CAE Forum 2015-06-10 · CAE in der Produktentwicklung - Zusammenspiel von Design, Berechnung, Versuch und Projektmanagement Active & Passive Safety Technology / Braking Systems Joachim

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?


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 / ….


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 /….


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


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


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


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%


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


g

“Hotline” support

Training

Jack of all trades Device (Eierlegende Wollmilchsau)


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


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)


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


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


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


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


• 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


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!


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


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


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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CAE Forum 2015-06-10 · CAE in der Produktentwicklung - Zusammenspiel von Design, Berechnung, Versuch und Projektmanagement Active & Passive Safety Technology / Braking Systems Joachim