This document discusses using cloud-based high-performance computing (HPC) services to enable an innovative virtual prototyping methodology for automotive applications. It aims to investigate the behavior of automotive components in structural performance simulations. The methodology utilizes a "Single Core Model" approach where multiple full-vehicle simulation models are all based on a single, central Body-in-White subsystem model. This allows for collaborative decision making across crash, durability, and noise, vibration, and harshness engineering disciplines. The document describes applying this approach using ESI Group's Virtual Performance Solution on Bull's Extreme Factory HPC cloud system. It details how the Single Core Model reduces model duplication and improves communication for multi-site companies. The experiment
The document discusses digitalizing information management from design to production. Specifically, it discusses how Scheepswerf Slob implemented CADMATIC eShare to reduce the number of printed drawings needed for production. eShare allows staff to access up-to-date drawings and information on tablets. It has saved paper, time, and improved access to current data. Scheepswerf Slob has also linked eShare with its nesting software, allowing it to track the status of parts through the building process.
The Virtual Dimension Center (VDC) provides an overview of the fields of application and trends of virtual technologies in automotive engineering. These are used in development, production, marketing, training and service, making physical prototypes increasingly redundant. In future, manufacturers will rely even more on these methods and tools.
This document summarizes a report on developing a total cost model for additive manufacturing (AM), also known as 3D printing. It conducted experiments using laser sintering (LS) and selective laser melting (SLM) to understand build failure rates, manual post-processing costs, and how costs decrease with higher machine utilization. The results provide a methodology to analyze the full economic costs of AM and understand when it may have a viable business case compared to traditional manufacturing.
This document discusses utilizing value stream mapping to optimize production lead times for heavy duty earth-moving vehicles. It presents a case study of applying lean tools like value stream mapping, kaizen, kanban, and production leveling to reduce waste and lead times in the production of dummy axles at an automobile manufacturing plant in India. Currently, the plant produces 247 dummy axles per day but wants to increase production to 270 axles per day without additional capital costs. It aims to reduce the manufacturing lead time from 60 to 45 minutes and reduce in-process inventory levels and non-value added time through this lean improvement project.
This document discusses how additive manufacturing (AM) can be used at different stages of the product design and development (PDD) process. It distinguishes between rapid prototyping (RP) and digitally optimal design (DOD). RP uses AM to create prototypes faster and cheaper but does not change the final product, while DOD designs products specifically for AM production, enabling new designs. The document outlines how AM benefits PDD for traditional manufacturing through communication, validation, replication and pre-production uses like models, prototypes, patterns and tools. It saves time and costs in the development cycle and enhances product quality by enabling more design iterations.
Prior to the Smart Automotive Variantcon 2013, we.CONECT spoke with Dr.-Ing. Harald Walter, Senior
Chief Engineer, Global Core Development Linkage & Suspension, TRW Automotive GmbH / Germany
The document discusses KlighD, a tool from the Kieler project for generating lightweight diagrams from complex data models. It provides automatic layout of diagrams to improve understandability. KlighD uses a graph-based metamodel to represent views and supports rendering shapes and layout. It generates diagrams directly from models, inverting the traditional approach of editing models through diagrams. This enables transient visualization of large and complex models with zooming and filtering capabilities.
The document discusses digitalizing information management from design to production. Specifically, it discusses how Scheepswerf Slob implemented CADMATIC eShare to reduce the number of printed drawings needed for production. eShare allows staff to access up-to-date drawings and information on tablets. It has saved paper, time, and improved access to current data. Scheepswerf Slob has also linked eShare with its nesting software, allowing it to track the status of parts through the building process.
The Virtual Dimension Center (VDC) provides an overview of the fields of application and trends of virtual technologies in automotive engineering. These are used in development, production, marketing, training and service, making physical prototypes increasingly redundant. In future, manufacturers will rely even more on these methods and tools.
This document summarizes a report on developing a total cost model for additive manufacturing (AM), also known as 3D printing. It conducted experiments using laser sintering (LS) and selective laser melting (SLM) to understand build failure rates, manual post-processing costs, and how costs decrease with higher machine utilization. The results provide a methodology to analyze the full economic costs of AM and understand when it may have a viable business case compared to traditional manufacturing.
This document discusses utilizing value stream mapping to optimize production lead times for heavy duty earth-moving vehicles. It presents a case study of applying lean tools like value stream mapping, kaizen, kanban, and production leveling to reduce waste and lead times in the production of dummy axles at an automobile manufacturing plant in India. Currently, the plant produces 247 dummy axles per day but wants to increase production to 270 axles per day without additional capital costs. It aims to reduce the manufacturing lead time from 60 to 45 minutes and reduce in-process inventory levels and non-value added time through this lean improvement project.
This document discusses how additive manufacturing (AM) can be used at different stages of the product design and development (PDD) process. It distinguishes between rapid prototyping (RP) and digitally optimal design (DOD). RP uses AM to create prototypes faster and cheaper but does not change the final product, while DOD designs products specifically for AM production, enabling new designs. The document outlines how AM benefits PDD for traditional manufacturing through communication, validation, replication and pre-production uses like models, prototypes, patterns and tools. It saves time and costs in the development cycle and enhances product quality by enabling more design iterations.
Prior to the Smart Automotive Variantcon 2013, we.CONECT spoke with Dr.-Ing. Harald Walter, Senior
Chief Engineer, Global Core Development Linkage & Suspension, TRW Automotive GmbH / Germany
The document discusses KlighD, a tool from the Kieler project for generating lightweight diagrams from complex data models. It provides automatic layout of diagrams to improve understandability. KlighD uses a graph-based metamodel to represent views and supports rendering shapes and layout. It generates diagrams directly from models, inverting the traditional approach of editing models through diagrams. This enables transient visualization of large and complex models with zooming and filtering capabilities.
Upstream oil and gas projects regularly suffer from cost overruns and delays. The article argues that companies must transform their project management practices by adopting four key principles: 1) Focusing on leaner engineering designs through standardization and reuse; 2) Developing closer long-term collaborations with key suppliers; 3) Tailoring growth strategies to match true capabilities; 4) Implementing robust central governance of large projects. Case studies from other industries and Anadarko show this approach can significantly reduce costs while improving performance if all principles are applied together through cultural change and over multiple project generations.
