17 Solutions Available For Body Engineering PDF

Solutions Available for Body Engineering Summary
Virtual Manufacturing
Copyright ESI Group, 2011. All rights reserved.
Task: Functional Design in a MultiMaterial Mix that Fulfills Specification
Cold Formed Steel
Aluminum Sections
Cast Aluminum
Hot Formed Steel

Sheet Aluminum
http://boronextrication.com/2011/08/2012-audi-a6-body-structure/
General Trends in the

Automotive Manufacturing Industry
Light weight
Mixed materials for functional design (Steel, Al, Mg, Carbon
Fiber), New Joining and Multi-Domain Optimization to validate
performance.
Market Trends in Steel

HS Steel
Standard Steels
Hot Formed Steel
www.carbodydesign.com
UHS Steel
Trends for Forming Processes of

Light Metals
Krajewski,
GM, Body &
Assembly
Congress
Troy 2011
Market Trends in Aluminum
Cast aluminum 44%

Aluminum sheet metal 28%
Aluminum sections 17%
Steel 8%
Other materials 3%
http://boronextrication.com/tag/body-structure/
Those are the Engineering Disciplines

Behind
Advancement in Vehicle
Structures & Safety
Materials Optimization for Body
Engineering
Body Engineering Digital
Optimization
Manufacturing Engineering
This is the Job to be Done
Virtual Prototyping means reducing tests and

physical prototypes with virtual test and prototypes.
This saves the cost for the physical try-out. Also
the time it takes to do the try-out is eliminated
The mandatory condition is the ability to deliver results good enough to
reliably replace the physical tests, in a time frame significantly shorter than
physical try-out would be
About ESI
Provider of Virtual Prototyping for the Industrial World
ESI is a world leading software editor for the numerical simulation of prototype
and manufacturing process engineering in applied mechanics
ESI Covers Most Aspects of Body &

Assembly
Structures & Safety
Engineering
Optimization
10
ESI Virtual Prototyping
Multi-Domain performance engineering solutions
Including the coupling effects between domains and

mechanical impact of manufacturing processes
Supported by a unified Visual Environment Platform, designed

to enable multi-task automation and support Engineering
Workflow management and collaborative Engineering.
Virtual Manufacturing
Comfort
Drivability
Stamping
Assembly
Acoustics
Crash &
Safety
Stiffness &
Strength
NVH &
Durability
11
End-to-End Virtual Prototyping

of a Stamped Component
Full chain simulation under Visual-Environment,
in early design phase
Tool milling
PAM-STAMP 2G: Full chain simulation with hemming assembly

PAM-DIEMAKER
for CATIA V5
Tool design
Forming
Springback
Restrike
Springback
Flanging
Springback
Hemming
Requirements on:
- Geometry?
-Cosmetic Defect?
-Material, Thickness?
Optimized production time

& tooling costs
Springback
Assembly
Virtual
Performance
Solution
Crash, Strength,
NVH, Durability
Requirements on: Requirements on:

- Geometry?
-Material, thickness?
-Cosmetic Defect?
Less hardware prototypes,

optimized safety margin
12

of a Hot Formed B-pillar
Tool milling
Full chain simulation under Visual-Environment,
in early design phase
PAM-DIEMAKER
for CATIA v5
Quick tool design
PAM-STAMP 2G
Fast Hotforming
with metallurgy
Material
Thk, ,
VPS
Crash (including
spot welds rupture),
Strength, NVH, Durability
% of Martensite
13

of a Composite B-pillar
Lay-up strategy defined
In CATIA CPD or SIEMENS FiberSim
Draping and RTM simulation with

PAM-RTM
Lay-up
+ material
Structural analysis with

Virtual Performance Solution
Part design
change
Draping and
Porosity
affect
Mechanical
properties
E/E0=AE*exp(BE/x)
s/s0=AT*exp(BT/x)
14

Behind
Structures & Safety
Engineering
Optimization
15
Materials Optimization Covers the

