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Proton Success Story

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Proton Success Story MSC.Software: User Case Study - Proton USER CASE STUDY PROTON Customer Profile: Noor Hisham Bin Ismail Mr Noor Hisham Bin Ismail is head of CAE at PROTON based in Kuala Lumpur, Malaysia. Mr Ismail and other members of the computer-aided engineering team are responsible for improving the virtual development of mechanical and structural components, sub systems and complete vehicle system at PROTON. Through Mr Ismail’s innovative process of probabilistic analysis, PROTON has been able to effectively identify areas of high-risk failure and fine-tuning engineering design alternatives. Challenge Mr Ismail’s foundation of probabilistic design methodology uses design In developing complex mechanical and structural automotive criteria based on reliability targets instead of deterministic criteria. components, going through multiple build-and-test hardware prototype First, design parameters such as applied loads, material strength, and cycles to verify performance, stress and fatigue life is just too time- operational parameters are researched and/or measured and then consuming and expensive. This issue can be addressed by evaluating statistically defined. A probabilistic analysis model is then developed for and refining designs with analysis tools up front in development, reducing the entire system and solutions performed to yield failure probabilities. test cycles later in the development process. PROTON’s pioneering spirit With MSC’s FEA, applied stress is obtained from finite element models. naturally has led Mr ismail to not just stop at traditional methodologies in The general concept is to integrate the joint probability of applied stress computer-aided engineering for design analysis. As the risk of failure in and material strength over the region where stress exceeds strength. The any design was becoming result of the integration is the probability of structural failure and this helps more and more significant to provide the necessary information for sensitivity analysis and design and he was constantly optimization. looking at areas to assess Relying on industry- risk parameters and minimize leading solutions such any risk factors, he needed as MSC’s FEA and to turn to industry-leading Adams, Mr Ismail is able simulation analysis tools that to build a “Reliability would be able to provide him Engineering” framework with the necessary accurate that provided the foundation to progress his foundation for accurate methodology. Mr Ismail Basic Stress and Material Cyclic Strength analysis. realized that conventional With MSC, Mr Ismail is virtual development approaches are no longer sufficient to meet the able to conduct multi- increasing standards of accuracy required at PROTON. Conventional Yield Stress and Operating Stress Performance run design improvement approaches do not take into consideration the variations that affect finite studies which can be used to assess design sensitivity to product and element analyses. Mr Ismail needed proven tools that produced the most environment variability, discover unknown design variable interactions, accurate results, allowing him to capture the potential failures and provide and provide a global view of the overall design space. the nature of failures so that these can be mitigated in the process. With resource efficiency on his mind, Ms Ismail also needed to manage test But the analysis does not stop here; as Mr Ismail has further incorporate accuracy while reducing the dependency on running too many variations. his finite analysis results in a stochastic simulation via the Monte Carlo technique that provides the statistical results of the variation distribution. Solution Mr Ismail then further combines the results with critical parameters MSC FEA (MSC Nastran and Patran),MSC Adams. yielding an even stronger and more robust solution. Benefits “All critical elements derived from simulation results are subjected to • Visible quantification of design risk or reliability additional quantifiable risk analysis, this helps to mitigate probability • Identifies areas of high risk in a design of failures later during the development stage,” said Mr Noor Hisham • Provides the ability to modify design variables relative to reliability bin Ismail, PROTON Holdings Berhad. “Computer-aided engineering technology has provided the foundation for PROTON’s success in a highly • Provides a means to compare differing designs competitive automotive industry. With MSC.Software, we have been able Case Study to cut costs while improving quality and reducing time-to-market. Our PROTON can shorten the time-to-market by getting designs right the first drive for engineering innovation will enable us to continue enhancing our time. Many of PROTON’s automotive components need extensive lead competitiveness by improving our engineering development process and times because of its strict adherence to safety and quality