automotive CAECompanion 2019/20

AUTOMOTIVE CAE COMPANION

Computer Aided Engineering Simulation Methods Automotive Engineering SEMINARS

CONFERENCES

KNOWLEDGE

News, Knowledge Exchange and Networking for Experts

Functional Development Material Characterization CAE Technology

gns – GESELLSCHAFT FÜR NUMERISCHE SIMULATION MBH Am Gaußberg 2 38114 Braunschweig Phone: 0531-80112-0 mbox@gns-mbh.com

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automotive CAE Companion 2019/2020

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Engineering

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automotive CAE Companion

Table of Contents 6 Preface 7 In-house Seminars 8 Seminar Guide

32 Seminar: Design and Simulation of Vehicle Vibration 33 Wissen: Topology Optimization for Crash- loaded Structures 35 Seminar: Structural Optimization in Automotive Design - Theory and Application 36 Wissen: Robust Design Strategies for CAE- based Virtual Prototyping 38 Seminar: Robust Design - Vehicle Development under Uncertainty Tools 40 Seminar: Introduction to the Python Programming Language 41 Wissen: Basics: Consistent Units 42 Seminar: Python-basedMachine Learning with CAE Applications  NEW 43 Seminar: Possibilities and Limitations of Virtual-based Development using the Example of Interior Components 44 Conference: HumanModeling and Simulation 46 Wissen: THUMS Version 6 AM50, AF05, AM95 Occupant Models 48 Wissen: Global Human Body Model Consortium (GHBMC) Detailed and Simplified Occupant Modeling  NEW Modeling of Materials & Connections 50 Wissen: Material Models and Failure Criteria of Glass for Crash Simulation – X-FEM 54 Wissen: Material Models for Metallic Materials 56 Seminar: Material Models of Metals for Crash Simulation 57 Wissen: Advanced ConstitutiveModels for Challenging Forming Simulations 59 Wissen: Material Models for Polymeric Materials

Engineering 10 Conference: automotive CAE Grand Challenge 11 Seminar: Crashworthy Car Body Design for new and classic vehicle concepts 12 Seminar: Car Body Design for Analysis Engineers 13 Seminar: Lightweight Design Strategies for Car Bodies 14 Conference: Lightweight Design Summit 15 Seminar: Design of Composite Structures 16 Seminar: CAE Intensive Training Course for Automotive Engineers 17 Seminar: Early Increase of DesignMaturity of Restraint System Components in the Reduced Prototype Vehicle Development Process 18 Seminar: Pedestrian Protection - Development Strategies 19 Wissen: Functional Development: Pedestrian Protection 21 Conference: PraxisConference Pedestrian Protection 22 Seminar: Introduction to Fatigue Analysis 24 Wissen: Computational Approaches and Simulation of Progressive Damage in Composite Structural Components 26 Wissen: Operational Strength under Consideration of Random Loads in the Frequency Domain 28 Seminar: Design for Durability - Lightweight Car Bodies and Fatigue 30 Seminar: NVH - Background, Practice and SimulationMethodology

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automotive CAE Companion

62 Seminar: Material Models of Plastics and Foams for Crash Simulation 64 Wissen: Material Models for FEMAnalysis of Short Fibre Reinforced Plastics 66 Wissen: Material Models of Composites for Crash Simulation 68 Seminar: Material Models of Composites for Crash Simulation 69 Seminar: Static and Dynamic Analysis of Long-Fibre-Reinforced Plastics 70 Wissen: Spot WeldModeling for Crash Simulation 72 Seminar: Modeling of Joints in Crash Simulation 73 Wissen: Material Parameter Identification - Reverse Engineering Theory 76 Wissen: Model Order Reduction Techniques for Real-time Parametric Crash and Safety Simulations  NEW 80 Wissen: Introduction and Examples of Multiphysics Simulation 82 Wissen: Principles and Applications of FDM, FVM and FEM 84 Wissen: Arbitrary Lagrangian-Eulerian Method (ALE) 86 Wissen: Advances in Direct Time Integration Schemes for Dynamic Analysis 90 Wissen: Meshfree Numerical Modelling of Flows and ContinuumMechanics  NEW 92 Wissen: Meshless Methods: Smoothed Particle Hydrodynamics Method 95 Wissen: Simulation of Fluid Structure Interaction 97 Wissen: Comparison of Notch Stresses from Elastic Plastic FEA and Neuber Approximation

Safety 98 Seminar: Introduction to Passive Safety 100 Seminar: Introduction to Active Safety 102 Conference: SafetyWeek 103 Conference: Automotive Safety Summit Shanghai 103 Conference: SafetyUpDate Graz 104 Seminar: Briefing on theWorldwide Status of Automated Vehicle Policies  NEW 106 Conference: PraxisConference AEB|AES 107 Seminar: International Safety & Crash-Test Regulations 108 Seminar: Vehicle Safety under Self- Certification  NEW 109 Seminar: NCAP - New Car Assessment Programs 110 Seminar: Euro NCAPMPDB Frontal Crash Workshop  NEW 111 Seminar: Crash Safety of Hybrid and Electric Vehicles 112 Seminar: Static Vehicle Safety Tests in Automotive Development 113 Seminar: Development of Frontal Restraint Systems 114 Wissen: Model Based Head Injury Criteria for Head Protection Optimization - SUFEHM 116 Seminar: Whiplash Testing and Evaluation in Rear Impacts

