First European Hyperworks User Konferenz

First European Hyperworks User Konferenz 

HyperWorks as Central CAE 

Platform at HBPO


Network of Partners 

- 2 - 

33% 

33% 

33% 

HBPO / 23-09-2007 / RD / Robert Raulf 

Three equal partners: 

• Competence in light and car electronics 

- Headlamps, lighting technology 

- Car body electronics 

- Sensory and driver assistance systems 

• Competence in 

- Air conditioning 

- Engine cooling 

• Competence in 

- Plastics 

- Crash management 

- Pedestrian protection 

The copying, distribution and utilization of this document as w ell as the 

communication of its contents to others w ithout expressed authorization 

is prohibited. Offenders will be held liable for the payment of damages. 

All rights reserved in the event of the grant of a patent, utility model or 

ornamental design registration. 

value added 

turnover 2006: 571 mill. € 

employees: 840 

World-wide the only company which is 

exclusively specialized in design, 

development, assembly and logistics of 

integrated front-end modules.


Core Competencies for System Integration 

Program Management 

- 3 - 

Assembly Logistics 


� Program team 

� Quality management 

� Supplier management 

� Engineering change 

management 

� Factory planning & 

construction 

� Industrial engineering 

� Module assembly 

TIME TO MARKET 

� Inbound logistics 

� JIS logistics 

� Containers 






� Advanced engineering 

� Design engineering 

� Simulation & FEA 

� Prototypes & validation 

� Information logistics 

ORDER TO DELIVERY 

Development


Overview Simulation Tools 

Hypermesh V8.0 (Pre- 

Processing): 

• Input Interface 

Catia, UG, IGES, STEP, 

Nastran, Abaqus, Marc, 

Ansys, Radioss, PamCrash, 

LS-Dyna 

• Output Interface 

Nastran, Abaqus, Marc, 

Ansys, Radioss, PamCrash, 

LS-Dyna, IGES 

- 4 - 


HyperView V8.0 (Post- 

Processing): 

• Input Interface 

Nastran, Abaqus, Radioss, 

PamCrash, LS-Dyna,h3d 

• Output Interface 

MSExcell, h3d, avi, jpeg 

• Higlights: 

Templex, Animator Scripts 

Batch Mesher 






• Quality Index controlled auto 

mesher 

• Meshing tool for topological 

optimization 

Optistruct V8.0 

• Frequency response 

analysis 

• Eigenvalue analysis 

• Linear statics 

• Topological optimization 

• Topographical optimization 

• Parametric optimization 

• Frequency Response 

Optimization



Hyper Form (One Step 

Stamping Simulation) 

Estimation of: 

• Blank Size 

• Formability 

• Material Thinning 

• Work Hardening Effect 

- 5 - 


Resultsmapper V8.0 

• Mapping Stamping 

Simulation Results form 

Hyper Form to ABAQUS 

Mapping Paramater: 

• Work Hardening Effect 

• Thinning 





ornamental design registration.



Abaqus V6.7-1 (FEA 

Solver) 

• Stiffness/Strength 

Analysis 

• Durability (estimation) 

• Frequency Response 

Analysis 

• Pedestrian Protection 

• Pendelum Impact 

• Insurance Tests 

• Hood Impact 

- 6 - 


PAM Crash 2004 (FEA 

Solver) 

• Pedestrian Protection 

• Pendelum Impact ECE 

R42 

• Insurance Tests 

• Hood Impact 






Star CD (CFD Solver by 

Hella & Behr) 

• Thermodynamic 

Calculations 

• Air Streaming 

• Cooling Optimization 

• Optimization of Tube Fin 

Systems 

• Fogging & Defogging of 

Headlamps 

Mold Flow (Soupport from 

Plastic Omnium) 

Estimation of: 

� Mold Flow 

� Filling Time 

� Pressure Distribution


HBPO Data Process 

- 7 - 

Abaqus 

20 Token 


CAD-Data (Catia, Ideas, UG) 

Pre Processing (Hypermesh) 

176 Token 

Pam Crash 

4 Licenses 

Direct Interface 

Opti Struct 

Direct Interface 

Direct Interface (Catia) 

VDA / STEP / IGES (IDEAS/ UG) 

Post Processing (HyperView , Hypermesh) 






LS Dyna 

By SHB 

Radioss 

STL / IGES


Simulation Process 

1. Concept Definition 

- 8 - 

I 1 = 49.400 mm 4 

740 

I 2 = 13.100 mm 4 

1.580 N 

420 N 

Task: 

