This conference paper was submitted for presentation at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

Material data consistency across computer-aided engineering (CAE) platforms is vital for optimizing design, safety, and performance in automotive applications. Managing material data for CAE poses several challenges, including data harmonization across diverse simulation tools, ensuring accuracy in material models, and maintaining regulatory compliance while meeting the dynamic needs of multiple brands. This presentation outlines the challenges faced, the innovative solutions implemented, and the significant benefits realized in managing material data for CAE applications. Automotive manufacturers operating in multi-CAE environments face significant obstacles. Data fragmentation is a major issue, as material test data originates from various laboratories, leading to inconsistencies and inefficiencies in aggregation. Accurate representation of material behavior under varying strain rates, temperatures, and stress states is another critical challenge, requiring precise model calibration. Regulatory compliance demands stringent management of material release and withdrawal processes, tailored to brand-specific needs while adhering to industry standards. Additionally, achieving vendor independence is essential for long-term sustainability, reducing reliance on proprietary software. The unified Material Master System was extended to address these challenges through innovative strategies. Standardized database representations of material cards were developed to ensure compatibility across platforms such as Pamcrash, LS-Dyna, and Abaqus. These universal cards are linked via bidirectional interfaces that streamline data flows and enhance cross-platform consistency. A centralized platform was implemented to integrate raw and processed test data, including key properties such as plasticity, damage, and fatigue. This system improves data retrieval and validation efficiency. Open-source methodologies, such as the use of the SciPy library, were incorporated to fit constitutive equations like Johnson-Cook and Zerilli-Armstrong models. This enabled precise calibration and parametrization of material models for simulations. Automated tools were developed to generate piecewise input data for CAE applications, reducing manual intervention and improving integration efficiency. To ensure robust data governance, Business Process Model and Notation (BPMN) workflows were implemented, standardizing material data processes and ensuring compliance across brands. The extended Material Master System at Volkswagen Group delivers transformative benefits. The unified approach fosters collaboration among multiple brands, facilitating cross-brand synergies while accommodating individual requirements. Streamlined workflows significantly accelerate applicability of new materials, enhancing operational efficiency. Harmonization of validations and data improve the reliability of simulations, ensuring higher accuracy. The incorporation of open-source tools provides flexibility and scalability to adapt to evolving requirements, while vendor independence and a centralized system support sustainable, long-term material data management. This presentation offers an overview of the challenges, solutions, and benefits involved in implementing a multi-CAE material management system. It provides actionable insights for industries seeking data harmonization, improved CAE integration, and sustainable material data management practices.