This document provides an overview of automotive manufacturing. It discusses the typical stages of automotive product development including conceptual design, clay modeling, product and process development, production tooling, process validation, and production. It also describes approaches used in high volume automotive manufacturing (HVAM) and low volume automotive manufacturing (LVAM), including platform commonization, set-based concurrent engineering, and customization concepts.
The document discusses software development in the automotive industry. It notes that automotive software is becoming increasingly complex, with modern vehicles containing over 100 million lines of code. The architecture of automotive software is also becoming more distributed across different vehicle systems. The document argues that future development will require improved collaboration across organizations involving thousands of people. It examines different organizational models and tooling approaches to support collaborative development at different levels, from individual users and projects to the enterprise level.
130226 open innovation in additive manufacturing v3dajkersten
1) Additive Industries will support companies to design for additive manufacturing and establish a shared additive manufacturing lab (AddLab) to allow companies to experiment with the technology.
2) By pooling volumes in high-tech applications, Additive Industries aims to justify investment in industrial-grade additive manufacturing equipment for printing functional metal and ceramic parts at larger volumes and with higher precision.
3) Additive Industries plans to develop as an OEM of dedicated additive manufacturing equipment and systems, and involve the regional supply base in co-developing and manufacturing the new equipment.
This document discusses additive manufacturing (AM) and its potential applications in the maritime and oil & gas industries. It provides an overview of important AM processes such as binder jetting, material jetting, powder bed fusion, sheet lamination, vat photopolymerization, and direct energy deposition. While AM currently only accounts for about 5% of these industries, its use is anticipated to rapidly expand. The document outlines both limiting and encouraging factors for AM adoption. It then presents a Bayesian network approach that can be used to assess risks to manufacturers and end users from AM part variability and lack of standards/regulations. Case studies demonstrate how this approach can evaluate risks from an original equipment manufacturer or end user perspective.
ISCRAM 2013: Building robust supply networks for effective and efficient disa...ISCRAM Events
The document discusses building robust supply networks for effective disaster response. It proposes an iterative dynamic approach for decision support involving problem structuring, optimization to generate alternatives, dynamic scenario construction to consider uncertainties, and evaluation. As a use case, it applies the approach to optimize locations for health care centers in Haiti after the 2010 earthquake. The approach aims to identify alternatives that perform relatively well across scenarios to create flexible, effective and efficient supply networks.
Product Development Project - project management introductionShaun West
This short presentation provides a simple introduction to project management. It is tool-light and visual heavy. This is material that is used to introduce project management in innovation projects at Lucerne University of Applied Sciences and Arts.
There is a book and a flyer that support this presentation.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document discusses the implementation of design for manufacturing (DFM) principles in mechanical engineering education. It provides examples of applying DFM to dimensional tolerancing using standards to ensure functionality and manufacturability. Advanced computer technologies like CAD/CAM and AI are also discussed in improving the link between design and manufacturing to better implement DFM concepts. The authors aim to integrate DFM training earlier in the manufacturing engineering curriculum.
Thyssenkrupp Tallent - Evolutionary Design in Chassis TechnologyAltair ProductDesign
This paper from Thyssenkrupp Tallent and Altair ProductDesign details the use of the eDICT process for the design of sheet metal chassis components. eDICT (evolutionary design in chassis technology) is an innovative structured process flow for the design of optimal structures. On recent projects eDICT has produced 25% mass reductions compared to the current series design. eDICT is also able to reduce development times and resource with an efficient solution production right from the outset.
Procedia social and behavioral sciences volume 109 issue 2014 [doi 10.1016%...Ria Fausika
The document discusses a quantitative research study on the use of business process management principles in Slovak enterprises. The study found that:
- Most enterprises were small-medium sized and produced in a job-order or batch style rather than mass production.
- Traditional functional management was more common than process management. The most used tools were activity-based costing and financial analysis, while newer tools like balanced scorecard were not used.
- Process management principles were not fully and systematically applied - activities were sometimes customer-oriented but barriers to knowledge sharing remained. Process owners and team-based work were limited.
- While some enterprises had defined or managed their processes, many others took an accidental or repeated approach rather
1. The document provides an overview of Gestamp Group's 2014 sustainability report. It discusses Gestamp's financial results, growth, investments, innovation initiatives, environmental commitments, and contributions to local communities.
2. Key highlights include 6.9% revenue growth to €6,256 million, 7.8% EBITDA growth to €656 million, and expanding presence in growing markets like China and North America.
3. Gestamp also discusses training initiatives, new facilities, partnerships with clients, and goals to continue innovation and sustainable growth.
Gestamp is a leading supplier of metal automobile components to major vehicle manufacturers worldwide. In 2014, Gestamp saw good economic results with sales totaling 6.256 billion euros and 32,331 employees across 93 manufacturing facilities in 20 countries. Some highlights included opening a new prototype design and testing plant in Germany, establishing closer relationships with clients through co-development of parts, and beginning construction of the Gestamp Technology Institute to provide training in new automotive technologies. Going forward, Gestamp will continue innovating its product offerings and globalizing its operations.
The document discusses steel innovations in hot stamping. It provides a history of hot stamping innovation from 1974 to present day, including the development of the first hot stamping line and products. It describes how Gestamp has 10 R&D centers globally that drive innovation. It also discusses 5 technologies Gestamp has developed that have yielded 4 innovative products: 1) a new zinc hot stamping process, 2) remote laser seam welding, 3) in-die soft zones, 4) flex laser soft zones, and 5) 3D laser cladding. Examples are given of how these technologies have been applied to products like front rails, rear rails, and B-pillars to improve performance and reduce weight.
The document provides an overview of the development of the all-new 2016 Honda Civic. Key points include:
- The development goal was to create the best C-segment vehicle in the world.
- It had a global development team and is produced in 10 plants worldwide.
- The package aims to be low and wide with best-in-class interior volume.
