5th ansa & meta international conference ansa & meta international conference ... abaqus...

5TH ANSA & META INTERNATIONAL CONFERENCE AN INSIGHT TO APPLICATIONS BASED ON ANSA TO THE BMW CAE PROCESSES

Josef Fürfanger, 5.6.2013

AGENDA

History of BMW – BETA Cooperation 1

Mapping Deep-Drawing Simulation 2

Convertible Top Lid Kinematics 3

APPLICATIONS BASED ON ANSA TO THE BMW CAE PROCESSES

Applications based on ANSA to the BMW CAE processes

Late 1980´s 1995 2005 2007 2008

BMW starts working with the Software tool BETA

HISTORY OF BMW – BETA COOPERATION



Late 1980´s 1995 2005 2007 2008


BMW starts using ANSA v5 as a mesher for complete models




Late 1980´s 1995 2005 2007 2008



Start of intensive Abaqus Explicit Support in ANSA




Late 1980´s 1995 2005 2007 2008




BMW switches all crash projects to work with Abaqus Explicit




Late 1980´s 1995 2005 2007 2008




BMW switches all crash projects to work with Abaqus Explicit

AFE – Spotwelding with Failure + Postprocessing




2008 2008 2009



Dummy/seat kinematics

2010 2011


2008 2008 2009 2010 2011


Morphing & Optimization




2008 2008 2009 2010 2011



Doorbag Generation Sideimpact

Dry Area

Wet Area

Acoustic Insulation




2008 2008 2009 2010 2011

EF Chassis Meshing







2008 2008 2009 2010 2011

Roof Kinematics




EF Chassis Meshing






2011 2011 2012


Composites Modeling

Al-Druckguss

Al-Schale / Al-Profil

Stahl Schale

CFK-Schale / CFK-Profil

2011 2011 2012

Mapping Deep-Drawing Simulation




Composites Modeling

2011 2011 2012

CFK Post Processing



Mapping Deep-Drawing Simulation


Composites Modeling

MAPPING DEEP-DRAWING SIMULATION THICKNESS AND HARDENING RESULTS

Influences on crash simulation

Using the deformation history of the material as input in a crashsimulation, provides significantly better simulation results (deformation and cracks) and helps to reduce material consumption and to optimize the weight of the part

Crash-Simulation (mesh and results)

mapped thickness distribution

Stamping-Simulation (mesh and results)

thickness distribution is displayed

Crash-Simulation (body with stamping results)

degree of hardening is displayed


Geometry Layup

END-TO-END CAE PROCESSES FOR COMPOSITE CRASH, DRAPING, FILLING AND WARPAGE MODELS

Transformation from tool cavities to parts

Mapping fiber orientation

Thickness distribution after preforming, RTM

Calculation of permeability for RTM

Fiber volume content

Laminate properties

Warpage Simulation

Draping Simulation

Filling Simulation

RTM-Tool Design

Crash Simulation

Preform feasibility


• Stiffness

• Acoustics NVH

KINETMATIC

STRENGTH

CRASH

• Opening process

• Closing process

• Dimensioning Conv. parts

• Joint loads

• High Speed Crash

(Front, Side, Rear)

PROCESS OVERVIEW. ROOF KINEMATICS.


Disadvantages

• Convertible hood “only“ consists of independent parts (Dead GEO) • Connections are “not” converted (CAE) acceptably • CAE starts again right from the beginning • Every modeling step by hand

FE Model (ABAQUS)

CAD Model (CATIA V5)

tran

slat

e

virtual dimensioning




CAD Model Basic

Kinematic Tool in CATIA V5

Add intelligence to the system


CAD Model with Attributes



CAD Model with Attributes CAD Model Basic

Kinematic Tool in CATIA V5

Add intelligence to the system

FE Model (ABAQUS)

Cleaned Geometry

- PreProcessing

Batch Mesher



Model Meshing

time in weeks

Old Process New Process

3,5 weeks

4 days

1 d

Start of Simulation

Add Kinematics

ca. 5,5 weeks Total Time



1 d

2 days

0 1 2 3 4 5

4 days

2,5 weeks

THANK YOU FOR YOUR ATTENTION!



5th ansa & meta international conference ansa & meta international conference ... abaqus...

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