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Hyperworks Technology Conference (HTC) 2011

Optimization of PMH Structures

Vasant Pednekar Application Dev. Automotive vasant.pednekar@lanxess.com

Agenda
Introduction to LANXESS and its business units Topology Optimization Clutch Pedal Wall thickness optimization Front end module

Optimization of PMH Structures June 23, 2011

Sales 3M / 2011 Sales in the year 2010 Employees worldwide

EUR 2.073 bn EUR 7.120 bn approx. 15,500 Performance Polymers Advanced Intermediates Performance Chemicals

Portfolio

Global orientation

46 production sites worldwide

LANXESS is one of Germanys most important providers of polymers and chemicals

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Facts and Figures

46 + 5* production sites
Brunsbuttel, DE Hamm-Uentrop, DE Marl, DE Krefeld-Uerdingen, DE Dormagen, DE Leverkusen, DE Bitterfeld, DE Mannheim, DE Nizhny Novgorod, RU*

Sarnia, CA Sittard-Geleen, NL Antwerp, BE Burgettstown/PA, US Chardon/OH, US Gastonia/NC, US* Branston, GB Port Jrme, FR La Wantzenau, FR Redmond/WA, US Baytown/TX, US Orange/TX, US Bushy Park/SC, US Vilassar de Mar, ES Zwijndrecht, BE

Toyohashi, JP Qingdao, CN Liyang, CN Changzhou, CN* Tongling, CN Wuxi, CN Nantong, CN* Jinshan, CN Taopu, CN Singapore, SG*

Filago, IT

Nagda, IN Jhagadia, IN Madurai, IN

Cabo de Santo Agostinho, BR Porto Feliz, BR Duque de Caxias, BR Triunfo, BR Colonia, UY Burzaco, AR Merlo, AR Zrate, AR * under construction

Rustenburg, ZA Isithebe, ZA Merebank, ZA Newcastle, ZA Sydney, AU

SCP Production sites Lanxess Production sites

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Sites

The Business Units

Performance Polymers Butyl Rubber Performance Butadiene Rubbers Technical Rubber Products Semi-Crystalline Products

Advanced Intermediates Advanced Industrial Intermediates Saltigo

Performance Chemicals Functional Chemicals Inorganic Pigments Ion Exchange Resins Leather Material Protection Products Rhein Chemie Rubber Chemicals

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Overview: Business Units

Topology Optimization Why we need it


Traditional Design Process Based on Intuition / Experience not always an optimal design initially more iterations needed for optimal design more testing required for material savings time consuming Optistruct Design Process based on loadcases for the part efficient design at initial stage material savings

lesser design time

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Agenda
Introduction to LANXESS and its business units Topology Optimization Clutch Pedal Wall thickness optimization Front end module

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Original Part Clutch Pedal

Issues: Load = 1300N 3 stamped parts cumbersome welding operations heavy and high lead time to manufacture

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Preliminary Design

Steel: 506gms Plastic: 302gms

Issues: Over engineered impractical to mold Load = 1300N need for design optimization

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Boundary Conditions Topology Optimization


Topology Optimization Parameters Responses: Compliance, Volume Fraction Constraint: Volume Fraction (25%) Objective: Minimize Compliance

Manufacturing Constraint Direction of Molding Material: Durethan BKV 30 H2.0 (30% GFR PA6)

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Optimization Iterations Design evolution

Iteration 5

Iteration 20

Iteration 30
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Iteration 40

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Final Optimization Topology Design

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Simulation Model

Steel: 506gms Plastic: 202gms


Final Design Part lighter and stiffer Easier to manufacture

Steel: 506gms Plastic: 302gms 100gms higher 13


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Replacement of Steel Pedal with PMH

Deflection relative to Preliminary design

140% 121% 120% 100% 88% 81% 80% 63% 60% 40% 28% 20% 0% 17% 57% 86% Displacement X Displacement Y Displacement Z Displacement Mag

PA 30% GFR
Nylon PA6 30% Glass Fiber Reinforced

PA 60% GFR
Nylon PA6 60% Glass Fiber Reinforced

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Agenda
Introduction to LANXESS and its business units Topology Optimization Clutch Pedal Wall thickness optimization Front end module

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Wall Thickness Optimization Why we need


Topology optimization (Linear Static, Linear material) gives us best position and placement of rib structure