Following
Die Face Design & Early feasibility based on geometry

Cold precision forming
Standard processes
Advanced springback for advanced materials
Class A buy-off including all following operations
Cosmetic defects
Hot forming
Casting
16
Parts Covered
17
Benefits of Materials Optimization

with Virtual Sheet Metal Forming
Time reduction
Early evaluation of manufacturing ability
Reduction in the development times
Reduction of the try-out times
Quick response to needed modifications
Bidding and
Planning
Cost reduction
Cheaper products
Reduction of the die costs
Press down sizing
Increase of reliability
Die Face
Design and
Validation
Increase of product quality

Optimal selection of the work piece material
Production of more complicated parts
Know-how accumulation for new materials
Press repeatability
Precision
Forming
Cold and Hot
Altan 2012
18
Sheet Metal Forming
EARLY FEASIBILITY
19
Major Trends in Sheet Metal

Forming
Only a few parts will remain mild steel
Complex technology - presented in a simple and accessible manner
From feasibility over precision forming to milling one model based on

geometry
Standard forming operations and compensation will go into early feasibility
Springback / precision needs to be as good as humanly possible
Robustness is interesting in case the major variables are matched
20
Expected Solution
Easy to use product

Several people using the tool would arrive at the same result
Minimum training requirements
Integrating customers experiences and best practices
Without need in specific numerical or finite element knowledge

All that for a market price
21
Die Face Design Next Generation Switch from Mesh
Die Face Design Based on Mesh
22
.to Geometry Approach - Design is Based on Geometry!
Die Face Design Based on

Geometry
23
New Proposed Work Flow

for Die Design
The conventional workflow is shown at the top and the new proposed workflow
based on CATIA V5 / Visual Environment is represented below clearly
showing the potential time savings
24
Die Face Design in CATIA Die

Maker - 15 to 20 Min
Part preparation
Export
~ 10 minutes Blankholder design
~ 1 minutes
Addendum design
~ 1 minutes
~ 5 minutes
25
Part Exchange - Initial Model

and New Model
Different outlines!
26
Capabilities of Part Exchange
Fully or semiautomatic replace:

Automatic recognition of new
flanges
Automatic definition of symmetry
E.g. recognition of redundant
rolling cylinder curves
Possibility to add new
functionalities (e.g. rolling
cylinders, profiles,..)
Recognition of missing input
(flange) surfaces for part on
binder
Automatic or manual re-assigning
start points of floating profiles
27
The Total Time to Target is in this

Example Less then 2 Minutes
28
Presented by Daimler AG at
German User Forum 2011
The milling result is very good and for a prototyping tool more than
sufficient. The programming in TEBIS caused no problems whatsoever.
The Offset-Surfaces could be processed directly in TEBIS without any
problems.
Uwe Fischer Mercedes-Benz Cars R&D
29
Following Operations
Transfer of geometry via IGES
Final forming simulation
Springback compensation
Return of the compensated mesh into
CATPart
Overbending of the die set with
DIGITIZED MORPHING
Offset
Generation of solid
tooling
30
Summary
PRECISION FORMING
31
Precision Forming - This is the Task
and make sure

material properties are
right for performance
considerations
32
Positioning
"Make sure that the panel comes off

successfully in the first shot"
33
Examples: Inverse/One-Step
Simulation
Blank development
Product design
Thinning
prediction
Forming Limit
Diagram (FLD)
34
Incremental Simulation: Overview

Applicable to :
Progressive dies
Line dies
Transfer dies
Deep draw
Crash forming
Superplastic forming
Sheet & tube hydroforming
Tube bending
Tube and sheet hydroforming
Hot forming
Ironing
Coining
Stretch forming
Flex forming
Material:
Titanium
Aluminum
Stainless
Copper
HSS
35
Example Progressive Die

Predicting common defects such as splits, wrinkles, spring back and
material thinning on computer
High thinning
Providing customers with right first time

tooling to run production with a minimum
of manufacturing risk
36
Standard Stamping
Wrinkling
prediction
Cracks
prediction
-Process requiring Solid elements
-Strong Solids capabilities in PAM-STAMP2G (also used for coining)
37
Why is High Strength Steel more

