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ANSYS Brake Simulation

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Brake Industry and Brake Simulation …

Brake Industry and Brake Simulation

This presentation discusses the business benefits to brake system design, thermal modeling, high fidelity CFD brake cooling and brake noise.

Presentation given by Mike Hebbes, ANSYS Regional Technical Manager
April 3, 2012

Published in: Automotive, Technology, Business

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  • If there would have been a analysis step by step procedure, it would be of great help and knowledge sharing............
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  • For more information: http://blog.ansys.com/2012/05/09/brake-noise-vibration-and-harshness-generate-billions-in-warranty-costs/
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  • Ford Business Drivers – “in housing”
  • TRW – 75 + programs, 20 NVH specialists, old “optimized” meshing methods = 2 weeksFord – 3 months to develop a correlated system modelSolution – bring the entire portfolio to bare, flexible enough for quick conceptual studies, “template-able” for global roll out and lock downBeyond state of the art – high fidelity, parametric, non-linear static thermally pre-stressed complex eigenvalue
  • FordVehicle, chassis and frame, brake, brake NVHPresentation to NA firstSME buy in and sponsorshipProcess compression, all in one toolTRW influence, tight knit communityTotal SolutionProcess compression (template with flexibility)quick clay studieslocked down template that can rolled outMultiphysics parametric optimization
  • TRW – start with near net shape, perform topology optimization to derive starting point CAD
  • Transcript

