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DEVELOPMENT AND OPTIMIZATION OF A LOWER CONTROL ARM (LCA)
USING HIGH STRENGTH STEELS
European Altair Technology Conference...
AGENDA
ABOUT US
LCAs AT A GLANCE
BENCHMARKING
FE ANALYSISES
RESULTS & COMMENTS
M.Kemal Coşkunöz
60 YEARS EXPERIENCE IN METAL FORMING
COŞKUNÖZ HOLDING
R&D CENTER MANAGEMENT
AUTOMOTIVE
TEAM
AUTOMATION
TEAM
MACHINERY
TEAM
FINITE
ELEMENT
ANALYSIS
PRODUCT
DEVELOPMENT
MATERIAL
...
Reverse Engineering
Computer Aided Design Test Verification
Prototyping
Computer Aided Analysis
CAPABILITIES
Optimization
...
MACHINERY
TEAM
LASER
TECHNOLOGIES
TEAM
AUTOMATION
TEAM
TOOL & DIE
TEAM
AUTOMOTIVE
TEAM
(12)
71
CAPABILITIES
Human Resource...
Magnesium IP Beam
TWIP Door Impact Beam
TWIP Roll Forming
Martensitic Roof Reinforcement
Bar
CFRP Composite Side Impact
Be...
Right Lower Control Arm Right Lower Control Arm
Front Bush
Rear Bush
Steering Knuckle
Lower control arms are mostly manufa...
Tire Volume Steering Knuckle Cross Member
Stabilizer Torque Wrench Rod Boot
L.C.A. AT A GLANCE
Rear Bush Zone
Front Bush Zone
Ball Joint
L.C.A. AT A GLANCE
Forged Steel
One-Sided Steel
Welded Metal
Forged Aluminium
Ball
Joint
Riveting
Bushing
Installation to
Flanged Hole
Welded...
Bending operation, one-sided steel
control arm Reinforcement Bracket
Ball joint, riveting , weld connection
BENCHMARKING
FB 540 M 800 HY / CP 800
TRIP 800 SPHN 590C / DOMEX 600
BENCHMARKING
BENCHMARKING
Ford Transit Ford Connect
Control Arms produced by Coşkunöz
Honda Civic
BENCHMARKING
F2
F1
F3
Steering Loads
Vertical Acceleration Loads
Braking Loads
Braking During Steering Loads
Reverse Acceleration Loads...
After definition of packaging data for LCA , design
and nondesign zones have been defined and
modelled on Hypermesh by usi...
As a result of optimization , that the area marked with 1 have been protected and it is so significant has been
seen .
Add...
Buttom Plate
700 MPa
Upper Plate
700MPa
Forge
Forge
Forge
Reinforcement tube
LINEAR ANALYSISES
Reinforcement tube has been used to reduce the
stresses around the mounting hole .
Representative Picture to show the rein...
Nonlinear analysises have been investigated in
two different sections as with rubbers and
without rubbers .
Goal in nonlin...
A Lower Control Arm must meet the requirements for energy absorption , durability and fatigue.
In our study , a material w...
As a result of nonlinear analysises and optimization studies for definition of ideal geometry and
material , it has been s...
In this analysis ;
 Maximum energy absorption value at the point of ultimate elongation strain are observed.
NONLINEAR AN...
Upper Plate
OPERATIONS
OP10 : Blanking
Op20 : Forming
Op30 : Piercing
Op40 : Restrike
Op50: Cam piercing
FORMING SIMULATIO...
COMPARISON
LESS SMALLER , MORE STRONGER DESIGN
PICTURE BELONGS TO 3D PRINT OUT OF NEW DESIGN LOWER CONTROL ARM.
 In this study , topology optimization which helps to reduce product costs and to find the optimum
design during the prod...
We applied for a patent on a local hardened and shot-peened lower control arm , with know-
how gained after this study.
20...
THANKS FOR YOUR ATTENTION
Acknowlegdements : Beltan&Vibracostic R&D Team and Ass.Prof. Mehmet Fırat
CONTACTS :
mcalli@cosk...
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DEVELOPMENT AND OPTIMIZATION OF A LOWER CONTROL ARM (LCA) USING HIGH STRENGTH STEELS

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The significance of high-strength steel concepts for vehicle parts has increased in the last years due to the meeting of reduction in weight and enhanced safety requirements. However these steels have high strength values , this feature is not adequate to reduce the weight of chasis parts due to the reason that weld zones have a limited strength without depending on the strength of steel. This case is a major problem in terms of fatigue requirements.