Challenging
Mild Steel
590TS
980TS
38
AHSS (Advanced High Strength

Steel) - Precision Forming
Mild Steel
590TS
980TS
Bad
Formability
Large
Springback
PamStamp 2G v2012 includes

more accurate and faster springback
for stamping of Ultra High Strength Steel
39
Spring-back/Compensation
Unbending
Opening
Wall curvature
Twisting
40
Find the Optimal Blank Size & Trim Lines

with Automatic Optimization
Blanking
Forming
Springback
Restrike
Springback
Flanging
Trimming
Springback
Flanging
blank shape
Forming
Trimming
Springback
Restrike
trim lines
41
LINE DIE OPTIMIZATION

Initial Blank shape optimization
Before optimization
18% up to 1mm
1st forming
2nd forming
After optimization
95% up to 1mm
restrike
42
Line Die Full Chain Simulation,

Optimization, Quality Control
Forming
Springback
Restrike
Springback
Flanging
Springback
Hemming
Springback
43
Virtual Prototyping of all OPs
Source: Europam Toulouse 2006
Forming
Springback
Restrike
Springback
Flanging
Springback
44
Formability Analysis of Complex

Automotive Panels and Full Process / Full
Cycle Simulation
Process validation and optimization, defects prediction before try-out

45
Correction of springback
Forming
Springback
Restrike
Flanging
Springback
Springback
Multi-Ops Die compensation

Draw die
compensation
Automatic draw
and trim die
compensation
Compensate die
from multi-OP
springback
Solve transfer: adapt

die from previous or
next OPs
46
Y-Tec manufactures an ultra high strength

steel bumper with PAM-STAMP 2G's
springback correction
Using the Yoshida-Uemori model in PAM-STAMP 2G improves the accuracy of springback prediction
to a point where it becomes possible to determine effective qualitative countermeasures. By analyzing
the stress and strain accumulated during forming, we were able to determine and eliminate the cause
of poor dimensional accuracy. Thanks to PAM-STAMP 2G, we reduced the number of modifications on
the stamping tool even in cases where the parts formability was challenging, such as Ultra High
Strength Steel parts.
Hiroki Kondo, Deputy Manager, Advanced Press
Engineering Group/Dept. Y-Tec Corporation
Improvement of springback by reducing plastic strain

Stress components which cause springback
Courtesy of Y-Tec Corporation

47
Gestamp successfully brings to market a

weight-optimized B-pillar stamped
from tailored blank using PAM-STAMP 2G
We achieved very good results thanks to

the accuracy of the simulation using PAMSTAMP 2G. We were able to use the
springback prediction tool to evaluate the
die compensation, despite the complexity
of such a case with three different
thicknesses and two weld lines.
Eduardo Sulato and Fbio Lichtenthler

Engenharia da Matriceria
Gestamp Automocin S.L.
Courtesy of Gestamp Automocion

48
Hot Forming - Formability

Temperature on blank / tool
Martensite fraction during quenching

After 4 s
After 8 s
After 14 s
49
Cooling Simulation of the Dies
3D tools with
cooling channels
Tool temperature at the end of quenching:
Courtesy of:
AP&T
50
Temperature at the End of Forming

and Quenching
Temperature at the
end of forming
Courtesy of:
AP&T
Temperature at the
end of quenching
51
Casting Covers all Aspects of

Components
Microstructure
Defects
Properties
States
Dimensions
The whole is more than the sum of its parts Aristotle
52
Summary
NON-METALLIC COMPONENTS
53
Get it right with End-to-End Virtual

Prototyping Solutions
Test it right
Component simulation
System-level Simulation
Deliver it right
Product Life Cycle

Infusion
Build it right
Draping
Forming
End-to-End Virtual Prototyping Solution allows customers to deliver the

physical prototype right the first time.
54
Composites Materials and Processes

Reinforced
Thermoplastics
Injection molding Thermocompression
Mechanical
Properties
/
Material
costs
Press Forming
Unidirectional
2 mm
Mats (GMT)
Short fibers Long fibers
unreinforced
Textile
Fiber length
Design flexibility / production rate
Reinforced
Thermosets
6 mm
20 mm
BMC
SMC
RTM / Infusion - Vacuum Forming

