Correlation of Simulation Models using Concept Modeling

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Correlation of Simulation Models using Concept Modeling

  1. 1. Correlation of Simulation Modelsusing Concept ModelingDr. Jörgen Hilmann, Joe Abramczyk Ford Motor CompanyDr. Salvatore Scalera RLE InternationalAndreas Arlt SFE GmbH Berlin
  2. 2. Correlation of Simulation Models using Concept ModelingDr. Jörgen Hilmann, Joe Abramczyk, Ford Motor CompanyDr. Salvatore Scalera, RLE International; Andreas Arlt, SFE GmbH BerlinKeywords: RADIOSS, HyperMesh, MotionView, SFE Concept, Correlation, Front Impact, Side ImpactABSTRACTPre-requisite for efficient vehicle programs is the CAE driven development process as described in [1], [2] "Up Front CAE". Both CAD and CAE modelsbased on special Concept Software as SFE CONCEPT are used to analyze the attribute performance as safety, NVH or durability and commodity studiesconcerning the weight, manufacturing, or package. A database of concept models is used to minimize the modeling effort and to maximize the re-usability ofcomponents [3]. The accuracy of the models increases over time and leads to an increasing amount of available Concept models in databases. Due to theincreased acceleration of the development process, these models are critical in providing direction on vehicle architecture in the early stages of a program.Due to the high importance of these decisions it is mandatory to trust the results of this early CAE models. Correlation of this Concept models to test orreference mainstream CAE models creates the confidence in this approach. The correlation focuses on two aspects: 1. the level of detail required to capturethe detailed folding characteristic of the structure (e.g. siderail or B-Pillar) and 2. the process chain used to process the raw output from SFE Concept intoRADIOSS Include files (e.g. gap, contacts, spot-welding, adhesives, bolts). This process chain is implemented using HyperMesh in batch mode, details maybe found in [4]. This process chain is tuned to latest program modeling approaches and to meet the desired correlation status.In this presentation RADIOSS safety concept models are correlated to different impact modes. Tools and methods are explained focusing on both theautomated evaluation of simulation output and the judgment of the correlation quality. The main criteria defining the correlation fitness are video overlay ofvehicle and dummies kinematics, curve comparison of vehicles acceleration, velocity, and intrusion. Furthermore the dummy sensors have been evaluated.The combination of the above mentioned steps enable an accelerated and more confident concept phase allowing for more alternatives being analyzed in amore holistic and detailed manner as described in [5], [3]. This is a pre-requisite for the creation of efficient designs under the constraints of an increasinglyaccelerated development process.BIBLIOGRAPHY[1] E. Schelkle and H. Elsenhans, "Virtual Vehicle Development in the Concept Stage – Current Status of CAE and Outlook on the Future", 3rd MSC Worldwide Aerospace Conference & Technology Showcase in Toulouse 2001[2] Jörgen Hilmann (Ford) und Uwe Wagner (Ford), „CAE driven development process for the early vehicle development phase.“ IABC Confernce 2007 in Berlin[3] Michael Keimes, Dr. Jörgen Hilmann, Martin Lichter, Dr. Uwe Wagner, "Optimierungsstrategien für Leichtbauprojekte" VDI Leichtbaukonfernz Ludwigsburg, 2011.[4] Jörgen Hilmann (Ford) und Hans Zimmer (SFE GmbH) „Development and application of an automated model built process chain for the Preprogram and Concept phase using SFE CONCEPT and the Altair Hyperworks package.“ EHTC Konferenz in Strassbourg 2008[5] K.H. Volz and H.Zimmer, "Optimizing Topology and Shape for Crashworthiness in Vehicle Product Development", IABC Confernce 2007 in Berlin 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  3. 3. Correlation of Simulation Models using Concept ModelingContents• Introduction• Motivation for Concept Modeling• Concept Models & Libraries• Model built and Include Files• Correlation quality: Procedure and Criteria• Vehicle Samples• Q&A 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  4. 4. IntroductionBasic Design … is a Mini Product Development Department Project Lead Project Lead Project Lead Project Lead B-Car C-Car CD-Car Commercial Body Exterior Body Body Interior & Attributes Electrical Total Basic Design Team Electrical with Matrix Organization Chassis - Technical Specialists Chassis & Veh.Dyn. - Supervisors - Base heads Veh. Dyn. SQ & V (NVH) - Contractors … Concepts Vehicle Integration Powertrain Integration Link to “LHS“ Mechanical Package 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  5. 