117 Seminar: Side Impact 118 Seminar: Head Impact

81 Imprint 119 Seminar Terms & Conditions 120 Index 121 Seminar Calendar

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automotive CAE Companion

AUTOMOTIVE CAE COMPANION

CAE KNOWLEDGE on 55 pages, more than 60 Seminars & Events A new spring time for CAE? In the last 10 years one could have got the impression, that there is little progress in automotive CAE. But this is not true, besides maturing of existing technology new and promising methods have developed that can lift the virtual car development process to the next level. Since the first use of linear FEM for the analysis of car body structures about 40 years ago a lot of progress has been achieved. Increasing compute power and advances in mathematics, physics and software technology soon allowed to simulate crash tests, aerodynamics and all kind of manufacturing processes. In parallel improvements in pre- and post-processing reduced model setup time drastically and allowed for fast results evaluation. When preparing this year’s automotive CAE Grand Challenge and the new edition of our automotive CAE-Companion, we found that a lot of inspiring things are going on that promise a new spring time for CAE. Partly they are driven by the new global challenges like electrification and autonomous driving the car industry is currently facing. New drivers like Reduced Order Mod- eling, Machine Learning and Artificial Intelligence promise wonderful possibilities and getting increased value out of numerical simulations. Examples of these new and promising technologies you find in this edition of our aCAE Companion among the seminars and knowledge pages. Our seminars and conferences provide in-depth knowledge and help to develop the capabilities to get the most out of the sim- ulation work. Furthermore the seminars will enable CAE specialists to learn how to employ the newmethods for their success. We are happy to present you the ninth edition of the automotive CAECompanion. This edition of the CAECompanion is the result of the work of many dedicated engineers from academics and industry. We would like to thank all contributors and also the advertisers. Their generous support allows us to distribute the CAECompanion free of charge to the worldwide CAE com- munity. We would like to encourage all readers, to get in touch with us if you feel you can also contribute to future editions.

Alzenau, March 2019

Rainer Hoffmann President & CEO

Ralf Reuter

Dr. Dirk Ulrich

Executive Vice President

Director Sales & CAE Training

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automotive CAE Companion

In-house Seminars Seminars at your site - efficient, flexible and customized

Are you looking for an individual and customized training for your employees?

„At BMWwe faced the challenge to train a large number of employees with different professional backgrounds as simulation engineers for crash and occu- pant safety. Based on their successful CAE Intensive Training program carhs.training developed an individual multi week train- ing program for us. This training program combined theory, software and project training in an ideal manor. We were very pleased about the success and the pro- fessional handling of the project. We can recommend carhs.training to companies that have individual and complex training needs as a partner for the design and execution of the training.“ Dr. Wolf Bartelheimer Manager Frontal Protection Small Cars BMWAG

Most of the seminars from our training program can also be booked as in-house seminars in German or English language. Whether on your com- pany site or at a venue of your choice, the scale of our in-house seminars is tailored to your needs. Your advantages „ „ You retain full cost control. We offer attractive fixed prices for our in-house seminars, depending on the number of participants and the related service.

„ „ Even for a small number of participants you can save a lot compared to the individual booking of seminars. Additionally, there are no costs for travel and time of your employees. „ „ We respect your target dates as far as possible – also upon short notice in „urgent cases“. „ „ You benefit from our professional organization and the top-quality seminar manuals. „ „ Our lecturers answer your individual questions. „ „ Even if you are interested in very specific questions – we are looking for a qualified lecturer and develop the seminar. Many of our customers have integrated our in-house seminars into their company’s training program. Take advantage of this offer, too! We will be pleased to prepare you an individual offer. Contact persons

Dr. Dirk Ulrich

Sofia Antoniadou

Tel. +49 6023 9640 66 dirk.ulrich@carhs.de

Tel. +49 6023 9640 76

sofia.antoniadou@carhs.de

References: ACTS, AUDI, Autoform, AZOS, Bentley Motors, Bertrandt, BMW, Bosch, Brose, CATARC, Continental, CSI, Daimler, Dalphimetal, Delphi, Dura Automotive, EDAG, Faurecia, Ford, Global NCAP, Grammer, HAITEC, Honda, IAV, IDIADA, IEE, JCI, IVM, Key Safety Systems, LEAR, Magna, Mahindra &Mahindra, MBtech, MESSRING, MGA, Opel, Open Air Systems, PATAC, P+Z, SAIC, SMP, SMSC, SEAT, Siemens, TAKATA, TASS, Tata, TECOSIM, TRW, TTTech, VIF, Visteon, Volkswagen Attractive Prices With reference to our regular seminar fees we offer attractive discounts on our in-house seminars: 1 Day Seminar Discount for the 2 Day Seminar Discount

for the 50% 5 th - 8 th participant 70% 9 th - 12 th participant 75% 13 th - 16 th participant 80% 17 th - 20 th participant 85% from the 21 st participant

30% 5 th - 8 th participant 60% 9 th - 12 th participant 70% 13 th - 16 th participant 75% 17 th - 20 th participant 80% from the 21 st participant

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automotive CAE Companion

Seminar Guide

Here you find the courses you need to get your job done!