- There are two new powertrains - a 1.5L turbo and 2.0L engine - that maximize performance and efficiency.
- Significant work went into improving crashworthiness, handling, noise reduction and fuel economy through changes to the body construction, chassis, and safety structures.
Thermostamping simulation for woven thermoplastic composites (PA) with HyperFormAltair
The thermostamping process of thermoplastic composites can be analyzed with simulation software. In addition to the optimization that can be brought to process (defects, raw material quantity …), the main interest is to integrate results from process into the performance simulation. This article presents an approach to simulate thermostamping of thermoplastic composites (PA) with HyperForm.
The material law is identified from Bias test trials, then, the simulation is performed by HyperForm with the solver Radioss or Ls-Dyna. Fiber orientations (for non-linear anisotropic behavior) and defects (global wrinkles, and wrinkles in the thickness, area with failure risk, thickness variation…) are identified and mapped on structural mesh for mechanical simulation.
Based on this approach, several test/simulation comparisons were performed on both static and dynamic. They demonstrate the necessity of considering the process phase, especially for complex geometries.
Regarding advanced application for such simulation tool: Faurecia Automotive Exterior is developing technologies to produce one-shot visible parts (CFRT thermostamping + overmolding injection in one step). This case study is the most challenging application we are working on. Combining thermostamping simulation and one-shot process brings benefits to both sides thanks to cross results on complex application.
Globaly, to improve the prediction of this simulation tool, next steps are the computation of local density; the consideration of thermal exchanges with the mold during the production process; the modelization improvement of boundary conditions during process (woven holding …, frames…).
Speakers
Guillaume CHAMBON, Product Research & Advanced Simulation Manager, FAURECIA Automotive Exterior
Cae technologies for efficient vibro acoustic vehicleCec deMille
This document discusses how computer-aided engineering (CAE) methods like the finite element method are increasingly being used in the automotive industry to predict vehicle performance like noise and vibration levels. This allows vehicle designs to be tested virtually through simulations before building physical prototypes, reducing costs and shortening development time. The document focuses on using CAE techniques like wave-based substructuring and modal modification to enable more efficient vehicle redesign iterations and predictions of how panel thickness and damping variations affect noise and vibration levels. It also discusses how these faster deterministic methods can speed up non-deterministic analyses that assess how uncertainty in panel properties impacts vehicle performance.
Development of new products is extremely essential for the success and smooth running of every industry. Companies have to constantly inject innovations and design efforts to make the design processes easy and to attract consumers in a constantly in a evolving and highly competitive market with best quality . Keeping ahead of the competition by bringing new and exciting products to market fast, and at the necessary level of quality, presents a major engineering challenge. A new casting bracket in place of old stamping brackets in snowmobile chassis development process is described, which introduces advanced FEM and Optimization technology into the concept development phase. Detailed predictions of interacting parts in a mechanism assembly are made possible through use of value engineering based process and material selection and advanced simulation technology. Design optimization is then employed using the modeling as a virtual testing ground for design variants. The approach provides clear design direction and helps to improve performance and reduce the unnecessary welding efforts of bracket manufacturing. Design is an intelligent activity that begins with design requirements and ends with a product description. Using Altair Optistruct was able to significantly reduce design time by sub modeling with structural optimization. The resultant casting bracket design showed superior performance characteristics. And finely the manufacturer had to put less efforts in stamping and part welding , which reduced the manufacturing time and cost also.
Testing and Verification through Virtual Product ModelsGergely Hidas
Modern engineering design and simulation software (CAD, CAM, CAE) allow for extensive use of virtual prototypes along the product and production development reducing the cost and time of physical prototyping. These software technologies in turn has also important role in testing and verification against the various regulations. This paper reviews the recent progress of virtual verification (ViVer) technology and the underlying emerging concepts with special focus on the role of certification service providers. The paper covers multiple aspects of the ViVer concept serving as a conceptual guideline for the development of
virtual verification systems of the future.
Upstream oil and gas projects regularly suffer from cost overruns and delays. The article argues that companies must transform their project management practices by adopting four key principles: 1) Focusing on leaner engineering designs through standardization and reuse; 2) Developing closer long-term collaborations with key suppliers; 3) Tailoring growth strategies to match true capabilities; 4) Implementing robust central governance of large projects. Case studies from other industries and Anadarko show this approach can significantly reduce costs while improving performance if all principles are applied together through cultural change and over multiple project generations.
This document provides an overview of automotive manufacturing. It discusses the typical stages of automotive product development including conceptual design, clay modeling, product and process development, production tooling, process validation, and production. It also describes approaches used in high volume automotive manufacturing (HVAM) and low volume automotive manufacturing (LVAM), including platform commonization, set-based concurrent engineering, and customization concepts.
The document discusses software development in the automotive industry. It notes that automotive software is becoming increasingly complex, with modern vehicles containing over 100 million lines of code. The architecture of automotive software is also becoming more distributed across different vehicle systems. The document argues that future development will require improved collaboration across organizations involving thousands of people. It examines different organizational models and tooling approaches to support collaborative development at different levels, from individual users and projects to the enterprise level.
130226 open innovation in additive manufacturing v3dajkersten
1) Additive Industries will support companies to design for additive manufacturing and establish a shared additive manufacturing lab (AddLab) to allow companies to experiment with the technology.
2) By pooling volumes in high-tech applications, Additive Industries aims to justify investment in industrial-grade additive manufacturing equipment for printing functional metal and ceramic parts at larger volumes and with higher precision.
3) Additive Industries plans to develop as an OEM of dedicated additive manufacturing equipment and systems, and involve the regional supply base in co-developing and manufacturing the new equipment.
This document discusses additive manufacturing (AM) and its potential applications in the maritime and oil & gas industries. It provides an overview of important AM processes such as binder jetting, material jetting, powder bed fusion, sheet lamination, vat photopolymerization, and direct energy deposition. While AM currently only accounts for about 5% of these industries, its use is anticipated to rapidly expand. The document outlines both limiting and encouraging factors for AM adoption. It then presents a Bayesian network approach that can be used to assess risks to manufacturers and end users from AM part variability and lack of standards/regulations. Case studies demonstrate how this approach can evaluate risks from an original equipment manufacturer or end user perspective.