5. Separate CAE Attribute Workstreams – OLD State Update Effort for each attribute & Risk for misaligned program assumptionsModel Quality Dev. Time SafetyPre Upda Update Update 3 Update ndecessor te1 2 NVH Pre-decessor Update Update Update b c x Durability Pre- Update Update dece I II ssor 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  6. 6. Concept Modeling in CAE driven development processUsage of Concept Module Libraries & Standardized Pre-Processing Procedure & Include Assembly Process Concept module library• Concept libraries are populated during the concept modeling work• Re-use of concept modules increases over time driven through best practice initiatives e.g. for joint execution or Pillar designs• A process chain is implemented using Altair Hypermesh processing re-occurring pre-processing tasks in automated batch mode Process Chain meshing, using HyperWorks package• The full vehicle models are assembled from different in batch mode sources using the RADIOSS Include files: - Correlated CAE models / modules from the RADIOSS mainstream development teams Include - Parts / Modules developed in the concept modeling Assembly department using e.g. SFE Concept Process 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  7. 7. Integrated CAE Attribute Workstreams – Current State Update Effort shared among the team & No risk for misaligned program assumptionsModel Quality Dev. Time Baseline study Concept development Virtual design verification Component studies & Iterations Pre New model model update model update decessor VCS 1 Level VCS 2 level VCS 3 Level Safety NVH Safety NVH Durability Safety NVH Durability 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  8. 8. Price of the new process: Demand for CorrelationStarting the work from correlated reference models does not require up front preparation• In order to built CAE concept model Concept module confidence it is mandatory to verify the predictive power of CAE Concept models using correlation studies.• Herein the full vehicle models (including the concept modules) reflect the <Job #1> design intent of the pre-decessor model.• The Correlation-Phase is used to familiarize Modules from the reference model the team with the new program and to ensure the processes used are capable. Correlated reference CAE Model• Two Objectives for Correlation: Substitution of concept modules 1. Geometry and Mesh level of detail 2. Process to built the full vehicle model Correlation of the new model Analysis of concept alternatives using the same processes 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  9. 9. Correlation typesStarting the work from correlated reference models does not require up front preparation Difficult to standardize the correlation approach, due to differentiation through: • Application to geometry or the model built process chain; or both. • Applied Car Line: B-CAR / C-CAR / CD-CAR / Light Commercial Vehicles • Availability of reference data: Mainstream CAE and/or real test results • Different Impact Modes: Front, Side, Rear, … • Different Requirements / Markets As a consequence the correlation task is challenging and the required timing difficult to predict. 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  10. 10. Required accuracy of the modelThe Level of detail is a function of the impact mode and FORD FOCUS SFE Concept Geometry SFE Concept FE MeshWithin Ford concept modelsusing the same numerical code,e.g. RADIOSS for Safety analysis. Mainstream CAEThe level of detail ranges between both:- A rough box section to represent an inertia effect of structure, which is not considered to deform- A detailed geometry with all holes and depressions if considered being important e.g. under axial compression in a frontal impact. 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  11. 11. Correlation Sample: Frontal OffsetKey take aways of this presentation ODB – EuroNCAP Frontal Offset / IIHS Model correlation status is satisfactory for: • Siderail behavior • Overall intrusion values (although slight under-prediction of Toeboard intrusion) • Crash pulse This CAE model is w.r.t. the offset impact well suited to support A to B comparisons of architecture studies Displacement delta values ridedown area Upper_Cowl Offset Dashboard CC_Beam ToeBoard A_Point Conventional Deformable Cowl CAE model Barrier 64kph Concept Reference model -- -- -- -- -- -- -- model Concept model -14mm -1mm 2mm 3mm -6mm 2mm -3mm delta to reference 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  12. 12. Correlation Sample: Full Frontal Rigid BarrierKey take aways of this presentation Straight Front – US-NCAP, SDG Model correlation status is overall satisfactory but there is a minor difference in the siderail bending. As a consequence the pulse shape show a slight deviation. For A to B Comparisons may be used. ridedown area Upper_Cowl Conventional Dashboard CC_Beam ToeBoard Full Frontal A_Point CAE model Cowl Rigid Barrier 56kph Concept model Reference model -- -- -- -- -- -- -- Concept model -12mm -15mm 2mm 9mm -3mm 2mm -5mm 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  13. 