Engineering Software for Designing Cost Effective Mixed Material Vehicles

Engineering Software for Designing Cost Effective Mixed Material Vehicles Edward Bernardon, Vice President Strategic Automotive initiatives, Siemens PLM Software

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Engineering Software for Designing Cost Effective Mixed Material Vehicles Edward Bernardon, Vice President Strategic Automotive initiatives, Siemens PLM Software