55
Thermoforming & Blowforming Simulation

Evaluate and optimize
Mold geometry
Process conditions
Vacuum strategy
Molding temperature
Through the prediction of

Wrinkles
Thickness
Taking into account

Thermal & strain rate effects
[email protected]
56
Industrial Examples of Applications:

Blow Forming (Gas Tank)
Sag under gravity (self-weight)

Blowforming
Thinning (%) Distribution
The Main Composites

Manufacturing Options
Pre-Pregs
Lay pre-cut individual plies to build the
laminate
OR forming of complete pre-impregnated
laminate
Draped preform
Coutesy Renault
Cure at high temperature and pressure in an

Autoclave
OR curing in forming tools (OOA)
Autoclave
LCM (Liquid Composites Molding)

Lay pre-cut dry fabrics to build the laminate
OR Forming of dry fabrics
Injection/Infusion of dry fabrics
Curing in Injection/Infusion tools
LCM Bracket Courtesy: CRCACS 2000+
58
Pre-Preg Forming Simulation

Evaluate different forming strategies:
Stamping, diaphragm (single or double) forming,
thermoforming
Clamping conditions, process parameters (tool velocity,
temperature, pressure)
Different Lay-up strategies
Upper tool
4 plies
Lower tool
Simulation setup
ESI solutions can help you:

Reduce wrinkling
Eliminate bridging
Predict thickness of material after forming
Deliver optimum flat patterns
Determine final fiber orientation
Initial flat
pattern
Poor part
quality
Optimized flat
pattern
Improved
part
59
Aircraft Wingbox Simulation 8

Plies (UD)
As-built Fiber Orientation

Thermoforming Process
Actual Formed Part

Simulated Part
Courtesy: British Aerospace
Ply 1
60
Autoclave Process
Draping
Curing
Fluid-Flow & Heat

Exchanges Calculation
Thermo-Mechanical Calculation
Demolding
Thermo-Mechanical
Calculation
Internal stresses generation
Local material properties

modification
Stress release
61
Liquid Composites Molding

Simulation
PAM-RTM can evaluate and optimize
Injection strategy (RTM, VACUUM INFUSION,
VARTM)
Injection pressure and flow rate
Injection gates, vents and vacuum ports location
Molding temperature
Flow media
Through the prediction of

Dry spots
Filling and curing times
Flow front velocity / Fiber washing
Pressure in the mold
Taking into account

Fiber angle variation (permeability variation) of the
preform
[email protected]
62
Resin Flow Front Analysis
CF Floor Pan Infusion Courtesy TECABS: RENAULT

Mines Douai
63
Effects of Injection Conditions

onto Mechanical Performance
For high performance composites, formation of micro-voids inside the
(J. Brard)
fiber tows should be minimized
Macro voids
Inter-tow
Micro voids
intra-tow
Micro-voids are directly proportional to the resin velocity
Critical impregnation velocity
64
Influence of Porosity on Stiffness

& Strength
Draping and RTM Model
Lay-up definition
Lay-up
+ material
Design
Iteration
Strength analysis
Draping and
Porosity effect
on mechanical
properties
65
Simplified Process Setup for

Engineers
Visual-Mesh
Read multiple native

CAD models CATIA,
Pro/E, UGS NX, etc.
Create stamping tools
blank, rubber pad, etc.
Execute simple model
operations like translate,
etc.
Visual-SDK, Visual-Process Exec
Create simulation
process in wizard mode.
Encapsulate PS2G to
generate the process.
Create Process block
library for future use
Visual-Viewer
Display results
Extract reports
66
What Makes the Difference:

Joining & Full Process Chain for Forming
1
Draw
2
Trim
3
Flange
4
Restrike
5
........
6
Welding
Roll
Hemming
OP 20 & 30
Casting ..
OP 40, 50, ..
Assembly
67