Durability & Fatigue ► ► Introduction to Fatigue Analysis p. 22 ► ► Design for Durability - Lightweight Car Bodies and Fatigue p. 28 ► ► automotive CAE Grand Challenge p. 10 ► ► Lightweight Design Strategies p. 13 ► ► Design and Simulation of Vehicle Vibration p. 32

Legend ► ► Seminar/Event that focusses on this topic ► ► Seminar/Event that deals with this topic (among others)

Crash & Safety ► ► Crashworthy Car Body Design for new and classic vehicle concepts p. 11 ► ► Early Increase of DesignMaturity of Restraint System Components in the Reduced Prototype Vehicle Development Process p. 17 ► ► Pedestrian Protection - Development Strategies p. 18 ► ► PraxisConference Pedestrian Protection p. 21 ► ► Possibilities and Limitations of Virtual-based Development p. 43 ► ► Material Models of Metals for Crash Simulation p. 56 ► ► Material Models of Plastics and Foams for Crash Simulation p. 62 ► ► Material Models of Composites for Crash Simulation p. 68 ► ► Introduction to Passive Safety of Vehicles p. 98 ► ► Introduction to Active Safety of Vehicles p. 100 ► ► SafetyWeek p. 102 ► ► Automotive Safety Summit Shanghai p. 103 ► ► SafetyUpDate Graz p. 103 ► ► Briefing on theWorldwide Status of Automated Vehicle Policies p. 104 ► ► PraxisConference AEB|AES p. 106 ► ► International Safety & Crash-Test Regulations: Current Status & Future Developments p. 107 ► ► Vehicle Safety under Self-Certification: Principles, p. 108

Se

Gu

► ► NCAP - New Car Assessment Programs p. 109 ► ► Euro NCAPMPDB Frontal CrashWorkshop p. 110 ► ► Crash Safety of Hybrid and Electric Vehicles p. 111 ► ► Static Vehicle Safety Tests in Automotive Development p. 112 ► ► Development of Frontal Restraint Systems p. 113 ► ► Whiplash Testing and Evaluation in Rear Impacts p. 116 ► ► Side Impact - Requirements and Development Strategies p. 117 ► ► Head Impact on Vehicle Interiors: FMVSS 201 and UN R21 p. 118 ► ► ... find many more seminars in our SAFETY COMPANION

Materials ► ► Design of Composite Structures p. 15 ► ► Material Models of Metals for Crash Simulation p. 56 ► ► Material Models of Plastics and Foams for Crash Simulation p. 62 ► ► Material Models of Composites for Crash Simulation p. 68 ► ► Static and Dynamic Analysis of Long-Fibre-Reinforced Plastics p. 69

► ► automotive CAE Grand Challenge p. 10 ► ► Lightweight Design Strategies p. 13 ► ► Lightweight Design Summit p. 14

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automotive CAE Companion

Car Bodies ► ► Crashworthy Car Body Design for new and classic vehicle concepts p. 11 ► ► Car Body Design for Analysis Engineers p. 12 ► ► Lightweight Design Strategies p. 13 ► ► Design for Durability - Lightweight Car Bodies and Fatigue p. 28 ► ► NVH - Background, Practice and SimulationMethodology p. 30 ► ► Design and Simulation of Vehicle Vibration p. 32 ► ► Robust Design - Vehicle Development under Uncertainty p. 38 ► ► Lightweight Design Summit p. 14 ► ► Structural Optimization in Automotive Design - Theory and Application p. 35

► ► Modeling of Joints in Crash Simulation p. 72 ► ► Introduction to Passive Safety of Vehicles p. 98 ► ► Crash Safety of Hybrid and Electric Vehicles p. 111

inar de

NVH - Noise Vibration Harshness ► ► NVH - Background, Practice and Simulation Methodology p. 30 ► ► Design and Simulation of Vehicle Vibration p. 32 ► ► automotive CAE Grand Challenge p. 10 ► ► Car Body Design for Analysis Engineers p. 12 ► ► Robust Design - Vehicle Development under Uncertainty p. 38

CAEMethods & Tools ► ► CAE Intensive Training p. 16 ► ► Introduction to Fatigue Analysis p. 22 ► ► NVH - Background, Practice and SimulationMethodology p. 30 ► ► Design and Simulation of Vehicle Vibration p. 32 ► ► Structural Optimization in Automotive Design - Theory and Appli- cation p. 35 ► ► Robust Design - Vehicle Development under Uncertainty p. 38 ► ► Introduction to the Python Programming Language p. 40 ► ► Python-basedMachine Learning with CAE Applications p. 42 ► ► Possibilities and Limitations of Virtual-based Development p. 43 ► ► Modeling of Joints in Crash Simulation p. 72 ► ► automotive CAE Grand Challenge p. 10

√ CAE Basics

► ► CAE Intensive Training p. 16 ► ► Possibilities and Limitations of Virtual-based Development p. 43

Haven’t found what you need? Get in touch with us!  +49 6023 9640 60

9

Engineering

Computer simulation has become an indispensable tool in automotive development. Tremendous progress in software and computer tech- nology makes it possible today to assess product and process perfor- mance before physical prototypes have been built. Despite of significant progress in simulation technology and impressive results in industrial application there remains a number of challenges which prevent a “100 % digital prototyping”. We at carhs.training call these Grand Challenges. Automotive CAE Grand Challenge offers a platform for dialog The automotive CAE Grand Challenge stimulates the exchange between users, scientists and software developers in order to solve these chal- lenges. Annually the current, critical challenges in automotive CAE are being identified through a survey among the simulation experts of the international automotive industry. In the conference one session is ded- icated to each of the most critical challenges, the so-called Grand Chal- lenges. In each session CAE experts from industry, research and software development will explain the importance of the individual Challenge for the virtual development process and talk about their efforts to solve the challenge. Who should attend?