� To compare different 

concept quickly 

Feature: 

� Flexible for different 

Concepts and 

design spaces 

� Able to recognize 

global an local 

effects 


2 . Optimization 

Task: 

� Topological 

optimization 

� Gauge Optimization 

� Shape Optimization 

Tool: 

� Altair Optistruct 

3. Nonlinear 

Simulation 

Task: 

� Nonlinear 

Confirmation and 

final Optimization 

Tool: 

� ABAQUS 

� PAM – Crash 






4. Testing and Correl. 

Task: 

� Final release of 

serial production 

Tool: 

� HyperVeiew


1. Concept Definition 

- 9 - 







Results: 

- latch bridge profile 

- sheet thickness 

- material selection 

- cost estimation 

Latch bridge 

Input: 

- package data 

- mechanical requirements


2. CAE process of weight and/or cost optimization 

- 10 - 







Optimization Process 

1. Topological Optimization 

to define the ribbing strategy 

2. Gauge Optimization 

to define the best gauges of the 

sheet metal insert and the 

plastic ribbs 

3. Manual shape optimization to 

optimize the shape of the sheet 

metal insert. Interaction between 

Gauge and Shape Optimization


2. CAE process of optimization Influence of BIW 

The blue model without DMIG, the gray model is the result together with vehicle. 

- 11 - 







Target of the study : 

� maximize the first eigenvalue of the BIW 

� to understand the influence of the BIW 

Result: 

� BIW has a huge influence of the Ribbing 

strategy. (blue w/o BIW , gray with BIW) 

� By taking the BIW into the topological 

optimization, the BIW performance can 

increase by 0.1 % without mass and cost 

increase


2. Gauge Optimization 

- 12 - 







Conditions: 

� BIW is represented through DMIG 

Matrix 

� Dynamic and static Load cases 

were optimized 

� Current design doesn’t meet the 

requirements 

Results after the Optimization 

� Improvement of the torsional rigidity 

by .15 mm/m 

� Improvement of the upper Cooling 

attachment by 47.2 % 

� Reduction in Weight -0.15 kg 

� Improvement of dynamic rigidity of 

cooling attachment by 7.3 %


2.0 Gain Analysis Optimization 

Optimization of Gain Function and minimization of Mass 

Conditions: 

� BIW is represented through DMIG 

Matrix 

� Dynamic and static Load cases 

were optimized 

Results after the Optimization 

� All static Requirements are fulfilled 

� Point Mobility almost fulfilled 

� Weight reduction of 1.07 kg 

- 13 - 








3. Confirmation Component Level 

Correlation of the natural swing modes ( Eigenfrequency) 

- 14 - 


Mod 

e 

1 

2 

3 

4 

5 






Test 

66,54 

78,45 

81,71 

86,15 

91,99 

Eigen frequencies : 

Sim 

66,62 

79,03 

80,42 

84,01 

91,14 

Delta 

-0,07 

-0,58 

1,29 

2,13 

0,85 

% 

-0,11 

-0,74 

1,58 

2,48 

0,92 

� Determination of the Eigenfrequency within a 

tolerance of 3% 

Usage: 

� Indication of Weight/Stiffness performance 

ratio 

� Elimination of Harmonics between different 

parts


3. Simulation Vehicle Level - Pedestrian Safety 

Styling Influences on Upper Leg Impact 

- 15 - 


Pedestrian Protection Calculation Tool (PPCT) 

Upper leg form OEM: 

according to 2004/90/EC Project: 

Copyright 2004 by HBPO, Dr. G. Zhao User: 

Assumption: 

Safety factor (recommendation: 0.8) 0,8 Only for the special case 

Kinematic factor (Fimpactor/structure) 0,85 max. impact energy, J 700 

Efficiency factor (recommendation: 0.75) 0,75 (Up to now: 700 J) 

Incompressible thichness, mm (depending on car) 15 

Input 

Y distance to Y0 mm 0 1 

Bonnet leading 

edge height (BLE) mm 738,9 715,3 

Bumper lead (BL) mm 83,5 74,3 

Results 

Velocity (V) km/h 35,8 33,4 

Impact angle ° 30,5 29,8 

Impact energy (E) J 633 501,9 

Impactor mass (M) kg 12,8 11,6 

min 139,12 111,6 

Intrusion 1), mm max 190,63 151,7 

defined 156 124 

1) possible value measured from hood outside surface No test necessary if the impact energy is lower than 200 J 

0 -1 -1 -1 -1 -1 -1 -1 -1 

Key Figures: 






N.N. 

