Merging the CAD and CAE Worlds

European HyperWorks Technology Conference 2010 Alicia_Schauz-Porsche_Engineering_Servies_GmbH-Session_9-20101018.pptAlicia Schauz, Porsche Engineering

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Merging the CAD and CAE WorldsImplementation of HyperShape/CATIA in Customer Development Projects at Porsche Engineering


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Porsche Engineering

Optimization History

Integration of HyperShape

Merging the CAD and CAE Worlds

HyperShape User Tools @ PE

Conclusions

Porsche EngineeringAreas of Expertise & Reference Projects

Porsche Engineering Group GmbH

Porsche EngineeringServices GmbH

Bietigheim-Bissingen

Porsche Engineering Services s.r.o.

Prag

PorscheR&D CenterWeissach

Complete Vehicle

Styling Body & Safety Engine Drivetrain Chassis Testing Production Engineering

Industrial Engineering

Electrics & Electronics


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Conclusions

HistoryStructural Optimization @ Porsche Engineering

2007 Altair brings HyperShape to the market

2008 Porsche Engineering carries out benchmark study for optimization software with a CAD interface

mid 1990’s Research Projects in optimization at Porsche AG

2001 Foundation of Porsche Engineering Group

2004 First projects utilizing structural optimization with Altair’s OptiStruct @ Porsche Engineering

2009 Porsche Engineering chooses Altair’s HyperShape as optimization software for customer products

2010 Porsche AG begins using HyperShape

Old DesignPivot point

Tensioner New Design


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Conclusions

Integration of HyperShape in the Product Development Process @ Porsche Engineering

CAD Design

FE calculations done in CAD environment

Conventional Product

Development


Redesignconversion of data

CAD Design RedesignRecalculation in CAD or CAE

Drawings

HyperShape/CATIAFE in CAD or CAE

Drawings

FE in CAE

Drawings

feedback

conversion of data

CAD Design

Recalc. in CAE

FE in CAD

n Challenges of customer development projects:n Technical skills and knowledge applied to new marketsn Need for “right first time” designn Competitive engineering services market

n Proposed design approach with HyperShape to deliver top-of-the-line engineered solutions in shorter time despite new development fields:

feedback


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Conclusions


Production RequirementsTolerances

Material PropertiesSurface Finish

Corrosion Charact.CATIA V5

PDM Systems…

Key Users Form the Intersection

Load CasesBoundary Conditions

Material Models Stress AnalysisHyperWorks/FE-

Tools…


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Conclusions


Production RequirementsTolerances

Material PropertiesSurface Finish

Corrosion Charact.CATIA V5

PDM Systems…

Load CasesBoundary Conditions

Material Models Stress AnalysisHyperWorks/FE-

Tools…

CATIA GPS/GAS CATIA EFD

HyperShape



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Conclusions


n Porsche Engineering’s approach to the challenge of merging the CAD and the CAE worlds on selected levels :

n Group of engineer key users trained in CAD/HyperShape/CAE

n Forum in intranet for exchange of ideas

n Documentation of optimization workflow

n Methodology of a process for putting the optimized data into design



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Conclusions

HyperShape Forum in Intranet

n Porsche Engineering’s CATIA V5 Forum offers a platform for exchange of experience among HyperShape users

n Build up of knowledge database

Software for part optimization in the CATIA environment. Discussions, exchange of experience and suggestions for potential improvement


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Conclusions

Documentation of the Optimization

1. Definition of load conditions

2. Parameters for structural optimization with HyperShape/CATIA

3. Control stress analysis with CATIA GPS/GAS

n Targets of Protocol:n Step-by-Step

documentation to reduce mistakes à quality assurance

n Foundation for discussions with experts

n Platform for Lessons-Learned

n Easy comparison of different optimization runs

n Collection of FAQ’s


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Conclusions

Method to Retrieve a Parametrized CAD Model from the Optimization Resultsn Optimization result often as IGES model or

FE-structure (i.e. morphing) n Transformation of the optimization results

to a parameterized CAD design model n Analysis of the optimization results

and definition of reasonable section cuts

n Creation of section cuts from the optimization results

n Creation of design model using the sketches from the section cuts

n Advantages of methodn Use of existing templates in the

design environment à no extra effort for the designer

n Small details of the optimization results can be analyzed carefully

optimizationresult transformation

of 3D model

parameterizedCAD model


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Conclusions

Conclusions

n In customer development projects, the target is to engineer completely new parts on a daily basis in shorter time and at lower costs without forfeiting product quality.

n The integration of HyperShape in the product development process offers potential to shorten the development time span:n CAD engineers gain an understanding of the effect of loads and boundary

conditions on their designs.n CAE engineers receive already stress-optimized and weight-optimized

designs, causing fewer design iterations and saving material costs.n Porsche Engineering’s approach to merge the CAE and CAD worlds on selected

levels opens new horizons for the communication and cooperation between CAD and CAE engineers.n Key users are defined who form the intersection between CAD and CAE.n Reasonable tools are developed to support this integration and ensure high

process quality.


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Conclusions

Thank you for your attention

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Merging the CAD and CAE Worlds