제품개발프로세스효율화방안 (Simulation based Design) 건국대학교다중물리해석및최적화연구실강병식 bkang@konkuk.ac.kr
AGENDA I. 제품개발프로세스효율화방안 1 II. Simulation Based Development 6 III. Democratizing CAE 11 IV. Topology Optimization 17 V. Summary 26
Product Development Process Product Planning Design Concept Build Product Development Manufacturing Preparation Planning Overall Process 1 Generate Product Idea 2 Evaluate Product Idea 3 Agree on Product Idea Consensus M0 Design Idea Efficient Evaluation Efficient Decision Making Concept Design Hardware #1 Detail Design Hardware #2 4 Define Product Concepts 5 Delineate Product Concepts 6 Freeze Product Concept Model Freeze 7 Product Target Design Product 8 Produce Product 9 Validate Product Validation Approval Courtesy of ITI How to -. increase Efficiency -. improve Quality -. reduce Time & Cost Manufacturing Check Hardware #3 10 Launch Clinic 11 12 Validate Confirm Pilot Mass Product Production Mass Production (Job 1) 1
Strategy for Improving Development Process Upfront Engineering : Evaluation in early stage of Development Process # of Problem Resolution [N(p)] Hit Product Assured 3 6 9 10 Design Change Cost Upfront Engineering (simulation based development) Digital Engineering (DMU/DPA) Conventional Design-Build-Test (hardware test based development) Design Change Cost Design Change Cost Design Change Cost = ΣN(phase)*C(Phase) DMU : Digital Mock Up DPA : Digital Pre Assembly For most OEM s the process focuses on activities between Conventional and Digital after detailed design Development Phase[p] Resolution Cost per Problem [C(p)] Concept Design 개념설계 Detail Design 상세설계 Prototyping Evaluation Production Ramp-Up Full Production 시제품제작시험평가양산준비양산 10 X 100 X 1000 X 10000 X 20000+ X Development Phase Courtesy of ITI Minimize Engineering Change after Start of Detail Design 2
Digital Development (VPD, Virtual Product Development) Digital Development Tools CAx (Computer Aided x) Digital Development : Prototyping & Manufacturing CAS CAD CAE CAM DPA / DFA DESIGN PLM MANAGEMENT EVALUATION Practice Upfront Engineering & Concurrent Engineering Automotive Engineering 3
Automotive Development Methodology Shift M-b 12~15 M0 12~15 M+a 상품제품제안구상 Platform 개발착수 패키지및개념설계상세설계생기검증양산Pilot Test Car Proto Car Pilot Car 양산 Powertrain 품평 승인 - 고정 플랫폼선정및 Test Car 개발 Styling 확정 Prototype 제작및시험 Hardware based Development DESIGN BUILD Prototype Trial & Error TEST 시험개발 by Design-Build-Test Iterations Simulation based Development SIMULATION OPTIMIZATION 시뮬레이션개발 시험확인 Minimize Design Change Less Hardware Stages 4
Digital Development in Automotive Industry Digital Car Project, 1997 50% shorter development cycle (60 30 mon.) -. Increase Parallelization of Design Tasks -. Elimination of some design iterations -. Quicker Completion of the remaining design iteration E-Class Reduce Development Time (44 20 mon.) by CAE based development & Platform Technology 5
AGENDA I. 제품개발프로세스효율화방안 1 II. Simulation Based Development 5 III. Democratizing CAE 11 IV. Topology Optimization 17 V. Summary 26
