A German automotive supplier for carbon components in the premium sector commissioned us to support them in the development of load-bearing fibre composite components in several areas of a newly developed vehicle. The client’s competencies lie primarily in the constructive development of the assemblies as well as production engineering. This is why our customer has been working with us for over 10 years to benefit from our extensive expertise in the areas of simulation and optimisation of highly stressed lightweight components.
The challenges and solutions in detail
Our customer has their own clients who define requirements that must be met by us in the development of the design. These boundary conditions are usually no longer negotiable. Therefore, on the one hand, it is also part of our job to protect our customers from not being able to meet the defined conditions when supplying to their clients. On the other hand, we are responsible for enabling an optimal component design. too complicated production processes or too high material usage would result in excessive production costs, it is essential to achieve the best balance between optimal structural-mechanical result and economic manufacturability for serial production.
The following competences at ar engineers led to success in this project:
- Strong expertise in the implementation of complex simulations and optimisation of assemblies for automotive serial production.
- Very good understanding of ultra-lightweight design with CFRP /carbon composites.
- Eye on feasibility of the component despite complex material composition.
- Expertise in numerical optimisation with Ansys.
- Automated result evaluation in order to be able to respond quickly to changing requirements from the requirements of the customer.
- Our direct consultations with the customer and their client enabled the project to run smoothly.
We reduced problem complexity to a “healthy” level, especially with regard to numerical optimisation tasks, so as not to lose sight of the calculation goals. In addition, there are some optimisation goals that cannot always be clearly defined in the context of simulation. Here, we use iterative processes to ensure the best possible achievement of objectives. Good manufacturability or simple implementation cannot be directly derived as a single value from an optimisation, but arise from the derivations of the calculation and assessments of our experienced engineers and the close cooperation with our customers.