Behind
Structures & Safety
Engineering
Optimization
68
Covers the Following
Hemming
Cold and hot joining (welding)
Welding including history from sheet metal

forming
69
Roll Hemming
70
Full forming process line

PamStamp 2G
Flanging with ironing

simulation & impact
on springback
Springback
enhanced
in v2012
OP
with Hillbetween
90, Barlat
Springback
between OP
Forming
Springback
Springback
Restrike
Springback
Springback
Flanging
Springback
Springback
Springback after
Hemming with glue
contact
enhanced in v2012
Hemming
Springback
Springback
With ironing
Springback
between OP
Table top and

Rollhemming
simulation
Without ironing
PamStamp 2G simulation
With TTS elements
Courtesy: UBS
LIMATB - Universit de Bretagne-Sud

Rue de Saint Maud - BP 92116
56321 Lorient Cedex
http://web.univ-ubs.fr/limatb
71
Distortion Engineering Weld Planner - Joints
72
Advanced Modeling for Accurate

Simulation: Weld - Fatigue Life Analysis
PSA Objective: Decrease development

delay and cost, improve the quality
84 welding joints (total length 5 m)
Metallurgy
Residual Stress
Fatigue Criteria
73
Goal Sheet Metal Forming and

Joining to Manage Building Systems
Die Face
Design Based
on Geometry
Forming
Spring
back
Restrike
Spring
back
Flanging
Spring
back
Hemming
Spring
back
Assembly
Based on one model and one platform

74
Sheet Metal Forming

with Spot Welding
Stamp
Spot-Weld Assembly
Assembly sequence
Compensation
75
Some Details
Import Component
Deformed Shape from Stamp result
Thickness
Import Spot Weld Points

Automatic spot weld point assignment
Spot Weld Validation tool based on user
criteria
Check Gap/Distance
Alignment /Angle
Component Penetration Area
Automatic Spot Weld Re-meshing tool

Export all information for Spot Welding
Assembly Simulation on Weld Planner
Spot Weld Sequence management
Penetration area for contact management
Spot Weld
geometrical validation
tool in visual
76
Stamp- Spot Weld Assembly

Simulation
Processing in Weld Planner
Sequence Definition
Automatic Gap Closing
Contact Management
77
Stamp- Spot Weld Assembly

Simulation
Final Stamp Spot Weld

Displacement Results
After Clamp Release
78
Full Stamp Spot Weld deformed shape

can easily be exported for hemming
79
Laser Weld Assembly Chaining Solution
80

Behind
Structures & Safety
Engineering
Optimization
81
Modeling Tasks:
Virtual Spot Weld Calibration
M1
M2
M3
M4
Material properties
CCT diagrams
Process conditions
Sample geometry
Test conditions
Rupture model
& parameters
Data base
Development
WELDING & HT
ANALYSES
3D SPOTWELD
MODEL
EQUIVALENT 1D
SPOTWELD
MODEL
SIMULATION
CONTENT Mgt.
Tests results
3D results
1D Models
Local properties
EWK parameters?
Force-deflection
Absorbed energy
Force-deflection
Absorbed energy
82
Simulation of Rupture Modes

Ex. Mild Steel 1 mm
T-tension
Lap shear
Cross tension
100%
75%
Partial nugget pull-out and peeling of model
50%
25%
0%
Martensite content:
83
Stamping Effects to Improve

Virtual Performance Evaluations
Applicable in the pre-design phase
Consider real part properties in performance simulation
84
Influence of Casting Defects

Ex: Porosity and Material Failure
no porosity
with porosity
Failure initiation
No Porosity Influence
With Porosity Influence

85
Virtual Performance Solution

based on a Single Core Model
Crash & Safety

Stiffness & Misuse
Comfort
Crash &
Safety
NVH & I.Acoustics
Durability
Stiffness &
Misuse cases
Drivability
Drivability
Comfort
Durability
NVH & Internal

Acoustics
Design iteration
Current
More Efficient
86
Body Manufacturing
PRODUCTS
88
What is Covered by VM - Materials