ISCRAM 2013: Building robust supply networks for effective and efficient disa...ISCRAM Events
The document discusses building robust supply networks for effective disaster response. It proposes an iterative dynamic approach for decision support involving problem structuring, optimization to generate alternatives, dynamic scenario construction to consider uncertainties, and evaluation. As a use case, it applies the approach to optimize locations for health care centers in Haiti after the 2010 earthquake. The approach aims to identify alternatives that perform relatively well across scenarios to create flexible, effective and efficient supply networks.
Product Development Project - project management introductionShaun West
This short presentation provides a simple introduction to project management. It is tool-light and visual heavy. This is material that is used to introduce project management in innovation projects at Lucerne University of Applied Sciences and Arts.
There is a book and a flyer that support this presentation.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document discusses the implementation of design for manufacturing (DFM) principles in mechanical engineering education. It provides examples of applying DFM to dimensional tolerancing using standards to ensure functionality and manufacturability. Advanced computer technologies like CAD/CAM and AI are also discussed in improving the link between design and manufacturing to better implement DFM concepts. The authors aim to integrate DFM training earlier in the manufacturing engineering curriculum.
Thyssenkrupp Tallent - Evolutionary Design in Chassis TechnologyAltair ProductDesign
This paper from Thyssenkrupp Tallent and Altair ProductDesign details the use of the eDICT process for the design of sheet metal chassis components. eDICT (evolutionary design in chassis technology) is an innovative structured process flow for the design of optimal structures. On recent projects eDICT has produced 25% mass reductions compared to the current series design. eDICT is also able to reduce development times and resource with an efficient solution production right from the outset.
Procedia social and behavioral sciences volume 109 issue 2014 [doi 10.1016%...Ria Fausika
The document discusses a quantitative research study on the use of business process management principles in Slovak enterprises. The study found that:
- Most enterprises were small-medium sized and produced in a job-order or batch style rather than mass production.
- Traditional functional management was more common than process management. The most used tools were activity-based costing and financial analysis, while newer tools like balanced scorecard were not used.
- Process management principles were not fully and systematically applied - activities were sometimes customer-oriented but barriers to knowledge sharing remained. Process owners and team-based work were limited.
- While some enterprises had defined or managed their processes, many others took an accidental or repeated approach rather
1. The document provides an overview of Gestamp Group's 2014 sustainability report. It discusses Gestamp's financial results, growth, investments, innovation initiatives, environmental commitments, and contributions to local communities.
2. Key highlights include 6.9% revenue growth to €6,256 million, 7.8% EBITDA growth to €656 million, and expanding presence in growing markets like China and North America.
3. Gestamp also discusses training initiatives, new facilities, partnerships with clients, and goals to continue innovation and sustainable growth.
Gestamp is a leading supplier of metal automobile components to major vehicle manufacturers worldwide. In 2014, Gestamp saw good economic results with sales totaling 6.256 billion euros and 32,331 employees across 93 manufacturing facilities in 20 countries. Some highlights included opening a new prototype design and testing plant in Germany, establishing closer relationships with clients through co-development of parts, and beginning construction of the Gestamp Technology Institute to provide training in new automotive technologies. Going forward, Gestamp will continue innovating its product offerings and globalizing its operations.
The document discusses steel innovations in hot stamping. It provides a history of hot stamping innovation from 1974 to present day, including the development of the first hot stamping line and products. It describes how Gestamp has 10 R&D centers globally that drive innovation. It also discusses 5 technologies Gestamp has developed that have yielded 4 innovative products: 1) a new zinc hot stamping process, 2) remote laser seam welding, 3) in-die soft zones, 4) flex laser soft zones, and 5) 3D laser cladding. Examples are given of how these technologies have been applied to products like front rails, rear rails, and B-pillars to improve performance and reduce weight.
The document provides an overview of the development of the all-new 2016 Honda Civic. Key points include:
- The development goal was to create the best C-segment vehicle in the world.
- It had a global development team and is produced in 10 plants worldwide.
- The package aims to be low and wide with best-in-class interior volume.
- There are two new powertrains - a 1.5L turbo and 2.0L engine - that maximize performance and efficiency.
- Significant work went into improving crashworthiness, handling, noise reduction and fuel economy through changes to the body construction, chassis, and safety structures.
Thermostamping simulation for woven thermoplastic composites (PA) with HyperFormAltair
The thermostamping process of thermoplastic composites can be analyzed with simulation software. In addition to the optimization that can be brought to process (defects, raw material quantity …), the main interest is to integrate results from process into the performance simulation. This article presents an approach to simulate thermostamping of thermoplastic composites (PA) with HyperForm.
The material law is identified from Bias test trials, then, the simulation is performed by HyperForm with the solver Radioss or Ls-Dyna. Fiber orientations (for non-linear anisotropic behavior) and defects (global wrinkles, and wrinkles in the thickness, area with failure risk, thickness variation…) are identified and mapped on structural mesh for mechanical simulation.
Based on this approach, several test/simulation comparisons were performed on both static and dynamic. They demonstrate the necessity of considering the process phase, especially for complex geometries.
Regarding advanced application for such simulation tool: Faurecia Automotive Exterior is developing technologies to produce one-shot visible parts (CFRT thermostamping + overmolding injection in one step). This case study is the most challenging application we are working on. Combining thermostamping simulation and one-shot process brings benefits to both sides thanks to cross results on complex application.
Globaly, to improve the prediction of this simulation tool, next steps are the computation of local density; the consideration of thermal exchanges with the mold during the production process; the modelization improvement of boundary conditions during process (woven holding …, frames…).
