A Importância da Modelagem Multifísica no Desenvolvimento de Veículos Dr. Cesareo de La Rosa Siqueira ESSS - Business Manager

Transcription

1 A Importância da Modelagem Multifísica no Desenvolvimento de Veículos Dr. Cesareo de La Rosa Siqueira ESSS - Business Manager 2007 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary

2 ESSS at a Glance PAGE 2 29% 22% Team 12% 37% Ph.D. Master Computer Scientist Divisions Computer Aided Engineering ~100 Members Engineer Sales Support Training Consulting Offices Software Development Custom Software Development Software Customization

3 PAGE 3

4 disciplines AGENDA Multiphysics Approach PAGE 4 Computational Fluid Dynamics (CFD) Finite Element Analysis (FEA) Electronic Design Automation (EDA) Multidisciplinary Optimization (MDO) VirtualPaintShop (VPS)

5 Multiphysics approach: CAE full discipline integration PAGE 5 Aerodynamics & Acoustics Multidisciplinary Optimization (MDO) Coupling CFD, 1D tools & MDO Coupling CFD, FEA & Acoustics Fluid-Structure Interaction Coupling FEA, 1-D tools & MDO Electronics Painting & FEA Coupling

6 Acoustics: Buffeting PAGE PT Cruiser, 60 mph, 5 o yaw Sound Pressure Level (db) Fluent Hz Experiment Hz Driver's Left Ear Frequency (Hz) Images courtesy DaimlerChrysler

7 2-Way Fluid-Structure Interaction in a Shock Absorber PAGE 7 CFD mesh FEA mesh

8 Optimization of cooling gallery location & shape - 1 Geometry modification Triangular derived shape PAGE 8 3D model (quarter model) without gallery several locations & shapes

9 Optimization of cooling gallery location & shape - 2 PAGE 9 Thermal boundary conditions Mechanical boundary conditions clamped region (simulating pin support)

10 Optimization of cooling gallery location & shape - 3 PAGE 10 Temperatures (ºC) Critical positions (bowl & gallery) Thermal stresses (MPa) Thermo-mechanical stresses (MPa)

11 Optimization of cooling gallery location & shape - 4 PAGE 11 # of input variables: 9 Initial population: 150 designs Optimization algorithm: MOGA (multi-objective genetic algorithm) Number of generations: 30 Total number of designs evaluated: 4500 # of feasible designs: 2790 Design with maximum gallery life Pareto frontier Original design Design with maximum bowl life

12 Optimization of cooling gallery location & shape - 5 PAGE 12 design ID dx1 dy1 dr1 dr2 dr3 dx2 dy2 dx3 dy3 Max bowl temp Max gal temp Log(#cycles) bowl Log(#cycles) gal % life increase bowl % life increase gal mm ºC ºC (-) (-) % 0% % 670% % -85% % 114% % 1463% % 1586% % 1461% % 39% % 558% % 217% % 834% % 1354% % 294% % 274% % 125% % 124% % 171% % 1177% % 1529% Intermediate designs: designs 3119 brings a life increase around 1460% in bowl and design 4046 brings a life increase around 1350% in gallery design 0 (original) design 3119 design 4046 bowl gal bowl gal 443% 1461% 1204% 1354% 5256% 39% 3266% 294%

13 CAE Integration B-402 Project - 1 FEA : Structural Modal, Harmonic & Head Impact CFD :HVAC system PAGE 13

14 CAE Integration B-402 Project - 2 PAGE 14 Structural Analysis Modal /Harmonic

15 CAE Integration B-402 Project - 3 PAGE 15 Impact area definition

16 CAE Integration B-402 Project - 4 PAGE 16 Defogging simulations HVAC system, acoustic and velocity profiles

17 CAE Integration B-402 Project - 5 PAGE 17 Ford Tatuí Proving Ground Defogging lines

18 CAE Integration B-402 Project - 6 PAGE 18 3,0 Ford Tatuí Proving Ground 2,5 2,0 1,5 1,0 0,5 0,0-0,5-1,0 V y 0,0 0,1 0,2 0,3 0,4 0,5 Velocity distribution V y (m/s)

