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Accelerate Innovation with Realistic Simulation
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My 16-year-old daughter tested for her driver’s license
recently in a car with antilock brakes, traction control, brake assist, active head restraints, side air bags, blind spot warnings and a backup camera. (She still hit a cone on the maneuverability test.) The safety technology alone in that car seems light years ahead of what I learned in, but it’s not even the state of the art today. Now consider the technology needed to implement lightweighting, hybrid and all-electric drivetrains, not to mention self-driving cars. How can automakers and their partners keep up, let alone meet their goals to exceed customer expectations?
They need a flexible and targeted solution that can be easily customized and updated. It needs to be scalable, as future-proof as possible, and focused on industry-specific best practices. It should all but disappear in the background while supporting seamless collaboration across departments, among suppliers and along the entire supply chain. It also needs to be available any time from anywhere to support the rapidly evolving digital enterprise.
That’s asking a lot. But on the following pages, you’ll see examples of how the transportation industry is collaborating to create innovative products to meet its customers’ specific needs, even as it faces significant business disruptions.
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StaffTom CooneyPublisher
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Drive Home New Opportunities 3How the transportation industry is bringing higher quality products to market for less by designing to value and delivering on target.
Powering Innovation with Simulation 6Leverage the benefits of simulation and optimization to power innovation.
Simulation Driven Design for Manufacture of a Pressed Composite Automotive Tailgate 8Overcoming the challenges of a carbon fiber design.
Software Gets Industry Specific
Driving Home New Opportunities
The transportation industry is racing toward the most significant disruptions since the transition from carriages to motorcars. Advances in technology, new
materials and heightened customer expecta-tions are raising the innovation stakes and fos-tering a more symbiotic relationship between OEMs and suppliers as they try to outpace the competition.
The supplier role is rapidly shifting from servicing original equipment manufacturer (OEM) design directives to becoming a strate-gic collaboration partner driving new vehicle development. Trends such as hybrid and elec-tric powertrains, onboard consumer electron-ics and autonomous vehicle operation fuel a level of specialized complexity that has many
OEMs pushing to share design responsibility with suppliers, as opposed to innovating or integrating system components on their own.
These close-knit partnerships are being forged against the backdrop of a market changing at a frenetic pace. New government regulations — most notably, the 2012 directive requiring the U.S. auto fleet to comply with a Corporate Average Fuel Economy (CAFÉ) standard of 54.5 miles per gallon by 2025, more than doubling today’s 25 MPG average — have encouraged OEMs to lean on suppliers more. Suppliers are providing design assis-tance in critical areas like smarter powertrains, lighter weight composite materials, and more efficient components to help meet rigorous fuel economy goals. As a result of the industry-wide
How the transportation industry is bringing higher quality products to market for less by designing for value and delivering on target.
“The Car of the Future” explores how autonomous cars change driving experience as well as improve efficiency focusing of traffic, safety and pollution.
Accelerate Innovation with Realistic Simulation Accelerate Innovation with Realistic Simulation
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push for energy efficiency, automotive suppli-ers now find themselves in the design hot seat, spearheading lightweighting strategies and opti-mizing designs in emerging areas like battery and autonomous driving technologies, including radar, sensors and cameras.
Economics is also helping to redefine the OEM-supplier relationship. With consum-ers increasingly focused on value purchases, suppliers’ ability to increase productivity and design efficiency helps reduce the cost
of existing components, allowing OEMs to onboard new vehicle technology related to safety, customization, entertainment and communications without significantly raising prices for consumers.
Another factor necessitating the need for tighter coupling between OEMs and suppliers is the unprecedented demand for shorter time-to-market cycles. Increased government regu-lation and heightened competition is spurring OEMs to increase the frequency of new releas-es, putting pressure on suppliers to stay abreast of rapid-fire engineering changes and product refreshes. According to market research firm IHS Automotive, new vehicle model launches will increase from 35 in 2016 to 47 in 2019 — a surge of about 25%.
To effectively engage in a more tightly-inte-grated relationship, suppliers and OEMs need to leverage technology and establish better global collaboration processes that can sup-port requirements management, engineering changes, compliance tracking and product data management while providing visibility into performance, quality, reliability and safety of components and subsystems. These demands require an open, robust platform tuned for innovation so suppliers can successfully and rap-idly navigate the industry changes as a strategic co-pilot along side of OEMs.
Take a Platform ApproachThe 3DEXPERIENCE® platform from Dassault Systèmes is a Business Experience platform. It provides software solutions for every organization in your company — from engineering to marketing to sales — that help you in your value creation process to create differentiating consumer experiences. With a single, easy-to-use interface, it powers In-dustry Solution Experiences — based on 3D design, analysis, simulation, and intelligence software in a collaborative, interactive en-vironment. It is available on premise and in public or private cloud.