Role of CAE in Automotive Development CAE Benefit : CAE Purpose : Efficiency / Completeness / Easiness Quality Design / Efficient Development Pass? / Fail? How to Improve? 1day turn around 6
CAE Role Evolution : Evaluation Tool Design Tool CAE 1 st Stage (~ late 90s) After Design Release Failure Analysis Improvement CAE 2 nd Stage (~ late 2000s) Before Design Release Design Evaluation Improvement CAE 3 rd Stage (mid 2010s ~) Before Detail Design Concept Evaluation Optimization Prototype Evaluation Design Review Concept Design Test-CAE correlation Design confirmation Topology Optimization Result Role Analysis Change : After Design Release Speed Concerned Before Release (6wks.) Concept Morphing Optimization Technique Accuracy Concerned 후행평가기능 Automation 선행평가 / Outsorcing 기능선행설계기능 Freeze Release Confirm Morning Pedestrian Protection Concept Design Phase Detail Design Phase Prototype Phase Pilot Phase Crashworthiness Ray Job1 ~170 Head Impact Points on Hood & Windshield Glass 8 weeks 1.5 weeks 7
Automotive Development Process Integration M-b 12~15 M0 12~15 M+a 상품제안 제품구상 개발착수 패키지및개념설계상세설계생기검증양산 Pilot 양산 개념설계 상세설계 L 시험개발 시작개념해석 (3 단계 ) 상세설계전최적설계도출 시작상세해석 (2 단계 ) 출도전도면검증해석 개선해석 (1 단계 ) 출도후도면검증해석 Concept Development (Test Car Stage) Package / Layout Concept Design Pre Evaluation (Simulation) Design Release Prototype Build Post Evaluation (Test) Product (Detail) Development (Proto Car Stage) Detail Design Pre Evaluation (Simulation) Design Release Prototype Build Post Evaluation (Test) * 각 Hardware 단계에서 설계 - 선행평가 - 설계출도 - 후행평가 ' 과정반복 8
CAE Role in each Stage of Development Process 법규강화 시점 : 도면작업前 검증 Tool 설계 Tool 설계방향제시 시점 : all 도출도前 설계협업기간확보 신속한검증및설계개선 시점 : 실차제작이후 문제점검증 / 효율적개선 해석기반예측정확도 개념설계단계 설계검증단계 시험검증단계 위상최적화기법 (Topology) 형상모델링 (Morphing) Routine Job 개발해석자동화 설계정보입수 모델링- 해석 (PLM) ( 자동화 ) 예 ) 보행자보호해석자동화 시험 - 해석 correlation 시험결과상세분석 예 ) 충돌시험 - 해석비교 48 개영역타격 165~170 개소타격 170 개소타격기준 - 해석기간 : 8 주 2 주 9
AGENDA I. 제품개발프로세스효율화방안 1 II. Simulation Based Development 5 III. Democratizing CAE 11 IV. Topology Optimization 17 V. Summary 26
Democratizing CAE Raised issue on rapidly increasing CAE demand at NAFEMS 2013 Resource limit to meet demand (not enough CAE engineers) Proposed Democratizing CAE at NAFEMS 2015 Allow Design engineers perform CAE evaluation in Design Process 11
Democratizing CAE (for Designer) Expanding CAE work Designer perform CAE FOA (First Order Analysis) Concept Study: Intuitive 1-D Analysis Tool (Toyota) CAD Tool base Analysis Full FEA Easy to use for Designers w/o CAE skill Limit: Single Part, Linear Analysis Currently Available Tools : Inspire / DesignSight 12
CAE Process Pre-Processing (Modeling) Solving Post-Processing Equivalent to Test Car Build Equivalent to Test Test / Design Engineer Function -. Meshing -. Solver Selection -. Result Analysis -. Property Assignment -. Parameter Set Up -. CAE / Test Correlation -. Material Assignment -. Output Set Up -. Engineering Judgment -. Assembly -. Boundary Condition -. Design Recommendation -. Loading Condition Optimization 13
