2012 htc durability workshop distribution -...

Innovation Intelligence®

Vehicle Durability Workshop – 2012 Americas HTCMulti-Body Dynamics Team, Altair

Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Agenda - Vehicle Durability Workshop

Start Time Topic

3 15 PM Introduction3.15 PM Introduction

3.25 PM HyperWorks for Vehicle Durability

3.50 PM MotionView for Durability Modeling

4.15 PM MotionSolve4.15 PM MotionSolve

4.30 PM CD-Tire Introduction

4.45 PM Flexbodies

5.00 PM Customer – Altair Development Interaction

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Don’t Miss! - MBD Customer Breakout Session

• When?• Thursday May 17th 2012 1 15 to 2 45 PM EST• Thursday, May 17th 2012 – 1.15 to 2.45 PM EST

• Who?H d R&D• Honda R&D

• Presenter: Hernan Mercado-Corujo• Full-Vehicle Multi-body Simulations on Virtual Roads - The Challenges of Success

• Fraunhofer• Presenter: Axel Gallrein• CDTire: State-of-the-Art Tire Models For Full Vehicle Simulation

• Altair• Multi Physics with MotionSolve• Multi-Physics with MotionSolve

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HyperWorks for Vehicle Durability


Presentation Outline

• Brief Introduction to Durability

• How are customers using HyperWorks for Durability?

• What are the key elements to assess durability?

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What is Durability?

• Ability to withstand to fatigue, corrosion, wear, creep, ... P d i t f il d i f ti• Predominant failure mode is fatigue

• Fatigue is failure due to repeated cyclic load, well below the failure strength of the material

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Physics of Fatigue

(Crack formation)

(Crack propagation)(Crack propagation)

• Caused by cyclic plastic deformation in a localized area. P f ll k• Presence of a small crack

• Pre-existing defect on the surface of a component

Not possible to model using traditional FE

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• Not possible to model using traditional FE


Causes of Varying Loads

Sources of Varying Loads on Structures

Road Profile Closures Wind Turbine etc..

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Which Areas Of The Vehicle Are Of Interest?

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Passenger Cars Light Trucks Heavy Trucks Buses Earth-Moving Rail Agricultural General Utility Military Vehicles Snowmobiles Motorcycles






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Application: Fatigue validation of motorcycle frame

• Customer: Piaggio, Italy

• Objective:• Establish a virtual simulation process for

motorcycle framemotorcycle frame

• Solution:• Roller test bench dynamic simulation using Multi-Roller test bench dynamic simulation using Multi

Body Dynamics (MotionView / MotionSolve)• High fidelity FTire tire model• Accurate load histories = Accurate life prediction!

• Benefits:• Exceptional correlation between simulation

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(MotionSolve) and test data


Application: Radiator test bench study

• Customer: Modine, USA

• Objective:• Perform multi-axes table simulation using Multi-body

DynamicsThe shaker table s bjected to a s ept sine motion• The shaker table subjected to a swept sine motion

• Solution:• Flexible Multi-body simulation using MotionView /

MotionSolve• Accurate flexbody generation using Radioss

• Benefits:Benefits:• Exceptional correlation between simulation

(MotionSolve) and test data• Robust flexbody solution• Seamless durability process within HyperWorks

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• Seamless durability process within HyperWorks


Application: Durability evaluation of a washer

• Customer: MABE, Mexico

• Objective:• Accurately study the behavior of the hydraulic

balance ring of a washing machineE tract forces on the s spension rods for fatig e• Extract forces on the suspension rods for fatigue evaluation

• Solution:• A Multi-body model of the flexible rotor and stator in

MotionView• A detailed balance ring crescent mechanism as a

sub-system simulated in MotionSolvey

• Benefits:• MotionSolve (simulation) force histories match well

with that of the force transducers (test)

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with that of the force transducers (test)


Application: Automotive closures durability

• Customer: Toyota, Japan

• Objective:• Complete evaluation of closures using CAE

• Component load generation using MBD• Reduce no of physical testsReduce no. of physical tests

• Solution:• MotionView to model the closure systems

Model non linearity of lock seal and rubber• Model non-linearity of lock, seal and rubber• Consider lap clearance on sealing parts and rubbers

• MotionSolve for accurate Multi-body simulations

• Benefits:• Benefits:• Excellent correlation between MotionSolve and test• A virtual process for door slam evaluation was

established using HyperWorks

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And More…

• Honda Reliability Group• Thursday May 17th 2012 1 15 to 2 45 PM EST• Thursday, May 17th 2012 – 1.15 to 2.45 PM EST

• Altair Bus Durability Project• Thursday, May 17th 2012 – 8.30 to 10.00 AM EST

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The Key Elements of Durability Evaluation

Real World Usage

Representative Duty Cycle

Component Loading HistoriesComponent Loading Histories

Fatigue Assessment

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The Key Elements of Fatigue Life Estimation

FE Model

Geometry

Fatigue Material Data

ComponentL d

S/N E/NAnalysis

Estimated life

Load spectrum

Load Spectrum

MBD model

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Road data acquisition


HyperWorks for Durability

• HyperWorks has comprehensive durability capabilities:• HyperGraph Duty cycle visualization (eg: Rainflow counting)• HyperGraph Duty cycle visualization (eg: Rainflow counting)…• MotionView Vehicle Library, Load Export,…• MotionSolve Component load generation, quasi-static and transient analyses..• Tire models FTire CD-Tire RMODK MF-SWIFT• Tire models FTire, CD-Tire, RMODK, MF-SWIFT,..• Radioss CMS (flexbodies), unit load analysis, linear static• HyperView Hot spot visualization..• OptiStruct, HyperStudy,….OptiStruct, HyperStudy,….• HWPA FEMFAT, DesignLife,..