New vehicle model launches will increase about 25% between 2016 and 2019.
— IHS Automotive
Solutions for Transportation & MobilityTo help the Transportation and Mo-bility sector meet its new energy reduction goals, shrink time-to-market schedules, and manage increasing sys-tem complexity, the 3DEXPERIENCE platform delivers solutions based on industry knowledge and domain-specif-ic best practices.
The platform delivers a systematic approach to 3D modeling, content and simulation, social and collaboration, and information intelligence in the context of specific challenges common to transportation and mobility com-panies. Among the Industry Solution Experiences tailored to this sector are:
• Global Validation, Proven Performance, which leverages simulation and other capabilities to improve both physical and virtual testing as well as validation to help companies enhance quality and reduce develop-ment costs.
• Smart, Safe and Connected accelerates prod-uct innovation to market, fortifies your ability to manage complex systems and provides an integrated
solution for mechanical, electron ics, software and simulation.
• Bid to Win, which brings together a variety of in-dustry-proven tools and processes to help companies analyze new opportunities, win new business, and then design, engineer, validate, manufacture and deliver products on target with customer requirements.
For more information, visit 3ds.com/transportation.
AKKA Shapes Future of Autonomous Transportation
Leading-edge innovator, AKKA Technologies, is proactive-ly pursuing new technologies and processes to address high-potential transportation markets. One of their ground-breaking projects is the Link & Go concept car (and its descendant, the Link & Go 2.0) which is a self-driving electric vehicle packed with innovations that could interest automotive OEMs for their future vehicle development.
The development of the Link & Go 2.0 is the collective achievement of 40 engineers working in AKKA’s offices around Europe. AKKA Research adopted the innovative applications of the 3DEXPERIENCE® platform, via the cloud, from Dassault Systèmes to enable their global stakeholders from multiple sites to collaborate smoothly together. With all product and project data centralized, everyone has real-time access to the vehicle’s 3D digital mock-up, allowing them to work on it and exchange ideas as if they were working in the same office.
Read the case study.
Watch this video to learn about the Bid to Win Industry Solution Experience from Dassault Systèmes tailored for the transportation sector.
Empowering Collaborative InnovationThe Brano Group, a diversified company that supplies automotive components, has 11 sites in the Czech Republic, offices in North America and Germany, and production locations in China and South Africa. Man-aging projects among the different sites was not always easy. Locating information, coordinating designers and engineers, sticking to schedules and delivering on time and on budget were becoming increasingly tedious and time-consuming tasks. To improve efficiencies, Brano selected the 3DEXPERIENCE platform from Dassault Systèmes, including its ENOVIA® brand application for collaborative innovation.
The ChallengeBrano was using manual processes to manage its projects across the extended enterprise, slowing customer response times and growth potential.
The BenefitsBrano is now able to manage ever growing market and OEM audit process quality requirements more efficiently, providing all members of higher manage-ment at Brano’s multiple sites with access to the latest product information. All projects are managed accord-ing to APQP (Advanced Product Quality Planning) and PPAP (Production Part Approval Process) standards, ensuring consistent process data traceability.
Read the full story.
Accelerate Innovation with Realistic Simulation Accelerate Innovation with Realistic Simulation
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Dassault Systèmes has made technical break-throughs in simulation and analysis technolo-gies, including: solver performance, accuracy, scalability, material modeling, assembly mod-eling, contact analysis, fracture and fatigue, multiphysics co-simulation and efficient opti-mization. However, robust technology on its own is no longer sufficient. The issue facing most companies is not just how to use more simulation technology, but how to integrate the technologies and leverage the benefits of simulation and optimization to power inno-vation. Companies need to bring simulation out from the back corner of the engineering department and onto center stage in their business processes.
Realistic Simulation, as an integral part of the 3DEXPERIENCE platform and adapt-ed to the requirements of a specific industry, enables requirements, design variants, simu-lation models and results to be maintained as part of the “single source of truth” throughout the development process. The integration of simulation and analysis, process capture, au-tomation, optimization and decision analytics enables organizations to share best practices and accelerate design exploration.
The 3DEXPERIENCE platform enables simultaneous collaboration on simulation processes and results. Any changes to the design and the simulation models are auto-
matically reflected in the system of record, which makes it possible for everyone to be fully aware of their colleagues’ contribution at each stage of development. For example, mechanical engineers are able to analyze designs against a number of parameters while manufacturing engineers evaluate whether a particular iteration can be produced effi-ciently at optimal cost, all the while keeping any changes and decisions in synch with the entire development process.
