Technical perfection, automotive passion.

Modern Seat Development Process in Faurecia supported by Hyper Works products

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Marcin Debniak, Faurecia Poland R&D European HyperWorks Technology Conference Berlin, Germany October 23-24, 2007

What is Faurecia Faurecia is an expert in 6 major modules

Technical perfection, automotive passion.

Acoustic package

Door panel / Modules

Exhaust system

Instrument panel / Cockpit

Seating

Front end

Faurecia basic key figures 2006

Sales: Over 11.6 billion R&D 5,2% of sales (610M) Over 4000 engineers Over 65,000 employees world wide 28 R&D centers Listed on the Euronext Paris - Eurolist
France Spain
Quart de Poblet Audincourt Brires Bavans Beaulieu Flers Frth Hagenbach Ingolstadt Munich Peine Sassenburg Scheuerfeld Stadthagen

Technical perfection, automotive passion.

Korea
Shihwa

Sweden
Torsas

China
Shanghai

ShinYokohama

Japan

Germany Poland
Grojec

India
Pune

Magny Mru Mouzon Nogent/Ver. Seloncourt

USA
Auburn Hills Toledo Troy

What Grojec is focus on Car Seats

One of six modules produced by Faurecia Very complex structure Up to 99 parts and 16 electrics engines Seat design takes into account numerous factors, including safety, comfort, and the standardization of parts that are not visible and an extreme customization of appearance More and more customers requirements as well as legal requirements Year by year number of seat features is permanently increasing Up to 80% of design given by safety issues Comfort becomes more and more important Around 100 test before being assemble in vehicle New ideas and permanent innovation

Technical perfection, automotive passion.

Faurecia R&D GROJEC Why CAE Department in Grojec (Poland)?

Biggest production plant in Poland (over 1500 employees) Good location, close to main strategic customers (France and Germany) mobility Great potential good educated young staff Fast growing market Low Cost Country

Technical perfection, automotive passion.

GRJEC

CAE GROJEC activity

28 Simulation Engineers

Technical perfection, automotive passion.

Work on complete seats projects as well on single parts modifications and optimization on following levels: Meshing Static and quasi-static calculations Dynamic calculations Optimization Used software: HyperWorks, ABAQUS and PAM-CRASH Support for Faurecia offices in Germany, France, China and USA

CAE GROJEC Altair Software used in Grojec:

HyperWorks

Technical perfection, automotive passion.

HyperMesh pre-processing (meshing and model preparation) HyperCrash pre-processing (model preparation) HyperGraph pre-processing + post-processing HyperView post-processing (model evaluation and results )

RADIOSS explicit solver

CAE GROJEC HyperMesh support Meshing HypeMesh

Single parts (wires, tubes, metal parts etc.) Assemblies Mechanisms (solid meshing) Complete seats

Technical perfection, automotive passion.

Car environment

CAE GROJEC HyperMesh support

Single parts Assemblies Mechanisms Complete seats Car environment

Technical perfection, automotive passion.

Welding and spot welds definition (up to 200 points) Pivots, screws , rivets Property definition (thickness, type of elements, materials, etc) Contact definition

CAE GROJEC HyperMesh support

Single parts Assemblies Mechanisms Complete seats Car environment

Technical perfection, automotive passion.

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CAE GROJEC HyperMesh support

Single parts Assemblies Mechanisms Complete seats Car environment

Technical perfection, automotive passion.

Include files creations Contact managements Occupants Boundary conditions and loads
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CAE GROJEC HyperMesh support Why HyperMesh?

Simple and friendly user interface User defined applications macros BOM (Bill Of Material) Compatible with most of CAD and FEA software CAD (Catia V5, Catia V4, Unigraphics) FEA (RADIOSS, ABAQUS, PAMCRASH, Ls-Dyna)

Technical perfection, automotive passion.

Smart and powerful algorithm for shell and solid meshing (Batchmesher, HyperMorph) Very efficient in daily work, stable (especially ver. 7) Easy managing of big models (include manager, groups etc. ) Good technical support (customization, trainings)
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CAE GROJEC HyperCrash support Why HyperCrash?

Software available only for RADIOSS (well suited) Visually clear, smart and simple functions: Foam compression tool Easy and fast dummy positioning Seat belts generator Contact interfaces manager Penetrations and intersections checker Quality manager

Technical perfection, automotive passion.

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CAE GROJEC Hyper View support Why HyperView?

One post processing tool for all codes Simple and user friendly interface Easy graph creation Possibility to compare crash- with calculation results Simple and intuitive results visualization Macros and user defined functions

Technical perfection, automotive passion.

