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1 | hexagonmi.com/mscsoftware
ICME THE BACKBONE FOR
LIGHTWEIGHT VEHICLE DEVELOPMENT
Michela GIUGLIANO AURICCHIO
Business Development Manager EMEA
Materials & ICME CoE and Digital Enterprise Solutions
June 9th – Automotive Lightweight Materials Europe 2022
2 | hexagonmi.com/mscsoftware
Materials are at the heart of any
products and innovations
Artificial
intelligence
Cloud
Ecosystem
Enterprise
integration
Data
management
Design &
engineering
Production
Quality &
Metrology
Materials
&
ICME
A design only comes to life
when materials enter manufacturing
ICME: Integrated Computational Material Engineering
Materials Digitization
is in our DNA
Hexagon MI is a pioneer and leader in ICME,
materials digitization and digital transformation
by building convergence between the physical
and digital worlds throughout the entire process:
from concept to customer.
150+
developments per year
Over 650
customers worldwide
Satisfied customers:
95% renewal rate
PHYSICAL
VIRTUAL
#1 in ICME
Trusted Material
Data Management
Enriching CAE
Digital
Material Lab
Sustainability &
compliance
Connecting real
& virtual
4 | Hexagon Overview
Hexagon Materials solution to drive innovations across the product
lifecycle
ICME for Manufacturing
• Zero prototyping
• Defects, curing, forming, ..
• Additive manufacturing
Material development & testing
• New materials, sustainable materials
• Thermoplastic, thermoset, metals,
ceramics, coating, …
Material Data Management
• Single point of truth for material
• Traceability
• Efficiency
Material Cost
Processability &
Assembly
Function
integration
Mechanical
strength
Impact/Crash
Durability
Weight
Recyclability
Vibration
absorption
Predictivity & reliability
• Stiffness, strength, plasticity,..
• Creep, Vibration, Durability, ..
• As designed vs as-manufactured
Materials Intelligence
• Leverage AI, ML & materials modeling
• Material data enrichment
5 | Hexagon Overview
5
Accelerating material development, testing and understanding
• Model materials
• Analyze and investigate material properties
• Investigate material’s behavior and damage
mechanisms
• Account for variability and defects
• Innovate and tune material’s properties
• Optimize microstructure and manufacturing
SFRP
DFC
CFRP SMC
Foams
Rubber
Metals CMC
6 | Hexagon Overview
6
The Digital Material laboratory
Import or Design Solve Analyze Explore
CPU time: 2
minutes
CPU time: 2 minutes
Fast &
accurate
Multi -materials
& -physics
Better decisions
with additional
insights
7 | Hexagon Overview
7
Anticipating defects, reducing costs, enhancing quality
Digital transformation in materials’ manufacturing
• The local microstructure and defects can be assessed
• By simulation
• Directly from the machines (toolpath)
• By CT-Scans
• Some applications in the field of composites
• Residual stresses after thermoforming
• Curing of thermoset
• Additive manufacturing
• Effects of defects (wrinkles, voids, …)
Quality
Functionality
Productivity
Zero waste
Innovation
Virtual testing
Time to market
Manufacturing
Materials
Design As Designed
As Manufactured
8 | Hexagon Overview
8
Anticipating defects, reducing costs, enhancing quality
Digital transformation in materials’ manufacturing
• Interface with VG Studio from Volume Graphics to
account for the ply/fiber orientation, gaps, defects, …
• Perform FEA on the real microstructure combined with
advanced & accurate material models
As-manufactured part’s performance
Scan
Transfer & assign relevant
material model
Solve
Or 3rd party SW
9 | Hexagon Overview
9
Application to polymer & composite additive manufacturing
Manufacturing and anticipating defects
Digimat-AM is a process simulation software
dedicated to the additive manufacturing of plastics
and composite materials. It allows engineers to
predict warpage, residual stresses and material
performance based on the local temperature
history during the build process.
• FDM & SLS
• Warpage & thermal analyses
• Unfilled & reinforced materials
• Crystallinity
• Counterwarped shape
• Layer adhesion
• Support failure
• Automatic superimposition STL/toolpath
• Inherent strain & full thermomechanical solvers
Capabilities
Simulating the AM process aims at
printing right the first time!