N.N. 

N.N. 

� by an optimized styling the impact 

Energy is reduced by 130 J


3. Simulation Vehicle Level - Pedestrian Safety 

Pedestrian Protection – Upper Leg 

- 16 - 


Force 4,7 kN 

Moment 

250 Nm 







4. Testing and Correlation 

Force [N] 

6000 

5000 

4000 

3000 

2000 

1000 

-1000 

- 17 - 

Test Force [N] 

Simulation Force [N] 

Force Displacement 

Test: 5000 N 13,43 mm 

2000 N 3,23 mm 

Simulation: 5000 N 13,16 mm 

2000 N 4,125 mm 


Force / Displacement 

0 

0 2 4 6 8 10 12 14 16 

Displacement [mm] 






Conditions: 

� Carrier is attached to a rigid 

buck representing the 

vehicle conditions 

� Force is applied through a 

rigid latch jig 

� Displacement measured 

close to the latch


5. Simulation Component Level - Hood Latch strength 

- 18 - 

PP Carrier 

Max. Force at 5020 N 

Testing 

Simulation 


Failure Location 

Link Arm RHS 

Link Arm RHS 






Failure Load 

5020 N 

4930 N 

Failure Mode 

crack 

crack


5. Correlation – Drop Tower Impact 

- 19 - 








5. Correlation Vehicle Level - Correlation Crash Analysis 

- 20 - 








Material Data / Material validation 

Validation Material Model @ 80°C 

- 21 - 








Material Data / Material Validation 

- 22 - 








Process for 30% Vertron MFX 

- 23 - 

1. Measurement of 

the true stress 

v/s true plastic 

strain curve at 

different strain 

rates with the 

same type of 

tensile bars and 

same test 

methology 


2. Create a Dyna 

Material Model 

with multiple 

strain rate 

curves 

3. Correlate this 

Material model 

with different 

speeds with the 

existing Curves 

from point 1 






4. Find the 

correlation 

factor for an 

“isotropic” 

material 

behavior with 

correlating to 

the dynatup test


Process for 30% Vertron MFX - Validation Dynatup 

- 24 - 

� Material Cards as per 

tensile strength data 

� Factor for isotropic behavior 

0.65 







� Disc thickness 3mm 

� Disc & clamp dimensions 

per ISO6603 

� Clamped area constrained 

in vertical DoFs 

� Rigid impactor constrained 

to move vertically at 7m/s 

� Load = contact force 

between impactor and 

specimen 

� Displacement = 

Displacement of Impactor


Vertron MFX 30% Modeling & Correlation 

- 25 - 

Energy (mm) 

14 

12 

10 


8 

6 

4 

2 

0 

0 2 4 6 8 10 12 

Disp (mm) 






ISO Test @ 7m/s 

Simulation Solids 

Simulation Shells


HBPO Hardware / Software strategy 

- 26 - 

HBPO Lippstadt 

Hella MTZ Lippstadt 

LAN 


Hella GE Lippstadt 

TCS1 [HP] 

2* Intanium 

8 GB Memory 

Redundant 

FLEX LM 

Server 

TCS2 [FUSI] 

2* Opteron 

12 GB Memory 

Hella Australia 

OS: Suse 10.1 






File 

Server 

WAN 

TCS4 [HP] 

2* Opteron 16 GB Memory 

TCS5 [HP] 

2* Opteron 16 GB Memory 

TCS6 [HP] 

2* Dual Core Opteron 

16 GB Memory 

Hella GE Shanghai 

HBPO Troy 

CAX Cluster 

TCS3 [FUSI] 

2* Opteron 

12 GB Memory 

TCS7 [HP] 

2* Dual Core Opteron 

16 GB Memory 

Queueing System 

PBS-PRO


CAE Location an Support Offices 

- 27 - 

CAE Main Loacation 

CAE temp. Support 

Office 

WAN Connection 

HBPO US 


HBPO DE 

HBPO CZ 






HBPO RKO 

HBPO JP


HBPO GmbH 

Rixbecker Straße 111 

59552 Lippstadt 

Germany 

HBPO GmbH, Rixbecker Straße 111, 59552 Lippstadt, Handelsregister Amtsgericht Paderborn HRB 5929 

Geschäftsführer: Martin Schüler, Jens Keller 

Phone: +49 2941 / 38 - 1515 

Fax: +49 2941 / 38 - 5659 

Web: www.hbpogroup.com 

E-Mail: info@hbpogroup.com

First European Hyperworks User Konferenz

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