C123 & MDO를이용한경량화및최적화기술제안

한국알테어이광원

Light Weight Technology: C123 & MDO

Introduction & Motivation

1. 경량소재 (72 %)

2. 엔진다운사이징 (65 %)

3. 최적설계 (45 %)

4. 차량다운사이징 (38 %)

5. 전기자동차 (34 %)

6. 최적공력설계 (19%)

7. 인텔리전트한전자장치 (18 %)

8. 기타 (5 %)

(**) et al. Bjelkengren, C. 2006 “The Impact of Mass Decompounding on

Assessing the Value of Vehicle Lightweighting” Master of Science Thesis, MIT, USA.

Advanced Materials

High Strength Steels

Non-ferrous metals

Composites

Design Change

More simulation

Optimization

Material modeling

Novel Processing

New structures

Mixed materials

Different needs

Light Weight Enabler(**)

(*) SAE Online Survey conducted for 3M and Automotive

Engineering International 2011

Most important factors for helping car

manufacturers reaching the new CAFE fuel

economy targets (*):

Fuel Economy and Light Weighting

Lightweight Technologies on the Time Axis

(*) „Leightweight Strategies for Automotive Industry“Stuttgart 10. and 11. Juni 2012, Müller, Porsche

ShapeLightweighting

MaterialLightweighting

ProductionLightweighting

ConceptLightweighting

EnvironmentalLightweighting

(*)

Change of Development Paradigm is necessary….

(*) Courtesy of Mercedes-Benz, Translated from Daimler EDM Forum – Topologieoptimierung / 2015-07-23 / ITC-PP

… ‘Simulation Driven Design’ is the Solution

CAD

CAD

CAE CAE

CAD

Modeling Results

Too late!

Traditional Approach

Time

Design Performance

Maturity

Details

Simulation Driven Design

Time

Design Performance

Maturity

Details

CAE

Predecessor/

Early Concept

CAD

CAD CAE

CAE

CAD

CAE Turn-around time ofminutes / hours

1. Increase design maturity during the concept phase

2. Balance design for weight, cost, and performance

3. Promote a culture of simulation driven innovation

NumericalOptimization

Advanced Materials

High Strength Steels

Non-ferrous metals

Composites

Design Change

More simulation

Optimization

Material modeling

Novel Processing

New structures

Mixed materials

Different needs

Advanced Materials

High Strength Steels

Non-ferrous metals

Composites

Design Change

More simulation

Optimization

Material modeling

Novel Processing

New structures

Mixed materials

Different needs

The strategic and systematic usage of optimization in order to generate

design alternatives, trade-off information, design sensitivities and best

balance designs to actively support the product design process.

Market Need

Exciting Times – perfect storm

Mixed Material Solutions are common place

New Manufacturing technologies create more freedom in design

Lighter, Stiffer, Stronger, Cheaper

New Powertrains; Hybrids and Full Electric Vehicles

Altair Simulation Driven Design Processes

Planned & Reactive Optimization

Simulation Driven Concept Design. C123

Multi-Disciplinary Optimization. MDO

Screening

C0 C1 C2 C3

S0 S1 S2 S3 SOP

Feasibility

Product Development

Concept Development

F0 F1

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C123 Process

Altair Simulation Driven Design Processes

Planned & Reactive Optimization

Simulation Driven Concept Design. C123

Multi-Disciplinary Optimization. MDO

Screening

C0 C1 C2 C3

S0 S1 S2 S3 SOP

Feasibility

Product Development

Concept Development

F0 F1

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Overview of Current Projects

Recent Projects – high level overview of size and length of projects

Application: C23

Status: C3

Duration: 9

Avg Team: 6

Ferrari 165

Application: Pilot C12

Status: Complete

Duration: 1 mnth

Avg Team: 1

PSA Research

Application: C12-2.5

Status: Complete

Duration: 6 mnths

Avg Team: 2

Renault Megane

Application: C123

Status: Complete

Duration: 18mnths

Avg Team: 4

Ferrari 164

Application: C123

Status: C1

Duration: 12 mnths

Avg Team: 4

Project Ghost

Application: C123

Status: C2.5

Duration: 8 mnths

Avg Team: 3

Daimler EVA2

C123 – A Three Step Simulation Driven Concept Process

Identification of Optimum

Structural Layout using Free

Form Models

프리폼모델을이용한최적구조레이아웃도출

C1

Detailed Optimum Sizing of

Manufacturable Sections & Joints

using High Fidelity Models

상세모델을 사용하여제작가능한단면및접합부의상세최적의사이즈결정

C3

Rapid Optimum Sizing of

Idealized Sections & Joints

using Low Fidelity Models

간략모델을사용하여이상적인단면및접합부의신속한최적사이즈결정

C2

Topology optimization

• Optimization setup

• MMO and single load case

optimization

• Tuning optimization

• Topology result interpretation

• Beam elements modeling

• Optimization of beam model

• Beam section library

• Joint correlation

• Study of load paths

Beam model optimization

• CAD data design

(by customer design team)

