cae forum 2015-06-10 · cae in der produktentwicklung - zusammenspiel von design, berechnung,...
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14. CADFEM FORUM
Konstruktion und Simulation – Teamarbeit oder Einzeldisziplinen?
CAE in der Produktentwicklung - Zusammenspiel von Design, Berechnung, Versuch und Projektmanagement
Active & Passive Safety Technology / Braking SystemsJoachim Noack
ZF Friedrichshafen AG
© ZF Friedrichshafen AG, 20151 Active & Passive Safety Technology / Braking Systems26.06.2015
Konstruktion und Simulation – Teamarbeit oder Einzeldisziplinen?
© ZF Friedrichshafen AG, 20152 Active & Passive Safety Technology / Braking Systems26.06.2015
Global Project Teams
Application projects requiresparticipation of all engineeringdisciplines:
Steering Committee
p
Project management
Requirement management
Design Design
Simulation
PrototypingProject
ManagementCAE
Bench testing
Vehicle testingDesign / Prototyping / Testing / ….
© ZF Friedrichshafen AG, 20153 Active & Passive Safety Technology / Braking Systems26.06.2015
Global Project Teams
Application projects requiresparticipation of all engineeringdisciplines:
Steering Committee
p
Project management
Requirement management
Design Design
Simulation
PrototypingProject
Management Bench testing
Vehicle testingDesign / Prototyping / Testing / CAE /….
© ZF Friedrichshafen AG, 20154 Active & Passive Safety Technology / Braking Systems26.06.2015
Brake Engineering / Engineering Footprint
Technical CenterTechnical CenterKoblenz, Germany
Technical CenterShirley, U.K.
China HeadquartersShanghai
World HeadquartersLivonia, Michigan
Technical CenterJablonec CZ
Korea Headquarters
Technical CenterShanghai, China
Jablonec, CZ
Technical CenterLivonia, Michigan
Seoul
Japan HeadquartersTokyo
European HeadquartersKoblenz, Germany
ASEAN HeadquartersKuala Lumpur, Malaysia
Technical CenterLimeira, BrazilWorld Headquarters
© ZF Friedrichshafen AG, 20156 Active & Passive Safety Technology / Braking Systems26.06.2015
p , y
South American HeadquartersLimeira, Brazil
Regional OfficesTechnical Centers
Simulation Responsibility Assignment
Design:
Simple FEA
– Linear structural and modal analyses
CAE:
Complex FEA
– Non-linear analysesLinear structural and modal analyses
Standardized and validated simulations
“short runners”
Non linear analyses
– CFD and multiphysics studies
– Optimization
Multy body dynamics– Multy body dynamics
Preparation of simulation standards
Support for Design FEA and sign-off
© ZF Friedrichshafen AG, 20158 Active & Passive Safety Technology / Braking Systems26.06.2015
Job Description Design Engineer
Design work:
CAD design
Operation:
Manufacturing feasibility
Tolerance calculation
Design space investigation / feasibility studies
Drawing definition
Costs
Simulation:
CAD model preparation for simulation teams
…
Supplier communication:
Feasibility discussions
CAE “Wizard” studies
Feasibility discussions
Design discussions
Customer communication:
D i t ti
© ZF Friedrichshafen AG, 20159 Active & Passive Safety Technology / Braking Systems26.06.2015
Design presentations
Requirement discussions
Design Engineer Tasks
simulation; 5% tolerance calculation; 5%
operations discussion; 5%
design space investigation /
feasibility studies; 5%
CAD Design; 30%
5%
drawing definition; 10%
customer communication:;
supplier communication;
10%internal
20%
© ZF Friedrichshafen AG, 201510 Active & Passive Safety Technology / Braking Systems26.06.2015
internal communication;
10%
Design work: Simulation:
Job Description CAE Engineer
Design work:
Manipulation of existing geometry data for simulation purpose
Supplier communication:
Simulation:
CAE analyses, result interpretation
Model generationSupplier communication:
CAE results discussions
Requirement definition
Model validation
Standardization
– For design departments Design discussions
Customer communication:
CAE presentations
– For global CAE teams
Methodology development
Coordination of global onshore and offshore Requirement discussions
Coordination of global onshore and offshore teams
Design support
Model and result check / CAE sign-off
© ZF Friedrichshafen AG, 201511 Active & Passive Safety Technology / Braking Systems26.06.2015
g
“Hotline” support
Training
Jack of all trades Device (Eierlegende Wollmilchsau)
© ZF Friedrichshafen AG, 201512 Active & Passive Safety Technology / Braking Systems26.06.2015
Benefits of sharing CAE work with Design
Advantage for the product and design
– Improved development process (efficiency) and product quality
– Increased throughput due to faster analysis response and design cycle time
– Products are more optimized ( increased “simulation depth”)
– Higher robustness and product quality
– Better product understanding and improved engineering skills
– Global standards
Advantage for the CAE specialist teams: Advantage for the CAE specialist teams:
– “simple” analyses are not longer at the desk of the experts, therefore resources are freed up to workon complex simulation topics
– CAE teams are able to develop and implement further standard analyses procedures for the design
© ZF Friedrichshafen AG, 201513 Active & Passive Safety Technology / Braking Systems26.06.2015
CAE teams are able to develop and implement further standard analyses procedures for the designteams
Changed Roles and Responsibilities (for Simulation)
Before
– Design Department
After
– Design Department
– Model preparation for CAE
– Requesting CAEsimulation
– CAE / Simulation Department
– Model preparation for CAE
– Requesting complex CAE simulation
– Performing standard component FEA
