Technical perfection, automotive passion.
Modern Seat Development Process
in Faurecia supported
by Hyper Works products
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Marcin Debniak, Faurecia Poland R&D
European HyperWorks Technology Conference
Berlin, Germany
October 23-24, 2007
What is Faurecia
Technical perfection, automotive passion.
Faurecia is an expert in 6 major modules
Acoustic package
Door panel / Modules
Exhaust system
Instrument panel / Cockpit
Seating
Front end
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Faurecia basic key figures 2006
• Sales: Over 11.6 billion €
• R&D 5,2% of sales (610M€)
• Over 4000 engineers
Fürth
Hagenbach
Ingolstadt
Munich
Peine
Sassenburg
Scheuerfeld
Stadthagen
Technical perfection, automotive passion.
Korea
Shihwa
Sweden
Torsas
Poland
Grojec
• Listed on the Euronext
Paris - Eurolist
France
Spain
Quart
de Poblet
Shanghai
Japan
Germany
• Over 65,000 employees
world wide
• 28 R&D centers
China
ShinYokohama
Audincourt
Brières
Bavans
Beaulieu
Flers
Magny
Méru
Mouzon
Nogent/Ver.
Seloncourt
India
Pune
USA
Auburn Hills
Toledo
Troy
3
3
What Grojec is focus on
Technical perfection, automotive passion.
Car Seats
• One of six modules produced by Faurecia
• Very complex structure
• Up to 99 parts and 16 electrics engines
• Seat design takes into account numerous factors,
including safety, comfort, and the
standardization of parts that are not visible
and an extreme customization of appearance
• More and more customers requirements as well as
legal requirements
• Year by year number of seat features is permanently
increasing
• Up to 80% of design given by safety issues
• Comfort becomes more and more important
• Around 100 test before being assemble in vehicle
• New ideas and permanent innovation
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Faurecia R&D GROJEC
Technical perfection, automotive passion.
Why CAE Department in Grojec (Poland)?
• Biggest production plant in Poland (over 1500 employees)
• Good location, close to main strategic customers (France and
Germany) – mobility
GRÓJEC
• Great potential – good educated young staff
• Fast growing market
• Low Cost Country
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CAE GROJEC activity
Technical perfection, automotive passion.
• 28 Simulation Engineers
• Work on complete seats projects as well on single parts modifications and optimization on
following levels:
• Meshing
• Static and quasi-static calculations
• Dynamic calculations
• Optimization
• Used software: HyperWorks, ABAQUS and PAM-CRASH
• Support for Faurecia offices in Germany, France, China and USA
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CAE GROJEC
Technical perfection, automotive passion.
Altair Software used in Grojec:
HyperWorks
HyperMesh – pre-processing (meshing and model preparation)
HyperCrash – pre-processing (model preparation)
HyperGraph – pre-processing + post-processing
HyperView – post-processing (model evaluation and results …)
RADIOSS – explicit solver
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CAE GROJEC – HyperMesh support
Technical perfection, automotive passion.
Meshing – HypeMesh
Single parts (wires, tubes, metal parts etc.)
Assemblies
Mechanisms (solid meshing)
Complete seats
Car environment
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CAE GROJEC – HyperMesh support
Single parts
Assemblies
Mechanisms
Technical perfection, automotive passion.
• Welding and spot welds definition (up to 200 points)
• Pivots, screws , rivets
• Property definition (thickness, type of elements,
materials, etc)
• Contact definition
Complete seats
Car environment
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CAE GROJEC – HyperMesh support
Technical perfection, automotive passion.
Single parts
Assemblies
Mechanisms
Complete seats
Car environment
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CAE GROJEC – HyperMesh support
Technical perfection, automotive passion.
Single parts
Assemblies
Mechanisms
Complete seats
Car environment
•
•
•
•
Include files creations
Contact managements
Occupants
Boundary conditions and loads
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CAE GROJEC – HyperMesh support
Technical perfection, automotive passion.
Why HyperMesh?
• Simple and friendly user interface
• User defined applications – macros
• BOM (Bill Of Material)
• Compatible with most of CAD and FEA software
• CAD (Catia V5, Catia V4, Unigraphics)
• FEA (RADIOSS, ABAQUS, PAMCRASH, Ls-Dyna)
• Smart and powerful algorithm for shell and solid meshing (Batchmesher, HyperMorph)
• Very efficient in daily work, stable (especially ver. 7)
• Easy managing of big models (include manager, groups etc. )
• Good technical support (customization, trainings)
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CAE GROJEC – HyperCrash support
Technical perfection, automotive passion.
Why HyperCrash?
• Software available only for RADIOSS (well suited)
• Visually clear, smart and simple functions:
• Foam compression tool
• Easy and fast dummy positioning
• Seat belts generator
• Contact interfaces manager
• Penetrations and intersections checker
• Quality manager
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CAE GROJEC – Hyper View support
Technical perfection, automotive passion.
Why HyperView?
