Microsoft NAFEMS Conference Altair Buchanan 101107 [Kompatibilitätsmodus] 12

2011-03-04

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Integrated CAE Driven Development
Within a HyperWorks Framework

Jamie Buchanan, Director Product Design, UK
Lars Fredriksson, Director Product Design, Germany
24th November 2010

Presentation Contents
• Altair
Alt i ProductDesign
P d tD i Introduction
I t d ti
• The Design Process Today
• Historic bottlenecks in the design process
• “Simulation Driven Design”

• What Processes are at our Disposal?
• Pre-processing automation examples
• Post-processing automation examples

• Vision
Vi i for
f the
th Future....or
F t
is
i it already
l
d here?
h
?
• “A Grand Challenge”

• Conclusions

Company Overview
Projected
$170M Revenue
1,300 Employees

A multi-disciplinary global product
d
development
l
t partner
t
th
thatt delivers
d li
innovative, end-to-end solutions.
We use our experience, methods
and technology leadership to turn
concepts
p into realities.

Founded ... In 1985 as a product
design consulting company
Today ... A global software and
technology company focused on
enterprise analytics, product
development and advanced computing

$44M Revenue
500 Engineers, Scientists,
Designers, Creative Thinkers

‘85

‘90

‘95

‘00

‘05

‘10

Design Process Today
• OEMs
OEM use CAE as core process
•
•
•
•

Well defined processes within vehicle development
Ever more sophisticated modelling techniques
R li t on CAE tto d
Reliant
deliver
li
performance
f
objectives
bj ti
Strong feedback into development process

• From simply a validation tool to ‘Simulation
Simulation Driven Design
Design’
• Historically lag in the CAE process
• CAD and test led; not CAE led

• Challenges are twofold
• Deliver timely input
• Efficiently manage large volumes of data

Modern Approach to Design

The Traditional Design Process…

The Simulation Driven Design Approach…

CAE Process Today
Automotive OEM HPC Capacity Growth
4500
OEM HPC Capacity

4000

OEM HPC Yearly 50% Growth Since 2000

HPC Capacity

3500

3000

2500

2000

1500

1000

500

0
1996

1997

1998

1999

2000

2001

2002

2003

Year Ending

2004

2005

2006

2007

2008

2009

Pre-Processing – Batch Meshing
Interactive Modeling
g
Example:
Automotive BIW modeling

1 Month

Batch CAE Process
•

Automatic quality criteria
based geometry
preparation and meshing

•

Automatic template based
model assembly

•

Easy part reuse when
combined with data
management

Days

smart fortwo Development CAE Partner

Altair ProductDesign Germany
formed team for CAE development
Project support 2003-2007
European and new US market
• Legislative requirements
• Consumer requirements
• Internal requirements
q
Coupe and Convertible versions with
a team of 15 Engineers
First Crash Tests of smart fortwo:
“DIMINUTIVE TWO-SEATER EARNS
TOP RATINGS FOR PROTECTING
PEOPLE IN FRONT & SIDE
CRASHES“ (Source IIHS)
Process automation essential

Model Development – Aspects of Data Receipt
CAD, BOM, Assembly & Material Data

A t
Automatic
ti Documentation
D
t ti

Is the Data Relevant?
No
Yes

Import in (V-CESS) CAE Database

Mesh Development

Model Assembly

• ~50% time saving through automation

Model Development – Assembly for Crash
Model Template
• BIW
• Door left
• Door right
• Engine
•…

Contacts
Connections
BOM

Module Manager
• Access data from database
• Get latest file version
• Exchange module
• Create new module versions
• Define vehicle variant
• Make correct connections
• Apply load cases
• Export run ready master & includes

Module Database
(~50 modules)

Material Database

Loadcase
Database

Include
Master

Includes

<20
20 Minutes
Mi t

Roewe 550 Development CAE Partner

Altair ProductDesign UK formed core
team for structural development
Responsible for:
Structural crash performance
Body & Closures Durability
NVH & Stiffness
Small core team of 12 Engineers
g
Tight timescales and modest budget
Achieved through:
HyperWorks based toolset
Process Automation
Massive deployment of optimisation
Unconstrained by OEM process
Si
Simulation
l i
Driven
Di
Design
D i

Automated Post Processing
post-process
control

crash run
input data

job submission to
cluster/cloud/local
machine

Solver

HyperView
running in batch
Output data: HTML,
MVW, H3D,
P
PowerPoint,
P i t Excel
E
l
AVI, JPEG etc.