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CAE GROJEC Radioss solver support

Technical perfection, automotive passion.

FEA explicit calculations using Altair Software - Radioss

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CAE GROJEC Radioss solver support

E C E R 17
H eadr estraint M om ent T e st M om ents:
Test with dummy (50%) Speed = 56km/h

Technical perfection, automotive passion.

ECE R94

Dynamic Test (Protection of the occupants in the event of a frontal collision into a 40% barrier)

ECE R17

Dyna m ic Test (Fron tal- and rear im pact ) Test wi thout Dumm y Speed = ca. 4 5 km /h Deceleratio n = 20 g for 30 ms

- Better part of: -Dynamic tests

M om ent about H -Point H e adrest

= 373 Nm = 373 Nm

ECE R14

E C E R 17
Load Test (H -Po int) M o men t = 530 Nm

-Static and quasi-static tests

Belt anchorage 3 Point Loads: Pelvic = 13500N Torso body block = 13500N Aditional: 20 x seat weight (if at least 1 Anchorage is at the seat)

ECE R21
Test of the minimum radius During the test, it is determined whether parts within the impact zone used for reinforcement may be displaced or protrude so as to increase the hazards to passengers or the severity of injuries.

Verzgerung in g

ECE R14
Dynamic Test 95th percentil dummy Pulse ECE R 16 50km/h Airbag deactivated

ECE R16
Dynamic Test Test with dummy (50%) Speed = 50km/h deceleration = 26g - 32g

35 30 25 20 15 10 5 0 0

G C D E

B A

EC E R 17 EC E R 25
I
80

F
20 40 Zeit in ms 60

Headrestraint Im pact Test Impact Speed Reduced m asse max. decele ration max. decele rations time = = = = 24,1km /h 6,8 kg 80 g 3m s

ECE R17
Dynamic Test (Luggage Load Protection) Two Types of Test Bodies Weight = 18kg and 10kg Speed = ca. 50km/h Deceleration: acc. to crash corr.

Verzgerung in g

ECE R95
Dynamic Test (Lateral collision) Test with EUROSID Dummy (50% Dummy) Speed = 50 km/h Deceleration = according to the mobile barrier

30 28

20

10

0 0 20

40 50

6065 80 Zeit in ms

100

120

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CAE GROJEC Radioss solver support Dynamic tests:

- Frontal Collison

Technical perfection, automotive passion.

- Rear Collision

- Luggage Load Protection

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CAE GROJEC Radioss solver support Static (quasi static) tests:

- Seat Belt Anchorage ECE R 14

Technical perfection, automotive passion.

- ISOFIX test ECE R 14

-Static (quasi static) and dynamic customer defined tests, with all requested configurations.

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CAE GROJEC Radioss solver support

Technical perfection, automotive passion.

Acceptable results compared to reality. Convergence 75-90%

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CAE GROJEC Radioss solver support Test calculation convergence: 92%

Technical perfection, automotive passion.

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CAE GROJEC Radioss solver support Why RADIOSS?

Included in HyperWorks package Code very stabile regarding unexpected issues

Technical perfection, automotive passion.

Work very well with big models (include structure, transform cards, C-Nodes, etc.) Proper material definitions for most of materials (i.e.. Foam) Able to work in DMP mode Efficient calculation time Convergence with real test (75-92%) Used by our customers (Peugeot, Citroen, Ford, FIAT, etc.)

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CAE GROJEC Conclusion!

Why we are using HyperWorks software?

Technical perfection, automotive passion.

One package for pre-, post-processing and explicit solver: Simple User friendly Well prepared user interface User defined functions and macros Ready to develop Open to customers suggestions and customization V7 release very stable HypeMesh best tool in terms of meshing and model preparation (interface, tools and graphic visualization) HyperView intuitive interface, powerful graphs , smart, fast, easy to customize, tpl RAIDOSS worldwide used by our customers, wide range of posibilities (explicit, implicit), acceptable accuracy

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CAE GROJEC Future view!

1. 2. 3. 4. 5. 6. 7. 8. 9.

Technical perfection, automotive passion.

Strong collaboration is expected between Faurecia and Altair Radioss explicit evaluation accuracy 90-95% Implementing Radioss as a main calculation code Dummy improvements (rigid, deformable) Sixth stars and Radioss calculation whiplash methodology Implementing Radios implicit as a stabile solution for qusi-static calculation Implementation more and more of Optistruct in seat development BatchMesher evaluation Stabilization of Hyper Works v8 on Linux platform

Technical perfection, automotive passion.

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European HyperWorks Technology Conference, Germany, Berlin 23-24 October

Technical perfection, automotive passion.

Thank You For attention !

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