Fraunhofer Institute for Algorithms and Scientific Computing SCAI
Fraunhofer Institute for Algorithms and Scientific Computing SCAI

MpCCI Mapper in Practice

MpCCI Mapper improves crash simulations

The models used in crash simulations are idealized – they usually do not take production-related local changes in geometry or material properties into account. The MPCCI Mapper helps to increase the informative value of crash calculations by integrating the results of manufacturing history into the crash model.

The behavior of relevant components during a crash is a function not only of their design but also of their manufacturing history. If crash models are to be more realistic, manufacturing-related information on local geometries and material parameters from the forming simulation or other processing simulations must also be applied to the crash model. This is why the Fraunhofer Institute SCAI developed the MPCCI Mapper software as part of a project with the German Association of the Automotive Industry. The MPCCI Mapper offers a function that enables models with incompatible relative positions to be aligned with one another in the coordinate system. Mapping functions for material thickness, pressure and tensile load, and other element or node-based data, and the option of inserting information about unit systems, support integration in the process chain.

The MPCCI Mapper offers a validation model for analyzing the quantities mapped. For validation, the association and nodal distances of the coupled models, together with the local differences of original and transferred values, are calculated and visualized. All of the functions in the MPCCI Mapper can be interactively controlled using a graphic interface. The MPCCI Mapper helps to load source and to target grids by supporting many of the codes used in file formats in forming and crash simulations:

  • Abaqus (read/write .inp files)
  • Indeed (read .gns)
  • LS-DYNA (read/write keyword files)
  • PAM-STAMP PAM-CRASH (read/write mapping files, read keyword files)
  • Radioss (read D00 starter input, read/write Ynnn output file)
  • Nastran (read, patch)
  • Sysweld (read .asc, write, patch)

Faurecia is working on the perfect car seat

Faurecia uses MpCCI­ Mapper throughout its design process for car seats.
© Faurecia Autositze GmbH
Faurecia uses MpCCI­ Mapper throughout its design process for car seats.

Ensuring that seats will withstand crash tests and still be as light as possible requires a closer view and consideration of the components’ manufacturing history. Since 2007, Faurecia has integrated SCAIMapper group-wide as its main transfer tool through all stages of the seat designing process. Whenever special physical forming variables (e.g. plastic strain, material strength) exceed or fall below critical threshold values, the forming results are mapped as a default setting for the noise-vibration-harshness, crash-model or finite-elements analysis to permit detailed analysis of the local influence of manufacturing. A major supplier to automobile manufacturers, Faurecia, also offers its customers these mapped data as part of the overall product description.

High performance fiber composites

© KIT FAST
Optimization CAE process chain of Carbon-Fiber reinforced composites components

The excellent mass-specific properties of high-performance fiber composite materials can be tailored to the specific requirements of lightweight construction. However, the economic exploitation of this potential is currently limited by inadequacies in manufacturing and production processes, by lack of knowledge about the material behavior, and by an unsatisfactory prediction of the structural properties.

In order to overcome these weaknesses, a close link between process and structural simulation is necessary, which also incorporates special features of the materials and the possible components.

Another important prerequisite for exploiting the material-specific potential of high-performance fiber composites is the integrated simulation of the entire associated process chain, whereby all significant process parameters and process results can be used by the individual simulation steps.

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