– Performing simulation (simple componentsand complex studies)
– CAE / Simulation Department
– Preparing simulation standards for design
– Specification tools training validationSpecification, tools, training, validation
– Internal CAE “hotline”
– Performing simulation (components andcomplex studies)
© ZF Friedrichshafen AG, 201514 Active & Passive Safety Technology / Braking Systems26.06.2015
complex studies)
– CAE sign-off
Enablers
Validated standard procedures / specifications / processes
Sufficient software tools have to be chosen, ideally the simulation approaches are as much automated(scripts templates programs) as possible(scripts, templates, programs) as possible
“easy-to-use” is required, no additional effort, short calculation times
Design engineers need to be trained in
– Tool usage
– Methodology
– FEA standards
© ZF Friedrichshafen AG, 201515 Active & Passive Safety Technology / Braking Systems26.06.2015
Simulation Integration in the Development Process
Opportunity Development
Concept Design & Verification (CV)
Detailed Design & Verification (DV)
Product & Process Validation (PV)
Kick Off
A-Sample Phase
A0-Sample Phase
Production
DataSheetProduct Launch Production
B-Sample Phase
C-Sample Phase
D-Sample Phase
EBP HiL and System Model
© ZF Friedrichshafen AG, 201516 Active & Passive Safety Technology / Braking Systems26.06.2015
CAE NVH Lab
Development Process
Opportunity Development
Concept Design & Verification (CV)
Detailed Design & Verification (DV)
Product & Process Validation (PV)
Kick Off
A-Sample Phase
A0-Sample Phase
Production
DataSheetProduct Launch Production
B-Sample Phase
C-Sample Phase
D-Sample Phase
EBP HiL and System Model
© ZF Friedrichshafen AG, 201517 Active & Passive Safety Technology / Braking Systems26.06.2015
CAE NVH Lab
Designer FEA Tools
• FEA tool programmed to support component development with
• Analyses process is represented menu-driven in the
• FEA tool programmed to support component development withcontrolled standard FEA in the design department
Analyses process is represented menu driven in thesimulation tool
• Enables 100% simulation support, quickresponse in the development process
“FEA Pocket Calculator”
History:• 1999: Simple CATIA V4 FEA
© ZF Friedrichshafen AG, 201518 Active & Passive Safety Technology / Braking Systems26.06.2015
• 2006: Wizard development• 2008: Global rollout
CAE Tasks to the Design ZF TRW History
C t A t ti iComponent analyses CAE Department
Automation in professional simulation tools, customized for use
5 h
in design teams
3 h
4 h
sle
ad ti
me
0 h
1 h
2 h
anal
yses
© ZF Friedrichshafen AG, 201519 Active & Passive Safety Technology / Braking Systems26.06.2015
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2012
2013
2014
2015
CAE Tasks to the Design ZF TRW History
C t A t ti iComponent analyses with off-shoring resources, handled by CAE
Automation in professional simulation tools, customized for use
FEA performed in CAE team (specialists) Bottleneck: lead time to perform all necessary
analyses in time!
5 h
yspecialists in design teams
y Data administration more time consuming
than analyses itself
3 h
4 h
sle
ad ti
me Off-shoring /
outsourcing of standard CAE
0 h
1 h
2 h
anal
yses
Automation!
© ZF Friedrichshafen AG, 201520 Active & Passive Safety Technology / Braking Systems26.06.2015
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2012
2013
2014
2015
Automation!
Benefit of doing FEA in the Design
Design / Test:• Standard Simulation Request • (Data collection / creation, CAD, loads, etc…)
2 days t
Design / Test:• Finite Element Analyses Request (Standard)• Data creation (CAD)• Finite Element Analysis with process oriented
guiding inside the simulation software
1h to 2h mto 4 days f
CAE:• Data collection and control of necessary data• Sending project data to off-shoring resource
Design NOK
guiding inside the simulation software• Automated report creation
max. for 1 aCAE:
for standarCAE:
analysis
CAE:• Providing validated standard procedures• Providing / compiling standard wizards and
template• User support (“Hotline”)• Training
Off-Shoring• Standard analysis and documentation
rd analyses
CAE:• Result control• Result interpretation• Providing results and discussion / explanation
with design / test
“New” Process: started in 2006!
Design OK
© ZF Friedrichshafen AG, 201521 Active & Passive Safety Technology / Braking Systems26.06.2015
s
Design / Test:• Release
“Old” Process: Needed Improvement!
Design OK
Example: Brake NVH Development
2.6 kHz = critical noise
Initial NVH testCorrelation to Simulation
Internal and customer NVH (rig)
testing
Mode A
Mode Brequirement testing
CAE
Root Cause Analyses:
NVH Package ÍIDisc & caliper (+180g)
d CAE + NVH +
Project Management
Mode A: Caliper
Mode B: Rotor
NVH Package ICaliper only (+470g & shim)
oise
rem
ove CAE + NVH +
DesignCAE + NVH
© ZF Friedrichshafen AG, 201524 Active & Passive Safety Technology / Braking Systems26.06.2015
No
Thank you for your attention
© ZF Friedrichshafen AG, 201525 Active & Passive Safety Technology / Braking Systems26.06.2015ZF Friedrichshafen AG behält sich sämtliche Rechte an den gezeigten technischen Informationen einschließlich der Rechte zur Hinterlegung von Schutzrechtsanmeldungen und an daraus entstehenden Schutzrechten im In- und Ausland vor.ZF Friedrichshafen AG reserves all rights regarding the shown technical information including the right to file industrial property right applications and the industrial property rights resulting from these in Germany and abroad.
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