Engineering Software for Designing Cost Effective Mixed Material Vehicles
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1 Engineering Software for Designing Cost Effective Mixed Material Vehicles Edward Bernardon, Vice President Strategic Automotive initiatives, Siemens PLM Software
2 New Member of Siemens PL Specialized Engineering Software - SES Vistagy acquired by Siemens Dec 2011 Business Segment of Siemens PL Specialized Domains Industry Focused End to End Solutions 300+ Global Customers Siemens AG 2013 All Rights Reserved Page 2 Siemens PLM Software
3 Siemens SES Product Portfolio Solutions for Composites Core Industry: Aero, Auto, and Wind Fibersim Solutions for Complex Assemblies Core Industry: Aero, and Auto* Syncrofit Solutions for Seat Design Core Industry: Auto SDE Seat Design Environment Siemens AG 2013 All Rights Reserved Page 3 Siemens PLM Software
4 High Volume Automotive Composite Engineering Software What is market size and timing? What is the nature of the product that will provide value? Siemens AG 2013 All Rights Reserved Page 4 Siemens PLM Software
5 Weight Reduction Spiral Lighter Vehicle Decreasing Weight Smaller Engine Fewer Batteries Less Braking Lighter Crash Structures Lighter Vehicle Smaller Engine Fewer Batteries Less Braking Lighter Crash Structures Siemens AG 2013 All Rights Reserved Page 5 Siemens PLM Software
6 Weight Reduction Spiral Lighter Vehicle Decreasing Weight Fewer Batteries Smaller Engine Transportation Technology Adoption Rates Lighter Crash Structures Smaller Engine 12 years 90% horse, 10% car to 10% Horse, 90% Car 6 Years 80% Open Wood Autobody to 70% Closed Steel Autobody Less Braking Lighter Vehicle Winning the Oil End game Amory Lovins 2005 Fewer Batteries Less Braking Lighter Crash Structures Siemens AG 2013 All Rights Reserved Page 6 Siemens PLM Software
7 What is the Nature of Composite Software for High Volume Auto Current composite engineering software must change for HIGH VOLUME automotive composite applications Current CAD/CAE tools/engineering processes for steel/aluminum cars must evolve Automotive has requirements than aerospace composite software In Emerging Markets What customers want may not match what they need Siemens AG 2013 All Rights Reserved Page 7 Siemens PLM Software
8 Presentation Outline 1 Review of aerospace composite engineering software 2 Design trends in high volume automotive that impact Engineering software Which industry trends impact the nature of software development High volume auto composites must evolve to be cost effective Shift to mixed materials at part and assembly level 3 Expected nature of future engineering software for mixed material vehicles Siemens AG 2013 All Rights Reserved Page 8 Siemens PLM Software
9 Designing Composites Geometry Shape, profile, curvature global and local Ply boundaries Thickness Part Geometry Material characteristics Forms Desired fiber orientations Compression limits Steering limits Process Limitations Processes limitations Machine configuration Achievable fiber orientations Process variance Knockdown factors and FOS material and process Material Siemens AG 2013 All Rights Reserved Page 9 Siemens PLM Software
10 Past Experience of Siemens SE Personnel in Automotive Composites Technologies Double Diaphragm Former Pick and Place Machinery Flexible Forming Tool Design Siemens AG 2013 All Rights Reserved Page 10 Siemens PLM Software
11 Aero Manufacturing Processes Siemens AG 2013 All Rights Reserved Page 11 Siemens PLM Software
12 Aerospace Composite Configuration and Shape Grid Based Design Boeing 787 Frame/Skin Assembly Grid Based Design Siemens AG 2013 All Rights Reserved Page 12 Siemens PLM Software
13 Challenges High Volume Commercial Automotive Composite Applications Economics Low to Medium Production (5k-50k parts/yr) High Production (~100k part/yr) Design/Manufacturing Processes Time to market is much less than aerospace High Production rates, fast cycle times New Material Forms/Processes Low cost Material Compatibility Process/Material Selection and Modeling Rapid Forming - 2D to 3D Performance Criteria - Analysis Tight coupling CAE/Design/Manufacturing Predictability with less safety margin Siemens AG 2013 All Rights Reserved Page 13 Siemens PLM Software
14 Requires Tight Integration between Analysis, Design Manufacturing Analysis Design Shorter Time Optimized Structure Fewer Prototypes Manufacturing Efficient communications between design and analysis Accommodate late changes to enable optimization Generate interfaces for mating parts Bring appropriate feedback early Siemens AG 2013 All Rights Reserved Page 14 Siemens PLM Software
