Optimization Culture Arena - Harald Hasselblad, Volvo Car Group

CAE has been used for a long time in the vehicle industry. It has been an efficient method for replacing expensive physical testing and predicting the performance of a component, system or complete model. This process has been supported by a rapid increase of computer power. CAE methods for replacing physical testing will continue to develop, however a shift in focus and application of CAE methods for the early development phases can be seen in the vehicle industry. This indicates a trend to a more CAE and knowledge driven development. This will put high demands of development of CAE methods and tools to drive the design. Some key areas for this is efficient use of e.g. topology, thickness and material optimization, performance balancing, etc.

To support this shift to more upfront CAE an “Optimization Culture Arena” has been launched at Volvo Car Group. This arena is a cross technical network for knowledge sharing and optimization competence development at VCG that consist of people from CAE, attribute areas, design, testing, technical specialists, academy etc. The arena function is to support implementation of an optimization driven culture and support development of guidelines and methods regarding optimization. The arena is supported by a knowledge hub to spread latest news and planned activities and also handle a competence matrix to support exchange of knowledge. A geographic area will serve as a place to meet, get support and share good examples of CAE driven development.

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1. Harald Hasselblad Weight Management & Optimization Volvo Car Group Göteborg Sweden Optimization Culture Arena Volvo Car Group
2. In 1999, the XC90 gen I was modelled with 300 000 finite elements. In 2014, the XC90 gen II was modelled with 10 000 000 elements. Detailed deformations including fractures, acceleration pulses, dummy behaviour etc. predicted well enough to lead product development process including sensor calibration. Safety CAE for virtual development
3. The Design Process ?
4. Upfront CAE: Benchmarking Porsche BMW Altair
5. Development of the XC90 front structure Topology Optimization of Vehicle Body Structures 1999-2005 Realization of load path ~2009 Detailed geometry ~2012 Archiecture study for SPA ~2007 Topology Optimization Animation: click to start XC90 and the SPA structure 2014 "The XC90 has an immensely strong body shell ...” 125 kg lighter than its predecessor.
6. An glimpse until today
7. Why an ARENA on simulation driven development? "It is important to generate a culture of optimization". The Design Process PhD Research project 1999-2005 Pilot: Optimization team 2011-2012
8. To be a Cross Technical Knowledge network for Common Optimization Competence Development Exchange Educate Execute Arena vision
9. Initial Organization Feedback What opportunities do you see? How can you contribute? What are the main challenges?
10. Front loaded and knowledge driven process Time Recourses Organization Change • Allocation of resources • Critical competences New methods and tools Earlier availability and decision making Time reduction Often there is a recourse increase in the end of a project Front loaded development process and a more knowledge driven decision process lead to: • organizational changes • need for new methods • increased use of IT technology Challenge: No extra resources!
11. Mission  Develop Internal Optimization Competence  Support and Promote an Optimization Driven Culture  More of CAE Driven CAD  Up Front CAE Optimization in Concept Phase  Optimized Solutions on Weight and Performance  Show the Good Samples  Workshops, Seminars  Coordinate Education  Guidelines and Templates  SharePoint and Newsletters  Knowledge Network  Weekly ”Drop-in” @ arena area Optimization Culture Arena How
12. Arena themes Project Optimization Planning Optimization as a natural part of our development process Concept Optimization Architecture and concept optimization in the early phases Local CAE Optimization together with, or performed by, the design engineers Method Development New optimization methods and tools, templates/guidelines, … Open Arena Environment for creativity, knowledge exchange, education, support
13. Project Optimization Planning Optimization as a natural part of our projects. • Perform benchmark • Identify the most weight driving targets • Make sensitivity study on dimensioning targets • Perform relevant optimization: • Topology 3D, 2D • Topography • Thickness • Parameter
14. Example: Guideline for Trunk lid optimization Background: Bead pattern and hole optimization is suitable to use on sheet metal structures in order to save weight and/or increase performance. Content: In this guideline the following topics will be covered. • Description of the optimization process • Model preparation & Optimization formulations • Topology and topography optimization • Case studies: Trunk lid optimization; Tailgate optimization • Lessons learned Limitations: • Only static stiffness load cases are studied • The body rear parts are not considered Developers: Related Methods: Body screening using topology optimization.
15. NATIONAL Optimization Arena Activities: • Workshops • Yearly conference • Master thesis projects • Course activities • PhD projects • National/international network • ... Cross-functional arena for competence development of optimization. Develop competence, methods, tools and processes for optimization driven development in order to enhance industry and academia. National Optimization arena with academy
16. Ask for optimization Define cross disciplinary engineering teams Do it as early as possible Identify need for method development Do your benchmarking Perform requirement balancing Generate lessons learned, guidelines and tutorials Keys to the culture Goal: Define an optimization strategy for CAE driven development
17. ” It is Important to Generate a Culture of Optimization ”
19. Harald Hasselblad Volvo Car Group Göteborg, Sweden +46-31-325 9707 Harald.Hasselblad@volvocars.com Abstract: CAE has been used for a long time in the vehicle industry. CAE methods for replacing physical testing will continue to develop however a shift in focus and application of CAE methods for the early development phases can be seen in the vehicle industry. This indicates a trend to a more CAE driven development. This will put high demands of development of CAE methods and tools to drive the design. To support this shift to more upfront CAE an Optimization Culture Arena has been launched at Volvo Car Group. This arena is a cross technical network for knowledge sharing and optimization competence development at VCG that consist of people from CAE, attribute areas, design, testing, technical specialists, academy etc. The arena function is to support implementation of an optimization culture and support development of guidelines and methods regarding optimization. The arena in general and some good examples from the organization and the future directions will be presented. Optimization culture arena at Volvo Car group