No thickness available

Initial approach, non-optimal thickness assumption for ribs Best possible weight reduction of part possible by iterative analysis approach

cumbersome close monitoring required non-feasible

Advantages Can model Non-linearity in Material and Part Freedom of solver Static / Explicit possible

Limitations Computational time high and costly (depends on the part dimensions) High diskspace (can be reduced by only saving the input files and deleting all analysis result files)

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Wall Thickness Optimization Prerequisites


Loadcases: Hoodlatch Cooler Support Palm Load Hoodslam Load Responses: Mass of Plastic part Displacements (Avg. Stiffness from all loadcases) Constraints: Ref. Objective: Solver: Optimizer:
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Mass (10% Min.) Min. Displacement (Increase Stiffness) Abaqus Hyperstudy

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Wall Thickness Optimization Simulation Model


Startdesign for automatic optimizer Parameters: 24 wall thicknesses t1 2.5 mm -> 2.5 mm t2 2.5 mm -> 3.2 mm t3 2.5 mm -> 4.2 mm t4 2.5 mm -> 1.9 mm . t24

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Wall Thickness Optimization Optimization Runs


Constraint: Total Mass Initial runs (= nos of design variables) and then >10% mass reduction for optimization Initial Runs Optimization Runs Objective: Mechanical Deficiency = 0 (Best value)

Just examples of how the thickness PIDs are changed to achieve the objective, keeping the constraint within limits

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Wall Thickness Optimization Material/Manufacturing feasibility

Durethan BKV 30 EF / BKV 60 EF 2-K


Nylon PA6 30% & 60% Glass Fiber Reinforced

Only Durethan BKV 30 Min.Wall thickness 1.6 mm


Nylon PA6 30% Glass Fiber Reinforced

Only Durethan BKV 60 EF Min. Wall thickness 1.8 mm


Nylon PA6 60% Glass Fiber Reinforced

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Wall Thickness Optimization Feasible Light weight design


End of iteration: wall thickness distribution converged

Durethan BKV 30 EF / BKV 60 EF 2-K Optimized weight: 3.3 kg All 9 loadcases OK

Only Durethan BKV 30 EF Optimized weight: 4.8 kg All 9 loadcases OK

Only Durethan BKV 60 EF Optimized weight: 3.6 kg All 9 loadcases OK

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Conclusion
Topology Optimization Vast reduction in number of design iterations Practically viable results Material savings at initial stage LANXESS plans to use this technology for more applications Wall Thickness Optimization Effective at final design phase Weight reduction for a part, meeting all loadcase criteria, possible Wall thickness can be accurately determined w.r.t. combined loadcases

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LANXESS Corporation 111 RIDC Park West Drive Pittsburgh, PA 15275 Phone: 1-800-LANXESS www.lanxess.us The manner in which you use and the purpose to which you put and utilize our products, technical assistance and information (whether verbal, written or by way of production evaluations), including any suggested formulations and recommendations are beyond our control. Therefore, it is imperative that you test our products, technical assistance and information to determine to your own satisfaction whether they are suitable for your intended uses and applications. This application-specific analysis must at least include testing to determine suitability from a technical as well as health, safety, and environmental standpoint. Such testing has not necessarily been done by us. Unless we otherwise agree in writing, all products are sold strictly pursuant to the terms of our standard conditions of sale. All information and technical assistance is given without warranty or guarantee and is subject to change without notice. It is expressly understood and agreed that you assume and hereby expressly release us from all liability, in tort, contract or otherwise, incurred in connection with the use of our products, technical assistance, and information. Any statement or recommendation not contained herein is unauthorized and shall not bind us. Nothing herein shall be construed as a recommendation to use any product in conflict with patents covering any material or its use. No license is implied or in fact granted under the claims of any patent.
Health and Safety Information: Appropriate literature has been assembled which provides information concerning the health and safety precautions that must be observed when handling the LANXESS products mentioned in this publication. For materials mentioned which are not LANXESS products, appropriate industrial hygiene and other safety precautions recommended by their manufacturers should be followed. Before working with any of these products, you must read and become familiar with the available information on their hazards, proper use, and handling. This cannot be overemphasized. Information is available in several forms, e.g., material safety data sheets and product labels. Consult your LANXESS Corporation representative or contact the Product Safety and Regulatory Affairs Department at LANXESS.

Note: The information contained in this publication is current as of June, 2011. Please contact LANXESS Corporation to determine if this publication has been revised.

Durethan is a registered trademark of LANXESS Deutschland GmbH.

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Thank You for Your Attention