The conference intends bringing together industrial users, researchers and software developers to discuss these current, critical challenges of automotive CAE and to initiate collaboration between these groups to help overcoming the Grand Challenges of automotive CAE. The presentation program of the conference provides both experts and beginners valuable information for their daily work. The possibility to meet and exchange with all stakeholders of automotive CAE is a great opportunity. In the accompanying exhibition participants can receive additional information from leading companies of CAE.

DATE

21.- 22.04.2020

HOMEPAGE

www.carhs.de/grandchallenge

VENUE

Congress Park Hanau, Schloßplatz 1, 63450 Hanau

LANGUAGE

10

Engineering

Crashworthy Car Body Design for new and classic vehicle concepts - Design, Simulation, Optimization

Course Description In the development of a car body different - sometimes con- flicting - design requirements have to be met. Depending on the intended drive unit, the fulfilling of the crash regulations is a key task. Therefore it is mandatory that designers have a good understanding of the crash behavior of mechanical structures. The combination of knowledge about mechanics and the ability to use modern design tools allows for an efficient development process without unnecessary design iterations. The objective of the seminar is to present new methods for crashworthy car body design. At the beginning of the course the mechanical phenomena of crash events will be discussed. Subsequently modern development methods (CAD design and crash simulation) will be treated. Thereafter modern implementations of safety design measures will be presented. Mathematical optimization of structural design - which is increasingly used in industry - will be covered at the end of the course. Who should attend? This 2 day course addresses designers, test and simulation engineers as well as project leaders and managers working in car body development and analysis.

Course Contents „ „ Mechanics of crash events „ „ Accelerations during collisions

„ „ Structural loading during collisions „ „ Examination of real crash events „ „ Stability problems „ „ Plasticity

„ „ Design methods

„ „ Function based design „ „ Car body design „ „ CAE conform design

„ „ Crash simulation

„ „ Finite Element modelling of a car body „ „ Finite Element analysis with explicit methods „ „ Possibilities and limitations „ „ Technical implementation of safety measures „ „ Energy absorbing members „ „ Car bodies „ „ Electric car bodies „ „ Safety systems „ „ Pedestrian protection „ „ Post crash „ „ Use of mathematical optimization procedures in real world applications „ „ Approximation techniques

„ „ Optimization software & strategies „ „ Shape and topology optimization

Prof. Dr.-Ing. Axel Schumacher (University of Wuppertal) studied mechanical engineering at the universities of Duisburg and Aachen. He received his doctorate on structural optimization from the Uni- versity of Siegen. Following research projects for Airbus were focused on the optimization of aircraft struc- tures. Thereafter he worked in the CAE methods development department of Adam Opel AG as project lead- er for structural optimization. From 2003 - 2012 he was a professor at the University of Applied Sciences in Hamburg and taught structural design, passive safety and structural optimization. Since 2012 he has been professor at the University of Wuppertal, where he holds the chair for optimization of mechanical structures.

DATE

COURSE ID

VENUE

DURATION PRICE

LANGUAGE

29.-30.04.2019 69/3319

Alzenau

2 Days 1.340,- EUR till 01.04.2019, thereafter 1.590,- EUR

05.-06.09.2019 69/3320

Alzenau

2 Days 1.340,- EUR till 08.08.2019, thereafter 1.590,- EUR

04.-05.05.2020 69/3465

Alzenau

2 Days 1.340,- EUR till 06.04.2020, thereafter 1.590,- EUR

11

Engineering

Car Body Design for Analysis Engineers

Course Description In general analysis engineers have a sound knowledge on numerical methods and experience in structural analysis with the Finite Element Method. To make a valuable contribu- tion to the vehicle development process using numerical simulation, knowledge on car body design and functional layout is required. To efficiently undertake lightweight design all fundamental requirements have to be taken into account early in the design process. These requirements will be outlined in the seminar. Additionally the characteristics of the specific organization of the development process have to be incorporated. Course Objectives The objective of the seminar is to transfer the knowledge needed for an analysis engineer to play a part in vehicle development. Especially the examination of design variants of existing car bodies makes the seminar descriptive and practical. Who should attend? This 2 day seminar is aimed at analysis engineers working in the automotive industry. Course Contents „ „ Load carrying principles of lightweight design

„ „ Development process described at the example of the improvement of static properties „ „ Principal structure of the development process „ „ CAE-compatible CAD „ „ Finite Element modelling of a car body „ „ Static behavior of the car body structure „ „ Finite Element Analysis of joints „ „ Measures for improved dynamic behavior „ „ Part dimensioning taking into account vehicle vibrations „ „ Dynamic analysis of full vehicles „ „ Measures for improved acoustic behavior „ „ Acoustic design of a car body „ „ Simulation methods „ „ Realization of safety measures „ „ Energy absorption elements „ „ Vehicle car bodies „ „ Safety systems „ „ Pedestrian protection „ „ Post crash „ „ Use of optimization methods in industrial applications „ „ Introduction into mathematical optimization „ „ Approximation techniques

„ „ Optimization software „ „ Optimization strategies „ „ Shape optimization „ „ Topology optimization

„ „ Load assumptions „ „ Design principles „ „ Technology of car body construction „ „ Car body architecture „ „ Structural materials and pre-products „ „ Material selection „ „ Manufacturing methods „ „ Joining techniques

Prof. Dr.-Ing. Axel Schumacher (University of Wuppertal) studied mechanical engineering at the universities of Duisburg and Aachen. He received his doctorate on structural optimization from the Uni- versity of Siegen. Following research projects for Airbus were focused on the optimization of aircraft struc- tures. Thereafter he worked in the CAE methods development department of Adam Opel AG as project lead- er for structural optimization. From 2003 - 2012 he was a professor at the University of Applied Sciences in Hamburg and taught structural design, passive safety and structural optimization. Since 2012 he has been professor at the University of Wuppertal, where he holds the chair for optimization of mechanical structures.