standards. driving production efficiency.” Besides, traditional physical testing can take weeks or even months to validate a design. Leveraging analysis early in the process can eliminate unforeseen changes and repetition of lengthy test cycles, providing significant reductions in overall development time. USER CASE STUDY MSC.Software: User Case Study - Proton MSC Products Used: MSC Nastran • Marc • Powerful Analysis Capabilities • Dytran MSC Adams • Static Stress • MSC Nastran Capabilities • Normal Modes • MD Nastran • 3rd party solvers • Creation or import of component geometry in • Linear Buckling wireframe or 3D solids • Dynamics Post-processing • Extensive library of joints and constraints to • Static and Transient Heat Transfer • Results Access define part connectivity • Dynamics • Nastran • Frequency / Harmonic Response • Internal and external forces definition on the • Dytran assembly to define your product’s operating • Static and Transient Nonlinear • Marc environment • Rotor Dynamics • 3rd party solvers • Interior Acoustics • Model refinement with part flexibility, automatic • Results Visualization control systems, joint friction and slip, hydraulic • Full range of material models • Contours and pneumatic actuators, and parametric • Isotropic • Vector arrows design relationships • Orthotropic • Fringe plots • Ability to iterate to optimal design through • Anisotropic • Isosurfaces definition of objectives, constraints, and • Temperature-dependent • Data History / Animation variables • Design Optimization • X-Y plots • Automatic generation of linear models and • Shape • Imaging complex loads for export to structural analyses • Size • Results Templates • Topology • Comprehensive linear/nonlinear results for testing complex, large-motion designs • Adams Integration • Superelements for increased collaboration and • Superior contact capabilities supporting 3D solution efficiency contact between modal flexible bodies and • Efficient Solvers solid geometry • Sparse matrix solvers Company Profile • Iterative solvers High Performance Computing (HPC) PROTON, established in 1983, is Malaysia’s • Parallel and vector processing • 64-bit support on Windows and largest manufacturer of automobiles. With Linux platforms operations in key market centers from UK and Patran Western Europe to the Middle East, and across • Parallel processing support for Pre-processing South-East Asia and Australasia, PROTON Adams/Tire results • Standard Geometry Access from produces cars to suit a range of consumer • Shared Memory Parallel solver demands and preferences. The offerings include • Parasolid versatile and reliable four-door family vehicles, • Obtain nonlinear results for testing complex, • STEP 203 and 209 two-door hatchbacks for the young-at-heart, large-motion designs • IGES luxurious and stylish executive sedans, spacious • VDA and affordable multi-purpose vehicle, as well as the world-renowned sports cars from Lotus. Adams Package includes: • I-DEAS PROTON’s inception as a key driver of national • Adams/Solver • Parametric Modeling Capabilities development has seen the brand accelerate • Adams/Linear • Wireframe and Solid Geometry Creation and its learning curve through technology transfer • Adams/View Modification with strategic partnerships and technical • Adams/Flex • Mesh Generation collaborations. PROTON cars are now steadily on track to achieving the mission for the future, • Adams/Durability • Automatic 2-D surface meshing gearing up to achieve the promise of a marquee • Automatic solid mesher • Adams/Vibration brand which builds cars with passion and soul; • Adams/Controls • Generalized 1-D, 2-D, 3-D mapped mesher cars which are a delight to drive and a pleasure • Adams/Exchange • Mesh on Mesh to own. • Adams/Foundation • Mesh editing and modification • Adams/Insight • Comprehensive Element Library • Postprocessor • Element Property Creation and Edit • Shared Memory Parallel (SMP) • Material Property Creation and Edit • Tire API • Load and Boundary Creation and Edit • Easy Contact Definitions Optional Modules • Model Visualization and Verification • Adams/Tire FTire • Support for multiple FEA solvers Corporate Europe, Middle East, Asia-Pacific Asia-Pacific MSC Software Corporation Africa MSC Software Japan LTD. MSC Software (S) Pte. Ltd. 2 MacArthur Place MSC Software GmbH Shinjuku First West 8F 100 Beach Road The MSC.Software corporate logo, MSC, and the names of the Santa Ana, California 92707 Am Moosfeld 13 23-7 Nishi Shinjuku #16-05 Shaw Tower MSC. Software products and services referenced herein are trademarks Telephone 714.540.8900 81829 Munich, Germany 1-Chome, Shinjuku-Ku Singapore 189702 or registered trademarks of the MSC.Software Corporation in the United www.mscsoftware.com Telephone 49.89.431.98.70 Tokyo, Japan 160-0023 Telephone 65.6272.0082 States and/or other countries. All other trademarks belong to their Telephone 81.3.6911.1200 respective owners. © 2010 MSC.Software Corporation. All rights reserved. PRO*2010JAN*UCS.
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