Faster and more accurate strength and durability analysis ... · Honda R&D Co., Ltd. Innovation for...

Faster and more accuratestrength and durability analysisusing 3D simulation

Unrestricted © Siemens AG 2019

Unrestricted © Siemens AG 20192019-02-13 Siemens PLM Software


The Digital Twin allow to

Understandthe testing

Design rightfirst time

Includemanufacturingand assembly


Define Durability Load Data Analysis Tasks

OfficeAnalysis Report & share

Test schedule creation

Test engineer

Office

Roads

Simulation

Measure

Simulation engineer

Test engineer

Roads/OfficeValidate

Test engineer

Inpu

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2:Si

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Test


Road Load Data PredictionEarlier access to real-world vehicle loads

Full Vehicle Simulation§ Hybrid Road§ Digital road

Component Simulation§ Test Rig in Simulation§ Subsystem simulation

Fatigue AnalysisRoad Load Data PredictionRoad Load DataAcquisition


Conducting complete fatigue analysis

Fiat Group Automobiles S.P.A.Using Simcenter Simulation & Test to verify and validate durability virtually

• Reduced margin of error in realloads between 8 and 15 percent

• Reduced overdesign by performingsimulation prior to building aprototype

• Diminished costs by developingequivalency between two provinggrounds

“Although we can’t measure the improvement because we previously didn’t usevirtual data, the results that we have received by using both Simcenter productsare absolutely excellent.”

Marco Spinelli, Head of the Chassis CAE Department

• Long-term partnership between Fiat and Siemens PLM Software• The ability of Siemens PLM Software to deliver customized solutions

Virtual prediction and use experimental datafor model validationProving grounds in Turin, Italy


Conducting customer correlated procedures

Ford OtosanCut time to reproduce 1.2 million kilometers of customer usage

• Reproduced 1.2 million kilometersof customer usage in a condensedproving ground test period

• Developed 4-week accelerated rigtest to represent 1.2 millionkilometers of customer usage

• Provided opportunity to optimizecost and weight

“We selected Siemens PLM Software for its capabilities and experience indurability field testing, load data analysis and test schedule development forvirtual simulation and durability track and rig testing.”

Vehicle Durability Supervisor

• Qualify and quantify the durability potential of vehicle loads with innovative analysis• Replace time-consuming and costly tests by deriving compressed load time histories

with an equivalent damage potential for uniaxial and multi-axial loading conditions

Cabin rig test to represent 1.2 millionkilometersCustomer correlated proving ground test


Model the real worldThe digital twin using real life load data

• Get real load data• Get a realistic digital twin• Durability loads in simulation

can be represented in multiple ways

Challenge

• Access to any load data format, and FE data• From simple block loads to hundreds of load channels

and FE cases• Transient events• Complex duty cycles

Key Points to enable the process

Model the real world

Interoperability

Efficient DurabilityModelling

Get the results at fingertip


Model the real worldThe digital twin using real life load data


Interoperability



The digital twin using real life load data


InteroperabilityGet the correct loads – use the current results


Interoperability



Work with one digital twin – Get the right data


Efficient Durability ModellingComplex Durability Setup – easy and efficient


Interoperability



Complex Durability Setup – easy and efficient


Get the results at fingertipKnow the reasons of fatigue and build better designs


Interoperability



Know the reasons of fatigue and build better designs


Fatigue analysis of a chassis part


Interoperability



Complex Durability Setup – easy and efficient

Work with one digital twin – Get the right data

The digital twin using real life load data

Know the reasons of fatigue and build better designs


ChallengeGeometry and Behavior of a (Seam) Weld … Not that simple

TheoreticallyPerfect

Asymmetric

Concave Convex

Simplified Cross-Sections Reality…

Weld Geometry: Penetration, Convexity, Continuity, Grinding

How to model – as not known before the assembling and scattering

?