DATE

COURSE ID

VENUE

DURATION PRICE

LANGUAGE

15.-16.10.2019 72/3321

Alzenau

2 Days 1.340,- EUR till 17.09.2019, thereafter 1.590,- EUR

12

Engineering

Lightweight Design Strategies for Car Bodies

Course Description Designing and developing light weight vehicles ready for series production is becoming increasingly important. Espe- cially for fully electric vehicles with large and heavy battery packs light car bodies are indispensable. But also for other propulsion concepts lightweight is desirable. This seminar will focus on production ready vehicle concepts. Ideas taken from the extreme light weight design are integrated into the considerations. A symbiosis of the use of modern lightweight materials and the design of appropriate lightweight struc- tures leads to efficient lightweight design. This multi-disci- plinary task is only possible with development strategies that can simultaneously handle requirements of crash protection, vehicle dynamics, comfort, acoustics, durability and produc- tion of the vehicle. The aim of this seminar is to provide the competencies for the development of light vehicle structures. Who should attend? This seminar is aimed at designers, analysis engineers and project managers from car body development. Course Contents „ „ Potentials of lightweight design

„ „ Materials and their specific design rules „ „ Material selection

„ „ Acquisition of material data „ „ Steel, aluminum, magnesium „ „ Fiber composites „ „ Material mix and recycling „ „ Structures of lightweight design „ „ Space-frame structures „ „ Shell structures (beads, ribs, ...) „ „ Foams and inlays „ „ Composite sandwich structures

„ „ Related joining techniques (adhesive bonding, ...) „ „ Advanced CAE methods for lightweight design „ „ Stability (buckling, ...) „ „ Dynamics and acoustics „ „ Fracture mechanics, multi-scale models (observation of cracks, etc.) „ „ Crash of small structures „ „ Analysis of joints „ „ Robustness analysis „ „ Optimization of shape and dimension „ „ Case studies „ „ Selected Vehicle Components

„ „ Motivation and problem definition „ „ Current lightweight vehicle concepts „ „ The "Lightweight Spiral"

„ „ Ultra-lightweight vehicle concepts „ „ Vehicle concepts for mass production

„ „ Principles of lightweight design „ „ Definition of requirements „ „ Determination of design loads

„ „ Principal design rules „ „ Approaches of bionics „ „ Fail-safe, safe life, damage tolerance „ „ Methodical concept finding (architecture, topology)

Prof. Dr.-Ing. Axel Schumacher (University of Wuppertal) studied mechanical engineering at the universities of Duisburg and Aachen. He received his doctorate on structural optimization from the Uni- versity of Siegen. Following research projects for Airbus were focused on the optimization of aircraft struc- tures. Thereafter he worked in the CAE methods development department of Adam Opel AG as project lead- er for structural optimization. From 2003 - 2012 he was a professor at the University of Applied Sciences in Hamburg and taught structural design, passive safety and structural optimization. Since 2012 he has been professor at the University of Wuppertal, where he holds the chair for optimization of mechanical structures.

DATE

COURSE ID

VENUE

DURATION PRICE

LANGUAGE

01.-02.04.2020 127/3466

Alzenau

2 Days 1.340,- EUR till 04.03.2020, thereafter 1.590,- EUR

13

Engineering

The »Automobil Industrie« - Lightweight Design Summit is the high- class networking event for trendsetters in lightweight design in the automotive industry. Meet OEMs and suppliers on 24./25. March 2020 at the Vogel Convention Center inWürzburg, Germany. Keynotes and expert presentations, technical sessions and live demonstrations highlight the importance of lightweighting for the future of the automotive industry. Discussions about innovative ideas and the networking between experts fromOEMs and suppliers are at the core of the Light Weight Design Summit. Who should attend? The Automobil Industrie Light Weight Design Summit is the plat- form for the communication between OEMs and suppliers. The summit addresses the technical management/CEO level of OEMs and suppliers, the purchasing management, heads of development and design, project engineers, innovation managers and materials specialists.

DATE

24.-25.03.2020

HOMEPAGE

www.leichtbau-gipfel.de

VENUE

Vogel Convention Center, Würzburg

LANGUAGE

German with simultaneous translation into English

14

Engineering

Design of Composite Structures

Course Description Since the mass is one of the main factors influencing the fuel consumption of vehicles, increasing demands to reduce energy usage and CO2 emissions, force the automotive industry to consider the use of alternative designs and new materials. Composite materials have proven their potential to reduce the weight of structures in many applications (e.g. aerospace and motorsports). As composites have a special set-up and behave completely different than traditional ma- terials, engineers must learn how to employ these materials to take advantage of their special characteristics in the design of vehicle structures. In the seminar real world examples are used to create a basic understanding of designing composite structures. Then the theoretical and practical foundations of composite design are explained. Course Objectives After participating in the seminar participants are able to design and develop composite structures. They understand the specific requirements of composite structures and the related design concepts. In the seminar special attention is directed to the concurrent consideration of loading, design and manufacturing related requirements. Accordingly, the different designs - integral, differential, fully laminated and sandwich - are addressed. The seminar also provides knowledge about preliminary design and FE analysis based on classical laminate theory.

Who should attend? This seminar is especially designed for engineers and technicians who work in the development departments of automotive manufacturers, suppliers and engineering service providers and deal with the design and development of composite components.