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Templates to Meet Specific Needs

ComponentLoading

Measured Loads

MBDANALYSIS

DUTYCYCLE

FATIGUEANALYSIS POST

DUTY MBD FATIGUE POST

Loading

ComponentLoad

Loads ANALYSISCYCLE ANALYSIS POST

ComponentStress State

Load Locations & Orientations

FE

FEA

FEANALYSIS

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ROAD

ROADMODEL

POSTFATIGUEMBD

Road + Driver

Inputs

Component

LoadingMBD

ANALYSISFATIGUE

ANALYSIS POST


Load Locations & O i t ti

DRIVERMODEL FE Stress StateOrientations

FEANALYSIS

FE

DRIVER

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FE FATIGUEDUTY POST

LoadsStress State

Measured Loads

DUTYCYCLE FEA FATIGUE POST

FATIGUEMBD POST

Component

Loading

Event

DefinitionMBD FATIGUE POST


Load Locations & Orientations

FE

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OrientationsFEA


Summary

• Altair offers a comprehensive solution for Vehicle Durability

Task ToolComponent modeling HyperMesh

Flex body creation Radioss

System modeling MotionView

Road & Tire Modeling FTire, CDTire, RMOD-K , MF-SWIFT

Loads generation MotionSolveLoads generation MotionSolve

Fatigue calculation HWPA (FEMFAT, Design Life)

Visualization HyperView/HyperGraph

• The solution is industry validated

Optimization OptiStruct, HyperStudy

Putting it all together Durability Director (ESG)

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• The solution is industry validated.• The solution is available to all HyperWorks customers


MotionView for Durability Modeling


Durability Analysis – Possible Approaches

• Static loads:• Model a representative vehicle in MotionViewp• Setup a quasi-static load template• Run (quasi-)static analysis in MotionSolve• Extract loads (body forces) from MotionSolve to RADIOSS

R i ti li f l i (INREL 2) i RADIOSS• Run inertia relief analysis (INREL -2) in RADIOSS• ….

• Semi-analytical durability:• Model a representative vehicle in MotionViewModel a representative vehicle in MotionView• Model a virtual test rig (eg: 4-poster) and input:

• Forces directly at spindle – need to control drift (or)• Acceleration at spindle – need to convert acceleration to displacement (or)• Back calculated displacement at tire – need to use Remote Parametric Controlp

• Run transient simulation in MotionSolve• Extract component loads (and accelerations) from MotionSolve • Unit load analysis in Radioss to extract stress states•

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• ….


Durability Analysis – Possible Approaches

• Fully analytical durability:• Model a representative vehicle in MotionView• Model a representative vehicle in MotionView• Model a virtual tire and a digitized rough road (virtual proving ground events..)• Setup a driver (controller)• Run transient simulation in MotionSolve• Run transient simulation in MotionSolve• Extract component loads (and accelerations) from MotionSolve • Unit load analysis in Radioss to extract stress states, etc• ….….

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How do you assure model fidelity?

• Before starting your durability runs, make sure that:1 You obtain good K&C correlation in half vehicle models1. You obtain good K&C correlation in half vehicle models2. Later assemble the two half’s of the vehicle to build full vehicle3. Run a static equilibrium analysis to get the CG and tire patch loads right4 Decide which parts need to be flexible4. Decide which parts need to be flexible

• Key is to capture the “correct” compliance

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Static Load Analysis

• Definition:• This is a quasi-static simulation to study the effect of various load cases applied at the wheel

center and tire patch.• Required input:

• Point of application of the load ( wheel center or tire patch )• Load direction• Load type ( force or displacement )• Load in Newton, Newton-mm or displacement in mm.• Load multiplier.• Load case number that the load belongs to.

D i ti f t k• Description of task:• To begin with a static simulation is performed with all the active loads belonging to a load

case. This is followed by resetting the set of loads in the load cases and the next set of load cases is applied. The process is repeated till all load cases are applied.

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MotionSolve Overview


What is MotionSolve?

• An Industry proven Multi-Body Solver based on the laws of mechanics

• Widely applicable across many industries and applications

• Deals with overall system behavior where large non-linear motion is the dominating characteristic

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What can MotionSolve do for you?

• Supports many types of analyses• Assembly• Assembly• Kinematics• Statics• Quasi-statics• Quasi-statics• Eigenvalue and State Matrix Generation• Transient dynamics

• Complex analyses modes can be created by chaining a sequence of basic analyses

• Capable of multi-disciplinary simulation involving FE, CFD and Controls

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Why is MotionSolve special?

• Accurate• Hundreds of models correlated between

MotionSolve & competition and MotionSolve & Test

• Comprehensive set of modeling elements• With unmatched solver customization

• Easy to use• Support for Python & Matlab user-

subroutinessubroutines.• No compiler required

• Hard to break• A robust solver used in a variety of industries y• >300 companies use MotionSolve!

• Fast• Efficient formulation for flexbodies

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Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Summary

• Altair is uniquely positioned to offer the combination of MBS, FE, Controls, 1D simulation, Optimization and process based solutions customer wants

• Altair offers a comprehensive MBS solution platform

• Altair solutions are open and easily customized. Altair is standardizing on Python

• Altair’s MBS team partners with customers to ensure their success

• Altair’s solution is available to ALL HyperWorks customers at no

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incremental cost, provided adequate tokens exist


Thank You!Keshav ([email protected])

2012 htc durability workshop distribution -...

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