ChallengeGeometry and Behavior of a (Seam) Weld … Not that simple

Reality… Other influences

Chemistry: Carbon, Manganese, HydrogenTemperature: Weld, Preheat, CoolingBase Material: Porosity, CompositionHeat Affected Zone: Uniformity, Property Degradation

(Ductility)Microcracking: at perimeter of WeldResidual Stress: after coolingPart Geometry: Surface Finish, Alignment, Warpage

Need for a simplified but still accurate approach


Seam Weld AnalysisTraditional methodologies

Nominal StressTraditional approachIn several certification processesRead/measure stress in distance toweld – Compare results with prescribedSN curves

D S

N2·106log

log

1·107

FAT class

Applicability

No modellingresrictions

All certifiedmethodologies

Accuracy

Notch stresses

Effectivestresses

ü

(ü)x

x

High safety factorsExpensive and heavy over design


Seam Weld AnalysisTraditional methodologies

Notch StressUse local stress valuesIn IIW guidelinesHigh accuracyIncludes local geometry effects andload dependency

D S

Nlog

log

1·107

Applicability



Accuracy

Notchstresses

Effectivestresses

x

(ü)

ü

ü

High effortNot applicable to large structures


Seam Weld AnalysisAccurate and efficient solution

Applicability



Accuracy

Notchstresses

Effectivestresses

Robustdefinition

Weld definition

Welddetection

ü

ü

ü

ü

ü

ü

Combine the accuracy of the notch stressapproach with ease of use of traditional

nominal stress methods


Magneti Marelli Sistemi SospensioniEnhancing strength and durability of suspension structural components

Using Simcenter solutions for durability analysis

• Enhanced strength and durabilityof components

• Optimized design beforedeveloping a prototype

• Enabled company to accuratelypredict the lifespan of componentsand assemblies

“What we appreciate about the Simcenter solution is reliability of theresults. With the Simcenter solutions, for the first time we were able toaccurately correlate with the bench test results”

Andrea Santini, Head of CAE and Innovation

• Validate more design variants for fatigue life within shorter development cycles• Use durability analysis to simulate performance of large and complex systems


ChallengesMaterials and Manufacturing and Weight

• New materials• New challenges

• Need new methods

Source Mark White, JLR, Global Automotive Lightweight materials Conference, London, 2012


Industry challengesTraditional idea fatigue simulation

Fatigue Results

Material

Geometry

Load

StandardFatigueSolver

Fatigue Results

Material

Geometry

Load

StandardFatigueSolver

Sur-face

Manu-facture

Hard-ening

Influence new materialsand manufacturingprocesses are simplified

Large safetyfactors

Over design


Injection molding of random fiber re-enforcesplasticProduction process leads to locally statisticallydistributed fibers.

UD or woven composites not only fatigue behaviordepends on manufacturing, but also damagemodelling depends on different damage modes andmaterials.

Production processes define material behaviorComposites - examples

aWmW

Fiber breaking

Matrix cracking

Delamination

Decohesionfibre/matrix

Using worst case apporaches leads to over design


Production processes define material behaviorAdditive manufacturing

ChallengeFatigue behavior of 3Dprinted parts depends onmany process parameters.

Solution• Isolate the influence of the

parameters• Simulation of the process

to get the parameters


Ready for expertsOpen Solver - Used in research and customer projects

Open Solver• One GUI• One Pre and Post• All interfaces to load and FE

• User defined methods• User defined parameters

Open but easy to apply for the end userNo overdesign

Fatigue Results

OpenSolver

StandardFunctionsSingle GUI

Para-meters

UserPara-

meters


Target: reaching 50 percent weight reduction by 2020 or 2030

Honda R&D Co., Ltd.Innovation for progressive damage analysis in composite design

• Predictive damage models atthe coupon level and atcomposite subsystem designconcept level

• Development of the parameteridentification procedure, basedon a limited amount of physicaltests on coupons

“Not only at Honda, but many engineers in this field think that we can still makevehicles that have a 50 percent lighter body structure using composites whilemaintaining the mechanical properties of the replaced metallic parts.”

Yuta Urushiyama, Composite body innovation programs Honda R&D Co., Ltd.

• Simcenter Samcef non-linear finite element solvers for accurate modelling• Simcenter Engineering Services for composite damage model identification

Innovative methodology for progressive damageanalysis of compositesDamage of a specimen after test


Simcenter for Vehicle Performance EngineeringVehicle Strength & Durability


The new era of durability engineeringDeliver lighter, stronger and more durable vehicles

Simcenter solutions• end-to-end durability engineering

approach• accelerate time to market• balance weight, strength & durability• avoid vehicle recalls• meet customer’s expectations.


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