cae-driven design methodology for semi-autonomous product development
TRANSCRIPT
CAE-Driven Design Methodology for Semi-
Autonomous Product Development
Designing the next generation light weight vehicle structures
www.DLR.de • Chart 1 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Dr.-Ing. Sivakumara Krishnamoorthy
Dipl.-Ing. Matthias Konzelmann
Sameer Chaudhari B.E.
Dipl.-Ing. Gundolf Kopp
Prof. Dr.-Ing. Horst E. Friedrich
DLR – Overview
• German national research center for aeronautics and space
• Development of environmentally-friendly technologies
• Promote mobility, communication and security
7 400 employees are working at 32 research institutes and
facilities in n 9 locations and 7 branch offices.
SPACE AERONAUTICS TRANSPORTATION ENERGY
www.DLR.de • Chart 2 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Motivation
www.DLR.de • Chart 3 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Global Challenges
• shortage of ressources
• climate change
Challenges in Mobility
• reduce fuel consumption
• reduce emissions
• adapt concepts for new mobility
Challenges for Vehicle Concepts
• short development time
• increase economic efficiency CAE-based design
methodology for
BIW-concepts
Objective CAE-based design methodology
www.DLR.de • Chart 4 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Comfort
Driving
characteristics
Safety
Lightweight
design
Economy
Approach
www.DLR.de • Chart 5 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Design-Space-Model
Topology Optimization Result
Light Weight Structure
Optimization Model
• Units and loads are
point masses
• Static loadcases:
• Torsion
• Bending
• Static loads representing
dynamic conditions:
• Front crash
• Rear crash
• Side crash
www.DLR.de • Chart 6 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Crash equivalent static loads
Topology Optimization Result
www.DLR.de • Chart 7 > CAE-driven design methodology > Matthias Konzelmann > 23.04.2013
Approach
www.DLR.de • Chart 8 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Design-Space-Model
Topology Optimization Result
Light Weight Structure
Interpretation of Structural Requirements
www.DLR.de • Chart 9 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Bending
Interpretation of Structural Requirements
www.DLR.de • Chart 10 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Axial load Torsion
Identifying Shear Locations
• Optimization algorithm disadvantages shear planes
• Identification necessary
• Plane structures are easy to manufacture
www.DLR.de • Chart 11 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Intermediate result
F
End result
F
Techno-Economic Criteria
www.DLR.de • Chart 12 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Material
Cost effectiveness
Branding/
Image Quantity
Space-Frame Monocoque Hybrid Shell
Interpreting the Results
• One purpose per loadcase (LC) and member
• Topology Optimization results contain complex equilibrium
• No loadcase disregarded
• Good performance for each loadcase
• No focus on particular loadcases
www.DLR.de • Chart 13 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
LC
1
LC
2
LC
3
LC
x
LC
1
LC
2
LC
3
LC
x
Initial calculation Final calculation
Pe
rfo
rma
nce
Example: Side-Rail
www.DLR.de • Chart 14 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
• Very high height to width ratio
• I-shape already in result
• Shear structure
Height
Width
Example: Roof-Structure
• No information in cross-section
• Further interpretation:
• Contour Signed VonMises
• Bending detected?
• In this case no Bending
www.DLR.de • Chart 15 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Example: Roof-Structure
www.DLR.de • Chart 17 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Cross-section shell structure
Example: Roof-Structure
www.DLR.de • Chart 18 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
Roof structure, reinforced with FRP +/-45°
www.DLR.de • Chart 19 > CAE-driven design methodology > Matthias Konzelmann > 23.04.2013
Decision Making in Design Process
Thank you for your attention