Meshless Methods 15
Democratizing CAE (for Designer & CAE Engineer) Assembly or System level Nonlinear Analysis 16
AGENDA I. 제품개발프로세스효율화방안 1 II. Simulation Based Development 5 III. Democratizing CAE 12 IV. Topology Optimization 17 V. Summary 26
Optimization Optimization is the Design Goal & CAE Purpose Sensitivity, 민감도 (for Linear Problem) DoE (Design of Experiment), 실험계획법 Shape Optimization, 형상최적화 Topology Optimization, 위상최적화 MDO (Multi-Disciplinary Optimization), 다분야최적설계 MOO (Multi-Objective Optimization), 다목적함수최적설계 RBDO (Reliability Based Design Optimization), 신뢰성기반최적설계 PIDO (Process Integration & Design Optimization) 18
Topology Optimization Easy to use for non expert in optimization (somewhat As it is concept) Design variable : Mass or Stiffness of Meshed Element < Typical Problem > Objective : Minimize Weight or Maximize Performance Design Variable : Elements Mass Constraints : Design Space 20
Topology Optimization Powerful Tool for Optimal Concept Design Easy to use even without CAE or Optimization Expert Knowledge Architects can get design concept 21
Topology Optimization by Students - AOC > 대학생최적화경진대회사례 - 자전거 Brake Arm 최적화 INITIAL DESIGN INITIAL DESIGN STRESS Max. Stress : 136.6 MPa Volume : 39,370 mm 3 DESIGN DOMAIN (* 08 알테어대학생최적화경진대회작품참조 ) TOPOLOGY OPTIMIZATION REDESIGN REDESIGN STRESS Max. Stress : 109 MPa (20% ) Volume : 32,350 mm 3 (18% ) 23
Optimization Case in Automotive Industry Topology Panel Bead Pattern 최적화 (Topology for NVH) 인텀플로어 TOPOGRAPHY ( 비드패턴최적화 ) 목적함수 : 변형에너지최소 최적화 비드적용필요 경계조건 : 전후스트럿고정하중 : 인텀플로어압력부과 제한조건 : 판넬떨림억제를위한판넬강성확보 2 단비정형비드 물결무늬비드 설계변수 : 판넬비드패턴 설계초기안 설계변수 설계반영안 인텀플로어판넬강성 190% 향상 : 0.85 1.4t 효과 (1.3Kg 절감효과 ) 22
Optimization Case in Automotive Industry Topology 위상최적화기법을활용한전단부언더커버리브형상최적화 양산개조 - 초기개조 - 최적화 Beyond engineer s intuition Learning from Nature Getting close to Nature? 23
Optimization Case in Automotive Industry Topology Topology Optimization ( 위상최적화 ) < Body Design Concept > < Wheel Styling Concept > < Floor Panel Bead Pattern > < Hood Inner Structure > Steel Aluminum head impact Strength 25
AGENDA I. 제품개발프로세스효율화방안 1 II. Simulation Based Development 5 III. Democratizing CAE 12 IV. Topology Optimization 17 V. Summary 26
Summary Simulation Based Development Hardware based Development DESIGN BUILD Prototype Trial & Error TEST 시험개발 by Design-Build-Test Iterations Simulation based Development SIMULATION OPTIMIZATION 시뮬레이션개발 시험확인 Minimize Design Change Less Hardware Stages Democratizing CAE Topology Optimization 26
Simulation based Development Process 법규강화 시점 : 도면작업前 검증 Tool 설계 Tool 설계방향제시 시점 : all 도출도前 설계협업기간확보 신속한검증및설계개선 시점 : 실차제작이후 문제점검증 / 효율적개선 해석기반예측정확도 개념설계단계 설계검증단계 시험검증단계 위상최적화기법 (Topology) 형상모델링 (Morphing) Routine Job 개발해석자동화 설계정보입수 모델링- 해석 Minimize (PLM) Design ( 자동화 Change ) Less 예 Hardware ) 보행자보호해석자동화 Test Stage Improve 48개영역 Quality 타격 165~170 & Reduce 개소타격Time 시험 - 해석 correlation 시험결과상세분석 예 ) 충돌시험 - 해석비교 170 개소타격기준 - 해석기간 : 8 주 2 주 27
bkang@konkuk.ac.kr