1. Improved mapping workflow with HM 11Dipl.-Ing.M. Meyer, M. Eng. D. Pielok, Dipl.-Ing. M. Heuse (all Faurecia) Dipl.-Ing. G. de los Rios, Dipl.-Ing. A. Hlsmann (all Altair) 8. November 2011

2. Improved mapping workflow with HM 11 Content Shortintroduction on Faurecia Mapping workflow Actual workflow New approach Part1: Results with HyperMesh 11 RIS HyperForm 11 Part 2: Parameter local bending Part 3: Parameter blank holder force Part 4: Parameter holes Part 5: variation of forming mesh sizeProperty of Faurecia - Duplication prohibited Conclusion 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 2

3. Improved mapping workflow with HM 11 Content Shortintroduction on Faurecia Mapping workflow Actual workflow New approach Part1: Results with HyperMesh 11 RIS HyperForm 11 Part 2: Parameter local bending Part 3: Parameter blank holder force Part 4: Parameter holes Part 5: variation of forming mesh sizeProperty of Faurecia - Duplication prohibited Conclusion 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 3

4. Improved mapping workflow with HM 11 Faurecia overview 2010 key figures The worlds top automotive equipment suppliers 75,000 employees* (2009 revenues b) 238 sites 1- Denso 2- Bosch 33 countries 3- Conti 4- Aisin Seiki Group revenues: 13.8 billion 5- Magna 6- Faurecia* 11,4 7- Delphi 38 R&D centers 8- ZF 9- Faurecia 2008 4,500 R&D engineers and 9- JCI auto 11- TRW technicians 10- Thyssen Krupp 12- BASF 300 patents filed in 2010 13- Valeo Annual R&D budget: 1 billion 14-Yazaki N6Property of Faurecia - Duplication prohibited 15- Lear 16- Toyota Boshoku worldwide 17- Mobis Listed on Euronext Paris 18- JTEKT equipment (SBF 120 - compartment A) 19- Hitachi supplier 20- Sumitomo electric *4 BGs + HQ 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 4

5. Improved mapping workflow with HM 11 2010 revenues by Business Group n2 worldwide 1.3 bn n1 worldwide 10% 4.8 bn 35% 22% Group revenues 13.8 bnProperty of Faurecia - Duplication prohibited n1 worldwide 33% n1 worldwide 3.1 bn in mechanisms 4.6 bn 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 5

6. Improved mapping workflow with HM 11 Faurecia Seating key figures 2010Property of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 6

7. Improved mapping workflow with HM 11 Content Shortintroduction on Faurecia Mapping workflow Actual workflow New approach Part1: Results with HyperMesh 11 RIS HyperForm 11 Part 2: Parameter local bending Part 3: Parameter blank holder force Part 4: Parameter holes Part 5: variation of forming mesh sizeProperty of Faurecia - Duplication prohibited Conclusion 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 7

8. Improved mapping workflow with HM 11 Problem: actual workflow Crash department Stamping department Stamping model Crash model one step One step Additional Crash simulation without mapping simulation simulation Time issue Thinning ? Buckling of parts ? Plastic strain ? Mapping with one step solver Issue: Efficiency and flexibility in project Stamping modelProperty of Faurecia - Duplication prohibited multi step Buckling of mapped parts ? Element based geometry change w/o CAD file Change of part thickness and Multi step Mapping with incremental solver material simulation 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 8

9. Improved mapping workflow with HM 11 New approach Crash department Crash model One step simulation Hyperform in HM 11 Crash simulation with one step mapping for all parts in force flow Stamping department Stamping model Buckling of mapped parts ?Property of Faurecia - Duplication prohibited multi step Multi step Mapping with incremental solver simulation 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 9

10. Improved mapping workflow with HM 11 New approach in HM 11 Workflow in HM 11: Create crash model with all (material, contact, fastener, etc.) Start Result Implementation Solver (RIS) tool in HM Choose parts for mapping Mesh, material and part thickness are taken from crash model More then 1 can be chosen One step solver starts Result: equivalent plastic strain and thicknessProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 10

11. Improved mapping workflow with HM 11 New approach in HM 11 Positive: Mapping one step will be standard for all parts Less crash simulations Faster time to implement one step mapping (>5 min per part) No need of additional meshing No need of CAD No need of additional material database Easy handling of tool, no need of stamping knowledge No need of additional license Negative: Additional simulations for FEA pilotsProperty of Faurecia - Duplication prohibited No check from stamping department if stamping results are ok One step simulation is done twice for formability check by stamping department and for mapping by crash department 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 11