Optimization Component Manufacturing
Structures & Safety
Engineering
Optimization
89
Task: Manufacturing of Components Under the

Aspect of Materials Optimization
Closures / Outers
Inners
Chassis
not shown
here
90
Materials Optimization - Manufacturing of

Components - Covers the Following
Die Face Design & Early feasibility based on geometry

Die Maker based on CATIA and Visual Platform + feasibility
Cold precision forming

PS2G
Getting the draw die right the first time
Zero tolerance buy off on the checking fixture all following
operations and quality checking at any stage
Hot Forming
PS2G
Casting
Quick / Procast
91
Composites Processes Summary

Unreinforced
Plastics
Process:
Continuous Fibers
Thermoforming/Blowforming
Process:
Draping/Thermoforming
Process:
Resin Infusion
Software:
PAM-FORM
Software:
PAM-FORM
Software:
PAM-RTM
Results:
Wrinkles
Thickness distribution (can be
used to update stress analysis
models)
Results:
Wrinkles
Thickness, strains & stresses
distributions
As-manufactured fiber
orientation (can be used to
update stress analysis models)
Results:
Filling time
Dry-spots
Micro & macro-voids (can be
used to update stress analysis
models)
92
What is Covered by VM Manufacturing

Engineering
Structures & Safety
Engineering
Optimization
93
Manufacturing Engineering - Putting Components

Together - Covers the Following
Roll Hemming
PS2G
Cold and Hot Joining

PS2G / Weld Planner (Feasibility) / Visual Weld
(validation)
Welding including history from sheet metal forming and
casting (innovation)
Body manufacturing (project level)
94
Goal
Structures & Safety
Engineering
Optimization
VMS
95

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Solutions Available for Body Engineering Summary

Copyright ESI Group, 2011. All rights reserved.

Task: Functional Design in a MultiMaterial Mix that Fulfills Specification

Cold Formed Steel

Hot Formed Steel

General Trends in the

Copyright ESI Group, 2011. All rights reserved.

Market Trends in Steel

Hot Formed Steel

Trends for Forming Processes of

Copyright ESI Group, 2011. All rights reserved.

Market Trends in Aluminum

Cast aluminum 44%

Those are the Engineering Disciplines

This is the Job to be Done

Virtual Prototyping means reducing tests and

Copyright ESI Group, 2011. All rights reserved.

ESI Covers Most Aspects of Body &

ESI Virtual Prototyping

Multi-Domain performance engineering solutions

Including the coupling effects between domains and

Supported by a unified Visual Environment Platform, designed

Copyright ESI Group, 2011. All rights reserved.

End-to-End Virtual Prototyping

PAM-STAMP 2G: Full chain simulation with hemming assembly

Optimized production time

Requirements on: Requirements on:

Less hardware prototypes,

Copyright ESI Group, 2011. All rights reserved.

End-to-End Virtual Prototyping

Copyright ESI Group, 2011. All rights reserved.

End-to-End Virtual Prototyping

Draping and RTM simulation with

Structural analysis with

Copyright ESI Group, 2011. All rights reserved.

Those are the Engineering Disciplines

Materials Optimization Covers the

Die Face Design & Early feasibility based on geometry

Copyright ESI Group, 2011. All rights reserved.

Copyright ESI Group, 2011. All rights reserved.

Benefits of Materials Optimization

Increase of product quality

Sheet Metal Forming

Copyright ESI Group, 2011. All rights reserved.

Major Trends in Sheet Metal

From feasibility over precision forming to milling one model based on

Robustness is interesting in case the major variables are matched

Copyright ESI Group, 2011. All rights reserved.

Easy to use product

Without need in specific numerical or finite element knowledge

Copyright ESI Group, 2011. All rights reserved.

Die Face Design Next Generation Switch from Mesh

Die Face Design Based on Mesh

Copyright ESI Group, 2011. All rights reserved.

.to Geometry Approach - Design is Based on Geometry!

Die Face Design Based on

Copyright ESI Group, 2011. All rights reserved.

New Proposed Work Flow

Die Face Design in CATIA Die