Speakers
Guillaume CHAMBON, Product Research & Advanced Simulation Manager, FAURECIA Automotive Exterior
Cae technologies for efficient vibro acoustic vehicleCec deMille
This document discusses how computer-aided engineering (CAE) methods like the finite element method are increasingly being used in the automotive industry to predict vehicle performance like noise and vibration levels. This allows vehicle designs to be tested virtually through simulations before building physical prototypes, reducing costs and shortening development time. The document focuses on using CAE techniques like wave-based substructuring and modal modification to enable more efficient vehicle redesign iterations and predictions of how panel thickness and damping variations affect noise and vibration levels. It also discusses how these faster deterministic methods can speed up non-deterministic analyses that assess how uncertainty in panel properties impacts vehicle performance.
Development of new products is extremely essential for the success and smooth running of every industry. Companies have to constantly inject innovations and design efforts to make the design processes easy and to attract consumers in a constantly in a evolving and highly competitive market with best quality . Keeping ahead of the competition by bringing new and exciting products to market fast, and at the necessary level of quality, presents a major engineering challenge. A new casting bracket in place of old stamping brackets in snowmobile chassis development process is described, which introduces advanced FEM and Optimization technology into the concept development phase. Detailed predictions of interacting parts in a mechanism assembly are made possible through use of value engineering based process and material selection and advanced simulation technology. Design optimization is then employed using the modeling as a virtual testing ground for design variants. The approach provides clear design direction and helps to improve performance and reduce the unnecessary welding efforts of bracket manufacturing. Design is an intelligent activity that begins with design requirements and ends with a product description. Using Altair Optistruct was able to significantly reduce design time by sub modeling with structural optimization. The resultant casting bracket design showed superior performance characteristics. And finely the manufacturer had to put less efforts in stamping and part welding , which reduced the manufacturing time and cost also.
Testing and Verification through Virtual Product ModelsGergely Hidas
Modern engineering design and simulation software (CAD, CAM, CAE) allow for extensive use of virtual prototypes along the product and production development reducing the cost and time of physical prototyping. These software technologies in turn has also important role in testing and verification against the various regulations. This paper reviews the recent progress of virtual verification (ViVer) technology and the underlying emerging concepts with special focus on the role of certification service providers. The paper covers multiple aspects of the ViVer concept serving as a conceptual guideline for the development of
virtual verification systems of the future.
Sirin et al A Model Identity Card to Support Simulation Model Development Pro...goknursirin
This document proposes a Model Identity Card (MIC) to help classify simulation models and support the simulation model development process in a collaborative multidisciplinary design environment. It aims to reduce inconsistencies, ambiguity, and rework between different domain experts and simulation model providers by establishing a common vocabulary and formalizing the model design phase early in the development process. The MIC would provide concise specifications for simulation models, including input/output parameters, method, and usage to improve knowledge sharing. An industrial case study is used to validate how the MIC and integrated model design phase could be implemented.
Concept development using Optimization, DFM & CAE - In DFSS Waynsahay
This document summarizes the optimization of powertrain components for an automotive vehicle development program using Design for Six Sigma (DFSS) methodology. It describes defining the optimization goals of reducing weight and increasing frequency while maintaining strength. Topology optimization was performed in Optistruct to generate optimized designs. Multiple concepts were evaluated based on design for manufacturability criteria, with the optimal concept selected. Finite element analysis in ANSYS validated the design meets the goals of over 600Hz frequency and a safety factor over 1.5 for strength. Customer feedback through an engagement performance assessment validated the optimized design satisfied requirements.
This document discusses how digital manufacturing tools within a PLM (product lifecycle management) environment can be used to analyze complex manufacturing scenarios for the aerospace industry. Specifically, it describes a case study of using CATIA, DELMIA, and QUEST software to simulate the assembly process of an airplane battery system. Through virtual prototyping, layout planning, ergonomic analysis, and factory flow simulation, the tools helped optimize the design of a support structure and riveting tool, arrange workstations, and evaluate the manufacturing process. The results demonstrated how digital manufacturing can build expertise, improve processes, and support decision making for aerospace production.
IRJET- Integrated Optimization of Multi-Period Supply Chains and Commonality ...IRJET Journal
This document discusses integrating optimization of multi-period supply chains with commonality decisions at the modular level across product families. It presents a mathematical model developed using integer linear programming to minimize total supply chain cost. The model determines the level of commonality, selected technology, and any common module inventory at each period. The results show that the optimal commonality decision depends on factors like the cost ratio of high-end to variant modules, quantity discount rates, and inventory costs. At low cost ratios, inventory dominates the decision, while at high ratios the discount rate is more influential.
The StreetScooter initiative aims to create affordable electric vehicles through collaboration between suppliers rather than a traditional OEM model. A network of over 50 small German suppliers are developing the vehicle using PTC's PLM tools to integrate their work. The project aims to deliver prototypes in 2011 and hopes to have mass-market EVs on German roads within the decade. PLM is critical to managing the complexity of collaborating with suppliers and designing an integrated electric vehicle.
This document describes a last mile delivery optimization project that aims to solve the vehicle routing problem and traveling salesperson problem. It does this by creating an algorithm that refers to an orders database and distributes the orders among available delivery vehicles to minimize total distance traveled. The algorithm uses concepts like distance matrix, resource allocation, and navigation APIs. It was created using technologies like Android Studio, OR Tools library, Google Maps API, and Firebase for authentication and data storage. The goal is to optimize delivery routes and provide an Android app for delivery personnel.
Hypercar Inc is developing a lightweight, high-volume production vehicle using composites for structural elements to gain advantages in performance and cost. Their showcase vehicle, the Revolution SUV, achieves 99 mpg equivalence using a composite body/chassis structure and hydrogen fuel cell. Their clean sheet approach and composites-intensive design has simplified production processes to make the vehicle affordable while meeting requirements for safety, efficiency, and emissions.
This document provides a summary of Aproop Ponnada's professional development activities from November 2016 to July 2017. It lists various online courses taken on topics like supply chain management, energy efficiency, and financial decision-making. It also outlines presentations, seminars, and conferences attended on emerging technologies, renewable energy trends, and challenges facing the maritime industry. The document demonstrates a focus on expanding knowledge of engineering, project management, and industry developments over the reporting period.