12. Improved mapping workflow with HM 11 Content Shortintroduction on Faurecia Mapping workflow Actual workflow New approach Part1: Results with HyperMesh 11 RIS HyperForm 11 Part 2: Parameter local bending Part 3: Parameter blank holder force Part 4: Parameter holes Part 5: variation of forming mesh sizeProperty of Faurecia - Duplication prohibited Conclusion 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 12

13. Improved mapping workflow with HM 11 Master thesis: September 2010 February 2011 Task of the study: Validation of new work flow 4 typical seat parts Static load case Deformation represents real deformation from crash test Master thesis is in cooperation with Altair Germany pull directionProperty of Faurecia - Duplication prohibited fixation 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 13

14. Improved mapping workflow with HM 11 Part 1: HyperMesh 11 result Comparison: Base model w/o mapping Mapping with forming suite results (one step) Mapping with LS-Dyna results (multi step) Mapping with RIS tool in HW 11 Target: RIS tool in HM 11 should reach: Minimum: forming suite result mapping Maximum: LS-Dyna result mappingProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 14

15. Improved mapping workflow with HM 11 Part 1: HyperMesh 11 result Difference between FS and Dyna Difference between HM and Dyna Dplast strain = Dyna FSProperty of Faurecia - Duplication prohibited Dplast strain = Dyna HM 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 15

16. Improved mapping workflow with HM 11 Part 1: HyperMesh 11 result Difference between FS and Dyna Difference between HM and Dyna Dthickness = Dyna FSProperty of Faurecia - Duplication prohibited Dthickness = Dyna HM 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 16

17. Improved mapping workflow with HM 11 Part 1: HyperMesh 11 result Force vs. displacement Deformation base w/o LS-Dyna forming suite HM 11 RIS mapping seat sidemeber A 100% 98,9% 91,1% 83,9% seat sidemeber B 100% 96,0% 90,9% 91,7% backrest sidemember A 100% 97,4% 96,1% 90,8%Property of Faurecia - Duplication prohibited backrest sidemember B 100% 98,4% 96,7% 88,5% The results with the actual version of HM 11 doesnt reach the result of forming suite process What is the reason for that ? 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 17

18. Improved mapping workflow with HM 11 Part 1: Conclusion and next steps The results are far away from the results with forming suite one step solver. What can be the reason ? In HyperForm the following functions are available: Local bending on / off Blank holder forces none / low / medium / high Additional remarks from stamping simulation: Holes are closed before forming and cut afterwards Stamping simulation is done with finer mesh as in crash simulationProperty of Faurecia - Duplication prohibited To get the potential we used for the next steps for forming process HyperForm, but we keep the same mesh size 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 18

19. Improved mapping workflow with HM 11 Content Shortintroduction on Faurecia Mapping workflow Actual workflow New approach Part1: Results with HyperMesh 11 RIS HyperForm 11 Part 2: Parameter local bending Part 3: Parameter blank holder force Part 4: Parameter holes Part 5: variation of forming mesh sizeProperty of Faurecia - Duplication prohibited Conclusion 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 19

20. Improved mapping workflow with HM 11 Part 2: HyperForm 11 result, Parameter local bending Local bending: Comparison of local bending on and off Explanation: Source: Stoughton, T.: Model of Drawbead Forces in Sheet Metal Forming. Michigan: 1990 With the local bending option the function of the draw beads is integrated in the one step solver The function of an draw bead is to prestrain the material. Also the flow of the material into the deep will be reduced. HyperForm as there is no geometry of the draw bead and no material makes an assumption of the influence. Material flowProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 20

21. Improved mapping workflow with HM 11 Part 2: HyperForm 11 result, Parameter local bending Difference between FS and Dyna Difference between HF and Dyna Dplast strain = Dyna FSProperty of Faurecia - Duplication prohibited Dplastic strain = Dyna HF lb 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 21

22. Improved mapping workflow with HM 11 Part 2: HyperForm 11 result, Parameter local bending Difference between FS and Dyna Difference between HF and Dyna Dthickness = Dyna FSProperty of Faurecia - Duplication prohibited Dthickness = LS HF lb 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 22

23. Improved mapping workflow with HM 11 Part 2: HyperForm 11 result, Parameter local bending Force vs. displacement Deformation HF 11 with HF 11 w/o LS-Dyna forming suite local bending local bending seat sidemeber A 100% 98,9% 91,1% 99,6% seat sidemeber B 100% 96,0% 90,9% 97,8% backrestProperty of Faurecia - Duplication prohibited sidemember A 100% 97,4% 96,1% 96,5% backrest sidemember B 100% 98,4% 96,7% 98,5% By deactivating local bending the results are close to forming suite 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 23