Course Contents „ „ Introduction

„ „ Elastic behavior of composites „ „ Failure of composite materials „ „ Mechanics of composite materials and structures „ „ Joining technologies for composites „ „ Design of composite structures „ „ Fatigue and strength of composites

Dr. Roland Hinterhölzl (University of Applied Sciences Upper Austria) has been heading the Professorship Composite Materials and the study degree program “Lightweight Design and Composite Materials” at the University of Applied Sciences Upper Austria since 2016. From 2010 to 2016 he was head of the numerical simulation department of the Institute for Carbon Composites at the Technical University of Munich. The focus of his work is on process simulation and structural analysis for the automotive and aviation industries. Dr. Hinterhölzl received his doctorate in 2000 at the University of Innsbruck on the simulation of the time-dependent behavior of composite materials, after he had spent several months at the Department of Aerospace Engineering and Engineering Mechanics at the University of Texas at Austin and CRREL (USA). Subsequently, he developed innovative composite components at the aerospace supplier FACC AG and head- ed the structural analysis department.

DATE

COURSE ID

VENUE

DURATION PRICE

LANGUAGE

24.-25.09.2019 135/3428

Alzenau

2 Days 1.340,- EUR till 27.08.2019, thereafter 1.590,- EUR

31.03.-01.04.2020 135/3476

Alzenau

2 Days 1.340,- EUR till 03.03.2020, thereafter 1.590,- EUR

15

Engineering

Become a CAE Specialist in 3½Weeks Intensive Training Course for Automotive Engineers

Content, Duration, Software The contents of the training and the software used can be adapted to individual customer needs. Through the adapta- tion of the content the training can be made to ideally fit the framework of the customer. At BMW, we had been facing the challenge to train a larger group of employees with very different backgrounds to become simulation engineers for crash and occupant simulation. carhs.training has - based on their proven CAE intensive training - developed a unique, multi-week training scheme, which has linked in ideal way theory, software and project training. We were very satisfied with the success of the action and the professional execution of this large training project. We can recommend carhs. training to companies that have individual and complex training requirements as a partner for the conception and implementation of large training programs. Dr. Wolf Bartelheimer, Head frontal protection small cars BMWAG Your Benefits Our goal is to train newcomers and job changers in the shortest time possible to become simulation engineers in the automotive industry. Participants benefit from the practical experience of the trainers and exercises from industrial practice. For the employer, our CAE intensive training is undoubtedly the most efficient way to train new simulation engineers: it is focused and fast, and binds no other employees of the company. Dates and prices upon request and subject to individual agreement with each customer.

In cooperation with experts from industry, engineering, research, software development, universities and our partner company TecosimGmbH, carhs.training offers an unique intensive training as a basic training for structural analysis engineers in automotive development. The training covers the areas of statics, dynamics and NVH, as well as crash and occupant simulation. The contents can be adapted to the needs of the customer. Focused on the Industrial Development Process The training program puts the theoretical background, the mastering of the industrial CAE processes and the use of numerical simulation in automobile development in the foreground. Therefore, in this training a complete CAE driven development process - from the compilation of the specifica- tions to the editing of the final reporting - is reproduced. Software Training The professional handling of current simulation software is part of the training, but not the main objective of it. Skilled analysis engineer must be able to use common software tools, but only well-founded expertise and knowledge of modern development processes and methods will allow to successfully contribute to vehicle development. Basics - Tools –Methods As part of this intensive training the participants will refresh the theory of numerical simulation and will learn to profes- sionally use popular simulation software such as ABAQUS, NASTRAN, OptiStruct, LS-DYNA, PAM-CRASH and pre-and post-processors such as HYPERMESH, ANSA and Animator within vehicle development. Ideal Learning Environment The training takes place in our modern training facilities in Alzenau, Cologne, Munich and Ruesselsheim or directly at the customer’s site. For the duration of the course powerful notebooks are provided free of charge allowing the partic- ipants to deepen theory and practice outside the course hours. Trainers from Simulation Practice The trainers are experts from universities and research institutes, the software manufacturers and experienced engi- neers from our partner company Tecosimwho daily perform industrial simulation projects and are familiar with the real challenges of simulation in automotive development.

In collaboration with:

16

Engineering

Early Increase of DesignMaturity of Restraint SystemComponents in the Re- duced Prototype Vehicle Development Process Course Description of the systems.

The number of hardware prototypes available for the devel- opment of restraint systems and restraint system compo- nents is declining steadily due to an increasing cost pressure in automotive development. In the project schedule the availability of hardware (restraint system components and / or vehicle environments) shifts to the late vehicle develop- ment phases. As a result, ensuring the required degree of ma- turity of restraint system components, in addition to the sole functional development of seatbelts and airbag, necessitates new strategies and development paths. In this seminar, current risks in the development of seatbelts and airbags are addressed and ideas for the early increase of maturity are elucidated. This is done by explaining the link between milestones in the development schedule, the functional requirements of restraint system components, the development duration of restraint system components and the description of approaches for the creation of substitutes of vehicle environments in the early development process. In addition the project schedules of conventional vehicle de- velopment processes and prototype-reduced development processes of base line models and derivatives are shown. Interactions of the development of seatbelts and airbags with surrounding components (e.g. trim parts) are also discussed. Course Objectives The course provides thoughts and ideas for a successful approach in the development of restraint systems within vehicle development processes in which only a small number of prototypes are available for verification and optimization