Leveraging simulation use — guided by analysis experts — on an enterprise scale encourages robust and fast design explora-tion, which is critical in today’s compressed time-to-market cycles. Employed early and continuously throughout each phase of design, simulation helps teams zero in on an optimal set of options when it’s less expen-sive and easier to make changes. Simulation can help suppliers capture valuable insights that will minimize their reliance on physical prototypes and protracted test cycles, helping to keep development costs in check. It also empowers teams to collaborate on evaluating design alternatives, which might have been impossible to consider with separated design and analysis processes.
Realistic simulation helps companies reduce uncertainty and risk, which is more critical in the transportation sector as rising product complexity steers suppliers and OEMs into un-charted territory. As suppliers continue to push the innovation curve in such cutting-edge areas as assistive braking technology, hybrid powertrains and com-posites, they will need to meet safety regulations and efficiency standards along with their OEM partners. Simulation-powered design is a proven way for suppliers to achieve compliance while validating that designs perform optimally.
The Industry Solution Experienc-es of the 3DEXPERIENCE plat-form combined with the power of SIMULIA® brand applications helps companies deliver high-performing, innovative products while reducing cost, time and risk. Transportation and mobility companies can tap Bid to Win, for example, to satisfy customer requirements with optimal designs, which helps win new business and achieve more profitable results. In that same vein, the Global Validation, Proven Performance Industry Solution Experience leverages simu-lation to help OEMs synchronize physical and virtual testing and validation to improve product
quality, reliability and performance. The com-plexity of today’s products demand streamlined collaboration and tighter design processes. By making best-in-class simulation and analysis tools and methods accessible throughout the en-tire development cycle to a wider range of design and engineering stakeholders, suppliers are more likely to position themselves as a strategic part-ner to OEMs. An open and collaborative plat-form geared toward specific industry challenges can enable suppliers and OEMS to steer toward a more innovative future.
See examples of how simulation accelerates innovation, reduces the number of physical prototypes and helps companies create market-winning experiences in the video above.
The transportation industry relies on realistic simulations to speed innovation. Learn more.
3DEXPERIENCE Powers Realistic SimulationThe 3DEXPERIENCE platform has been architected from the ground up to make simulation an integral part of a holistic, cross-disciplinary design workflow. SIMULIA is actively integrating these robust technologies into the 3DEXPERIENCE platform:
• Abaqus for FEA and multiphysics analysis • fe-safe for fatigue and durability • Isight for process integration and design exploration• Simpack for multibody dynamic simulation• Simpoe-Mold for plastic simulation and injection molding analysis • Tosca for structural and fluid optimization • Solutions for Simulation Process & Data ManagementThe newest release provides breakthrough capabilities to improve efficiency, throughput and
collaboration for all simulation users including: high-performance visualization, batch and rule-based meshing, collaborative assembly, results analytics and process and data management.
Multiphysics simulations help engineers understand what’s taking place inside today’s high-efficiency engines. Image courtesy of Adam Opel AG.
Powering Innovation with SimulationLeverage the benefits of simulation and optimization to power innovation.
Accelerate Innovation with Realistic Simulation Accelerate Innovation with Realistic Simulation
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composite manufacturing team to develop preliminary ply shapes and overlap joint locations suitable for manual draping and Penso’s pressed composite technology. Once the ply layup and overlap locations had been developed for manufacture, the ply boundaries documented by the laminator in their draped configuration were sent to Penso’s analysis team along with information regarding fiber distor-tion. These ply boundaries, overlap locations and material directions were updated and modeled in the FE model for further refinement, for prediction of finalized mass/perfor-mance and generation of layup manuals.
Material directions gained from layup trials were com-pared to that in the analysis model and corrections made where large inconsistencies existed between the two sets of data. Because the parts will be manufactured using layup books generated directly from the FE models, the laminates needed to be accurately defined.
The laminate tool within ANSA, from Beta CAE, was utilized for the ease of building, handling and modifying of all the layers of the composite model, which exploits a special ANSA laminate property. This ANSA laminate property simplifies the number of layers the user has to manage during pre and post-processing. Ply shapes of the final tailgate design were transferred to Penso’s design team by outputting ply boundaries as curves within an IGES
file. By taking into account the ply shapes and ply thickness the B-Surface was generated for the composite parts of the tailgate, by modeling the layup from the A-Surface. The A and B-surfaces of the composite parts can then be used to create tool geometry for manufacturing.
Results gained from FE analysis of the tailgate showed that all strength and stiffness targets were achieved, while having equivalent or better structural performance to the production design. The final design of parts gave a combined mass savings of over 65% compared to the equivalent SMC/steel panels. The overall mass saving of the tailgate assembly was great-er than this, due to the use of a new lightweight rear screen glass and removal of components such as the anti-pinch strips and interior trim.
