lightweight design integrated with the product development process
Post on 13-Sep-2014
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DESCRIPTION
Using “Simulation Driven Design” as facilitator to optimize the balance between performance, weight and cost. The pressure on developers to improve both the development process and the product efficiency of each new product generation is continuously growing. At the same time, products are getting increasingly complex with added functional integration, higher demands on product flexibility, more legislative regulations and internal performance measures to be fulfilled with more ambitious targets for theses performance measures. This should be accomplished within shorter development cycles and tighter limits on the development budget. In order to coop with these challenges in a sustainable way, development engineers need efficient tools, methods and processes that support the development process better than today. The introduction of CAE and optimization (Simulation Driven Design) as design drivers has been proven to be an efficient method to significantly improve the development efficiency. Tightly integrated with the standard design process, simulation driven design can continuously support development engineers with design proposals, information from trade-off studies, information from what-if analyses, etc. in order to continuously find the best balance between multiple performance targets, weight and cost. This presentation will discuss how simulation and optimization can be used to drive design, how simulation driven design support can be integrated within the development process at the OEM and will additionally show examples of successful applications in recent years.TRANSCRIPT
Innovation Intelligence®
Lightweight Design integrated with
the Product Development Process
Lars Fredriksson - Director Business Development Europe
Altair Engineering AB
Holländargatan 27
113 59 Stockholm
25th June 2014
“Excess weight kills any self-propelled vehicle. There are a lot of fool ideas about weight …
…. Whenever anyone suggests to me that I might increase weight or add a part, I look into decreasing weight and eliminating a part!” (*)
(*) Ford, H. (2009). My Life and Work.
CreateSpace.
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Most important factors for helping
car manufacturers reaching the new
CAFE fuel economy targets (*):
1. Lightweight Materials (72 %)
2. Engine Downsizing (65 %)
3. Design Optimization (45 %)
4. Vehicle Downsizing (38 %)
5. Vehicle Electrification (34 %)
6. Aerodynamics (19%)
7. Intelligent Electronics (18 %)
8. Others (5 %)
Fuel Economy and Light Weighting
(**) et al. Bjelkengren, C. 2006 “The Impact of Mass Decompounding on
Assessing the Value of Vehicle Lightweighting” Master of Science Thesis, MIT, USA.
Advanced Materials
High Strength Steels
Non-ferrous metals
Composites
Design Change
More simulation
Optimization
Material modeling
Novel Processing
New structures
Mixed materials
Different needs
Light Weight Enabler(**)
(*) SAE Online Survey conducted for 3M and Automotive
Engineering International 2011
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair positioning in Light Weighting..…
(*) Leichtbaustrategien für den Automobilbau, Stuttgart 10. und 11. Juni 2012, Müller, Porsche
(*) Design Opt. / Shape Design Opt. / Concept
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
A system approach is necessary (*)
Design Change
as Facilitator: “……. In material substitution, very little consideration is
given to the effect a substituted part has on adjacent
parts or other performance criteria of the vehicle beyond
its primary function…….”
“….. Engineers will need to understand and use systems
analysis techniques to develop the next generation of
lightweight vehicles…….”
“…….. There have been several research projects
indicating that a systems approach will be necessary to
maximize weight reduction while maintaining
performance and cost…….”
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Baseline:
Weight:
Design Period:
9.15 kg
3 months
Goal:
Weight:
Design Period:
7.50 kg
3 weeks
Experience
Benchmarks
System Optimization to Support the Design Process
Predecessors
New Technology
Carry-Over Production
Methods
New Materials
Added complexity and integration
More legislation constraints
Higher targets on attributes
Shorter development times
More product variants
Reverse the weight spiral
Cost efficiency
Increasing quality demands
Integration
Situation
Packaging
Simulation
&
Optimization!
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Innovation with Simulation Driven Design
Innovation Simulation Inspiration
Team Organization?