10 | Hexagon Overview
10
Application to polymer & composite additive manufacturing
Designing reliable products
• Predictive simulations before print
• By accounting for the toolpath from the machine
• Accurate material cards including failure behavior
• Validate toolpath and material choices before print
11 | Hexagon Overview
11
Enriching FEA with advanced material information connected to manufacturing
Designing reliable products
Process
simulation
Design
Structural
simulation
Post-processing Pre-processing
Batch mode
to enrich structural input decks with
lower effort and automate workflows
Valve gate control
to manage gate sequencing
during fiber orientation
tensor estimation
Acknowledgement for the model
to CCSA/GMU and the FHWA
Fatigue post-processing
improved user experience with hot
spot detection, cut views and more
Advanced creep
with temperature and strain rate
dependent elasto-plastic model
Strain
Time
Multi-physics
Crash and NVH
Lifetime
Static
Unified
Data Source
Global
Accessibility
Highly
Secure
AI Oriented All-in-one
Platform
Full
Traceability
MaterialCenter
Supplier /
LIMS Data
Materials &
Lab
Manufacturing
& Methods
Physical & Virtual
Testing
CAD – Config
Storage, link to PLM
Design Values
Manufacturing Data
Capture & Cost
Eco-Design -
Compliance
Sustainability
Design &
Simulation
Single Source of Truth for Materials
13 | Hexagon Overview
13
Unlocking the power of materials data
Industry Context Challenges Innovative Solutions
• Design times shrink
• Increasing demand for accurate FEA
• High demand for accurate material cards
• Material data isn’t always available when
design work starts
• Material cards require a substantial amount
of material data
Leverage AI & ML to generate material data
• AI/ML only
• AI/ML + physics based meta-models
• AI/ML + virtual testing using ICME modeling solutions
Properties
Materials
Exp. test data
Properties
Materials
Fill in your Private DB Train AI/ML Engine
Exp. test data
Virtual data
Virtually Generate Material Data
Populate DB
Using MaterialCenter
• Structure, traceability
• Connect, reuse, collaborate
>> often Incomplete data sets
MISSING ELEMENT / DATA
External Databanks (optional)
Virtual
Real
Accuracy Level
14 | Hexagon Overview
14
Materials data enrichment: Fast, accurate and agile by combining artificial
intelligence and material modeling
Time saving
120,000 €
Cost saving
80 days
Material waste
27 kg
Energy
XXX
15 | Hexagon Overview
Air Intake
Bearing System
Electronic Connectors
Aircooler Brackets
Lower-Pillar
Oil Pan
Car Roof
FAN System
Engine Cover
Engine
Cooling Radiator
Seat
Pillar
Front-end
Pedal
Air Duct
Airbag Housings
Pedestrian
Protection
Viscous Fans
Side Impact
Pads
Engine Mount
Car Body
Oil Filter
Overmol
ded
Lightweighting with
no compromise of
safety & quality
17 | Hexagon Overview
17
Could we develop faster lightweight component at lower cost?