13. Correlation Sample: Ford Mondeo Frontal OffsetConcept Upper Structure combined with mainstream residual modulesDual Color Overlay: A to B comparison Blue: Mondeo reference CAE model Gold: Mondeo SFE CONCEPT Model (with carry over parts e.g. Platform, PT,…) 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  14. 14. Correlation Sample: Ford Mondeo Side Impact Concept Upper Structure combined with mainstream residual modulesBlue: Mondeo reference CAE modelGold: Mondeo SFE CONCEPT Model (with carry over parts e.g. Platform, PT,…) B-Pillar velocities B-Pillar velocities @ @ B-Pillar-Mid Striker Door @ Pelvis @ Thorax velocities 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  15. 15. Correlation Method: Film / CAE OverlayOverlay of a physical Test Film with a RADIOSS Crash Simulation: High Speed barrier side impact 0 ms 50 ms AVI 100 ms 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  16. 16. Correlation Method: Curve comparison using channelsOverlay of a physical curve measurements with RADIOSS time history readingsAccelerometer readings Black: CAE model Black: CAE model B-pillar @ Gray: Test curves beltline Gray: Test curves Blue channel borders Blue channel borders A B-pillar @ striker B C A B B- pillar @ rocker Method: Black: CAE model Gray: Test curves - Create the average curve of all test curves Blue channel borders - Add ±15% of the average peak of the curves to define a channel Observation: • The accelerations evaluated using CAE model are almost always contained in the band fluctuation of real acceleration • The peak of the B-pillar_@_rocker acceleration is slightly C underestimated 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  17. 17. Correlation Method: Peak curve comparisonOverlay of a physical curve measurements with RADIOSS time history readingsNormalization: The bar charts represent the max. injury criteria divided by the arithmetic mean of available test max. injury criteria. “1” being the average of the available test curve maxima for this criteria, e.g. HIC36Test Variation: The CAE results (orange bar) are in the range of test values, except the Pubic Load for the 1st row and Spine Acceleration in the 2nd row. 1,45 1,55 1,40 1,35 1st row 1,50 1,45 2nd row 1,30 1,40 1,25 1,35 1,30 1,20 1,25 1,15 1,20 1,10 1,15 1,05 1,10 1,00 1,05 0,95 1,00 0,90 0,95 0,85 0,90 0,80 0,85 0,75 0,80 0,75 0,70 0,70 0,65 0,65 0,60 0,60 0,55 0,55 0,50 0,50 0,45 0,45 0,40 0,40 0,35 0,35 0,30 0,30 0,25 0,25 0,20 0,20 0,15 0,15 0,10 0,10 0,05 0,05 0,00 0,00 Ave5RibDis [mm] Iliac Fy HIC36 MaxThoRib Abdomen Force Spine lowe Pelvis acceleration Pubic Fy HIC36 T12 acceleration [g´s] acceleration Shoulder deflection [mm] T1 acceleration [g´s] Pelvis acceleration [g´s] Acetabulum Fy 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  18. 18. ConclusionsKey take aways of this presentation• Concept modeling significantly changed the vehicle development towards a CAE driven Development Process, however requires to built confidence in the used simulation models. Demand for correlation!• Methods are presented using visual and statistical methods to determine the correlation quality• These methods are objective and measurable; they help to be as accurate as necessary to reflect the system behavior without capturing all details of one single test result, prevents the risk of overfitting / overpredicting to one test.• Having solutions for concept modeling, process chain and correlation under control you can use this approach as a generic approach for structure development.• Very helpful is the coupling with Topology Optimization e.g. Optistruct. and the consideration of system noises Robustness. 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera, Andreas Arlt
  19. 19. Selecting the best Subsystems A holistic Approach of Evolution & Revolution SWOT Architecture Study Topology Opt. Demands / Wishes Altair Optistruct• System xyz is not weight efficient enough• Demand to improve vehicle performance abc Competitor Evolution “white Paper”• Part t.b.d. is not package Reference Predecessor Part D Other Part F model Part B Segment efficient enough Part A Part C Part E•… Beam representation of the major Load Pathes incl. Sensitivities Concept development considering all available findings Materialgaugeoptimization and Materialgrade optimization ? Safety NVH Weight ODB/FF Static / Dyn. 2011 European HyperWorks Technology Conference Jörgen Hilmann, Joe Abramczyk, Salvatore Scalera Andreas Arlt
  20. 20. Thanks for your attention!Correlation of Simulation Models usingConcept ModelingTeam of Authors:Dr. Jörgen Hilmann, Joe Abramczyk Ford Motor CompanyDr. Salvatore Scalera RLE InternationalAndreas Arlt SFE GmbH Berlin

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