremental Simulation: Overview


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Highthinning

Predicting common defects such as splits, wrinkles, spring back and

material thinning on computer

Providing customers with right first time

tooling to run production with a minimum

of manufacturing risk

Example Progressive Die

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-Process requiring Solid elements

-Strong Solids capabilities in PAM-STAMP2G (also used for coining)

Cracksprediction

Wrinklingprediction

Standard Stamping

Wh i Hi h St th St l


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Why is High Strength Steel more

Challenging

38

Mild Steel

590TS

980TS

AHSS (Ad d Hi h St th


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AHSS (Advanced High Strength

Steel) - Precision Forming

Bad

Formability

PamStamp 2G v2012 includes

more accurate and faster springback

for stamping of Ultra High Strength Steel

Mild Steel

590TS

980TS

Large

Springback

39


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Unbending

Opening

Twisting

Wall curvature

Spring-back/Compensation

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Fi d th O ti l Bl k Si & T i Li


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Find the Optimal Blank Size & Trim Lines

with Automatic Optimization

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Forming Restrike FlangingSpringback SpringbackBlanking

blank shape

Trimming Restrike FlangingSpringback SpringbackForming Trimming

trim lines


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Initial Blank shape optimization

LINE DIE OPTIMIZATION

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After optimization

95% up to 1mm

Before optimization

18% up to 1mm

1stforming

2ndforming

restrike

Line Die Full Chain Simulation


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Line DieFull ChainSimulation,

Optimization, Quality Control

43

Forming Restrike Flanging HemmingSpringback Springback Springback Springback



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Virtual Prototyping of all OPs

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Forming Restrike FlangingSpringback Springback Springback

Source: Europam Toulouse 2006

Formability Analysis of Complex


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y y p

Automotive Panels and Full Process / Full

Cycle Simulation

45

Process validation and optimization, defects prediction before try-out


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Forming Restrike FlangingSpringback Springback Springback

Correction of springback

Multi-Ops Die compensation

Solve transfer: adapt

die from previous or

next OPs

Draw die

compensation

Compensate die

from multi-OP

springback

Automatic draw

and trim die

compensation

Y Tec manufactures an ultra high strength


47/95


Using the Yoshida-Uemori model in PAM-STAMP 2G improves the accuracy of springback prediction

to a point where it becomes possible to determine effective qualitative countermeasures. By analyzing

the stress and strain accumulated during forming, we were able to determine and eliminate the cause

of poor dimensional accuracy. Thanks to PAM-STAMP 2G, we reduced the number of modifications on

the stamping tool even in cases where the parts formability was challenging, such as Ultra High

Strength Steel parts.

Y-Tec manufactures an ultra high strength

steel bumper with PAM-STAMP 2G's

springback correction

47

Hiroki Kondo, Deputy Manager, Advanced Press

Engineering Group/Dept. Y-Tec Corporation

Stress components which cause springback

Improvement of springback by reducing plastic strain

Courtesy of Y-Tec Corporation


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Gestamp successfully brings to market a

weight-optimized B-pillar stamped

from tailored blank using PAM-STAMP 2G

48

We achieved very good results thanks to

the accuracy of the simulation using PAM-

STAMP 2G. We were able to use thespringback prediction tool to evaluate the

die compensation, despite the complexity

of such a case with three different

thicknesses and two weld lines.

Eduardo Sulato and FbioLichtenthler

Engenharia da Matriceria

GestampAutomocinS.L.

Courtesy of Gestamp Automocion


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Hot Forming - Formability

Temperature on blank / tool

Martensite fraction during quenchingAfter 4 s After 8 s After 14 s

49


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Cooling Simulation of the Dies

50

3D tools with

cooling channels

Tool temperature at the end of quenching:

Courtesy of:

AP&T

Temperature at the End of Forming


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Temperature at the End of Forming

and Quenching

Temperature at the

end of forming

Temperature at the

end of quenchingCourtesy of:

AP&T

Casting Covers all Aspects of


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Casting Covers all Aspects of

Components

The whole is more than the sum of its partsAristotle

Microstructure Defects Properties States Dimensions

52


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NON-METALLIC COMPONENTS

Summary

53

Get it right with End-to-End Virtual


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End-to-End Virtual Prototyping Solution allows customers to deliver the

physical prototype right the first time.

