Altair > Case Studies > HyperWorks Streamlines Development Processes in Automotive Industry: A Case Study on PWO Germany

HyperWorks Streamlines Development Processes in Automotive Industry: A Case Study on PWO Germany

Technology Category

Analytics & Modeling - Digital Twin / Simulation
Sensors - Autonomous Driving Sensors

Applicable Industries

Automotive
Metals

Applicable Functions

Product Research & Development
Quality Assurance

Use Cases

Virtual Prototyping & Product Testing
Virtual Reality

Services

System Integration
Testing & Certification

About The Customer

PWO Germany (Progress-Werk Oberkirch AG) is a leading supplier of high-precision metal components for the automotive industry, specializing in vehicle safety and comfort. The company has nearly ninety years of expertise in metal forming and joining technologies. PWO's German production site in Oberkirch employs around 1,100 people, and with additional sites in the Czech Republic, China, Mexico, and Canada, the company has a global presence with a total workforce of around 1,900 employees. PWO acts as a partner to the automotive industry in the development and production of innovative products, manufacturing millions of components on a just-in-time and zero-defect basis.

The Challenge

In 2008, PWO Germany was tasked with the development and production of a new steel automotive cross car beam (CCB) for the dashboard of a new car. The challenge was to develop this component based on the CAD model, design space definition, and other pre-defined standards provided by the customer. The component had to meet various specifications related to modal analyses and dynamic loads, which were determined by the expected use of the component. For instance, the eigenfrequency of the cross car beam, when connected to the steering wheel, could not exceed a certain preset value to avoid undesirable vibrations within the vehicle at certain speeds. Other specifications were related to crash and vehicle safety. The challenge was to meet these often conflicting specifications while developing the component in a timely and cost-effective manner.

The Solution

PWO used the HyperWorks Suite to develop the component. HyperMesh was used to convert the CAD model into a FEA model, which was then used for dedicated analysis and simulation tasks. To meet the requirements for crash and modal analysis, OptiStruct was used to optimize the component, while RADIOSS and other external solvers were used to run the calculations. HyperView was used for post-processing, and HyperForm was used to check the production feasibility of the individual components and for metal forming simulation tasks. The entire system was analyzed and specifications were met before a prototype was built. The results were validated with physical testing, which showed a very good correlation with the simulation results.

Operational Impact

The use of the HyperWorks Suite offered a complete CAE product family for all simulation and analysis tasks within the development process. This allowed PWO to handle many of the necessary development iterations virtually, saving on physical prototypes and enabling the study of more variants in the same time. The development cycle was shortened by driving the design with simulation, allowing for important decisions to be made earlier in the development process. Contradicting specifications could be analyzed and the best possible solution could be found. The open architecture and licensing system of HyperWorks also provided flexibility, as users only paid for the tool they actually used.

Quantitative Benefit