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  • Fraunhofer SCAI SIDACT GmbH

    Robustness analysis Significant reduction of scatter occurrence

    Dominik Borsotto, Robin Strickstrock, Clemens A. Thole

    Dominik Borsotto

  • Fraunhofer SCAI SIDACT GmbH

    Agenda Background

    Methods

    Example

    Summary

  • Fraunhofer SCAI SIDACT GmbH

    "The model has been developed by The National Crash Analysis Center (NCAC) of The George Washington University under a contract with the FHWA and NHTSA of the US DOT http://www.ncac.gwu.edu/vml/models.html

    Background

    Simulation FE Model Sim.Result

    Crash Test Car Result

    Verification

  • Fraunhofer SCAI SIDACT GmbH

    "The model has been developed by The National Crash Analysis Center (NCAC) of The George Washington University under a contract with the FHWA and NHTSA of the US DOT http://www.ncac.gwu.edu/vml/models.html

    Background

    Simulation FE Model Sim.Result

    Crash Test Car Result

    Manufacturing

    tolerances

    Verification

  • Fraunhofer SCAI SIDACT GmbH

    "The model has been developed by The National Crash Analysis Center (NCAC) of The George Washington University under a contract with the FHWA and NHTSA of the US DOT http://www.ncac.gwu.edu/vml/models.html

    Background

    Simulation FE Model Sim.Result

    Crash Test Car Result

    Manufacturing

    tolerances

    Verification Emulate m.-

    tolerances

  • Fraunhofer SCAI SIDACT GmbH

    Background

    Contact / no contact 90 contact buckling

    Element failures friction

  • Fraunhofer SCAI SIDACT GmbH

    Background

    Approach:

    Part based thickness variation representing production tolerances

    Generate series of simulations

    Analyze all simulations at once

    Simulation i

    Statistics

    + PCA

    Fringeplots

    Scattermodes

    Standard

    Postprocessor

  • Fraunhofer SCAI SIDACT GmbH

    Managing variability can be important

    R. Brown, JLR at LS-Dyna conference 2013: Relating Scatter in Occupant Injury to Airbag Behavior

    Methods

  • Fraunhofer SCAI SIDACT GmbH

    Wind (environment)

    Shake (design)

    Variability may have a structure

    Methods

    R. Brown, JLR at LS-Dyna conference 2013: Relating Scatter in Occupant Injury to Airbag Behavior

  • Fraunhofer SCAI SIDACT GmbH

    X = X + *Mode 1 + *Mode 2 +..

    Mode 1 => horizontal scatter

    Mode 2 => vertical scatter

    Scatter mode representation

    Wind (environment)

    Shake (design)

    Methods

    R. Brown, JLR at LS-Dyna conference 2013: Relating Scatter in Occupant Injury to Airbag Behavior

  • Fraunhofer SCAI SIDACT GmbH

    Can rank by importance

    X = X + *Mode 1 + *Mode 2 +..

    Principal Component Analysis

    Wind (environment)

    Shake (design)

    Methods

    R. Brown, JLR at LS-Dyna conference 2013: Relating Scatter in Occupant Injury to Airbag Behavior

  • Fraunhofer SCAI SIDACT GmbH

    Example: Chevrolet Silverado

    Chevrolet Silverado

    "The model has been developed by The National Crash Analysis Center (NCAC) of The George Washington University under a contract with the FHWA and NHTSA of the US DOT http://www.ncac.gwu.edu/vml/models.html

    Model Chevrolet

    Silverado

    Year 2007

    Number of Parts 679

    Finite-Elements

    929,131

  • Fraunhofer SCAI SIDACT GmbH

    Maximum variation of node position in [mm]

    Example: Chevrolet Silverado

  • Fraunhofer SCAI SIDACT GmbH

    Example: Chevrolet Silverado

    Firewall mode information? X = X + *Mode 1 + *Mode 2 +

  • Fraunhofer SCAI SIDACT GmbH

    Example: Chevrolet Silverado

    1 dominating mode

  • Fraunhofer SCAI SIDACT GmbH

    Example: Chevrolet Silverado

    2 Cluster

  • Fraunhofer SCAI SIDACT GmbH

    Example: Chevrolet Silverado

    Dominating firewall scatter mode at power-brake

  • Fraunhofer SCAI SIDACT GmbH

    Example: Chevrolet Silverado

    Subtraction of power-brake

  • Fraunhofer SCAI SIDACT GmbH

    Example: Chevrolet Silverado

    Dominating firewall scatter mode at longitudinal rail

  • Fraunhofer SCAI SIDACT GmbH

    Subtraction of longitudinal rail

    Example: Chevrolet Silverado

  • Fraunhofer SCAI SIDACT GmbH

    Firewall scatter after design adaptations

    Example: Chevrolet Silverado

    Desig

    n a

    da

    pta

    tions

  • Fraunhofer SCAI SIDACT GmbH

    Summary

    Production tolerances can have a big impact on simulation results

    Easy emulation of thickness variation triggers model instabilities

    PCA based scatter modes reveal instabilities

    More robust design

  • Fraunhofer SCAI SIDACT GmbH

    Thank you for your attention!

    Dominik Borsotto

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