Get it right with End to End Virtual

Prototyping Solutions

Build it right

Test it right

Deliver it right

Product Life Cycle

Forming

Infusion

Draping

Component simulation

System-level Simulation

54

Composites Materials and Processes


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Design flexibility / production rate

55

Reinforced

Thermoplastics

Mechanical

Properties/

Material

costs

Reinforced

Thermosets

Long fibersShort fibersunreinforced

2 mm

Injection molding Thermocompression Press Forming

RTM / Infusion - Vacuum Forming

Fiber length

Composites Materials and Processes

BMC SMC

6 mm 20 mm

Mats (GMT) Textile

Unidirectional


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Evaluate and optimize

Mold geometryProcess conditions

Vacuum strategy

Molding temperature

Through the prediction ofWrinkles

Thickness

Taking into accountThermal & strain rate effects

Thermoforming & Blowforming Simulation

[email protected]

Industrial Examples of Applications:


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Blow Forming (Gas Tank)

Thinning (%) DistributionSag under gravity (self-weight)

Blowforming

The Main Composites


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Pre-PregsLay pre-cut individualplies to build thelaminate

ORforming of complete pre-impregnatedlaminate

Cure at high temperature and pressure in anAutoclave

ORcuring in forming tools (OOA)

LCM (Liquid Composites Molding)Lay pre-cut dry fabrics to build the laminate

ORForming of dry fabrics

Injection/Infusion of dry fabrics

Curing in Injection/Infusion tools

The Main Composites

Manufacturing Options

Autoclave

Draped preform

Coutesy Renault

LCM Bracket Courtesy: CRCACS 2000+

58

P P F i Si l ti


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Pre-Preg Forming Simulation

Evaluate different forming strategies:Stamping, diaphragm (single or double) forming,

thermoforming

Clamping conditions, process parameters (tool velocity,

temperature, pressure)

Different Lay-up strategies

ESI solutions can help you:Reduce wrinkling

Eliminate bridging

Predict thickness of material after forming

Deliver optimum flat patternsDetermine final fiber orientation

Initial flat

pattern

Optimized flat

pattern

Poor part

quality

Improved

part

Simulation setup

Lower tool

Upper tool

4 plies

59

Aircraft Wingbox Simulation 8


60/95


Courtesy: Br i t ish Aerospace

Actual Formed Part Simulated Part

Aircraft Wingbox Simulation 8

Plies (UD)

Thermoforming Process

Ply 1

As-built Fiber Orientation

60

A t l P


61/95


Autoclave Process

Draping Curing Demolding

Thermo-Mechanical

Calculation

Fluid-Flow & Heat

Exchanges Calculation

Stress releaseLocal material properties

modification

Thermo-Mechanical Calculation

Internal stresses generation

61

Liquid Composites Molding


62/95


PAM-RTM can evaluate and optimizeInjection strategy (RTM, VACUUM INFUSION,

VARTM)

Injection pressure and flow rate

Injection gates, vents and vacuum ports location

Molding temperature

Flow media

Through the prediction ofDry spots

Filling and curing times

Flow front velocity / Fiber washing

Pressure in the mold

Taking into accountFiber angle variation (permeability variation) of the

preform

Liquid Composites Molding

Simulation

[email protected]

R i Fl F t A l i


63/95


Resin Flow Front Analysis

63

CF Floor Pan Infusion Courtesy TECABS: RENAULT

Mines Douai

Effects of Injection Conditions


64/95


Micro-voids are directly proportional to the resin velocity

Critical impregnation velocity

For high performance composites, formation of micro-voids inside the

fiber tows should be minimizedMacro voids

Inter-tow

onto Mechanical Performance

(J. Brard)

64

Micro voidsintra-tow

Influence of Porosity on Stiffness


65/95


y

& Strength

65

Draping and RTM Model

Lay-up

+ material

Lay-up definition

Draping and

Porosity effect

on mechanical

properties

Strength analysisDesign

Iteration

Simplified Process Setup for


66/95


Engineers

66

Read multiple native

CAD modelsCATIA,

Pro/E, UGS NX, etc.

Create stamping tools

blank, rubber pad, etc.

Execute simple model

operations like translate,

etc.

Visual-Mesh

Create simulationprocess in wizard mode.

Encapsulate PS2Gto

generate the process.

Create Process block

library for future use

Visual-SDK, Visual-Process Exec

Display results

Extract reports

Visual-Viewer

What Makes the Difference:


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Assembly

OP 20 & 30 OP 40, 50, ..

Joining & Full Process Chain for Forming

Draw

Trim

Flange

Restrike

........

RollHemming

1

2

3

4

56

Welding

67

Casting ..



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g g p

Behind

68



69/95


Hemming

Cold and hot joining (welding)

Welding including history from sheet metalforming

g g g

Covers the Following

69

Roll Hemming


70/95


Roll Hemming

70

Full forming process line


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Copyright ESI Group, 2011.All rights reserved.

