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Agenda
Introduction to LANXESS and its business units Topology Optimization Clutch Pedal Wall thickness optimization Front end module
EUR 2.073 bn EUR 7.120 bn approx. 15,500 Performance Polymers Advanced Intermediates Performance Chemicals
Portfolio
Global orientation
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
Cabo de Santo Agostinho, BR Porto Feliz, BR Duque de Caxias, BR Triunfo, BR Colonia, UY Burzaco, AR Merlo, AR Zrate, AR * under construction
Sites
Performance Polymers Butyl Rubber Performance Butadiene Rubbers Technical Rubber Products Semi-Crystalline Products
Performance Chemicals Functional Chemicals Inorganic Pigments Ion Exchange Resins Leather Material Protection Products Rhein Chemie Rubber Chemicals
Agenda
Introduction to LANXESS and its business units Topology Optimization Clutch Pedal Wall thickness optimization Front end module
Issues: Load = 1300N 3 stamped parts cumbersome welding operations heavy and high lead time to manufacture
Preliminary Design
Issues: Over engineered impractical to mold Load = 1300N need for design optimization
Manufacturing Constraint Direction of Molding Material: Durethan BKV 30 H2.0 (30% GFR PA6)
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Iteration 5
Iteration 20
Iteration 30
Optimization of PMH Structures June 23, 2011
Iteration 40
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Simulation Model
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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No thickness available
Initial approach, non-optimal thickness assumption for ribs Best possible weight reduction of part possible by iterative analysis approach
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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Just examples of how the thickness PIDs are changed to achieve the objective, keeping the constraint within limits
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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.
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