Shell is using business simulation software to improve its front-end planning processes for oil and gas projects. The software allows for faster modeling and scenario analysis compared to traditional spreadsheet methods. It also facilitates integrative planning across subsurface, surface, and economic domains. The new approach aims to reduce time spent on opportunity evaluations and planning while maintaining understanding of complex projects. Shell managers emphasize that successful adoption requires changes to workflows and thinking, not just the software itself.
SGI HPC Systems Help Fuel Manufacturing Rebirth 2015Josh Goergen
This document discusses how high performance computing (HPC) systems are helping fuel the resurgence of manufacturing. It outlines the ongoing challenges manufacturers face including stringent regulations, cost pressures, and intense global competition. SGI provides HPC solutions like the UV, Rackable, and ICE X clusters along with storage solutions to help manufacturers address these challenges and meet goals like faster time to market. Case studies describe how SGI systems helped companies like SL-Rasch perform complex simulations of umbrella structures and Škoda accelerate product development.
Transformation based monetary cost optimizations for workflows in the cloudNexgen Technology
Ecruitment Solutions (ECS) is one of the leading Delhi based Software Development & HR Consulting Firm, which is assessed at the level of ISO 9001:2008 standard. ECS offers an awesome project and product based solutions to many customers around the globe.
In addition, ECS has also widened its wings by the way consummating academic projects especially for the final year professional degree students in India. ECS consist of a technical team that has solved many IEEE papers and delivered world-class solutions .
Multiagent multiobjective interaction game system for service provisoning veh...redpel dot com
Multiagent multiobjective interaction game system for service provisoning vehicular cloud
for more ieee paper / full abstract / implementation , just visit www.redpel.com
This document discusses how engineering simulation is playing a critical role in driving innovation in the automotive industry. It covers how simulation is being used across various areas like body and chassis design, powertrains, electric vehicles, and autonomous systems to reduce costs and development time while improving quality, safety, and reliability. Specific companies like DENSO, ZF-TRW, and Toyota are highlighted for how they are leveraging simulation throughout their design and testing processes. The automotive industry's increasing reliance on simulation is seen as integral to addressing challenges like fuel efficiency standards while developing new technologies.
This document summarizes research on the potential benefits of implementing 3D parametric modeling in precast concrete construction. Leading precast concrete companies have invested in developing such modeling software solutions with the goal of improving productivity throughout the precast business process. Initial experiences are beginning to confirm expectations of productivity gains and error reduction. This paper provides benchmarks for quantifying various direct and indirect benefits that have been identified, including estimated economic benefits for a large precast company over four years of adoption. It outlines how 3D modeling can automate routine tasks, apply standardized details, and maintain consistency through parametric relationships to improve engineering productivity.
Similar to Cloud Based HPC for Innovative Virtual Prototyping Methodology Automotive Applications (20)
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competitiveness: reducing the development period, shortening time to market, and improving quality at competitive
pricing.
2. Introduction
The Green Vehicle initiative is a major driver for the automotive industry to answer environmental requirements
and regulations. This challenge calls for disruptive innovation in vehicle design and materials. Steel remains the
main cost effective material for Body In White mass production for the foreseeable future. This challenge is a good
business opportunity for the emergence of new industry leaders like GESTAMP, who have developed a new grade
of steel called Press Hardening with the associated manufacturing processes. It is one of the major innovations
successfully introduced to the market in answer to the weight reduction constraints of the vehicle with recognized
world-wide advantages.
However, the industrialization and the customization of this innovation also requires new design and
development processes in order to enable engineering & business trade-offs between conflicting requirements such
as weight and cost reduction, passive safety enhancement and manufacturing constraints.
Business scale-up is one of the main competitiveness factors. This required mastering an efficient and flexible
process for customization and localization.
Divergence of the models are inherent phenomena with the current silo approach due to the complexity of the
interactions; CAD-CAE, CAE-CAE. To answer this challenge, we propose a holistic solution using Virtual
Prototyping, several full vehicle simulation models all based on one unique central Body In White subsystem,
namely the Single Core Model approach. This disruptive approach will enable to support collaborative decision
making process during the Product Development phase; including engineering stakeholders from different
disciplines and regulations requirements: Crash & Safety and Static Stiffness. Figure 1 illustrates the drawbacks of
the traditional silo approach and the single Core Model concept.
Fig. 1. Silo Approach and Single Core Model advantages.
Single Core Modelling will reduce the CAD-CAE synchronization efforts, and eliminate the conversion
& consolidation between different CAE-CAE Models for Design reviews and trade-offs. Today’s approach is a very
time-consuming task and a source of errors. The Single Core Model approach will replace human efforts by
computing resources on low value tasks. This approach will enable a reduction in the effort required for Full Vehicle
Model handling directly related to the number applications involved. Thus, it will enable better use of engineering
expertise to improve product quality.
This breakthrough will help to take into account the regionalization and customization constraints upfront, to
avoid last minute engineering design changes, and should result in a shorter ramp-up phase and improved
competitiveness.
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3. User requirements
Gestamp’s user requirements are, on one hand to improve the handling, the interaction and the lead time of full
vehicle numerical models used by several disciplines, and, on the other, to evaluate the use of an HPC cloud to run
Crash, Static and NVH Finite Element simulations. Based on these needs, we defined the performance and
validation criteria for the experiment. Table 1 illustrates typical Key Performance Indicators for targeted
performance of the Single Core Model Solution implementation in an industrial context. The HPC Cloud is an
excellent opportunity, but software access, adaptation and upgrades will be needed. In order to reach these
performance targets in particular a sustained, heavily repetitive iterative mode needs to be supported, which should
reach the target of a maximum of 4 hours per iteration.
3.1. Single Core Model Concept
Figure 2 illustrates the traditional generic organization with non-shared includes between models of different
applications and load cases which require updating all includes separately in each model. Hence, the same task
would need to be repeated several times, which leads to possible divergence errors in the prepared model and
especially to a waste of time. This is exactly what the Single Core Approach is able to avoid. Compared to the
previous structure, with the Single Core Model, detailed in Figure 3, each model keeps the master file with the
include organization. One of the differences is that at least one include (the Body In White include) is shared by all
models. Besides this update, all includes and all models parameters are fitted in order to accept BIW updates without
needing to open every model to make the changes.