OEMs usually prefer forged lower control arms as well as the control arms which consist of welded two or more parts on the commercial vehicles. Reduction of stresses on weld zones is one of the targets.

Lower control arms are mostly manufactured from forged , cast and sheet steels and absorb the loads such as braking , acceleration, lateral , longitudinal.

In this study , a lower control arm (LCA) for a light-commercial vehicle is designed by welding of double metal sheets. LCA design has been analyzed on FEA softwares in order to obtain linear and nonlinear test requirements by using inertia relief option , tensile test requirements by using rubbers.

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Transcript of "DEVELOPMENT AND OPTIMIZATION OF A LOWER CONTROL ARM (LCA) USING HIGH STRENGTH STEELS"

  1. 1. DEVELOPMENT AND OPTIMIZATION OF A LOWER CONTROL ARM (LCA) USING HIGH STRENGTH STEELS European Altair Technology Conference- Munih June 2014 Metin Çallı, Mesut Kaya , Emre Yiğitoğlu , Nihal Efe
  2. 2. AGENDA ABOUT US LCAs AT A GLANCE BENCHMARKING FE ANALYSISES RESULTS & COMMENTS
  3. 3. M.Kemal Coşkunöz 60 YEARS EXPERIENCE IN METAL FORMING COŞKUNÖZ HOLDING
  4. 4. R&D CENTER MANAGEMENT AUTOMOTIVE TEAM AUTOMATION TEAM MACHINERY TEAM FINITE ELEMENT ANALYSIS PRODUCT DEVELOPMENT MATERIAL DEVELOPMENT TEST & PROTOTYPE INTELLECTUAL PROPERTIES LASER CUTTING 3D MACHINES 2D MACHINES LASER WELDING SIMULATION PROCESS DEVELOPMENT TOOL & DIE DESIGN CAM NC CNC PLC HMI ROBOTIC APPLICATIONS LASER TECHNOLOGIES TEAM TOOL & DIE TEAM PRODUCT DEVELOPMENT PRESS MACHINES AND REFURBISHMENT COŞKUNÖZ R&D CENTER DOCUMENTATION
  5. 5. Reverse Engineering Computer Aided Design Test Verification Prototyping Computer Aided Analysis CAPABILITIES Optimization Benchmarking Data Acquisition
  6. 6. MACHINERY TEAM LASER TECHNOLOGIES TEAM AUTOMATION TEAM TOOL & DIE TEAM AUTOMOTIVE TEAM (12) 71 CAPABILITIES Human Resources Software Resources  DESIGN Catia V5 – 32 licenses SolidWorks - 14 licenses UniGraphics - 1 license  FORMING Autoform Hyperform  FEA HyperMesh Radioss Optistruct (Optimization) Acusolve CFD  KINEMATIC ANALYSIS Expressus  BENCHMARK A2MAC1
  7. 7. Magnesium IP Beam TWIP Door Impact Beam TWIP Roll Forming Martensitic Roof Reinforcement Bar CFRP Composite Side Impact Beam CFRP Composite Suspension Parts CP Salıncak Kolu TRIP Tünel Sacı CFRP Composite + DP Bumper Beam Martensitic Side Impact Beam 22MnB5 and 22MnV6 Rear Axle Beam CP Lower Control Arm Aluminium Hood Reinforcement CAPABILITIES
  8. 8. Right Lower Control Arm Right Lower Control Arm Front Bush Rear Bush Steering Knuckle Lower control arms are mostly manufactured from forged , cast and sheet steels and absorb the loads such as braking , acceleration, lateral , longitudinal. LOWER CONTROL ARM AT A GLANCE
  9. 9. Tire Volume Steering Knuckle Cross Member Stabilizer Torque Wrench Rod Boot L.C.A. AT A GLANCE
  10. 10. Rear Bush Zone Front Bush Zone Ball Joint L.C.A. AT A GLANCE
  11. 11. Forged Steel One-Sided Steel Welded Metal Forged Aluminium Ball Joint Riveting Bushing Installation to Flanged Hole Welded Tube for Reinforcement Ball Joint Connection with Bolts BENCHMARKING
  12. 12. Bending operation, one-sided steel control arm Reinforcement Bracket Ball joint, riveting , weld connection BENCHMARKING
  13. 13. FB 540 M 800 HY / CP 800 TRIP 800 SPHN 590C / DOMEX 600 BENCHMARKING
  14. 14. BENCHMARKING