19 CAE Integration B-402 Project - 7 PAGE 19 CFD HVAC system model

20 CAE Integration B-402 Project - 8 PAGE 20 First looping

21 CAE Integration B-402 Project - 9 PAGE 21 First looping Divergent streamlines 5 o central vortex (60 s)

22 PAGE 22 Final Configuration CAE Integration B-402 Project - 10 Balanced mass flow rate at both sides

23 CAE Integration B-402 Project - 11 PAGE 23 Final Configuration Streamlines at defogging exhausting ducts

24 CAE Integration B-402 Project - 12 PAGE 24 Noise prediction Air exhaust through defogging and side mirror ducts

25 CAE Integration B-402 Project - 13 PAGE 25 Noise prediction Comparasion Simuation x Experimental x Ford target

26 Design methodologies PAGE 26 Traditional design Initial Configuration Simulate Labor intensive Evaluate Results OK? No Modify Configuration Only a limited number of configurations can be investigated Try and error: optimal solution is not assured Yes Accept

27 Design methodologies PAGE 27 Optimization Approach Parametric model Optimization goals & design variables Automated process Large number of configurations can evaluated Scientific method: Optimal solution is obtained Accept

28 Optimization example: Connecting rod PAGE 28 Optimization Goals minimize MASS minimize STRESS modefrontier workflow Design Variables R1 R2 L1 L2 T CAD&FEA: Ansys WB

29 Results PAGE 29 Optimization Run: 1370 analyses in 17 hrs* Pareto Frontier (trade-off curve): Minimum mass Trade-off solution Minimum Stress * Using a single processor on a Intel duo core P GHz

30 Results PAGE 30 Sensitivity analysis:

31 Exhaust manifold 1D-3D coupling - 1 PAGE 31 1D Model GT Power EGR Intake manifold 54

32 Exhaust manifold 1D-3D coupling - 2 3D Model and Mesh - FLUENT PAGE 32 Manifold Inlet Cylinder 1 Cylinder 2 Cylinder 3 EGR inlet Cylinder 4 Manifold Geometry CFD Finite volume mesh 55 MAHLE

33 Exhaust manifold 1D-3D coupling - 3 PAGE 33 Coupling GT CFD connection allows 1D and 3D models to exchange data GT CFD component substitutes intake manifold 56 MAHLE

34 Results Exhaust manifold 1D-3D coupling - 4 1D results show the same percentages of EGR in each cylinder which is not real considering the manifold geometry 3D results show different percentages of EGR in each intake manifold runner. Cylinder 1 receives more EGR due to its proximity to the EGR inlet. PAGE 34 % of EGR (from 100% EGR per cycle) Cylinder1: 31.6% Cylinder2: 31.6% Cylinder3: 31.5% Cylinder4: 31.6% % of EGR Cylinder1: 26.9% Cylinder2: 25.4% Cylinder3: 22.5% Cylinder4: 21.9% 57 MAHLE

35 Results Exhaust manifold 1D-3D coupling - 5 PAGE 35 3D results show different maximum temperature in each cylinder. Cylinder 1 receives more EGR, it helps to decrease temperature and pollutants creation (NOx) Gas temperature Cylinder1: C Cylinder2: C Cylinder3: C Cylinder4: C Gas temperature Cylinder1: C Cylinder2: C Cylinder3: C Cylinder4: C 58 MAHLE

36 Auto Applications in Hybrid Electric Vehicles & Electric Vehicles PAGE 36

37 Full Vehicle EMC/EMI Studies PAGE 37 Source Locations The DVD Player PCB is used as a radiation source inside the vehicle model Electromagnetic field could be visualized in any point of the vehicle model

38 Possibility to Evaluate Several Aspects of Radiation Cases PAGE 38 Car body was the return path for the common mode currents in wire harness; The body was part of the radiator; Solve mobile device alone and impress fields from this solution into simulation car.

39 Antennas Design/Analysis Capability PAGE 39

40 Painting process - 1 PAGE 40 Pretreatment Electrocoating Electrostatic Coating Cavity Protection and Flange Sealing Thermal Drying or Ultraviolet Curing

41 Painting process - 2 PAGE 41 Temperature Deformation Stress

42 Concluding Remarks PAGE 42 Multiphysics analysis is always possible and feasible; Multiphysics analysis are crucial to get reliable results;

43 THANKS!!! PAGE 43

44 World Cup 2014 PAGE 44