Body Structure & Chassis Optimization

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  • 1. Dipl.-Ing. Elmar Teipen Dr.-Ing. Michel PaasR&A – Global Vehicle Dynamics Ford of Europe – Body EngineeringDipl.-Ing. Hessel van Dijk Dr.-Ing. Axel HänschkeFord of Europe – Body Engineering Ford of Europe – Analytical PrototypeBody Structure & Chassis OptimizationFor Improving Driving Maneuvers2011 European Hyperworks Technology Conference – Bonn
  • 2. 2011 European Hyperworks Technology Conference - Bonn Agenda • Why Body Structure Is Important To Vehicle Dynamics • What Is The Body Doing During Driving ? • How To Investigate Structural Performance For VD ? • Customized Hyperstudy Approach • MDO Application Examples • Summary & Next StepsPage 2 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 3. 2011 European Hyperworks Technology Conference - Bonn Why Body Structure Is Important To Vehicle Dynamics Steering – Straight Ahead Controllability (On-Center)  Compliance  Response: Amount, Linearity, Delay  Steering Wheel Torque Feedback  Modulation (Torque vs. Response) Ride – Primary Ride  Control / Comfort – Secondary Ride  Shake  Rolling Feel / Plushness – Impacts Solidity / Rigidity / Quality Impression  Vehicle Dynamics Performance Influenced By Structural Stiffness & WeightPage 3 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 4. 2011 European Hyperworks Technology Conference - Bonn What Is The Body Doing During Driving ? – Front End Lateral Bending  On-Center Compliance  Steering Precision  Response Delay, Non-Linearity – Torsion  Front-to-Rear Balance  Compliance  Body Shake, S&R, Rigidity Feel – Vertical Bending  Impact Harshness  Front End Shake, (S&R)  Trade-Off : Body / Chassis Lightweight  Vehicle Dynamics PerformancePage 4 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 5. 2011 European Hyperworks Technology Conference - Bonn How To Investigate Structural Performance For VD ? Local EWS HPC Local EWS Hypermesh Competitor SW ADAMS/Chassis Hyperworks Preprocessing MNF-Creation Solving Postprocessing - ADAMS/Chassis: MBS Pre-Processing (With Vehicle Templates) & Solving - Embedded FE-Structures Of Body, Subframes, etc. » Manual Hypermesh Preparation (Superelements, Interface Nodes, ...) » Modal Reduction With Competitor Software On HPC Supercomputer » Sequential MNF-Creation: Up To 3 h Per Run / Up To 16 GB mnf To Transfer » Implementation With Python-Templates (Manually Edited) - Hyperworks: VD Postprocessing (Based On Maneuver-Dependent Reports) - Body & Chassis Structural Modifications Based On Individual Results  Time-Consuming – Manual Interactions – Limited Variations – Not EfficientPage 5 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 6. 2011 European Hyperworks Technology Conference - Bonn Customized Hyperstudy Approach HPC TCL-Templates Radioss ADAMS/Chassis TCL-Templates Preprocessing MNF-Creation Solving Postprocessing Customized Hyperstudy Control & PP - Hyperstudy Customized Integration: » Selection Of Design Variables (In FE And MBS Templates) User Friendly  » In-The-Loop Generation / Calculation Of Combined Models Automated Pre+Post  » Fully Automated DOE Control From Local EWS No Manual Interaction  » Data-Intensive Work Completely On HPC Supercomputer Reduced File Transfer  » Semi-Parallel Runs Possible Reduced Run Time  » Collection Of Final Results (Some kB Per Run) On EWS Reduced Data  » Optimized License Application Reduced Cost   Customized Hyperstudy = Key Enabler For Statistical FE + MBS Analysis on HPCPage 6 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 7. 