15 Material Properties May Vary Over Part Surface Part Properties impacted by changes in Fiber Orientation Fiber orientation impacted by Material Process Geometric features Combination of above and processing parameters 15 degree misalignment results in 75% reduction in strength Siemens AG 2013 All Rights Reserved Page 15 Siemens PLM Software
16 Automotive Composite Processes Choices Resin infusion RTM RFI Automated deposition Braiding Fiber placement Tape laying Winding Spray Fiber Forming Dry Preform Wet/Infused Hot TP Pultrusion Each process imposes unique constraints Siemens AG 2013 All Rights Reserved Page 16 Siemens PLM Software
17 The Path to a Fully Optimized Lightweight Composite Automotive Structures CAD integrated solution Optimize using bidirection interface CAD - CAE Define laminate, material and process Assure producible designs Generate drawings, data for weight, cost, PLM Fully optimized light weight automotive structure Generate data for tooling surfaces, and automated machinery Siemens AG 2013 All Rights Reserved Page 17 Siemens PLM Software
18 Defining Non-Geometric/Geometric master Model Siemens AG 2013 All Rights Reserved Page 18 Siemens PLM Software
19 True Fiber Orientations Fiber Deviation Simulation Siemens AG 2013 All Rights Reserved Page 19 Siemens PLM Software
20 Bi-Directional CAD/CAE Workflow CAD Model+ ANSA Pre/Post Mesh Loads Boundary Conditions Materials Define Composite Layers (plies) Thickness Rosette/Orientations Solve and Optimize Layers (plies) Thickness Orientations Import/Update Layers (plies) Materials Orientations CAD System + FiberSIM CAE Import Plies Rosette Material Detailed ply design Splice Dart Mfg Simulation CAE Update Outputs: Documentation Solids Laser/Cutter Solve/Verify Make Changes Siemens AG 2013 All Rights Reserved Page 20 Siemens PLM Software
21 Design for Manufacturing 2006 Confidential Siemens AG 2013 All Rights Reserved Page 21 Siemens PLM Software
22 NCF - Non Crimp Fabrics BIAXIAL 0/90 QUADAXIAL 0/-45/90/+45 Straight Stitch Zig-Zag Stitch Factors influencing behavior of stitched materials Stitch Size Stitch Type Stitch Spacing Number of Material Layers Fiber Orientation Siemens AG 2013 All Rights Reserved Page 22 Siemens PLM Software
23 Direct 3D Link to Manufacturing Master Model Cutting Pick/Place Fiber place Forming Injection Siemens AG 2013 All Rights Reserved Page 23 Siemens PLM Software
24 Tesla Evolution of Frame Structures Roadster Aluminum Frame (bonded) Carbon Panels Model S Aluminum BIW (bonded, riveted, weld) Aluminum Panels Composites Eliminated in Frame Siemens AG 2013 All Rights Reserved Page 24 Siemens PLM Software
25 BMW i3 All Composite Passenger Compartment City Car Siemens AG 2013 All Rights Reserved Page 25 Siemens PLM Software
26 Composite Reinforced Space Frame Panel Siemens AG 2013 All Rights Reserved Page 26 Siemens PLM Software
27 Design Optimization (TFP) Cost Competitive Composites IFB Institute of Aircraft Design, Stuttgart, Germany Siemens AG 2013 All Rights Reserved Page 27 Siemens PLM Software
28 Design Optimization (TFP) Costly Hi-Performance Material Only Where Needed Topology Optimization Principal Stress Optimization Final TFP Part Design F F F IFB Institute of Aircraft Design, Stuttgart, Germany Siemens AG 2013 All Rights Reserved Page 28 Siemens PLM Software
29 Tradeoff Assembly vs Part complexity Issues Eliminate but Joint Added Red - Issues with Large complex composite part T made of alternate material Siemens AG 2013 All Rights Reserved Page 29 Siemens PLM Software
30 Designing the Joint Joint characteristics Fastening requirements Adhesive type Torque specifications Welding processes Cure time Hold pressure Surface area Adhesive application method Clinch Joining Punch Elements Riveting, Screws Adhesive Bonding Brazing Hybrid Joining Hemming Process and Product Related Resistance Welding Laser Welding Arc Splash Welding Shielded Arc Welding Siemens AG 2013 All Rights Reserved Page 30 Siemens PLM Software
31 DESIGN Cost Analysis is Critical Part Engineers make million dollar decisions and don t know it Steve Luby CEO VISTAGY Siemens AG 2013 All Rights Reserved Page 31 Siemens PLM Software
32 Engineering Software for Designing Cost Effective Mixed Material Vehicles Edward Bernardon, Vice President Strategic Automotive initiatives, Siemens PLM Software
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