Who should attend? The seminar is aimed at engineers and project managers of restraint systems and restraint system components develop- ment, as well as heads of teams or departments in the field of passive safety, which want to gain, in addition to the pure functional development of restraint systems, an overview of the requirements of the prototype-reduced restraint system development with regard to achieving and ensuring the necessary degree of maturity of belts and airbags. Course Contents „ „ Overview and differences of vehicle development schedules „ „ Standard project schedule „ „ Prototype-reduced development of lead series „ „ Prototype-reduced development of derivatives „ „ Safety belts „ „ Examples of requirements for safety belts „ „ Prerequisites and timing for functional development „ „ Timing for homologation and certification „ „ Ideas / possibilities for creating vehicle environments „ „ Interactions with surrounding components „ „ Airbags „ „ Examples of requirements for airbags

„ „ Prerequisites and timing for functional development „ „ Ideas / possibilities for creating vehicle environments „ „ Interactions with surrounding components

Sandro Hübner (EDAG Engineering GmbH) studied mechanical engineering at the University of Applied Sciences Schmalkalden. After completing his studies he worked as an engineer in the FEM laboratory of Schmalkalden University of Applied Sciences. From 2003 he worked as a CAE engineer for occupant safety at EASi Engineering GmbH. In 2006, he moved to EDAG Engineering GmbH as a CAE engineer for vehicle safety and has been project manager for vehicle safety and CAE since 2013.

DATE

COURSE ID

VENUE

DURATION PRICE

LANGUAGE

03.06.2019 166/3329

Alzenau

1 Day 790,- EUR till 06.05.2019, thereafter 940,- EUR

14.10.2019 166/3328

Alzenau

1 Day 790,- EUR till 16.09.2019, thereafter 940,- EUR

17

Engineering

Pedestrian Protection - Development Strategies

Course Description Euro NCAP annually adjusts details in its pedestrian rating protocols and even U.S. NCAP plans to introduce a pedestrian protection assessment. Stricter injury criteria, modified testing areas and the testing of vehicles that were previously not tested because of their weight, require the thorough knowledge of the requirements and a strict implementation of the requirements in the development process. In the introduction the seminar informs about the different impactors that are used for pedestrian safety testing. There- after the various requirements (regulations and consumer tests) are explained and compared. The focus of the seminar is on the development strategy: Which decisions have to be taken in which development phase?What are the tasks and priorities of the person in charge of pedestrian protection? As a background, ideas and approaches towards the design of a vehicle front end in order to meet the pedestrian protection requirements are discussed. In addition to that, the seminar explains how the function of active bonnets can be proven by means of numer- ical simulation. This includes both, the pedestrian detection that need to be proven with various impactors or human models, as well as the proof that the bonnet is fully deployed at the time of impact.

Who should attend? The seminar is intended for development, project or simula- tion engineers working in the field of vehicle safety, dealing with the design of motor vehicles with regard to pedestrian protection. Course Contents „ „ Introduction with an overview of current requirements regarding pedestrian protection „ „ Legal requirements (EU, UN Regulations, Japan, GTR) „ „ Consumer tests (Euro NCAP, U.S. NCAP, JNCAP, KNCAP) „ „ Presentation and discussion of the design and application of the impactors „ „ Leg impactors (Flex PLI, Upper Legform) „ „ Head impactors (Child head, Adult head) „ „ Methods in numerical simulation, testing and system development „ „ Requirements on the design of vehicle front ends for pedestrian protection „ „ Development strategy

„ „ Interaction between simulation and testing „ „ Integration in the vehicle development process „ „ Solutions to fulfill the requirements „ „ Passive solutions „ „ Active solutions (active bonnets, airbags)

Maren Finck (carhs.training gmbh) is a Project Manager at carhs.training gmbh. From 2008 - 2015 she worked at EDAG as a project manager responsible for passive vehicle safety. Previously, she worked sev- eral years at carhs GmbH and TECOSIM as an analysis engineer with a focus on pedestrian safety and biome- chanics.

DATE

COURSE ID

VENUE

DURATION PRICE

LANGUAGE

28.10.2019 152/3370

Alzenau

1 Day 790,- EUR till 30.09.2019, thereafter 940,- EUR

19.12.2019 152/3369

Alzenau

1 Day 790,- EUR till 21.11.2019, thereafter 940,- EUR

18

Engineering WISSEN CAE

Functional Development: Pedestrian Protection - Lower Leg Impact

Requirements/Critical Target Values: „ „ UN R127: Impactor:

Flex PLI Legform Impactor

Test Conditions:

40 km/h (11.1 m/s), 0°, 75 mm over ground

Criteria: Tibia Bending Moment

< 340 Nm (up to 264 mm: 380 Nm)

MCL Elongation

< 22 mm < 13 mm

ACL/PCL Elongation

„ „ Euro NCAP

Impactor:

Flex PLI Legform Impactor

Test Conditions:

