session: designing for cost effective weight · pdf filesession: designing for cost effective...

Session: Designing for Cost Effective Weight Reduction

Engineering Software for Design of Cost Effective Lightweight Mixed Material Vehicles

Edward Bernardon, Vice President Strategic Automotive initiatives, Siemens PLM Software

April 24, 2013

Siemens AG 2013. All Rights Reserved.

. 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



.

Solutions for Seat Design !  Core Industry: Auto

Solutions for Complex Assemblies !  Core Industry: Aero, and Auto*

Solutions for Composites !  Core Industry: Aero, Auto, and Wind

SDE Seat Design Environment

Siemens SES Product Portfolio

Syncrofit

Fibersim



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High Volume Automotive Composite Engineering Software

•  What is market size and timing?

•  What is the nature of the product that will provide value ?



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Weight Reduction Spiral

Decreasing Weight Lighter Vehicle

Smaller Engine

Fewer Batteries

Less Braking

Lighter Crash Structures

Lighter Vehicle

Smaller Engine

Fewer Batteries

Less Braking

Lighter Crash Structures

Transportation Technology Adoption Rates

12 years 90% horse, 10% car to

10% Horse, 90% Car

6 Years 80% Open Wood Autobody to

70% Closed Steel Autobody

Winning the Oil End game Amory Lovins 2005



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What is the Nature of Composite Software for High Volume Auto

•  Automotive has unique requirements relative to traditional aerospace composite applications

•  Current composite engineering software must change for HIGH VOLUME automotive composite applications

In Emerging Markets

What customers want

may not match what they need



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Presentation Outline

1.  Unique demands of High Volume Automotive Composite Structure Engineering

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



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Designing Composites

•  Geometry •  Shape, profile, curvature – global and local •  Ply boundaries •  Thickness

•  Material characteristics •  Forms •  Desired fiber orientations •  Compression limits •  Steering limits

•  Processes limitations •  Machine configuration •  Achievable fiber orientations •  Process variance •  Knockdown factors and FOS – material and process

Part Geometry

Material Process Limitations



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Aerospace Composite Configuration and Shape Grid Based Design

Boeing 787

Frame/Skin Assembly

Grid Based Design



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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



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Requires Tight Integration between Analysis, Design Manufacturing

Efficient communications between design and analysis Accommodate late changes to enable optimization Generate interfaces for mating parts Bring appropriate feedback early

Analysis

Design

Manufacturing

Shorter Time Optimized Structure

Fewer Prototypes



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Material Properties May Vary Over Part Surface

15 degree misalignment results in 75% reduction in strength

•  Part Properties impacted by changes in Fiber Orientation"

•  Fiber orientation impacted by"•  Material"•  Process "•  Geometric features"•  Combination of above and

processing parameters "



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Impact of Initial Forming Contact Point on Fiber Orientation

~15 Deg.



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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 ! !"#$%!&'($)**!+,&(*)*!-.+/-)!$(.*0'#+.0*!



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Composite Processing Choices

2D Broadgoods Woven, NCF

Weaving Warp Knitting

Tow

2D Braiding

3D Braiding

Pultrusion

Tubes Overbraid

Robotic or Manual 2D Stackup

2D Preform Forming

(Matched Metal, Diaprhagm, w/ or w/o progressive tooling,

constraints...)

Selective Binding

Stitching

3D Preform Tailored

Fiber Placement

3D Hand Layup

Injection (RTM, VARI, SRIM....)

Finished Part

Thermoplastic Resin

TP Broadgoods

TP Forming

Thermoset Resin

Thermoplastic Prepregging



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Composites Eliminated in Frame

Tesla Evolution of Frame Structures

Model S Aluminum BIW (bonded, riveted, weld) Aluminum Panels

Roadster Aluminum Frame (bonded) Carbon Panels



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BMW i3 All Composite Passenger Compartment City Car



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Edison 2 Space Frame w/Composite Skin



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T27 - Composite Reinforced Space Frame



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Composite Reinforced Space Frame Panel



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Design Optimization (TFP) Cost Competitive Composites

IFB Institute of Aircraft Design, Stuttgart, Germany



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Design Optimization (TFP) Costly Hi-Performance Material Only Where Needed

F F

!"#"$"%&'(#)*+,-)".'

F

/0+.1+#-$'230455'(#)*+,-)".' 6+.-$'!6/'/-03'745+%.'

IFB Institute of Aircraft Design, Stuttgart, Germany



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Hybrid Part Examples

Injection Molded

Eggcrate Stiffener

Metal Insert Carbon Fiber

Laminate

SMC

Random Mat

Etc…..

Select Area woven, directional fibers



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! Tradeoff assembly vs. part complexity for mixed metal, plastic composite structures !  Many simple shaped parts (many joints) !  Few complex shaped parts (less joints) !  How to assess tradeoff of assembly or part complexity

! Representation of various Joint Types !  Bonded Joints !  Hybrid metallic/composite joints !  Other fasteners, rivets, bolts…

! Provide tools to tradeoff !  Performance !  Cost !  Producibility

Composite and Hybrid Assemblies/Joints



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Designing the Joint

Resistance Welding Laser Welding

Brazing

Adhesive Bonding Clinch Joining Riveting, Screws

Shielded Arc Welding Arc Splash Welding

Hybrid Joining

Hemming

Punch Elements

Process and Product Related

Joint characteristics !  Fastening requirements !  Adhesive type !  Torque specifications !  Welding processes

!  Cure time !  Hold pressure !  Surface area !  Adhesive application method



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Multi-materials will lead to Multi-Joining Methods

!  Different material combinations driven by need to cost-effectively lightweight vehicles

!  Potential combinations of materials !  Composites !  High strength steel !  Aluminum !  Magnesium !  Plastics

!  Avoiding corrosion and thermal deformation issues



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Tradeoff Assembly vs. Part complexity

Red - Issues with Large complex composite part

Issues Eliminate but Joint Added

“T” made of alternate material



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Lightweight Hybrid Structure Design Tradeoffs

“Slider Bar”

What will you pay for Performance/Weight ratio

1 10 High cost

uni hand layup (i.e. F1)

Low cost Steel

Performance-Weight / Cost Ratio Find cost optimal combination of materials,

assembly configuration, joining etc…



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DESIGN Cost Analysis is Critical Part

“Engineers make million dollar decisions and don’t know it.”

Steve Luby CEO VISTAGY

Session: Designing for Cost Effective Weight Reduction

Engineering Software for Design of Cost Effective Lightweight Mixed Material Vehicles

Edward Bernardon, Vice President Strategic Automotive initiatives, Siemens PLM Software

April 24, 2013



.

Aero Manufacturing Processes



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Double Diaphragm Former" Pick and Place Machinery"

Past Experience of Siemens SE Personnel in Automotive Composites Technologies

Flexible Forming Tool Design"



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Revolution in Automotive Design

Service “at your home” Order your car on the Internet

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