    • 1. ANSYS Brake Simulation Mike Hebbes Regional Technical Manager April 3, 20121 © 2011 ANSYS, Inc. May 9, 2012
    • 2. The Brake IndustryBusiness Drivers Brake System Design Challenges• Customer satisfaction • Virtual design of costs effective,• Increase number of platforms quiet braking systems under ever• Innovation increasing time pressure • System Complexity • Physics Complexity • Number of Platforms • Designers productivity • In-sync models with production • OEM and supply chain interaction2 © 2011 ANSYS, Inc. May 9, 2012
    • 3. ANSYS, Inc. Brake System SolutionsSolutions Business Benefits ANSYS brake application  50% faster in problem setup experience  45% faster in project ANSYS system modeling, completion Mechanical, CFD and  New product innovation electromagnetics Multiphysics parametric optimization with geometry Interfaces to CAD Advanced capabilities to model brake instability3 © 2011 ANSYS, Inc. May 9, 2012
    • 4. Brake System Design Considerations System Modeling Hydraulic Control Structural Electromagnetic Thermal stress Dynamic loading Non-linear statics Thermal Dynamics Steady and NVH Transient MBD FEA and/or CFD Durability Crash Electromagnetic Low and high frequency Actuators, sensors4 © 2011 ANSYS, Inc. May 9, 2012
    • 5. Thermal Modeling High Fidelity CFD Brake CoolingChallenges – Durability – Predict local temperature distributions and thermal loads – Optimize brake venting – Transient Drive Cycles Advantages of ANSYS CAE – MRF models, Conjugate heat transfer – Easy and seamless transfer of CFD and FEA data between applications5 © 2011 ANSYS, Inc. May 9, 2012
    • 6. Brake Instability Analysis • Brake disk develop friction induced oscillations which are heard as “brake squeal”. • Brake noise has been a challenging issue for automotive industry. • Brake Noise Categories  Low frequency noise (100-1000 Hz) – Groan and Moan noise  Low frequency squeal (1000 – 7000 Hz) – Coupling of out of plane modes of rotor with bending modes of pads.  High frequency squeal (8000-16000 Hz) – Coupling of in plane modes of rotor with Courtesy of: bending modes of pads. Automotive Company6 © 2011 ANSYS, Inc. May 9, 2012
    • 7. Early Approach Standard FE Model provides M and K Discrete 2 node (springs) elements are used to provide Friction stiffness (MATRIX27) Drawbacks →Requires matching nodes at the sliding interface →Tedious and time consuming →Rotor-pad interface is not treated ‘consistent’ “Complex Eigenvalue Analysis for Reducing Low Frequency Brake →Impractical for parametric studies Squeal” by Shih-Wei Kung, K. Brent Dunlap and Robert S. Ballinger,Delphi Automotive Systems7 © 2011 ANSYS, Inc. May 9, 2012
    • 8. ANSYS Workbench: Brake - System Model Instability Procedure • Provides for sliding • Complex Eigen solution contact with friction • Animations: Complex • Does not require Mode Shape • Manual and/or Parametric Studies matching meshes • Contact Status at Pads Scripted Meshing • Supports higher order elements Single Simulation Environment Mesh & Setup & Post CAD Connections solver Processing • Bi-Directional CAD • Automated Contact • Flexibility to use Linear • Root locus plots Connectivity Detection & Non-linear solver • Correlation of modes • Automated Joint capabilities • Strain energy per Sensitivity Studies and Counter Measures Detection component per mode • Parametric Studies • Geometry variants • Friction coefficient variations • Material Properties (Anistotropic) • RST MAC (Modal Assurance Criteria)8 © 2011 ANSYS, Inc. May 9, 2012
    • 9. Training/Documentation9 © 2011 ANSYS, Inc. May 9, 2012
    • 10. Production Intent CAD – CATIA V510 © 2011 ANSYS, Inc. May 9, 2012
    • 11. Parametric Optimization Pad Assembly Rotor System Model Caliper Knuckle11 © 2011 ANSYS, Inc. May 9, 2012
    • 12. Component Models Pad (Friction Material)12 © 2011 ANSYS, Inc. May 9, 2012
    • 13. Goal Driven Optimization13 © 2011 ANSYS, Inc. May 9, 2012
    • 14. System Model14 © 2011 ANSYS, Inc. May 9, 2012
    • 15. Parametric Geometry Pre-Processing Option 1: ANSYS DesignModeler15 © 2011 ANSYS, Inc. May 9, 2012
    • 16. Parametric and Persistent ANSYS Geometry Interface for CATIA V5 Geometric Parameter16 © 2011 ANSYS, Inc. May 9, 2012
    • 17. Parametric Geometry Pre-Processing Option 2: ANSYS SpaceClaim Direct Modeler17 © 2011 ANSYS, Inc. May 9, 2012
    • 18. Parametric and Persistent ANSYS Geometry Interface for CATIA V518 © 2011 ANSYS, Inc. May 9, 2012
    • 19. Geometry Simplification19 © 2011 ANSYS, Inc. May 9, 2012
    • 20. Material Properties20 © 2011 ANSYS, Inc. May 9, 2012
    • 21. Contact Summary21 © 2011 ANSYS, Inc. May 9, 2012
    • 22. Contacts22 © 2011 ANSYS, Inc. May 9, 2012
    • 23. Contact - Bonded23 © 2011 ANSYS, Inc. May 9, 2012
    • 24. Contact - Frictional24 © 2011 ANSYS, Inc. May 9, 2012
    • 25. Joints25 © 2011 ANSYS, Inc. May 9, 2012
    • 26. Meshing Integrated, Automated, Flexible26 © 2011 ANSYS, Inc. May 9, 2012
    • 27. Meshing27 © 2011 ANSYS, Inc. May 9, 2012
    • 28. Meshing28 © 2011 ANSYS, Inc. May 9, 2012
    • 29. Meshing Automated Hex Meshing Examples29 © 2011 ANSYS, Inc. May 9, 2012
    • 30. Non Pre-Stressed, Complex Eigenvalue30 © 2011 ANSYS, Inc. May 9, 2012
    • 31. Full or Partial Pre-Stressed, Complex Eigenvalue31 © 2011 ANSYS, Inc. May 9, 2012
    • 32. Non Linear Static Structural Boundary Conditions and Loads32 © 2011 ANSYS, Inc. May 9, 2012
    • 33. Contact Status Capture33 © 2011 ANSYS, Inc. May 9, 2012
    • 34. Restarts34 © 2011 ANSYS, Inc. May 9, 2012
    • 35. Non Pre-Stressed, Complex Eigenvalue Post Processing: Damped Frequencies35 © 2011 ANSYS, Inc. May 9, 2012
    • 36. Non Pre-Stressed, Complex Eigenvalue Post Processing: Stability36 © 2011 ANSYS, Inc. May 9, 2012
    • 37. Partial Pre-Stressed, Complex Eigenvalue37 © 2011 ANSYS, Inc. May 9, 2012
    • 38. Partial Pre-Stressed, Complex Eigenvalue Post Processing: Stability38 © 2011 ANSYS, Inc. May 9, 2012
    • 39. Post Processing Complex Eigenvalue39 © 2011 ANSYS, Inc. May 9, 2012
    • 40. Post Processing Complex Eigenvalue Animations40 © 2011 ANSYS, Inc. May 9, 2012