Fig. 2. Generic model structure vs. Single Core structure.
3.2. Enabling software for cloud
Static and NVH models are usually based on a coarse model. Moving to the Single Core model, the model sizes
increase in order to unify the model representation of the different domains (Crash, Static and NVH); thus requiring
higher CPU resources. The HPC-Cloud enables the access to necessary computing resources to meet these business
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requirements. However, the current NVH solver performance needs to be improved to handle larger models in order
to leverage the benefits of the Single Core Model methodology. The Cloud based HPC architecture requires a highly
scalable solver to allow efficient software use of the resources and to deliver results quickly, it also requires high
transfer volumes for the simulation data.
Three kinds of performance are targeted: CPU, Memory and IO optimization to avoid read/write of over-sized
files. Based on that adaptation, enhancement and upgrade the overall solver performance improvements enable the
experiment to reach the performance metric as defined in Table 1.
Technical environment validation (HPC Cloud)
Jobs have been performed on extreme factory HPC cloud with BULL clusters. Processing was performed as
follows:
Data upload
Job submission
Run control (Info/Warning/Error messages)
Data download
As this procedure is now well known, it will be possible to use such remote cluster services as a production tool.
Remote visualization was not available due to Gestamp IT security recommendations: opening network ports is
not compliant with internal security rules, especially with ports ranges involved.
3.3. Baseline Body In White definition
The start of a co-development project is in most cases linked to the reception of OEM shared data. This data can
be provided under different format types, from the simplest with only Bill Of Material and CAD data, to the richest
with a full vehicle crash simulation model with CAD data. The shared concept always represents the starting point
of the study, the solution optimized by the OEM that is usually validated in all load cases. The goal of the Gestamp
optimization process consists in the development of an alternative concept that should be lighter and more cost-
-effective than the described baseline, but achieving the same performance requirements.
Pillars and rails depictured in Figure 4 represent the structural parts that are the most commonly studied in our
Co-Development projects. The yellow front rails are the most important load carrying set of parts for frontal crash
impact, the clear and dark blue pillars with purple rocker for lateral crash and the orange rear rails for rear crash
impact.
Thus, in order to define a meaningful baseline for this business case, it has been chosen to create a Body In White
reference concept that would match the average employed Design configuration (thickness, material and design) that
have been observed during a benchmark of the typical OEM Body In White in year 2014.
Fig. 3. GLAB10 Body In White main structural parts.
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The result of this benchmark can be observed in Figure 4. Most of the structural parts of the Body In White use
cold stamped steel with an Ultimate Tensile Strength (UTS) between 400 MPa and 1200 MPa. It should be noted
that that Press Hardened Steel (in Red) with UTS of 1500 MPa is already used by several OEMs, especially in A-,
B- and C-Pillar area.
Fig. 4. GLAB10 Body In White baseline with associated material grade strength.
3.4. Baseline BIW performance investigation
To demonstrate the Single Core Model effectiveness in our business case, it has been decided to use four
applications that are commonly used for Body In White validation and that also represent the simulation area of Co-
-Development projects:
Crash domain – USNCAP Side Impact MDB 55 kph (Full Vehicle)
Crash domain – USNCAP Frontal Impact 0° 56 kph (Full Vehicle)
Static Domain – Stiffness Analysis (Body In White)
NVH Domain – Modal Analysis (Body In White)
Fig. 5. Applications used as examples in the business case – load case details.
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3.5. Final Gestamp BIW lightweight validated concept through BIW optimization
Starting from the baseline Single Core Model, the latest innovations in terms of material and processes have been
implemented into the GLAB10 Body In White. Technologies such as Press Hardening with tailored properties also
called Soft Zones (applied on B-Pillar, Front Rails Inner & Outer), Tailor Welded Blanks Press Hardening
USIBOR1500/DUCTIBOR500 (applied on Rear Rails) and Press Hardening with patch (applied on B-Pillar) all
participate in the lightweight design of this optimized Body In White (see material grade distribution on Figure 7).
Fig. 6. GLAB10 Body In White optimization with associated material grade strength.
With many years of experience and know-how with the manufacturing process of hot stamped steel, Gestamp is
one of the pioneers in this manufacturing process. Significant investments have been made over the past years aimed
at developing and extending this technology around the world, enabling them to meet a growing demand from
automobile manufacturers for all Body In White products. As a consequence of that, Gestamp became the world's
largest supplier of hot-stamping parts.
Through the use of this know how in terms of hot stamping products combined with ESI’s Co-Development
project experiences, we were able to put the right material with corresponding thickness at the right place and thus to
significantly reduce the thicknesses of most of the structural parts, by achieving similar performances as the
reference in both crash requirements. The global Body In White weight for the baseline is 322 kg. The use of Press
Hardened Steel enables to come down to a weight of 290 kg, about 10% weight saving on the whole Body In White.
Finally, the Single Core approach combined with HPC cloud solution enables us to achieve lightweight Press
Hardened optimized Body In White validated in four automotive simulation domains: frontal crash, side crash, static
stiffness and NVH. The optimization loops cycles to reach similar performances with our leading technology,
starting from a conventional BIW, have been considerably accelerated through the use of a single Body In White,
the heart of the Single Core Models.
4. Achievements
4.1. Simulation results
The overall NVH improvement of the full automotive Body-in-White showed a factor of 70% time reduction for
the industrial model running on 8 cores.
This performance will enable us to run the case in an industrial context. It means it could run in less than 1 hour
by allocating 16 Cores. HPC on the cloud will offer these resources flexibly and at affordable cost.
This allows to speed up the design changes verification and validation in order to meet the business requirements.
No further scalability tests were tried with more cores as the dimensioning factor is the memory available for the
run (2 × 128 GB).
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Fig. 7. NVH improvement.
4.2. Cloud licensing
BULL is the hardware provider with its extreme factory service. An end user will use extreme factory to run ESI
Group software. The new system for managing the license will support individualization of users. The different
companies will be managed with their own rights.