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Design Optimization
Support
CAE
Optimization integretad in Product Development
Virtual Testing Simulation Driven Product Design
Product Development
CAE
Tests / Verification/ Homologation Testing / Verification / Certification Design
Powertr. BiW Closures
Product Design
Chassis NVH Crash Fatigue Statics
Functional Attributes
Support
NVH Crash
Fatigue Statics
Light Weight Center
Optimization Arena
Simulation Driven Design
Processing Weight Packaging
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
…..and helps improve Development Efficiency
Costs efficiency:
• Weight reduction, simplification, material
change
Weight management efficiency:
• Control weight and reduce development risk,
support weight management decisions
Development process efficiency:
• Save development loops, improve concept
maturity, improve decision material
Production process efficiency:
• Simplify geometry and reduce part count,
optimize connections
Cost
Weight
Performance
Weight Distribution for optimal Performance
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Managing weight in Product Design
Optimization for design engineers
Test and verifaction of design ideas
Efficient software solution to support
weight related decision
making processes
Customer Development Processes
Altair supports simulation driven design
during concept and development phases
strategically and integrated into
OEM organisation
Altair Solutions
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
SolidThinking Inspire
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Simulation driven design
Single Attribute
Low Integration
Complexity
Low Load
Complexity
Multiple Attributes
High Integration
Complexity
High Load
Complexity
Design Complexity
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Managing weight in Product Design
Optimization for design engineers
Test and verifaction of design ideas
Customer Development Processes
Altair supports simulation driven design
during concept and development phases
strategically and integrated into
OEM organisation
Altair Solutions
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair‘s Light Weight Design Support
Concept Design
Des
ign
Sta
ge
Vehicle Development
C123 – Simulation Driven Concept Design
Sim
ula
tio
n D
rive
n
Des
ign
,
C1: Find Structure
C2: Verify and Optimize
C3: Realistic Sections
Shape, Thickness
An Process
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
C123 - A three step simulation driven concept process
Steps:
• Find Load Paths and
Structure
• Package Trade-Off
Studies
• Study Influence of
Design Directions
C1
• Convert to Real Life
Cross Sections
• Use Cross Section
Library
• Refine Concept, Shape
and Size Opt.
C3 • Verification of Load
Path Concept
• Sizing of Structures
and Joints
• Packaging / Structural
Trade-Off Studies
C2
An Process
16kg weight saving
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Altair‘s Light Weight Design Support
Concept Design
Des
ign
Sta
ge
Vehicle Development
C123 – Simulation Driven Concept Design
Sim
ula
tio
n D
rive
n
Des
ign
,
C1: Find Structure
C2: Verify and Optimize
C3: Realistic Sections
Shape, Thickness
i-MDO, a-MDO – Multidisciplinary Optimization
An Process
Up-gauged Panels
Down-gauged Panels
Thickness Change
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
i-MDO – Design Optimization Support
Ma
ss
Sa
vin
gs
[kg
]
Iteration
An Process
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Managing weight in Product Design
Optimization for design engineers
Test and verifaction of design ideas
Efficient software solution to support
weight related decision
making processes
Customer Development Processes
Altair supports simulation driven design
during concept and development phases
strategically and integrated into
OEM organisation
Altair Solutions
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Weight analytics – overview
Monitor and analyze KPI based on Mass, CoG and Inertia through single Web-based interface
retrieving information from various company systems
• Supports Weight and Balance Engineering all over the phases of
product life cycle
• Accommodates the forecast of weight bandwidths for parts and
sub-assemblies, risk and opportunities, and analyze what-if scenarios
throughout the entire product life cycle
• Provides access to powerful Business Analytics features through
HiQube integration
• Automates the data retrieval and management of multiple data sources, with secure access management
Reduce the time to consolidate data sources by up to 80%
Improve process to make informed decisions by up to 50%
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
The Benefits
Flexibility
• Providing a solution tailored to your specific needs
Fast Deployment
• Configurable software base module already available
• Get work started quickly by adding only your unique custom requirements
Cost Effective
• Leverage existing HWU pool
• Support and maintenance process similar to HyperWorks
• Minimize customization and cost of ownership
Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Open the door to efficient LightWeight Design
Thank You for
The Attention!