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CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
CAE-Driven Design Methodology for Semi-Autonomous Product Development
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CAE-Driven Design Methodology for Semi-Autonomous Product Development

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  • 1. CAE-Driven Design Methodology for Semi-Autonomous Product DevelopmentDesigning the next generation light weight vehicle structureswww.DLR.de • Chart 1 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013Dr.-Ing. Sivakumara KrishnamoorthyDipl.-Ing. Matthias KonzelmannSameer Chaudhari B.E.Dipl.-Ing. Gundolf KoppProf. Dr.-Ing. Horst E. Friedrich
  • 2. DLR – Overview• German national research center for aeronautics and space• Development of environmentally-friendly technologies• Promote mobility, communication and security7 400 employees are working at 32 research institutes andfacilities in n 9 locations and  7 branch offices.SPACE AERONAUTICS TRANSPORTATION ENERGYwww.DLR.de • Chart 2 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
  • 3. Motivationwww.DLR.de • Chart 3 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013Global Challenges• shortage of ressources• climate changeChallenges in Mobility• reduce fuel consumption• reduce emissions• adapt concepts for new mobilityChallenges for Vehicle Concepts• short development time• increase economic efficiencyCAE-based designmethodology forBIW-concepts
  • 4. ObjectiveCAE-based design methodologywww.DLR.de • Chart 4 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013ComfortDrivingcharacteristicsSafetyLightweightdesignEconomy
  • 5. Approachwww.DLR.de • Chart 5 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013Design-Space-ModelTopology Optimization ResultLight Weight Structure
  • 6. Optimization Model• Units and loads arepoint masses• Static loadcases:• Torsion• Bending• Static loads representingdynamic conditions:• Front crash• Rear crash• Side crashwww.DLR.de • Chart 6 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013Crash equivalent static loads
  • 7. Topology Optimization Resultwww.DLR.de • Chart 7 > CAE-driven design methodology > Matthias Konzelmann > 23.04.2013
  • 8. Approachwww.DLR.de • Chart 8 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013Design-Space-ModelTopology Optimization ResultLight Weight Structure
  • 9. Interpretation of Structural Requirementswww.DLR.de • Chart 9 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
  • 10. BendingInterpretation of Structural Requirementswww.DLR.de • Chart 10 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013Axial load Torsion
  • 11. Identifying Shear Locations• Optimization algorithm disadvantages shear planes• Identification necessary• Plane structures are easy to manufacturewww.DLR.de • Chart 11 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013Intermediate resultFEnd resultF
  • 12. Techno-Economic Criteriawww.DLR.de • Chart 12 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013MaterialCost effectivenessBranding/ImageQuantitySpace-Frame Monocoque Hybrid Shell
  • 13. Interpreting the Results• One purpose per loadcase (LC) and member• Topology Optimization results contain complex equilibrium• No loadcase disregarded• Good performance for each loadcase• No focus on particular loadcaseswww.DLR.de • Chart 13 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013LC1LC2LC3LCxLC1LC2LC3LCxInitial calculation Final calculationPerformance
  • 14. Example: Side-Railwww.DLR.de • Chart 14 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013• Very high height to width ratio• I-shape already in result• Shear structureHeightWidth
  • 15. Example: Roof-Structure• No information in cross-section• Further interpretation:• Contour Signed VonMises• Bending detected?• In this case no Bendingwww.DLR.de • Chart 15 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013
  • 16. Example: Roof-Structurewww.DLR.de • Chart 17 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013Cross-section shell structure
  • 17. Example: Roof-Structurewww.DLR.de • Chart 18 > 2013 European Altair Technology Conference Torino > Matthias Konzelmann > 23.04.2013Roof structure, reinforced with FRP +/-45°
  • 18. www.DLR.de • Chart 19 > CAE-driven design methodology > Matthias Konzelmann > 23.04.2013Decision Making in Design Process
  • 19. Thank you for your attentionmatthias.konzelmann@dlr.de

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