• One post processing tool for all codes
• Simple and user friendly interface
• Easy graph creation
• Possibility to compare crash- with
calculation results
• Simple and intuitive results visualization
• Macros and user defined functions
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CAE GROJEC – Radioss solver support
Technical perfection, automotive passion.
FEA explicit calculations using Altair Software - Radioss
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CAE GROJEC – Radioss solver support
ECE R94
E C E R 17
Dynamic Test
(Protection of the occupants in the event of
a frontal collision into a 40% barrier)
Technical perfection, automotive passion.
ECE R17
Dyna m ic Test
(Fron tal- and rear im pact )
Test wi thout Dumm y
Speed
= ca. 4 5 km /h
Deceleratio n
= 20 g for 30 ms
H eadr estraint M om ent T e st
Test with dummy (50%)
Speed = 56km/h
M om ents:
- Better part of:
M om ent about H -Point
H e adrest
= 373 Nm
= 373 Nm
-Dynamic tests
E C E R 17
ECE R14
Load Test (H -Po int)
Loads:
M o men t = 530 Nm
ECE R14
ECE R95
Dynamic Test
(Lateral collision)
ECE R16
Airbag deactivated
Dynamic Test
ECE R17
Dynamic Test
(Luggage Load Protection)
G
30
25
20
15
10
5
Two Types of Test Bodies
Weight = 18kg and 10kg
Speed = ca. 50km/h
Deceleration: acc. to crash corr.
EC E R 17
EC E R 25
H
B
C
D
E
A
I
F
0
20
40
Zeit in ms
60
80
Headrestraint Im pact Test
Impact Speed
Reduced m asse
max. decele ration
max. decele rations time
=
=
=
=
24,1km /h
6,8 kg
80 g
3m s
30
28
20
10
0
Test with EUROSID Dummy
(50% Dummy)
Speed
= 50 km/h
Deceleration
= according to the
mobile barrier
35
0
Test with dummy (50%)
Speed
= 50km/h
deceleration
= 26g - 32g
Verzögerung in g
Dynamic Test
95th percentil dummy
Pulse ECE R 16
50km/h
ECE R21
Test of the minimum radius
During the test, it is determined whether parts
within the impact zone used for reinforcement
may be displaced or protrude so as to increase
the hazards to passengers or the severity of
injuries.
Pelvic = 13500N
Torso body block = 13500N
Aditional: 20 x seat weight (if at least
1 Anchorage is at the seat)
Verzögerung in g
-Static and quasi-static tests
Belt anchorage 3 Point
0
20
40 50
6065
80
Zeit in ms
100
120
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CAE GROJEC – Radioss solver support
Technical perfection, automotive passion.
Dynamic tests:
- Frontal Collison
- Rear Collision
- Luggage Load Protection
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CAE GROJEC – Radioss solver support
Technical perfection, automotive passion.
Static (quasi static) tests:
- Seat Belt Anchorage
ECE R 14
- ISOFIX test
ECE R 14
-Static (quasi static) and dynamic customer defined tests, with all requested
configurations.
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CAE GROJEC – Radioss solver support
Technical perfection, automotive passion.
Acceptable results compared to reality. Convergence 75-90%
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CAE GROJEC – Radioss solver support
Technical perfection, automotive passion.
Test – calculation convergence: 92%
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CAE GROJEC – Radioss solver support
Technical perfection, automotive passion.
Why RADIOSS?
• Included in HyperWorks package
• Code very stabile regarding unexpected issues
• Work very well with big models (include structure, transform cards, C-Nodes, etc.)
• Proper material definitions for most of materials (i.e.. Foam)
• Able to work in DMP mode
• Efficient – calculation time
• Convergence with real test (75-92%)
• Used by our customers (Peugeot, Citroen, Ford, FIAT, etc.)
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CAE GROJEC
Technical perfection, automotive passion.
Conclusion!
Why we are using HyperWorks software?
•
•
•
•
One package for pre-, post-processing and explicit solver:
•
Simple
•
User friendly
•
Well prepared user interface
•
User defined functions and macros
•
Ready to develop
•
Open to customers suggestions and customization
•
V7 release very stable
HypeMesh – best tool in terms of meshing and model preparation (interface,
tools and graphic visualization)
HyperView – intuitive interface, powerful graphs , smart, fast, easy to customize, tpl
RAIDOSS – worldwide used by our customers, wide range of
posibilities (explicit, implicit), acceptable accuracy
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CAE GROJEC
Technical perfection, automotive passion.
Future view!
1.
2.
3.
4.
5.
6.
7.
8.
9.
Strong collaboration is expected between Faurecia and Altair
Radioss explicit evaluation – accuracy 90-95%
Implementing Radioss as a main calculation code
Dummy improvements (rigid, deformable)
Sixth stars and Radioss calculation – whiplash methodology
Implementing Radios implicit as a stabile solution for qusi-static calculation
Implementation more and more of Optistruct in seat development
BatchMesher evaluation
Stabilization of Hyper Works v8 on Linux platform
Technical perfection,
automotive passion.
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European HyperWorks Technology Conference,
Germany, Berlin 23-24 October
Technical perfection, automotive passion.
Thank You
For attention !
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