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Author Guillaume Minault, Numerical Simulation Engineer PSA Peugeot Citron - Vlizy-Villacoublay (78) Phone : + 33 1 57 59 27 23 / E-mail : guillaume.minault@mpsa.com
Abstract In a very competitive cars and light commercial vehicles market, accelerating the development of new models is a key factor of success. Computational analysis has become an efficient tool for this. PSA Peugeot Citron is investigating how to improve the efficiency and quality of the major steps used in this process. Among them, meshing must be much faster using batch technologies. Recently, we have performed a benchmark with three major software editors among which Altair. It has shown that by using HyperMesh and BatchMesher for example, we could mesh typical body in white models faster provided the three following conditions are fulfilled. First, the process must guaranty good orthogonal property of the resulting mesh (software editor part). Second, we have to use finer mesh than today in our RADIOSS crash simulation models (PSA Peugeot Citron part). Third, the use of batch meshing in our complete simulation process must be validated. For this validation, we are working with Altair on a step by step program, from a single part to a complete body in white analysis. This presentation gives our conclusions (efficiency and quality) on one of the first validation cases: axial compression of a part component of the body in white.
Guillaume Minault
27/08/2007
Guillaume Minault
27/08/2007
Introduction
Context A highly competitive market : Cars and light commercial vehicles market A constant need of accelerating our new models development Today, computational analysis are systematically used on our projects We investigate how to improve the efficiency and the quality of the major steps of our numerical process. Among them : Meshing & Assembly
Post Processing Analysis Meshing Assembly
Goal & Objectives Reduce the length of our meshing phases Maintain or improve quality of meshes First Applications targeted Crash Computation Body in White & Openings
Computation
Pre Processing
Guillaume Minault
27/08/2007
Guillaume Minault
Guillaume Minault
27/08/2007
Batch Meshing
Run BatchMesher, export results (mesh, quality summary)
Guillaume Minault
* BOM File (Build Of Material File) = necessary input file of BatchMesher with parts information. 27/08/2007
Batch Meshing with Altair products : Is already fully operational on CAD with simplified geometry Can be quicker than usual hand-meshing (with a substantial gain of time) Leads generally to a Good Elementary Quality (warp, skew, taper) Is efficient when proceeded on high quality CADs Can deliver incorrect results which need Manual Improvement in particular : Correction of mesh orthogonality Is not available for volumes meshing with HEXA To Batch Mesh CADs with accurate geometry efficiently, we need: A smaller element size (around 5mm) than the one used today A good Data Organisation (CADs, Thickness, Material Vector, Material)
Guillaume Minault
27/08/2007
Guillaume Minault
27/08/2007
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Axial Compression
Mobile Part
Guillaume Minault
Fixed Part
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Four different meshes realized : HM_12mm : 12mm Hand-Mesh HM_5mm : 5mm Hand-mesh BM_5mm : 5mm Batch-Mesh BM-MI_5mm : 5mm Batch-Mesh with Manual Improvement
Batch Meshes (with or without Manual Improvement) have : A correct percentage of triangular elements A very good elementary quality
Guillaume Minault 27/08/2007
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HM_5mm 5.25mm
4.75mm
Analysis : All fine meshes have a very little dispersion of element sizes Altair Batch Meshes have a symmetric distribution around the element size target Our 5mm Hand Mesh has a great number of elements under the element size target
BM_5mm
BM-MI_5mm
Guillaume Minault
27/08/2007
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5mm Batch Mesh of a multi constrained area : Global Mesh Flow versus Hole Representation 5mm Batch Mesh of 3 stiffeners
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BM_5mm
BM-MI_5mm
Guillaume Minault 27/08/2007
50ms
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All Batch Meshes lead to a good representation of first buckling peaks 27/08/2007
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Conclusions On the first step of our Validation Program, the 5mm Batch Meshing leads to :
A substantial gain of meshing time A very good elementary quality A very little element size dispersion A symmetric distribution of element sizes around the targeted size A correct orthogonality due to an efficient manual pre-processing A good geometric representation of buckling An accurate computation of the first buckling force peaks
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So, we validate the use of 5mm Batch Meshing on this first step. We also found several points to be improved such as:
Batch Meshing Repeatability (Mesh Patterns) Batch Meshing of multi-constrained areas (preserving orthogonality)
Perspectives At present, due to these first encouraging results, we are proceeding with our Validation Program in order to make in 2008 :
Guillaume Minault
27/08/2007
Conclusions On the first step of our Validation Program, the 5mm Batch Meshing leads to :
A substantial gain of meshing time A very good elementary quality A very little element size dispersion A symmetric distribution of element sizes around the targeted size A correct orthogonality due to an efficient manual pre-processing A good geometric representation of buckling An accurate computation of the first buckling force peaks
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So, we validate the use of 5mm Batch Meshing on this first step. We also found several points to be improved such as:
Batch Meshing Repeatability (Mesh Patterns) Batch Meshing of multi-constrained areas (preserving orthogonality)
Perspectives At present, due to these first encouraging results, we are proceeding with our Validation Program in order to make in 2008 :
our dream of Batch Meshing for Car Crash Test Simulations a reality
Guillaume Minault 27/08/2007
Acknowledgements
I would like to thank all the people from ALTAIR who worked on this project. In particular: Stephano Deiana, Mauro Guglielminotti and Arnaud Stauffer.
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Many thanks to the other editors teams who performed our Benchmark.
Many thanks also to all my PSA colleagues who are also working on this topics.
Finally, very special thanks to Jrme Thibaut (from ALTAIR) for his strong involvement both on our Benchmark and our Validation Program.
Guillaume Minault
27/08/2007