— The work presented in this publication was undertaken as part of the VARCITY project. This project was co-funded
by Innovate UK as part of the IDP7 programme. The project partners in this Research and Development project were Jaguar
Land Rover, Penso, Cytec (Solvay Group), Sika, the Advanced Manufacturing Research Centre (AMRC) , Avdel (Stanley),
Expert Tooling and Warwick Manufacturing Group (WMG). Penso were the VARCITY manufacturing project lead.
Click here to read the full conference paper.
A current key automotive industry initiative is delivery of mass savings through the use of lightweight materials, to reduce vehicle C02 emissions. Penso, a world leading
manufacturing specialist, based in the UK and India, was commissioned by a European automo-tive OEM to design and manufacture a continu-ous fiber reinforced composite tailgate prototype. This would be a lightweight alternative to the current production tailgate that is molded from Sheet Molding Compound (SMC), a discontinu-ous-fiber reinforced composite material.
The new carbon fiber design had to meet all existing strength and stiffness targets, while maintaining existing A-surface geometry and all hardware. The three main parts of the tailgate considered for lightweighting were the tailgate inner panel, tailgate outer panel and spoiler mechanism carrier. The structural performance targets against which the tailgate would be eval-uated were torsion, cantilevered bending, latch load, and margin and flushness.
To perform the analysis a mesh was created on the A-surface which corresponded to the preform tool surface, such that the laminate plies stacked from A to B surface. Each panel was meshed with first order conventional S4 and S3R shell elements, having a nominal element edge length of 5mm. Abaqus/Standard was then used for the non-linear static finite element analysis for the tailgate load cases.
To complete the tailgate model, the metallic mounting plates were modeled as shell elements referencing non-linear elastic-plastic material properties, while the rear screen glass was mod-eled with shell elements referencing isotropic elastic material properties. The adhesive was modeled using solid elements referencing iso-tropic elastic materials properties. The adhesive elements connected to neighboring panels using the distributing coupling constraints.
Once the finite element (FE) models were
complete, two methods of optimization were carried out on the tailgate, using a manual method and design optimization software. These methods assisted in developing an opti-mized layup for the composite panels, to com-ply with the structural performance targets, while also minimizing mass.
The Tsai-Wu Failure Measure and a user de-fined Inter-Laminar Failure Criterion were used as composite design metrics in post processing, to determine if ply failure or inter-laminar shear failure would occur between the laminate. These ply boundaries and material directions were up-dated in the FE model for further refinement of ply joint locations, prediction of finalized mass/performance and generation of layup manuals.
The design was then evaluated with Penso’s
Simulation Driven Design for Manufacture of a Pressed Composite Automotive Tailgate
Tailgate parts considered for lightweighting.
Strain energy plot for torsion load case.
Topology Optimization of a Motorcycle Swing Arm Under Service Loads Using Abaqus and Tosca In research and development as well as concept design, people involved in new projects often need to design a completely new shape for the structure target of the analysis. The loading conditions and constraints are usually known but the designer hardly knows how to create the geometry of the structure that meets the requirements of the project and that can be manufactured at the same time respecting the target costs. Weight is known to be one of the main factors that affect performance and costs. For this reason its reduction often becomes a main objective in the product development process.
Often geometries are realized based on experience or on similarity to previous projects, but this approach can be long and expansive, without the certainty of being able to reach the optimum design. The use of the CAE (computer-aided engineering) is strategic in this environment, in order to virtually simulate and verify different types of geometries to avoid the cost and time of prototyping and testing.
In the case of topology optimization of a motorcycle swing arm, the goal is to minimize mass while maximizing stiffness. SIMULIA Tosca Structure was used to drive the FEM (finite element method) simulation of the swing arm performed with Abaqus. The benefits using Tosca Structure include saving about 30% of the time to market, and obtaining a shape that meets the requirements of the project and that can be manufactured while at the same time respecting the target costs.
—Roberto Saponelli, Protesa Spa (SACMI Group) & University of modena and Reggio Modena and Reggio Emilia Massimo Damasio , Exemplar srl. Click here to read the full conference paper.
Swing arm optimized with SIMULIA Tosca Structure.
By Andy Ngai, Senior Engineer and Mark Arnold, Technical Specialist; Penso
It takes a special kind of compass to understand the present and navigate the future.
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Innovative thinkers everywhere use INDUSTRY SOLUTION EXPERIENCES from Dassault Systèmes to explore the true impact of their ideas. Insights from the 3D virtual world are unlocking new and innovative ways to create and manufacture automotive parts from unconventional and biodegradable raw materials. How many more secrets does the sea still hold?
want sustainable transportation, could we look to the sea?
Algae-based bioplastic materials – a dream our software could bring to life.