24. Improved mapping workflow with HM 11 Part 3: HyperForm 11 result, Parameter blank holder die Blank holder force: blank holder Possible choice: None, low, medium, high Comparison here: None and low blank Explanation: In one step simulation the force will be implemented at the edges of the shells in plane direction HyperForm calculates the forces internally blank holder force depending on the sheet thickness in one step solver The user can define the force by the choice of none (0%), low (20%), medium (50%) and highProperty of Faurecia - Duplication prohibited (80%) The blank holder avoids the material flow into the tool. Source: Tschtsch, H. u. Dietrich, J.: Praxis der Umformtechnik Arbeitsverfahren, Maschinen, Werkzeuge. 9. Auflage. Wiesbaden: Vieweg Teubner, 2008 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 24

25. Improved mapping workflow with HM 11 Part 3: HyperForm 11 result, Parameter blank holder The plastic strain increase Increase by 18% The thickness decrease decrease about 0,1 mmProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 25

26. Improved mapping workflow with HM 11 Part 3: HyperForm 11 result, Parameter blank holder Force vs. displacement Deformation HF 11 HF 11 LS-Dyna forming suite blankholder blankholder none low seat sidemeber A 100% 98,9% 99,6% 81,9% backrest 100% 97,4% 96,5% 90,3%Property of Faurecia - Duplication prohibited sidemember A The blank holder force low has a negative influence on the result. 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 26

27. Improved mapping workflow with HM 11 Part 4: HyperForm 11 result, Parameter holes Closed holes: Forming of inner contour Trimming operation Turning down of flangeProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 27

28. Improved mapping workflow with HM 11 Part 4: HyperForm 11 result, Parameter holes Difference between closed and opened holes Dplastic strain = open - closedProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 28

29. Improved mapping workflow with HM 11 Part 4: HyperForm 11 result, Parameter holes Difference between closed and opened holes Dthickness = open - closedProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 29

30. Improved mapping workflow with HM 11 Part 4: HyperForm 11 result, Parameter holesProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 30

31. Improved mapping workflow with HM 11 Part 4: HyperForm 11 result, Parameter holes Force vs. displacement Deformation HF 11 closed LS-Dyna forming suite HF 11 open holes holes seat sidemeber A 100% 98,9% 99,6% 100,1% seat sidemeber B 100% 96,0% 97,8% 97,5% backrest 100% 97,4% 96,5% 96,6%Property of Faurecia - Duplication prohibited sidemember A backrest sidemember B 100% 98,4% 98,5% 98,3% The effect of closed holes is visible. The influence on the result is in these examples less 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 31

32. Improved mapping workflow with HM 11 Part 5: HyperForm 11 result, variation of forming mesh size Classic process Fine meshed model for stamping Coarse meshed model for crash Mapping process: Lose of details New process Coarse meshed model for stamping Coarse meshed model for crashProperty of Faurecia - Duplication prohibited Lose of geometrical details 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 32

33. Improved mapping workflow with HM 11 Part 5: HyperForm 11 result, variation of forming mesh size Difference between fine and crash mesh for mapping Dplastic strain = fine - crashProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 33

34. Improved mapping workflow with HM 11 Part 5: HyperForm 11 result, variation of forming mesh size Difference between fine and crash mesh for mapping Dthickness = open - closedProperty of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 34

35. Improved mapping workflow with HM 11 Part 5: HyperForm V11 result, variation of forming mesh size Force vs. displacement Deformation HF 11 HF 11 LS-Dyna forming suite crash mesh fine mesh seat sidemeber A 100% 98,9% 99,6% 100,1% seat sidemeber B 100% 96,0% 97,8% 100,7% backrest sidemember A 100% 97,4% 96,5% 97,2%Property of Faurecia - Duplication prohibited backrest sidemember B 100% 98,4% 98,5% 98,7% Results by using crash mesh for forming simulation as good as using results from fine meshed parts 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 35

36. Improved mapping workflow with HM 11 Content Shortintroduction on Faurecia Mapping workflow Actual workflow New approach Part1: Results with HyperMesh 11 RIS HyperForm 11 Part 2: Parameter local bending Part 3: Parameter blankholder Part 4: Parameter holes Part 5: variation of forming mesh sizeProperty of Faurecia - Duplication prohibited Conclusion 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 36

37. Improved mapping workflow with HM 11 Conclusion RIS tool in HyperMesh 11: The mapping by using the RIS tool in HW 11 will be usable if: Local bending will be deactivated Blank holder force set to none Preference file planed to do the predefined standards In the moment bending force are set to middle. Can be changed by the user to none Holes are closed Tool for automatic close and reopen will be available These options be available with the HyperWorks V11 1.0.1 updateProperty of Faurecia - Duplication prohibited planed for Q4 2011 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 37

38. Improved mapping workflow with HM 11 Thank you for your attention !Property of Faurecia - Duplication prohibited 5th European HTC Users Conference, Bonn November 2011 M. Meyer / FAS Tools & Methods 38