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Digital Mock-Up Functional Simulation for Product Conception and Do wnstream Processes

Objective


Based on the analysis of user requirements in four different areas of application (dynamics, flexible parts, electro-magnetic compatibility ad aerodynamics), a set of common user requirements was identified. This led to the definition of the integration tools required, the core system, which contains common functionality as:
- Data base;
- Visualisation;
- Application manager;
- Drivers and tool boxes;
- The Core system and existing simulation tools were used to build demonstrators for different areas of applications. This way the integration of simulation tools could be demonstrated and tested. Most of the concepts and software of this project have been inserted into commercial products that are generally available by the time of this report.

The following software products were involved:
Dassault Systèmes;
Catia V5;
LMS
Virtual.lab;
Fraunhofer Gesellschaft, Institut für graphische Datenverarbeitung;
Visualisation system;
University of Parma.
PARTICLE
Samtech
BOSS Quattro
SAMCEF/MECANO.

The Benefits:
The benefits of that project are two-fold, depending on the view of the end users and of the IT vendors:
The application of the results within user companies, like automotive and aerospace industries, as well as other industries, will achieve dramatic changes in the processes and the benefits from the resulting changes will be:
- Dramatic reduction of the development time;
- Product quality improvement;
- Reduction of redesign costs.

The economic benefits will accumulate within the next four to five years to:
- Reduction of physical mock-ups - 10%;
- Reduction of costs due to late design changes - 10%;
- Reduction of scrapping volume - 15%;
- Reduction of resources and service tools not necessary - 20%.

On the other hand, the IT vendors gained from the user input of new ideas to enhance their existing products or develop new ones. Some parts of the evaluated prototype software are already available in the market. That means that the positions of those companies were already strengthened and will continue to be in the future.
Current industrial practice in automotive, aerospace and other manufacturing industries involves the creation of physical product models (physical mock ups) as a help to designers, manufacturing planners, etc. The objective of the(se) project(s) is to depart from this practice and develop the technology that allows designers, manufacturing planners and even the management to work on Virtual Products /Digital Mock Up s (DMU). So they can make decisions related to the concept, design and all downstream processes. This technology will allow companies to work in a concurrent engineering environment independent of their size and product configuration. To achieve this goal a cluster of projects including modelling, simulation,
visualisation, etc. is proposed.
Within this cluster of projects the objectives of the DMU FS project is to develop the technology which allows the designer to simulate all product functionalities under operating conditions within a Digital Mock Up. This includes simulation of rigid, flexible and deformed product parts with their operational attributes. Primarily adressed are physical effects of mechanics/loads, thermodynamics,
electromagnetics or fluid dynamics that will cause part deformations, function failures, or collision of parts.
Especially the following four domains will be covered in this project: Aerodynamics in the early design phase
Electromagnetic compatibility (EMC)
Dynamic behaviour of engine / undercarriage in terms of thermal and/or space aspects
Behaviour of tubes and flexible parts.
The benefits of this technology will include substantial improvement of product launch quality. Furthermore a DMU with the ability to simulate every possible product function, product state and product environment condition will finally beat a "traditional" physical mock up in every way. Dismissing physical mock ups will reduce development time significantly (at least 15%).
It is expected that the functional simulation technology will benefit not only automotive and aerospace industry but other industrial manufacturing sectors such as house appliances, machine building industry, ship building etc. The composition of this consortium includes end users, technology vendors and institutes and guarantees a successful performance of the project.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Volkswagen AG
Address
2,Berliner Ring 2
38436 Wolfsburg
Germany

Participants (8)

Alenia Aerospazio Un'Azienda Finmeccanica SpA
Italy
Address
Corso Marche 41
10146 Torino
Dassault Systèmes SA
France
Address
9,Quai Marcel Dassault 9
92156 Suresnes
Fraunhofer-Gesellschaft zur Förderungder Angewandten Forschung e.V.
Germany
Address
Wilhelminenstrasse
64283 Darmstadt
LEUVEN MEASUREMENTS AND SYSTEMS INTERNATIONAL NV
Belgium
Address
68,Interleuvenlaan 68, Researchpark Haasrode
3001 Heverlee
Rover Group Ltd.
United Kingdom
Address
Fletchamstead Highway B41
CV4 9DB Coventry
Régie Nationale des Usines Renault
France
Address
8/10,Avenue Emile Zola
92109 Boulogne-billancourt
SAMTECH SA
Belgium
Address
25,Parc Scientifique Du Sart-tilman, Rue Des Chasseur
4031 Angleur
UNIVERSITÀ DEGLI STUDI DI PARMA
Italy
Address
Viale Delle Scienze
43100 Parma