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Knowledge based engineering of side impact beams
2009 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

Product development is a race against time to meet the specified customer demands with as competitive price as possible. Gestamp HardTech is one of the leading manufacturers of side impact beams for automotives in the world. To stay competitive Gestamp HardTech works very hard improving key issues such as manufacturing methods, quality, material usage and product development processes. In an industry where every gram counts even small improvements can make a great difference. The objective with this master thesis is to cut development time and improve the final product by implementing Knowledge Based Engineering in the early stages of product design and product optimisation. The developed tools reassure a good starting point of every beam considering manufacturability, cost and energy absorption. As a direct result, the development time can be shortened which gives more opportunities for geometric optimisation. This results in a lighter and stronger beam, which means safer and more energy efficient automobiles. By developing a superior and more profitable product Gestamp HardTech will most likely increase their market share as well as product margins. Another great bonus worth mentioning is that these tools also act as an educational framework presenting most of the information necessary to consider when designing a side impact beam. This thesis has been conducted in line with the method referred to as systematic product development together with influences from similar methodologies. The project has, in short, been divided into a number of phases: Feasibility Study, Identification of Product Demands, Implementation followed by Product Testing and Evaluation. Through interviews and company documentation we could distinguish important design rules required by different departments such as economy, production and quality. These rules were implemented to already existing CAD starting models by using the NX Knowledge Based Engineering module called Knowledge Fusion. Designing a side impact beam includes several time consuming and repetitive tasks which could more or less be automated by creating standalone programs using the NXOpen API. The final directive included in this thesis proposed a connection between the CAD-geometry to optimisation software LS-OPT and FEM software LS-DYNA. Such a bridge would make it possible to automate the optimisation process and thus connecting the whole design development circle. The extent of this thesis is significant, covering all of the early stages in the design process. By addressing the whole process we have aimed at making a set of tools that work seamlessly together from the first rough design through a set of optimisation runs and final design review. The developed tools offer a quick and stable way to visualize a new design in matter of minutes instead of hours. With a logical graphical user interface, issued within NX, features such as beam type, clearance, flange angle and top width can easily be changed to match the customer specifications. This first rough beam design can with little manual means be initiated in an optimisation process that considers the weight of the beam. The developed tools makes it possible for the design and simulation software to interact, updating the beam geometry continuously while simulating the best possible energy absorption compared to the overall weight of the beam.

Place, publisher, year, edition, pages
Keyword [en]
Technology, KBE, knowledge based engineering, produktutveckling, product, development, industriell design, design, industridesign, CAD, sidokrockskydd, optimering, LS-OPT, LS-DYNA, NX, Side Impact, Beams
Keyword [sv]
URN: urn:nbn:se:ltu:diva-58042ISRN: LTU-EX--09/045--SELocal ID: ea18b9e9-3e00-470b-a2d3-634c7fa14dd2OAI: diva2:1031430
Subject / course
Student thesis, at least 30 credits
Educational program
Ergonomic Design & Production Engineering, master's level
Validerat; 20101217 (root)Available from: 2016-10-04 Created: 2016-10-04Bibliographically approved

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