40 km/h (11.1 m/s), 0°, 75 mm over ground

Criteria:

maximum Score

0 Points

Tibia Bending Moment

< 282 Nm < 19 mm < 10 mm

≥ 340 Nm ≥ 22 mm ≥ 10 mm

MCL Elongation

ACL/PCL Elongation

Procedures: „ „ Use of full vehicle models (impact area: detailed models of all components; motor package can be rigid) „ „ High detailing for bumper, radiator, grill, optional accessories (head light cleaning system, parking sensors etc.) „ „ Proper material characterization for plastic parts is required incl. failure definition „ „ Connection modeling is highly significant (clips, sliding components) „ „ Use of validated impactor model „ „ Typical simulation duration: 40 ms (up tp complete rebound→ legform impactor completely separated from vehicle) Critical Modeling Parameters: „ „ Strain rate dependency of materials in the impact area „ „ Details of spatial discretization Evaluation Criteria: „ „ Tibia Bending Moment „ „ MCL Elongation „ „ ACL/PCL Elongation „ „ For the optimization: Plot the above criteria vs. displacement to identify jamming Main Influencing Factors: „ „ Geometry of vehicle front (impact points, impact behavior) „ „ Material stiffness at impact point (potential for optimization) „ „ Stiffness of geometrical package „ „ Clearance between outer bumper shell and bumper beam (minimum 80 mm, filled with energy-absorbing foam or deformation elements) „ „ No jamming elements (e.g. parking sensors) should be placed directly in front of the bumper beam „ „ Homogeneous support of the impactor along the full vehicle width is required. „ „ Sharp stiffness gradient should be avoided.

19

Engineering WISSEN CAE

Functional Development: Pedestrian Protection - Head Impact

Requirements/Critical Target Values: „ „ UN R127: Impactors:

3.5 kg & 4.5 kg Headform Impactor

Test Conditions & Criteria:

Phase 2

Child/Small Adult

3.5 kg / 35 km/h (9.7 m/s) / 50° BLE/WAD 1000 - WAD 1700 / Bonnet rear edge 4.5 kg / 35 km/h / 65° WAD 1700 - Bonnet rear edge/WAD 2100 < 1000 (1/2 of the Child head impact area AND 2/3 of the total impact area) <1700 (remaining area)

Adult HIC 15

„ „ Euro NCAP:

Impactors:

3.5 kg & 4.5 kg Headform Impactor

Test Conditions:

Child/Small Adult 3.5 kg / 40 km/h (11.1 m/s) / 50° BLE/WAD 1000 - WAD 1500 Adult 4.5 kg / 40 km/h (11.1 m/s) / 65° WAD1500 -WAD2100 (if points betweenWAD1500 and1700 areonbonnet, use childhead)

Criteria:

maximum Score

0 Points

HIC 15

< 650

≥ 1700

Procedures: „ „ Use of full vehicle models (impact area: detailed models of all components; engine package can be rigid) „ „ High detailing for bonnet attachments, hinges, locks, sealing structures, bonnet shock damper, head light attachments, windshield wiper assemblies „ „ Connection modeling is highly significant (spot welds, adhesives etc.) „ „ Use of validated material model for windshield failure

„ „ Use of validated impactor model „ „ Typical simulation duration: 20 ms Critical Modelling Parameters: „ „ Strain rate dependency of materials in the impact area „ „ Details of spatial discretization Evaluation Criteria: „ „ Head Injury Criterion (HIC 15 ) „ „ For the optimization: use of acceleration - displacement diagrams to identify jamming Main Influencing Factors:

„ „ Geometry of vehicle front (impact points, impact behavior) „ „ Material stiffness at impact point (potential for optimization) „ „ Stiffness of geometrical package (sheet metal thickness, structural reinforcements in direction of impact, inlays, application of adhesives) „ „ Clearance between bonnet outer shell and package (min. 60 - 80 mm free displacement required, otherwise an active bonnet should be considered) „ „ No jamming elements (e.g. bonnet shock dampers, wiper axles) should be packaged directly in the impact area „ „ Homogenous support of the impactor along the full bonnet/vehicle width is required (e.g. muffin-like structure for the bonnet inner shell). „ „ Sharp stiffness gradient should be avoided.

20

Engineering

14 th PraxisConference Pedestrian Prote on

The PraxisConference Pedestrian Protection is held every June or July with about 170 par- ticipants, including delegates from all major OEMs. It is the world’s largest expert meeting in the field of pedestrian protection. The intensive discussions at the info-points and be- tween the presentations show that the participants value the innovative conference con- cept. Highlights of the event are the demonstrations in the laboratory of Germany’s Federal Highway Research Institute and theOEM’s presentations of pedestrianprotecting solutions implemented in current car models. Although the industry has been working on pedestrian protection for many years now, the constant development of the requirements (regulations and NCAP) continuously raises new questions that will be answered during this conference. Expert speakers provide concentrated information regarding current and future require- ments, latest research findings and technical solutions. Both, testing and numerical simula- tion are covered in the conference presentations. In addition to this the conference offers hands-on praxis session in the laboratory. Here, test equipment and impactors are demonstrated and explained in detail. The preparation, execution and analysis of pedestrian impact tests are shown in live demonstrations. Conference Topics: „ „ Current status and future development of the regulations (UN R127, GTR 9) „ „ Global consumer protection requirements for pedestrian protection „ „ Future development of impactors (e.g. aPLI) „ „ Pedestrian AEB systems „ „ Pedestrian safety technologies (active bonnets, airbags)

„ „ Test equipment Who should attend?

The PraxisConference is suited for pedestrian protection experts from throughout the in- dustry. Even beginners will find the event an excellent opportunity to quickly acquire theo- retical and practical knowledge and become part of the expert community.

DATE

26.-27. June 2019

Co-hosted with

HOMEPAGE

www.carhs.de/pkf

VENUE

Bundesanstalt für Straßenwesen, Brüderstraße 53, 51427 Bergisch Gladbach

LANGUAGE

German with simultaneous translation into English

PRICE

1.490,- EUR till 29.05.2019, thereafter 1.750,- EUR

BGS Böhme & Gehring GmbH

21

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