Significant Benefits to Automation
• Significant
Si ifi
t time
ti
for
f manuall reporting
ti
• High risk of inconsistency
• Multiple data sets required
•
•
•
•
•

Accelerometer
A
l
t outputs
t t
Intrusions
Energies
g , animations,, H3D
Still Images,
Dummy metrics....

• Comparison to target or existing data

• Benefits of Automation:
•
•
•
•
•
•

Reduced time and cost overhead
100% consistency – quality
Reporting format is defined by template
Summary reporting in seconds
“Automated post processing saved
Estimated to save 1-3hrs/run
(SAIC) severall hundred
h d d man hours”,
h
”
Applies to physical & simulation data John Johnston, Vice Director Body &

Trim, SAIC Motors

Automated Post Processing ROI

€70 per hour

1 hour per run

Minimum 224 per year

6..........

Savings
g of €780,000
,
per
p team of 50 Crash Engineers!
g

Costs €15,680 per year

Virtual Vehicle Development - Vision

Vibration
New
Design

Modeling
Meshing
Meshing
y
Assembly
Assembly

Motion
Forming
Durability

W
Workload
Manager
M

Stress

Crash
CFD

Optimisation

CAE Data Management

Automated
CAE
Process

Reporting

Visu
ualisation/In
nterpretatiion

Analysis

Engineering Simulation Platform

On-demand Computing Technology

CAD2Crash24

Product Innovation Consulting

A Grand Challenge
Enterprise Analytics Solutions

Models courtesy of
Solid State Lighting Products

Mar. 2010

Industrial Design Technology

CAD2Crash24: A Grand Challenge
Full Car
• Over 1000 Assemblies
• Over 2000 Parts
• Over 3 Weeks

Process Overview
Batch Mesher

Model Check

Failed Parts

Batch Assembler

Model Verification & Fixing
g

Crash Setup

Model Validation

Job Submission

Reporting

Model Details
• BIW meshed from CAD data for a generic sedan provided by Ford
• IP, Powertrain, Front bumper, Seat assemblies, Tires, Suspension
components were meshes from a NHTSA model morphed to be
assembled in the generic model provided by Ford
• Final Model : ~1M elements (990 K)

Technical Details
• Loadcase
• NCAP Frontal crash simulated for 65 ms
• FTSS 50th percentile
til H
Hybrid
b id III dummy
d
used
d
• Airbag used
• Materials
• Ford materials used for the BIW and sub assemblies since the parts
were supplied
li d by
b Ford
F d
• Generic materials used for parts that were created by Altair
• Connections
• BIW, Closures were connected using spotwelds
• Bolts were connected with rigid spiders

Taking the Grand Challenge

Animations

Timing Report
Task

Budget (Hours)

Actual (Hours)

BIW BatchMesh

1.5

Sub Assembly BatchMesh

Assembly – BIW (Welding)

1.5

Assembly – Sub-Assembly

Mass Trimming

2.75

Crash Set up

3.25

Model Validation

1.5

Solution (64 CPUS) (Final Iteration)

6.5

Reporting

Total

(Bolts, Welds, Glues)

Conclusions

• Enablers to Simulation Driven Design are already here!
• Massive compute is widely available
• HyperWorks Framework to minimise pre and post processing

• Brings significant savings
•
•
•
•

Strong ROI calculation
St
l l ti th
through
h reduced
d
d titime
Greater value delivered by CAE – “Simulation Driven Design”
Improvements to quality and data management
E i
Engineers
h
have greater
t ffreedom
d
to
t Engineer
E i

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Microsoft NAFEMS Conference Altair Buchanan 101107 [Kompatibilitätsmodus] 12

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