7th E-ATC • Munich 24 June 2014

Matthieu Debray

Efficient Pre/Post operations at Faurecia Seating

with Hyperworks products

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Agenda

Faurecia

FEA @ Faurecia automotive seating

Faurecia / Altair cooperation

Customization Basic examples

Customization Advanced examples

FEA reports

Q&A

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Faurecia

Faurecia is Tier1 automotive supplier split in 4 business groups:

Padding

Headrest

Cover

Mechanism

s

Frames

97,500 employees

320 sites

34 countries

30 R&D centers

500 patents filed in

2012

2013 Key figures

Complete exhaust lines

Mufflers

Catalytic converters

Manifolds

Diesel particulate filter

Commercial vehicles

Cockpits

Acoustic

modules

Door

panels

Instrument

panels

Decoration

Center

consoles • Front End Modules (FEM)

• Front End Carriers / GOR

• Engine cooling systems

(ECS)

• Bumpers

• Trims & rocker panels

• Outside body panels

• A-class

• Semi-structural (closure)

• Structural

FAS FIS FECT FAE

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Simulation & Testing in Seating Division

One worldwide Team:

Test and FEA managed by the

same engineer

Standard tests methods WW

Standard FEA methods WW

FEA / Test lab FEA Test lab

Simulation Portfolio:

Mainly Safety & Regulations

~20 loadcases per project

>20 000 single iteration per year

worldwide

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Department Target

What we want:

Right @ 1st physical test FEA vs Tests > 85%

High Confidence in FEA Models

FEA roadmap to improve model quality

More & more detailed in models

Huge numbers of iterations

Fast parts replacement including connections

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Our métier

Seat versions

FEA iterations

Seat adjustment

Testing

configurations

Constraint : 20 loads cases per project

Safety

Test Dummy Position

Front Impact

R BFR 56 HIII 95 Mid/Mid

R BFR 56 HIII 95 Rm/Lm -> Rm/Mid

R BFR 56 HIII 50 Mid/Mid

N 56km/h HIII 95 Mid :: Mid/Lm F GR114627 F GR114496 F GR115460 F GR114897 F GR114890 F GR115470

N 56km/h HIII 50 Mid :: Mid/Lm F GR114625 F GR114708 F GR115462 F GR114900 F GR114941 F GR115475

Rear Impact

R ADAC HIII 95 Rm :: Mid/Rm

R ADAC HIII 50

N PHEV (32g) HIII 95 F GR115461 F GR115264 F GR115467 F GR115644 F GR115477

N PHEV HIII 50 F GR115641 F GR115643 F GR115480

Luggage Retention

DIN 75410 Part2 Rm -1 notch / Lm

Side Impact

Corridor 1

Corridor 3

Corridor 4 F GR114756 F GR114764 F GR114873 F GR114885 F GR114874

Corridor 5 F GR114759 F GR114772

Corridor 6

Regulation

Anch. Resistance

FMVSS/ECE curve Rm/Lm F GR115524 GR115713 F GR115722 F GR115525 F GR115900 F GR115720

FMVSS/ECE curve Fm/Um

FMVSS/ECE curve Mid/Mid F GR114750 GR115810 GR115811

M M

4W 6W 4W 6W

- - - --

- - - --

Manual / Power

Version

Easy Entry

Tablefold

4W 4W

P P

Memo

M P

- - - -

-

-

- -

-ODS ODS ODS- -

Design & Validate Seats fulfilling OEMS & Regulations Specs

Deliver Seat FEA Models to OEMS for Complete Vehicule Synthesis

Constraint : deliver in OEM Solver format

Since 2008 : One internal solver for all Operations + Conversions

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A nightmare for every pre-processor 7

FEA models architecture

2 levels of includes files

Each file can be called several time

handle by a Simulation Data Manager

One solver : fine but …

Hypermesh (up to v10) was not able to fully open/save without issues our models

Main root cause:

Load case diversity leads to define a complex architecture to be efficient

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FAS / Altair cooperation

2 years of cooperation with Altair development team to:

Open & save ls-dyna models while preserving include file structure

Develop management of isolated includes files

Improve efficiency : creation, review, modification of entities

This work have impacted / created:

LS-Dyna FAS Keywords support

Femzip support

Transformation manager

IDs manager

Review button

Properties area

Parameter browser

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Replace Part A by Part B : looks simple but …

Leads to update all Part B environment

Screws replacement

Laser welding update

Mapping of stamping process

Renumbering

Checks

…

Is Hypermesh “Core” able to do that in 5 clicks ?

NO !! Strongly linked to Enterprise methods

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Efficiency Tools

Scripting :

Tcl/Tk

XML

skills needed

No limit

Efficiency tools Altair solutions to reach the “5 Clicks” is to

develop métier tools :

Session replay :

TPL

.cmf

no developers skills

Limited possibilities

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Basic tools – HM: Renumber

need to repeat for all entities

Not follow internal rules

HM core FAS customization

All entities are renumbered in one click

Follow internal rules

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Basic tool – HV : LS-Dyna groups

Hyperview core : to display only the seat frame

FAS customization: only

@opening:

Groups per

includes

Groups per

materials

A% retrieved from

our matDB

Colors setup

Show/Hide

function for

groups on

contextual menu

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Advanced tool : Screws

« Old » Since 5 years

Tools:

Connectors feature in HM

Some minutes

1 Screw model =

9 parts , 6 sections & Material

3 entity sets, 2 coordinate system

1 preforce, 2 contacts

Time to put 1 screw manually = 20 min at least

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Advanced tool : Screws

In 2012, a tool has been created by Altair

Replace part use case: screw deletion + screw creation

Take head/nut & matrial

from database

Position the screw

Create washers

Calculate all diameter

and contact gap

Setup contact, sets

Create preforce

Put each parts in the

correct include

Respect the numbering

rules

14

From 20 min to <1min

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Advanced tool : Screws

Failure assessment:

HV/HG core : Very boring, several hours of post-treatment

Customization is mandatory script inside HV (internal development)

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Advanced tool : Laser welding line

Previously Today

Row of spotwelds

~3 mm mesh

Tied contact

Hexa elements

1.4 mm mesh

Transition zone

Coincident nodes

Connectors features

Some minutes

Tools:

By hand :

Several additional hours of mesh/pre

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Advanced tool : Laser welding line

Internal development done to automate / assist the FEA pilots

Use case: change the welding line shape

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Advanced tool : Laser welding line

For post processing, tool with user interaction that assist him to

assess the risk of failure.

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Automate FEA reports ?

Now:

Take CAD

Make FEA

Send report

Simulation

Data

Manager

Old approach

Dead document

Service provider

Time consuming

Take CAD

Make FEA

Analyse jobs

Capitalization

Data Mining

Stored automatically in DB

Key results

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Key results in SDM

Example: In rear crash, one of the key criterion is the maximum dynamic backrest angle.

Using customization in HV: the value is automatically stored in the SDM database

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Conclusion

Hypermesh is now a good pre-processor for LS-Dyna

But Core function of HW are “general” ones

Our game field

More & more complex models

Less & Less time to pre & post process them

Customization is mandatory

Tcl/Tk

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Q&A

Thanks for your attention.