Using efficiently materials in part’s development
❑ Lightweight vs Performance
❑ Predictive simulation
❑ Anticipate manufacturing issues
❑ Quick decision
❑ Cost optimization
❑ Multiscale predictive FEA
❑ Account for local microstructure
induced by manufacturing
❑ Account for manufacturing defect
❑ Virtual prototyping
❑ Weight reduction (up to 40%)
❑ Reduce cost of changes by 70%
❑ Design to cost & to manufacturing
Industry needs Field of applications
SFRP
DFC
CFRP SMC
Foams
Rubber
Metals CMC
Productivity Cost savings Sustainability
Predictivity
Accuracy
What ICME enables
18 | Hexagon Overview
18
Suspension control arm strength
The Challenge MSC Simulation Solution Value Realized
• Three load cases tested
• Dry
• Conditioned
• Conditioned & restrained
• Digimat result showed correct
failure locations, isotropic did not
• Digimat showed average of ~6%
overestimation of force at failure
• Isotropic material properties
were not able to capture
failure locations
• Refinement of material, and
anisotropic modeling, are
investigated to improve FEA
accuracy
• Digimat creates the link between the
manufacturing process & the
structural analysis
• Fiber orientations are brought into
the anisotropic Digimat material
model and accounted for in the three
loading scenarios
19 | Hexagon Overview
19
Valeo engine cooling flap
The Challenge MSC Simulation Solution Value Realized
• On average, Digimat showed
much better correlation to
experimental results than the
isotropic assumption
• Mode shapes were also
noticeably different between the
two methodologies
• Modal analysis is needed on
the flaps of the engine cooling
system
• Eigenfrequencies and mode
shapes, calculated through
simulation, are then compared
to experimental
measurements
• Digimat created the link between the
manufacturing process and
structural simulation
• Digimat was compared to Valeo’s
isotropic assumption
Fan System
Flaps Shroud
Motor
Fan
Fiber Orientation Tensor
20 | Hexagon Overview
20
Ford Oil pan
The Challenge MSC Simulation Solution Value Realized
• Frequencies: Digimat shows
average improvement of 8% over
isotropic assumption
• Acceleration peaks: Digimat
shows average improvement of
43% over isotropic assumption
• NVH simulation accuracy
using standard approaches
may require corrective action,
potentially involving mass
increase, due to spatially
varying microstructure leading
to stiffness and damping
discrepancy
• Digimat provides the link between
the process simulation and the
structural simulation
• Digimat provides an anisotropic and
frequency dependent solution to
address Ford’s needs
Z
Experiment
Digimat
Isotropic
21 | Hexagon Overview
21
Volvo front end carrier
The Challenge MSC Simulation Solution Value Realized
• Superpositioned video of test vs.
FEA simulation is shown on left
• Force-displacement curve of FEA
with Digimat vs. experimental
tests is shown on top right
• Dynamic impact tests on the
front end carrier are vital to
determining a vehicles
crashworthiness
• Volvo was seeing issues with
their correlation when using
their conventional isotropic
material assumption
• Digimat was incorporated into their
workflow and used to connect the
manufacturing process with the
structural simulation
• Strain rate dependent material
model was calibrated and used to
perform correlation work on a front
end carrier
Volvo XC90 FEC
22 | Hexagon Overview
22
Dynamic Strength
The Challenge MSC Simulation Solution Value Realized
• Faurecia looking to capture three
significant events – rib buckling,
rib failure & failure evolution
• Only Digimat was able to capture
all three failure phenomena
accurately
• Dynamic testing is needed to
validate the metal-to-plastic
seat pan transition to
determine safety
• Faurecia was seeing issues
with their isotropic material
model & their knocked down
isotropic material model
• Digimat created the link between the
manufacturing process and
structural simulation
• Digimat was compared to isotropic
(ISO527) and knocked down
isotropic (ISO527 scaled) material
models
Event ISO 527 ISO 527
scaled
MMI / Digimat
Rib buckling - + +
Rib failure o - +
Failure evolution - - +
23 | Hexagon Overview
23
Automotive OEM inner seat part made of SMC material
The Challenge MSC Simulation Solution Value Realized
• Digimat simulation achieves
much better fit with respect to
test data for most load cases,
including head impact (puncture)
• Provides good indication of hot
spot localizations
• Material anisotropy, thus far,
considered as isotropic
• Failure initiation and damage
propagation
• Weld lines – weakest SMC
defect
• Rely on Digimat mean-field and
compression molding technology to
account for material anisotropy
• Use latest damage propagation laws
for discontinuous fibers
• Identify weld line locations and
account for weakness at structural
level with knock down factor
Test data
Digimat
24 | Hexagon Overview
Material eXchange
25 | Hexagon Overview
Building, Managing and Sharing Data is Challenging!
Conditions
Rays
Temperature
Moisture
Liquids
Salts Speed
Tension
Compression
Shear
Creep
High speed
Damping
Tests
Fatigue
Materials
Foams
Metals
Composites
Plastics
Special materials
Rubber
26 | Hexagon Overview
New grades in our Public Material database
+24% in one year!
