Due to the fiber reorientation during the manufacturing process, the consideration of the finale fiber orientation distribution is crucial for the structural simulation. Since this also affects the design, a holistic approach is necessary. Therefore, the Institute of Vehicle System Technology (FAST) – Lightweight Technology is focusing on the CAE-Chain, which combines different simulation tools and enables the transfer of information between them. Therefore, the single FE simulation tools, which are used during the steps Design, Optimization, Process Simulation, Mapping and Structural Simulation, are connected. In this CAE-chain, each step has criteria that must be fulfilled before results are passed to the next step. Otherwise, a process internal optimization tries to fulfill the criteria by changing free parameters. If this is not possible or if the internal optimization fails, the previous step is done again with a varied parameter set.
In this presentation, the FAST CAE-Chain is presented and their capability is shown by the development process of an automotive underfloor structure. This structure contains continues and discontinuous fibers as well as metal parts, which are considered in the process and the structural simulation, including the crash simulation. By using the CAE-Chain the weight was reduced by 25 % with a positive LCA balance.