Courtesy: UBSLIMATB - Universit de Bretagne-Sud

Rue de Saint Maud- BP 92116

56321 Lorient Cedexhttp://web.univ-ubs.fr/limatb


Springback

between OP

g p

PamStamp 2G

71


Flanging with ironing

simulation & impact

on springback

enhanced in v2012

with Hill 90, Barlat

Springback after

Hemming with glue

contact

enhanced in v2012

Table top and

Rollhemmingsimulation

Springback

between OP

Springback

between OP

Flanging HemmingSpringback Springback Springback Springback

PamStamp 2G simulation

With TTS elements

With ironing

Without ironing
http://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatbhttp://web.univ-ubs.fr/limatb


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PSA Objective: Decrease developmentdelay and cost, improve the quality

84 welding joints (total length 5 m)

Simulation: Weld - Fatigue Life Analysis

73

Metallurgy Residual Stress Fatigue Criteria

GoalSheet Metal Forming and


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Joining to Manage Building Systems

74

AssemblyForming Restrike Flanging HemmingSpringback

Spring

back

Spring

back

Spring

back

Based on one model and one platform


Die Face

Design Based

on Geometry

Sheet Metal Forming


75/95


with Spot Welding

75

Spot-Weld AssemblyStamp Assembly sequence

Compensation

Some Details


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Import ComponentDeformed Shape from Stamp result

Thickness

Import Spot Weld Points

Automatic spot weld point assignment

Spot Weld Validation tool based on user

criteriaCheck Gap/Distance

Alignment /Angle

Component Penetration Area

Automatic Spot Weld Re-meshing tool

Export all information for Spot Welding

Assembly Simulation on Weld PlannerSpot Weld Sequence management

Penetration area for contact management

Some Details

76

Spot Weld

geometrical validationtool in visual

Stamp- Spot Weld Assembly


77/95


p p y

Simulation

77

Processing in Weld PlannerSequence DefinitionAutomatic Gap Closing

Contact Management

Stamp- Spot Weld Assembly


78/95


Final Stamp Spot Weld

Displacement Results

After Clamp Release

p p y

Simulation

Full Stamp Spot Weld deformed shape


79/95


p p p

can easily be exported for hemming

79

Laser Weld Assembly Chaining Solution


80/95


Laser Weld Assembly Chaining Solution

80



81/95



Materials Optimization for Body

Engineering



Behind

81

Modeling Tasks:


82/95


Virtual Spot Weld Calibration

WELDING & HT

ANALYSES

3D SPOTWELD

MODEL

EQUIVALENT 1D

SPOTWELDMODEL

EI

Material properties

CCT diagrams

Process conditions

Local properties

EWK parameters?

Sample geometry

Test conditions

Force-deflection

Absorbed energy

Rupture model

& parameters

Force-deflection

Absorbed energy

M1 M2 M3

SIMULATION

CONTENT Mgt.

Data base

Development

M4

Tests results

3D results

1D Models

82

Simulation of Rupture Modes


83/95


Partial nugget pull-out and peeling of model

Ex. Mild Steel1 mm

100%

75%

50%

25%

0%

Martensite content:

T-tension Lap shear Cross tension

83

Stamping Effects to Improve


84/95


Applicable in the pre-design phase

Consider real part properties in performance simulation

p g p

Virtual Performance Evaluations

84


85/95

Virtual Performance Solution

b d Si l C M d l


86/95


based on a Single Core Model

Crash & Safety

Stiffness & Misuse

NVH & I.Acoustics

Durability

Drivability

Comfort

Design iteration

Crash &

Safety

Stiffness &

Misuse cases

NVH & Internal

AcousticsDurability

Drivability

Comfort

86

Current More Efficient


87/95



88/95


PRODUCTS

Body Manufacturing

88

What is Covered by VM - Materials

Optimization Component Manufacturing


89/95




Engineering



OptimizationComponent Manufacturing

89

Task: Manufacturing of Components Under the

Aspect of Materials Optimization


90/95


Aspect of Materials Optimization

90

Closures / Outers

Inners

Chassis

not shown

here

Materials Optimization - Manufacturing of

Components Covers the Following


91/95


Die Face Design & Early feasibility based on geometry

Die Maker based on CATIA and Visual Platform + feasibility

Cold precision forming

PS2G Getting the draw die right the first time

Zero tolerance buy off on the checking fixtureall followingoperations and quality checking at any stage

Hot Forming

PS2G

Casting

Quick / Procast

Components - Covers the Following

91

Composites Processes Summary


92/95


Unreinforced

Plastics

Continuous Fibers

Process:

Draping/Thermoforming

Process:

Resin Infusion

Process:

Thermoforming/Blowforming

Software:

PAM-FORM

Software:

PAM-FORM

Software:

PAM-RTM

Results: Results: Results:

Wrinkles

Thickness distribution (can be

used to update stress analysis

models)

Wrinkles

Thickness, strains & stresses

distributions

As-manufactured fiber

orientation (can be used to

update stress analysis models)

Filling time

Dry-spots

Micro & macro-voids (can be

used to update stress analysis

models)

92

What is Covered by VMManufacturing

Engineering


93/95




Engineering



Engineering

93

Manufacturing Engineering - Putting Components

Together - Covers the Following


94/95


Roll Hemming

PS2G

Cold and Hot Joining

PS2G / Weld Planner (Feasibility) / Visual Weld(validation)

Welding including history from sheet metal forming andcasting (innovation)

Body manufacturing (project level)

Together - Covers the Following

94

Goal


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Engineering



VMS

17 solutions available for body engineering.pdf

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