27 World Materials Forum | 19 June 2021 | Closing Session: WMF Top 10 Technologies | Speaker: Ola Rollèn, Hexagon President and CEO
Thank you
27 | hexagonmi.com
HexagonMI
@HexagonMI
@hexagon_mi
Chat
+39 338 7219 336
Connect
www.linkedin.com/in/michela-giugliano-auricchio
michela.giuglianoauricchio@hexagon.com
Reach out

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ICME THE BACKBONE FOR LIGHTWEIGHT VEHICLE DEVELOPMENT

  • 1. 1 | hexagonmi.com/mscsoftware ICME THE BACKBONE FOR LIGHTWEIGHT VEHICLE DEVELOPMENT Michela GIUGLIANO AURICCHIO Business Development Manager EMEA Materials & ICME CoE and Digital Enterprise Solutions June 9th – Automotive Lightweight Materials Europe 2022
  • 2. 2 | hexagonmi.com/mscsoftware Materials are at the heart of any products and innovations Artificial intelligence Cloud Ecosystem Enterprise integration Data management Design & engineering Production Quality & Metrology Materials & ICME A design only comes to life when materials enter manufacturing ICME: Integrated Computational Material Engineering
  • 3. Materials Digitization is in our DNA Hexagon MI is a pioneer and leader in ICME, materials digitization and digital transformation by building convergence between the physical and digital worlds throughout the entire process: from concept to customer. 150+ developments per year Over 650 customers worldwide Satisfied customers: 95% renewal rate PHYSICAL VIRTUAL #1 in ICME Trusted Material Data Management Enriching CAE Digital Material Lab Sustainability & compliance Connecting real & virtual
  • 4. 4 | Hexagon Overview Hexagon Materials solution to drive innovations across the product lifecycle ICME for Manufacturing • Zero prototyping • Defects, curing, forming, .. • Additive manufacturing Material development & testing • New materials, sustainable materials • Thermoplastic, thermoset, metals, ceramics, coating, … Material Data Management • Single point of truth for material • Traceability • Efficiency Material Cost Processability & Assembly Function integration Mechanical strength Impact/Crash Durability Weight Recyclability Vibration absorption Predictivity & reliability • Stiffness, strength, plasticity,.. • Creep, Vibration, Durability, .. • As designed vs as-manufactured Materials Intelligence • Leverage AI, ML & materials modeling • Material data enrichment
  • 5. 5 | Hexagon Overview 5 Accelerating material development, testing and understanding • Model materials • Analyze and investigate material properties • Investigate material’s behavior and damage mechanisms • Account for variability and defects • Innovate and tune material’s properties • Optimize microstructure and manufacturing SFRP DFC CFRP SMC Foams Rubber Metals CMC
  • 6. 6 | Hexagon Overview 6 The Digital Material laboratory Import or Design Solve Analyze Explore CPU time: 2 minutes CPU time: 2 minutes Fast & accurate Multi -materials & -physics Better decisions with additional insights
  • 7. 7 | Hexagon Overview 7 Anticipating defects, reducing costs, enhancing quality Digital transformation in materials’ manufacturing • The local microstructure and defects can be assessed • By simulation • Directly from the machines (toolpath) • By CT-Scans • Some applications in the field of composites • Residual stresses after thermoforming • Curing of thermoset • Additive manufacturing • Effects of defects (wrinkles, voids, …) Quality Functionality Productivity Zero waste Innovation Virtual testing Time to market Manufacturing Materials Design As Designed As Manufactured
  • 8. 8 | Hexagon Overview 8 Anticipating defects, reducing costs, enhancing quality Digital transformation in materials’ manufacturing • Interface with VG Studio from Volume Graphics to account for the ply/fiber orientation, gaps, defects, … • Perform FEA on the real microstructure combined with advanced & accurate material models As-manufactured part’s performance Scan Transfer & assign relevant material model Solve Or 3rd party SW
  • 9. 9 | Hexagon Overview 9 Application to polymer & composite additive manufacturing Manufacturing and anticipating defects Digimat-AM is a process simulation software dedicated to the additive manufacturing of plastics and composite materials. It allows engineers to predict warpage, residual stresses and material performance based on the local temperature history during the build process. • FDM & SLS • Warpage & thermal analyses • Unfilled & reinforced materials • Crystallinity • Counterwarped shape • Layer adhesion • Support failure • Automatic superimposition STL/toolpath • Inherent strain & full thermomechanical solvers Capabilities Simulating the AM process aims at printing right the first time!