  15. 15. Ford Transit Ford Connect Control Arms produced by Coşkunöz Honda Civic BENCHMARKING
  16. 16. F2 F1 F3 Steering Loads Vertical Acceleration Loads Braking Loads Braking During Steering Loads Reverse Acceleration Loads Longitudinal Acceleration Loads DESIGN INPUTS / FORCES
  17. 17. After definition of packaging data for LCA , design and nondesign zones have been defined and modelled on Hypermesh by using critical load conditions. TOPOLOGY OPTIMIZATION Design Area Non-design Area
  18. 18. As a result of optimization , that the area marked with 1 have been protected and it is so significant has been seen . Additional to this , it has been identified that excessive material in the area 2 is unnecessary. TOPOLOGY OPTIMIZATION 1 2
  19. 19. Buttom Plate 700 MPa Upper Plate 700MPa Forge Forge Forge Reinforcement tube LINEAR ANALYSISES
  20. 20. Reinforcement tube has been used to reduce the stresses around the mounting hole . Representative Picture to show the reinforcement effect on stresses Reinforcement Tube LINEAR ANALYSISES
  21. 21. Nonlinear analysises have been investigated in two different sections as with rubbers and without rubbers . Goal in nonlinear analysises without rubbers is that LCA must provide plastic deformation requirements after unloading . F2 F1 F3 Extrapolated Rubber Test Data have been used on FEA software. NONLINEAR ANALYSISES
  22. 22. A Lower Control Arm must meet the requirements for energy absorption , durability and fatigue. In our study , a material which has high strength value , high weldability and high fatigue resistance has been choosen. MATERIAL SELECTION
  23. 23. As a result of nonlinear analysises and optimization studies for definition of ideal geometry and material , it has been seen that plastic strains occured on the close zone to cross member. NONLINEAR ANALYSISES
  24. 24. In this analysis ;  Maximum energy absorption value at the point of ultimate elongation strain are observed. NONLINEAR ANALYSISES Nonlinear Rubber ( Tensile Test ) Fix Fix Force Displacement [mm] Force[N]
  25. 25. Upper Plate OPERATIONS OP10 : Blanking Op20 : Forming Op30 : Piercing Op40 : Restrike Op50: Cam piercing FORMING SIMULATIONS
  26. 26. COMPARISON LESS SMALLER , MORE STRONGER DESIGN PICTURE BELONGS TO 3D PRINT OUT OF NEW DESIGN LOWER CONTROL ARM.
  27. 27.  In this study , topology optimization which helps to reduce product costs and to find the optimum design during the product development has been used.  Maximum stresses have been seen on the neck zone which is close to connection points of lower control arm to cross member during the critical loads .  That the material which is low-alloyed and has 700 Mpa yield strength is ideal for lower control arm and meets the loads enough has been seen.  Consequently , a lower control arm which meets structural durability requirements has been designed , analyzed under linear and nonlinear conditions , and simulated by using forming analysis . RESULTS & COMMENTS
  28. 28. We applied for a patent on a local hardened and shot-peened lower control arm , with know- how gained after this study. 2013/10157 Lower Control Arm It is about a suspension part. PATENT APPLICATION
  29. 29. THANKS FOR YOUR ATTENTION Acknowlegdements : Beltan&Vibracostic R&D Team and Ass.Prof. Mehmet Fırat CONTACTS : mcalli@coskunoz.com.tr mekaya@coskunoz.com.tr eyigitoglu@coskunoz.com.tr nefe@coskunoz.com.tr
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