• Shell model creation

• Performance recovery

• Size optimization and detailed

optimization

Concept CAD data design

performance recovery

C1 – Topology Optimization

Size: E

Size: D, Var 1

Size: D, Var 2

Architectural Layout & Load Paths

Identification of Optimum Structural

Layout using Free Form Models

C1

Application of structural loadcase

characterisation and target cascade

process

Multi-disciplinary Optimizationin Series Development

MDO focused Development SupportC1 C2 C3

Load Path Identification

Load Path Dimensioning

Mature, Join, BOM, POB

C0

Def. of Package,Loads, Targets.

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C2 – Beam Model Optimization

Cross SectionDimensioning

W1

W2

W3

W4

W5

X Scale

Y S

cale

Rapid Optimum Sizing of Idealized

Sections & Joints using Low Fidelity

Models

C2

Design Exploration

Extensive interrogation of design

space – rapid design tool

Multi-disciplinary Optimizationin Series Development

MDO focused Development SupportC1 C2 C3

Load Path Identification

Load Path Dimensioning

Mature, Join, BOM, POB

C0

Def. of Package,Loads, Targets.

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Joint Penalty Mapping

C3 – Concept CAD Data Design

Detailed Optimum Sizing of

Manufacturable Sections & Joints

using High Fidelity Models

C3

Maturing the Structure

+ +

=> =>

Free-Size Gauge Topology Grade Value Eng.

DESVAR LABEL DESCRIPTION 30km/h Barrier BOF10 Roof BOF10 Front BOF10 Rear ECER29 Roll Over 90 ECER29 Roll Over1801 PSHELL_37 CROSS MEMBER YES

3 PSHELL_40 VERTICAL MEMBERS FRT

6 PSHELL_81 MEMBER YES

10 PSHELL_168 SIDE PANEL LFT YES YES YES YES YES

11 PSHELL_172 A-PILLAR LFT YES YES YES YES

13 PSHELL_181 REINFORCING PLATE LFT YES

14 PSHELL_197 B-PILLAR LFT YES YES YES YES

15 PSHELL_200 C-PILLAR LFT INR YES YES YES

16 PSHELL_206 SIDE REINFORCEMENT UPR LFT YES YES

17 PSHELL_210 DOOR FRAME LFT YES YES YES YES

18 PSHELL_211 C-PILLAR LFT OTR YES YES

19 PSHELL_225 REINFORCING PLATE RGT YES

21 PSHELL_272 SIDE PANEL RGT YES YES YES

22 PSHELL_279 A-PILLAR RGT YES YES

23 PSHELL_280 C-PILLAR RGT INR YES YES

25 PSHELL_293 B-PILLAR RGT YES YES

26 PSHELL_314 SIDE REINFORCEMENT UPR RGT YES

27 PSHELL_317 C-PILLAR RGT OTR YES

28 PSHELL_318 DOOR FRAME RGT YES YES

30 PSHELL_369 REINFORCEMENT A-PLR RGT YES YES

31 PSHELL_380 REINFORCEMENT A-PLR LFT YES YES

35 PSHELL_5739 PLATE YES

Load Paths Cross Sections Structural Joints

Optimization and Design Exploration

Full suite of optimization

and solver technology

Multi-disciplinary Optimizationin Series Development

MDO focused Development SupportC1 C2 C3

Load Path Identification

Load Path Dimensioning

Mature, Join, BOM, POB

C0

Def. of Package,Loads, Targets.

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C123 Integration

Process Int.