The following image shows globally how the system will work:
The user (company) buys a license from ESI and receives an identification key. This key will be used to identify
the user when he runs a simulation on extreme factory.
The scope of the prototype concerns the usage of this license bought by a client. The purchasing process will not
be covered here.
The following lines describe the different steps that the system will follow to process the simulation in the cloud:
1. The user connects to extreme factory to run ESI solver, then he will give his identification key as one of the
parameters of the run,
2. Once the runs begins, the application will check for the valid license:
a. An Https request is sent to the web service shown on the right side of the image above. Some information
will be provided with the request (Company name, user name, Identification key,…)
b. After checking the web service will send a reply. If the request is valid, the system will send the application
all the information needed for the run (dedicated license file).
c. Then the application will run the calculation on extreme factory.
The benefits will be measured in 2 distinct ways: First in terms of time saving thanks to the leverage of HPC
resources which enable the introduction of the Single Core Modelling as new collaborative engineering approach to
support Decision making process. A second natural benefit is the overall financial gain which can be obtained by
using the HPC Cloud just for the time necessary to complete the run, instead of provisioning hardware, staff and
licences for the whole year. Quantifying this financial benefit is dependent on overall simulation usage at the
customer site, and utilization ratios of its HPC infrastructures.
Single Core Modelling enables the handling of only one Body In White numerical model for several applications
(four applications in our example). Thus, once concepts of Body In White have to be updated, instead of
implementing the changes in the 4 former models, only one single core model needs to be modified. Time spent on
setting up and afterwards updating the model is then divided per 3.5 to 4 (see table below). Indeed, the simulation
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model setup for one application lasts approximately 50 hours, so 200 hours for all four applications. With the Single
Core Model, only 60 hours are needed to build up the Core Model (10 hours more due to the higher complexity of
the system). Moreover, as only one Core Model is used, the risk of having four divergent models, in terms of
concepts, is consequently reduced to zero. The compute cost difference between a classic crash model and one using
the Single Core approach is close to zero. Thanks to this innovative approach, the expert team involved in such tasks
will be able to spend more time in developing and optimizing lighter and better cost-effectives solutions for Body In
White.
Table 1. Typical benefits of Single Core Approach.
Time Saving/Single Core
Application dedicated models Single Core Model
Crash
Stiffnesss NVH Crash/Stiffness/NVH
Front Side
Set Up 50 h 50 h 50 h 50 h 60 h
Maintenance & Evolution 1–4 h 1–4 h 1–4 h 1–4 h 1–4 h
Model Convergence percentage for several test cases 30% 30% 30% 30% 100%
Synchronization CAD-CAE Need to do it 4 times 1 time
Synchronization CAE-CAE Need to do it 4 times 1 time
The use of HPC cloud services will also be a huge benefit for multi-site companies. Indeed, Gestamp R&D
Centers located in Paris (France), Luleå (Sweden) and Barcelona (Spain) increasingly needs to manage projects over
several locations. Consequently, HPC enables to access and share the data, to run simulations and to analyse the
results in all the relevant locations through a conventional web browser. In summary, this HPC cloud application
will enable a more efficient project handling by reducing data transfer time and by improving the communication
between the different stakeholders of a project.
5. Conclusion and perspectives
The use of HPC resources have allowed to run those four types of models with same sharp detail level linked to
Single Core modelling. Indeed, those four application fields demonstrated the efficiency of such an approach: model
build-up time has been divided by four; previous risk of divergences in the four models is now reduced to zero.
Thanks to this innovative approach, the expert team involved in such tasks will be able to spend more time in the
product optimization phase.
Using HPC cloud services will also be a huge benefit for multi-site companies. Indeed, Gestamp R&D Centers
increasingly need to manage projects over several locations. Consequently, HPC enables to access and share the
data, to run simulations and to analyze the results in all the relevant locations through a conventional web browser.
In summary, this HPC cloud application will enable a more efficient project management by reducing data transfer
time and by improving the communication between the different stakeholders of a project.
These positive conclusions will lead Gestamp to further develop this Single Core approach on GLAB10
demonstrator, combined with HPC Cloud services as driving innovation for the development and the optimization of
lighter and more cost-effective solutions for Body In White.
As a first output this experiment has helped to validate the specifications and the 100% Minimum Requirements
for the platform needed to provide the expected services. The diagram below gives an overview of the main modules
and workflow.
This experiment showed that the HPC Cloud benefits are not limited to flexible access to HPC resources, and
providing flexible services at an affordable, competitive cost.
In fact, the HPC-Cloud will most likely be a key enabler or accelerator for disruptive changes with a deep impact
on a company’s competitiveness. It will enable the upgrade of a company’s overall Process & Methodology to
leverage the new potential for Virtual Prototyping.
The Fortissimo experiment was a typical example of this disruptive methodology. It showed how the HPC Cloud
enables efficient support for Gestamp specialization in their unique competence in the Hot Forming Value chain.
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The Single Core Model is a key enabler to capitalize on this competitive differentiator by scaling on the world-wide
market accounting for the local and regional market requirements.
The Fortissimo project helped ESI Group to validate an industrial service approach and to adapt the methodology
for Gestamp’s specific business context.
In addition to the Product portfolio, this customized service will be available for the industry partners during the
deployment phase. It will enforce their smart specialization.
Cloud Based HPC lowers the barrier of the initial investment to implement the Virtual Prototyping methodology,
in particular for Mid-Caps, SME’s and also start-ups. This experiment gave good indications on how to the leverage
the current solution portfolio and Customers’ installed base needs for new methodologies. Figure 8 illustrates the
depth and breadth of the potential HPC-Cloud market for Virtual Prototyping.
Fig. 8. Virtual Prototyping – Cloud Based Platform.
Acknowledgements
Acknowledgement of EC funding: This project has received funding from the
European Union’s Horizon 2020 research and innovation programme under grant
agreement Fortissimo project n°609029 under the 7th
Framework Programme.
Disclaimer: The dissemination of results herein reflects only the author’s view
and the Commission is not responsible for any use that may be made of the
information it contains”.
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