  • 10. 10 | Hexagon Overview 10 Application to polymer & composite additive manufacturing Designing reliable products • Predictive simulations before print • By accounting for the toolpath from the machine • Accurate material cards including failure behavior • Validate toolpath and material choices before print
  • 11. 11 | Hexagon Overview 11 Enriching FEA with advanced material information connected to manufacturing Designing reliable products Process simulation Design Structural simulation Post-processing Pre-processing Batch mode to enrich structural input decks with lower effort and automate workflows Valve gate control to manage gate sequencing during fiber orientation tensor estimation Acknowledgement for the model to CCSA/GMU and the FHWA Fatigue post-processing improved user experience with hot spot detection, cut views and more Advanced creep with temperature and strain rate dependent elasto-plastic model Strain Time Multi-physics Crash and NVH Lifetime Static
  • 12. Unified Data Source Global Accessibility Highly Secure AI Oriented All-in-one Platform Full Traceability MaterialCenter Supplier / LIMS Data Materials & Lab Manufacturing & Methods Physical & Virtual Testing CAD – Config Storage, link to PLM Design Values Manufacturing Data Capture & Cost Eco-Design - Compliance Sustainability Design & Simulation Single Source of Truth for Materials
  • 13. 13 | Hexagon Overview 13 Unlocking the power of materials data Industry Context Challenges Innovative Solutions • Design times shrink • Increasing demand for accurate FEA • High demand for accurate material cards • Material data isn’t always available when design work starts • Material cards require a substantial amount of material data Leverage AI & ML to generate material data • AI/ML only • AI/ML + physics based meta-models • AI/ML + virtual testing using ICME modeling solutions Properties Materials Exp. test data Properties Materials Fill in your Private DB Train AI/ML Engine Exp. test data Virtual data Virtually Generate Material Data Populate DB Using MaterialCenter • Structure, traceability • Connect, reuse, collaborate >> often Incomplete data sets MISSING ELEMENT / DATA External Databanks (optional) Virtual Real Accuracy Level
  • 14. 14 | Hexagon Overview 14 Materials data enrichment: Fast, accurate and agile by combining artificial intelligence and material modeling Time saving 120,000 € Cost saving 80 days Material waste 27 kg Energy XXX
  • 15. 15 | Hexagon Overview Air Intake Bearing System Electronic Connectors Aircooler Brackets Lower-Pillar Oil Pan Car Roof FAN System Engine Cover Engine Cooling Radiator Seat Pillar Front-end Pedal Air Duct Airbag Housings Pedestrian Protection Viscous Fans Side Impact Pads Engine Mount Car Body Oil Filter Overmol ded Lightweighting with no compromise of safety & quality
  • 16. 17 | Hexagon Overview 17 Could we develop faster lightweight component at lower cost? Using efficiently materials in part’s development ❑ Lightweight vs Performance ❑ Predictive simulation ❑ Anticipate manufacturing issues ❑ Quick decision ❑ Cost optimization ❑ Multiscale predictive FEA ❑ Account for local microstructure induced by manufacturing ❑ Account for manufacturing defect ❑ Virtual prototyping ❑ Weight reduction (up to 40%) ❑ Reduce cost of changes by 70% ❑ Design to cost & to manufacturing Industry needs Field of applications SFRP DFC CFRP SMC Foams Rubber Metals CMC Productivity Cost savings Sustainability Predictivity Accuracy What ICME enables
  • 17. 18 | Hexagon Overview 18 Suspension control arm strength The Challenge MSC Simulation Solution Value Realized • Three load cases tested • Dry • Conditioned • Conditioned & restrained • Digimat result showed correct failure locations, isotropic did not • Digimat showed average of ~6% overestimation of force at failure • Isotropic material properties were not able to capture failure locations • Refinement of material, and anisotropic modeling, are investigated to improve FEA accuracy • Digimat creates the link between the manufacturing process & the structural analysis • Fiber orientations are brought into the anisotropic Digimat material model and accounted for in the three loading scenarios