Process Data

Meetings

Daily Comm.Optimization results- Direct import xml*- CSV file

Export (OEM CAD) – prt (parametric) or xml*

CAD Export (OEM CAD) – prt (parametric)

CAD Export (OEM CAD) – iges or prt

CAD Export (OEM CAD) - iges or prt- Bounding boxes

CAD Export (OEM CAD) – prt (parametric)

Section / Joint Mapping- Real / Box Sections- Joint Efficiency

Geometry Export- Surfaces – stl or iges- Line data - iges

Design Space- Voxel mesh- .Stl output

Skeleton (1D model)- Voxel mesh- .Stl output

Section / Joint Data Parametric Data Skeleton LayoutPackage Data 3D Geometry

C123 Overview

MDO Process

Altair Simulation Driven Design Processes

Planned & Reactive Optimization

Simulation Driven Concept Design. C123

Multi-Disciplinary Optimization. MDO

Screening

C0 C1 C2 C3

S0 S1 S2 S3 SOP

Feasibility

Product Development

Concept Development

F0 F1

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Multi-disciplinary Optimization

Front crash

NVH acoustics

Side crash

Rear crash

NVH global stiffnessNVH ESS

Occupant safety

The Principle of Multi-disciplinary Optimization

Solution

Crash NVH Durability

Load Cases

600 mm

StructureClosed Section Beam

Baseline Optimizations

Crash NVH Durab. MDO

Crash response 91% 100% 141% 81% 78%

NVH response 79% 654% 100% 406% 99%

Durability response 86% 198% 218% 100% 100%

Objective (Mass) 100% 48% 53% 72% 76%

MDO Solution

Attributes for Typical Body MDO Studies

Rear Crash

Side Crash

Front Crash

Body NVH

Weight

Durability

Example of Vehicle Body MDO Process

MDO Project Execution Time Line

Baseline Body

Up-Gauge

Down-Gauge

-6.5 kg Body Mass ✓

Study Preparation

• Import of Models• Synchronization• Definition of DVs• Definition of Resp.• Setup of DOE

Front crash

NVH acoustic

Side crash

Rear crash

NVH global stiffness

NVH equivalent static stiffness

DOE

Validation

Optimization

Pre-processing Post-processing

Targets / DV Bounds

Meta Model Generation

Mastering the MDO Challenges

Design Exploration

Process Control

Methods & Technology

Front Crash Rear Crash

Side Crash

NVH

The Challenges

Speed of ProcessInformation gathered too late

is of less value to the design

Integration into Design Process The MDO process must seamlessly integrate

into the standard development process

Master the DevelopmentSetting up MDO processes with many disciplines

is complex and an errorproof system is required

The Goal

Efficiently provide input from MDO

studies to support the design process

Full Space Optimization

4N708 Crash runs177 NVH runs

252 Crash runs161 NVH runs

Front Crash20 DV

Side Crash12 DV

Rear Crash10 DV

Body NVH40 DV

Front Crash44 DV

Side Crash44 DV

Rear Crash44 DV

Body NVH44 DV

Sub-Space Modelling해석시간을현저히감소시킴

A total of 44 Design Variables

Methods & TechnologyFront Crash Rear Crash

Side Crash

NVH

Preserve Execution Flexibility

Model Import Post ProcessingModel Sync aMDO

DV Setup

Loadcases

Responses

Targets

iMDO

DV Setup

Loadcases

Responses

Targets

OptiStruct

Optimisation

MDO Validation

&

Overcheck

Compute

Resources

DoE & FitOvercheck

iMDO

aMDO

Reusable

Data

Methods & Technology

Front Crash Rear Crash

Side Crash

NVH Design Exploration

• 선형 – OptiStruct

• 선형&비선형 – HyperStudy

Preserve Execution Flexibility

Methods & Technology

Front Crash Rear Crash

Side Crash

NVH Design Exploration

i-MDOOptimize in

OptiStruct

Overcheck

&

Recover

a-MDORun

DOE

Overcheck

&

Recover

Evaluate

& Explore

Optimize in

HyperStudy

Evaluate

Prepare,

Setup &

Control

Load

Case

List

Design Variables

& BoundsTargetsTargets

Design Variables

& BoundsTargets

Targets

Design Variables

& Bounds

Targets

Design Variables

& Bounds

TargetsDesign Variables

& Bounds

crash linear

linear

crash linear

MDO GUI Snap shots

Process Driven Work Flow

(반)자동화 된 서로 다른 모델의 동일한 파트 간 링크 정의 기능로드케이스 별 모델 분할 기능근사 모델 생성을 위한 해석 기능

Process Control

Benefit of C123 & MDO Director in Vehicle Development

1. Active management of vehicle design balance

2. More informed design decisions

3. Increased maturity of design

4. Reduction of development risk

=> supports innovation by allowing to consider larger design change

Cost

Weight

Performance

Balanced

Design

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