Virtual Product Development (VPD) deployed on Durability

Transcription

1 IAR FENet December 2003 Virtual Product Development (VPD) deployed on Durability Christoph Ortmann Business Development Director Agenda Introductions VPD Overview VPD Durability: The Honda ATV Story Question and Answer Period Brian Cheung Brian Cheung Virtual Product Development Durability 1960 s Major warranty issue Today, Design Bottleneck Packaging Handling Safety Ride & Handling NVH Durability 1

2 MSC Virtual Durability Durability Testing MSC.NASTRAN MSC.ADAMS MSC.Fatigue Real World Usage Test Track Test Lab Reality Durability Testing Replicated Virtually Case Study: John Deere Business: Agriculture equipment manufacturer Challenge: Shorten the durability design process Environment Spindle Loads Component Loads Fatigue Life Solution: Replicate the durability testing in a virtual lab Value: Identify critical locations before the first hardware prototype is built Using the new method, we have reduced the number of physical prototypes from three or four previously, down to one on our two most recent designs. Terry Ewanochko Product Engineer, John Deere Welland Works 2

3 The Design Scenario Can an existing frame be used for a vehicle with larger payload capacity? ING SAE FD and E Committee Collaborative group focused on researching fatigue and using fatigue tools more intelligently ATV project goals to evaluate the current simulation processes as they relate to structural durability to develop new correlated software to measure the durability of components of proposed vehicles by means of a digital prototype simulation All data used in this project are public domain at Virtual Load Calculation Virtual creation of input loads possible for discrete events Physical testing necessary for service life 3

4 ATV Durability Testing Durability Real World Test Track Schedule Test Lab ING Field Data Collection Onboard edaqs allow data acquisition in extreme testing environments Processing of Acquired Data Transducers acquiring data are rotating with wheels Shock tested to withstand up to 20Gs Ideal for many industries, including automotive, agricultural, heavy construction, motorcycles, off-highway and rail Signal conditioning for all sensors, including vehicle network ncode Flowbuilder 4

5 Virtual ATV ING Flexible Body Export to MSC.ADAMS Input Measured Loads MSC.Patran MSC.Nastran MSC.ADAMS Spindle Forces MSC.ADAMS 5

6 Dynamic Simulation ADAMS/Durability ING Stress History Data Transfer The New Integrated Solution For more than 66 channels Unit Load Case Deformations Time Histories ADAMS/Durability Export Stress Shapes Time Histories 6

7 Fatigue Properties MSC.Fatigue Material database Over 200 materials Generated properties Surface corrections Weld data Durability of welds Welds are typically location of failures Detailed analysis is impractical Special approaches included to handle welds Weld Toe Volvo/Chalmers/nCode Approach Designed and validated for thin sheet automotive structures Based on structural stress at weld toe Simple shell meshing rules Differentiates between flexible and stiff joints Uses generic damage curves Heat affected zone 7

8 Fatigue Editing Shorten time histories while retaining damaging cycles Check for if resulting load files retain frequency and damage content Multiple channels to maintain phasing across all vehicle responses Virtual strains for damage analysis ING Input wheel forces Lab Durability Test Time based to reproduce variable amplitudes and vibratory modes Multiple hydraulic actuators directly coupled to vehicle frame Wheel forces for rig control Strain gages are desired for correlation High test acceleration factor needed due to long service life and short development cycle ING 8

9 Strain Gauge Correlation Summary Strain gauge Virtual strain gauge Correlation Durability is a major bottleneck in today's design process. Durability in VPD increases efficiency of real world testing. Obtain loads for all components, which are costly to measure if possible at all. Streamlined process for optimal exchange of information between the different technologies greatly shortens the design cycle and reduces cost. IAR FENet December 2003 Thank you 9