  • 18. 19 | Hexagon Overview 19 Valeo engine cooling flap The Challenge MSC Simulation Solution Value Realized • On average, Digimat showed much better correlation to experimental results than the isotropic assumption • Mode shapes were also noticeably different between the two methodologies • Modal analysis is needed on the flaps of the engine cooling system • Eigenfrequencies and mode shapes, calculated through simulation, are then compared to experimental measurements • Digimat created the link between the manufacturing process and structural simulation • Digimat was compared to Valeo’s isotropic assumption Fan System Flaps Shroud Motor Fan Fiber Orientation Tensor
  • 19. 20 | Hexagon Overview 20 Ford Oil pan The Challenge MSC Simulation Solution Value Realized • Frequencies: Digimat shows average improvement of 8% over isotropic assumption • Acceleration peaks: Digimat shows average improvement of 43% over isotropic assumption • NVH simulation accuracy using standard approaches may require corrective action, potentially involving mass increase, due to spatially varying microstructure leading to stiffness and damping discrepancy • Digimat provides the link between the process simulation and the structural simulation • Digimat provides an anisotropic and frequency dependent solution to address Ford’s needs Z Experiment Digimat Isotropic
  • 20. 21 | Hexagon Overview 21 Volvo front end carrier The Challenge MSC Simulation Solution Value Realized • Superpositioned video of test vs. FEA simulation is shown on left • Force-displacement curve of FEA with Digimat vs. experimental tests is shown on top right • Dynamic impact tests on the front end carrier are vital to determining a vehicles crashworthiness • Volvo was seeing issues with their correlation when using their conventional isotropic material assumption • Digimat was incorporated into their workflow and used to connect the manufacturing process with the structural simulation • Strain rate dependent material model was calibrated and used to perform correlation work on a front end carrier Volvo XC90 FEC
  • 21. 22 | Hexagon Overview 22 Dynamic Strength The Challenge MSC Simulation Solution Value Realized • Faurecia looking to capture three significant events – rib buckling, rib failure & failure evolution • Only Digimat was able to capture all three failure phenomena accurately • Dynamic testing is needed to validate the metal-to-plastic seat pan transition to determine safety • Faurecia was seeing issues with their isotropic material model & their knocked down isotropic material model • Digimat created the link between the manufacturing process and structural simulation • Digimat was compared to isotropic (ISO527) and knocked down isotropic (ISO527 scaled) material models Event ISO 527 ISO 527 scaled MMI / Digimat Rib buckling - + + Rib failure o - + Failure evolution - - +
  • 22. 23 | Hexagon Overview 23 Automotive OEM inner seat part made of SMC material The Challenge MSC Simulation Solution Value Realized • Digimat simulation achieves much better fit with respect to test data for most load cases, including head impact (puncture) • Provides good indication of hot spot localizations • Material anisotropy, thus far, considered as isotropic • Failure initiation and damage propagation • Weld lines – weakest SMC defect • Rely on Digimat mean-field and compression molding technology to account for material anisotropy • Use latest damage propagation laws for discontinuous fibers • Identify weld line locations and account for weakness at structural level with knock down factor Test data Digimat
  • 23. 24 | Hexagon Overview Material eXchange
  • 24. 25 | Hexagon Overview Building, Managing and Sharing Data is Challenging! Conditions Rays Temperature Moisture Liquids Salts Speed Tension Compression Shear Creep High speed Damping Tests Fatigue Materials Foams Metals Composites Plastics Special materials Rubber
  • 25. 26 | Hexagon Overview New grades in our Public Material database +24% in one year!
  • 26. 27 World Materials Forum | 19 June 2021 | Closing Session: WMF Top 10 Technologies | Speaker: Ola Rollèn, Hexagon President and CEO Thank you 27 | hexagonmi.com HexagonMI @HexagonMI @hexagon_mi Chat +39 338 7219 336 Connect www.linkedin.com/in/michela-giugliano-auricchio michela.giuglianoauricchio@hexagon.com Reach out