Development of a composite seat for a WRC racing car 2013 European Altair Technology Conference
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Development of a composite seat for a WRC racing car 2013 European Altair Technology Conference

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Development of a composite seat for a WRC racing car 2013 European Altair Technology Conference Development of a composite seat for a WRC racing car 2013 European Altair Technology Conference Presentation Transcript

  • MotorsportMarcel Zeisberg / Dirk Bordiehn (co-author)Development of a composite seat for a WRC racing car2013 European Altair Technology Conference2013-04-24Motorsport
  • MotorsportTable of content• The Volkswagen Motorsport GmbH…........................................ 3• Motivation for building an own seat..……………………………... 4• Material models……................................................................... 5• Finding a suitable geometry........................................................ 11• Optimization process for the layup…………………………………16• Final FE calculation of the seat……………………………………. 20• Conclusion…………………………………………………………… 212013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 2- Public Version -Material information of this document are property of the Volkswagen Motorsport GmbH. Thepermission for the use of information can be assigned only through the Volkswagen MotorsportGmbH. Violation of the copyright will be prosecuted under civil and criminal law and placesinter alia an obligation of compensation for damage on the responsible party.
  • MotorsportThe Volkswagen Motorsport GmbHHistory:- founded in 1966; started with Formel V- 1976: Scirocco-Cup (first one-make cup)- 1977: Golf GTI at the German Rally Championship- 1979-1994 engine manufacturer of the Formel 3- 1980: Winner of the Rally Dakar (Race Iltis)- 1998: Class winner 24H of Nürburgring (VW Scirocco GT24)- 1998: Lupo Cup begins, later the ADAC Volkswagen Polo Cup- 2003-2011: Rally Dakar with Volkswagen Race Touareg (Winner 2009-2011)- since 2007: Formel 3 Euro Series- since 2013: World Rally ChampionshipCompany:- 180 employees at the factory in Hannover- 100% subsidiary of the Volkswagen AG2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 3
  • MotorsportMotivation for building an own seatThe main reasons why a seat development is necessary:- improvement of the ergonomics by designing a seat for driver and co-driver- reduction of rotational inertia around all axis and decrease COG`s height byrealize a better packaging- mass reduction (minimum weight for WRC cars=1200kg empty with spare wheel)- improvement of passive safety2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 4
  • MotorsportMaterial models2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 5The way to generate a FE material modelmaterial tests with sandwich piecesfor validationmake clear what values you needsimulation of the material testsmaterial testsdefine material cards in HyperMesh(CFRP and core separate)optimize the material cards1stvalidationloopsimulation of sandwich test piecesmaterial model finished2ndvalidationloop
  • MotorsportMaterial models2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 6make clear what values you need- material cards which were used for the development process:MAT1: foam core for 2D and 3D elements (ROHACELL® etc.)MAT2: honeycomb core for 2D elements (aluminum and aramid)MAT9: core for 3D elementsMAT8: fiber reinforced plastic (CFRP and AFRP)
  • MotorsportMaterial models2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 7define material cards in HyperMesh(CFRP and core separate)Attention!before entering this values usethe HW help; order does not fitwith established literature
  • MotorsportMaterial models2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 8- all values which are not provided by the manufacturer have to be determined byphysical testsmaterial testssimulation of the material tests
  • MotorsportMaterial models2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 9- define a layup you want to validate, for example zone-based with HyperLaminate- check all times material orientation and element normals (2D->composites/)simulation of sandwich test piecesAttention!orientation of 3D elements is not mapped bythe 2D elements (faces);  orientation haveto be defined by assign coordinate system atthe property (tick PSOLIDX, assign CORDM)
  • Motorsport- it is very important to define the rightmaterial orientation for the core (3D elements)- influence of wrong material orientation at 3D elements:Material models2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 10simulation of sandwich test piecesSource:(1) WHZ Racing Team; UAS Zwickau(1)
  • MotorsportFinding a suitable geometry2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 111. Comparison of different side cut contours and edge designs- use of isotropic imaginary materials for composite shell in combination with knownmaterial models for the core- evaluation matrix with relation number for a qualitative comparison (e.g. stiffnessper surface content) „Before you make it complicated, make it useful!“ CR
  • MotorsportFinding a suitable geometry2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 122. Topology-Optimization by using the SKO method- to get an idea for a possible design, especially for the core, Topology-Optimizationmaking sense- use less constraints and a maximum of design space for the first optimizations- all load cases have to be included; for weighting factors pre simulations are useful- include adjacent components for realistic deformation behaviorsymmetryconstraint onlydraw directionand min.member sizeconstraintsadded You will not receive satisfactory results by the first run. Modify constraints step by step!