2011 European Hyperworks Technology Conference - Bonn Application Examples: Stepsteer & Ride 4-Poster Vehicle Dynamics Metrics vs. Sheets - Steering (Sinesteer, Stepsteer, On-Center) - Ride (4-Poster, Road 10 Old Part, Blauwe Kei) - Handling - Braking – BIP content within a Trimmed Body + Subframes – Design Variables: Sheet Thicknesses + ADAMS Bushings – Generic Responses » Wheel Loads (nominal, min, max) » Full Vehicle properties » Frt Axle Load, Total Weight – Stepsteer Responses (Time Domain): » Peak Yaw Rate, Peak LatAcc » Steady-State LatAcc, Sideslip Angle, ... – 4-Poster Responses (Frequency Domain): » 50 PSDs (each 1 – 30 Hz) (Tpmnts, Seatrails, FrtBending, FulTors, Engine,...) – Total Time To Complete: 2 Days (1000 Runs)  Customized HS : Complete In-/Output Matrix  Vehicle Dynamics Attribute Requirements In Body / Chassis Lightweight MDOPage 7 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 8. 2011 European Hyperworks Technology Conference - Bonn MDO Approach Meta Modelling HyperStudy DOE Data Mining CART Clustering Analysis Correlations Optimization ValidationPage 8 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 9. 2011 European Hyperworks Technology Conference - Bonn MDO Approach Meta Modelling HyperStudy DOE Data Mining Optimization ValidationPage 9 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 10. 2011 European Hyperworks Technology Conference - Bonn MDO Approach Meta Modelling HyperStudy DOE Data Mining Optimization ValidationPage 10 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 11. 2011 European Hyperworks Technology Conference - Bonn MDO Approach Meta Modelling HyperStudy DOE Data Mining Optimization HyperStudy ValidationPage 11 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 12. 2011 European Hyperworks Technology Conference - Bonn Application Example: Body Impact @ Full Vehicle Ride Data-Mining Zoom: Full Torsion (1 – 30 Hz) FV Frequency Responses: Ride Design Variables Body DVsPage 12 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 13. 2011 European Hyperworks Technology Conference - Bonn MDO Toolkit Example: Frequency-Dependent Correlations Data-Mining FV Response Body DVs  MDO Toolkit Available To Visualize Structural Effects Against Full Vehicle MetricsPage 13 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 14. 2011 European Hyperworks Technology Conference - Bonn MDO Subcase Extension Meta 1. Total Mass Modelling & Optimization 2. Stat. Stiffness 3. Dyn. Stiffness 4. Modes /Tors. Stiffn. 5. EUNCAP ODB 6. Rear Impact 7. LINCAP 8. Meta Models incl.Steering eqs. Vehicle Dynamics / constraint DVs RVs + + 9. Vehicle Dynamics / Ride  Additional VD Loadcases To MDO Process = X-Attribute Trade-Off StudiesPage 14 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 15. 2011 European Hyperworks Technology Conference - Bonn Summary • Vehicle Dynamics Attribute Significantly Influenced By Structural Stiffness & Weight • Lightweight Trend: Potentials & Risks For Vehicle Dynamics • Standard Process Inefficient To Systematically Investigate Trade-Offs • Customized Hyperstudy Enables X-Attribute MDO Including Vehicle Dynamics – From Manual Iterations To Automatic Process – From Local EWS To Supercomputer – From Competitor Software To Radioss – From Single Attribute Optimization To X-Attribute MDO Next Steps • Process Refinements • Implementation Of Structural ConceptsPage 15 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 16. 2011 European Hyperworks Technology Conference - Bonn Contacts Elmar Teipen Dr. Michel Paas +49 (0)221 9034526 +49 (0)221 9037755 eteipen@ford.com mpaas@ford.com Hessel van Dijk Dr. Axel Hänschke +49 (0)221 9036333 +49 (0)221 9033441 hvandijk@ford.com ahaensch@ford.com Special Thanks … • Axel Flick, Altair Office Cologne • Alexander Koch, Altair Office Cologne • Thomas Kowalewski, Altair Office Cologne • Arno Klein, P+Z Engineering • Matthias Stenkamp, P+Z EngineeringPage 16 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
  • 17. 2011 European Hyperworks Technology Conference - Bonn Thank you for your attention !Dipl.-Ing. Elmar Teipen – Global Vehicle DynamicsDipl.-Ing. Hessel van Dijk – Body Engineering Europe