  • MotorsportFinding a suitable geometry2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 133. Topology-Optimization with 2D elements only- main flux of force recognizable (helpful for UD-layer definition)- results not as important for seat shape design as 3D optimization resultssymmetryconstraint onlyincreased min.member size??
  • MotorsportFinding a suitable geometry2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 144. Topography-Optimization / Shape-Optimization- core = 3D elements with MAT1 and MAT9 cards; surface = 2D elements- design component = outer shell; automatically morphing of the core structure- giving an idea where constant core thickness is makes sense- adequate results to the Topology-Optimizationno non designareas; no edgenon designarea and edgeadded;increased min.width and drawheight Results should be used for Gauge-Optimization process which coming next.? ?
  • MotorsportFinding a suitable geometry2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 155. Core and shell thickness Free-Size-, Size- and Gauge-Optimization The first calculations should be Free-Size-Optimizations with appropriate constraints.- 2D elements combined with final material models, quasi isotropiccomposite layup and core defined with HyperLaminate- alternately Gauge- and Free-Size-Optimization of the differentdesign areas- refining of the design areas after every optimization- with the Gauge-Optimization choice of core material can be done????
  • MotorsportOptimization process for the layup2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 16- by using the Size-Optimization results the final seat was generated with a CAD tool- final model for all calculations and optimizations consist of a 3D element core and2D facesFree-Size-OptimizationComposite-Size-OptimizationComposite-Shuffle-Optimization creates a thickness distribution for each ply calculates the number of plies for each plycontour you reimport with the FSTOSZ results giving you the best stacking order for the plies?
  • MotorsportOptimization process for the layup2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 17- ply based layup definition by using the PCOMPP property- OptiStruct is not able to increase ply thickness; because of that “super plies” with amaximum material thickness have to be created- input manufacturing constraints at the Free Size Desvar(type: Stack); e.g.:Free-Size-Optimization with super plies
  • MotorsportOptimization process for the layup2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 18Composite-Size-Optimization- Variant 1:- activate control card FSTOSZ before starting the Free-Size-Optimization- import Modelname_sizingXX.fem-input deck (a Free-Size output file)- Variant 2:- generate own plies, Size-Optimization will also work (perfect if you aredesigning the composite part in CAD parallel to the CAE work)- activate control card SZTOSH before running Size-Optimization- set manufacturing constraints (e.g. same as Free Size Desvar plus stress bounds)HintIf you are interested in composite optimization methods visitwww.altairuniversity.com/structural/optimization/composites/enter prepregthickness
  • MotorsportOptimization process for the layup2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 19Composite-Shuffle-Optimization- Variant 1:- import Modelname_shuffling.XX.fem-input deck (a comp.-size output file)- Variant 2:- use the own plies, Size-Optimization is not necessary before running aComposite-Shuffle-Optimization- set manufacturing constraintsnumber ofsuccessive pliesorientation of coverply-0.9mm deflection
  • MotorsportFinal FE calculation of the seat2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 20- with the results of the optimization process for the layup a final model of the seatwas created (inclusive UD tapes)- focus on producibility of the plies, composite failure index and observing of thedesign targets regarding compliance (FIA tests)
  • MotorsportConclusion2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 21• What has the biggest influence on the optimization results for composite parts?• Which process gives me a satisfying result if the inner or outer shell of a compositepart is given by the design dept.? (e.g. monocoques)• When I start to design a composite layup according to the load? material models, model quality (material orientation, element normals), adjacent parts,design constraints “quick and dirty:” Free-Size-, Size- / Gauge-Optimization of a 2D element model withzone based plies and core defined at HyperLaminate going more in detail: Topography-Optimization of a sandwich model(3D core and faces) combined with Free-Size-, Composite-Size-, andComposite-Shuffle-Optimization (ply based layup) geometry investigation, material choice and core design have to befinished before you start the layup optimization; otherwise you willwaste a lot of time because of the big number of variables
  • Motorsport2013-04-24 Development of a composite seat for a WRC racing car - Marcel Zeisberg 22Thank you for your attention!