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#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
#NXCAE13: American Axel NX & LMS Test.Lab Integration
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#NXCAE13: American Axel NX & LMS Test.Lab Integration

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Alexander Sandstrom graduated with a bachelors in mechanical engineering from the University of North Carolina at Charlotte in 1999. Started in the Chrysler Technical Center in the NVH lab in early …

Alexander Sandstrom graduated with a bachelors in mechanical engineering from the University of North Carolina at Charlotte in 1999. Started in the Chrysler Technical Center in the NVH lab in early 2000 until the middle of 2001 when he joined LMS. At LMS he was responsible for project management in the Engineering Services Department as well as business development activities and gained extensive experience using LMS Test.Lab and Virtual.Lab. In the fall of 2010 Alexander started at American Axel & Manufacturing as Sr. NVH Project Engineer and was responsible for the NVH performance of the newly productionized Eco-Trac system. He since moved to the NVH CAE team and is involved in the upfront prediction of axle gear mesh excitation and vehicle integration issues.

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  • Bernard, Jim [jim.bernard@siemens.com] - compliment
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    1. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 Title 11/5/2013 1
    2. NX and LMS Test.Lab Integration at AAM Company Background NX CAE Symposium 2013 Introduction: About AAM Europe North America South America Key Facts • $2.93 Billion USD Sales (2012) • 33 Locations in 13 Countries • 11,000 Associates • 20 Manufacturing Facilities • 11 Business, Technical and Engineering Centers • 2 Joint Venture Operations 11/5/2013 Asia World Headquarters Technical Center 2
    3. NX and LMS Test.Lab Integration at AAM AAM’s products NX CAE Symposium 2013 Company Background Light Truck and SUV Passenger Car & Crossover Vehicle Multi-piece Propeller shaft Rear Drive Module w/ Torque Transfer Device Transfer Case Rear Beam Axle Front Axle (Independent & Steerable) eAAM electric AWD Front & Rear Propeller shafts Chassis Components Power Transfer Unit Other 1.6% 11.5% Rear Beam Axle Propeller Shafts 8.0% Metal Formed 6.3% Products 16.8% Driveshafts Front Axle 11/5/2013 Commercial Vehicle 55.8% Front Axles Rear Axle Systems (Includes Rear Drive Modules) 3
    4. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 Company Background AAM’s Customers Light Truck / SUV Transfer Cases Driveshafts Rear Axles Front Axles Passenger Car / Crossover Transmission Differentials Multi-Piece Driveshafts Independent Rear Drive Axles (IRDAs) Independent Front Drive Axles (IFDAs) Torque Transfer Devices (TTDs) Power Transfer Units (PTUs) Commercial Vehicle Front Axles Rear Axles Metal Formed Products Bus Axles (Rear Engine) Ring / Pinion Gears Tandem Transmission Components Axle / Output Shafts 11/5/2013 Differential Gears 4
    5. NX and LMS Test.Lab Integration at AAM NVH Background NX CAE Symposium 2013 Typical Automotive Driveline System NVH Problems • Gear Whine • Driveline 1st order (imbalance and pitch line run-out) • Driveshaft critical speed • Driveline 2nd order (Cardan joint kinematics) • Engine torque fluctuation • Propshaft instability • Gear Rattle • Chain noise • Shudder / Moan / Chatter • Wheel imbalance • Clunk • Engine idle shake AAM NVH CAE Responsibilities 1. Early upfront analysis and optimization to minimize NVH risks 2. Model correlation and physical validation during product development 1. Product behavior with different boundary conditions (Dyno vs Vehicle etc.) 2. Model methodology and database improvement 3. Problem troubleshooting and identification 3. Assist with Production and Field NVH Issues • NVH CAE Team resides in NVH Product Engineering Department • 11/5/2013 Test, Project Management, CAE 5
    6. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 AAM Software History Timeline Test 1990s 2000 2001 2002 … 2010 2011 2012 LMS Cada-X 2013 LMS Test.Lab CAE I-DEAS I-DEAS I-DEAS Windows 7 Upgrade • LMS Cada-X • No CAE functionality • I-DEAS • Thoroughly integrated Test and CAE functionality • Entire group used the • Few individuals software efficiently could use the through use of scripts software efficiently 11/5/2013 • LMS Test.Lab Siemens NX 8.5 Siemens LMS Acquisition • Siemens NX • No CAE functionality • Very easy user interface • Mature CAE Environment • Entire group has learned • Easy transition from I-DEAS how to use the software effectively • Entire CAE group is very capable within the • Used by CAE for Function software Math and Plotting 6
    7. NX and LMS Test.Lab Integration at AAM CAE Analysis Process NX CAE Symposium 2013 • Generating correlated CAE results involves a fairly standard iterative loop consisting of : 1. Model Construction 2. Model Solution 3. Calculating Responses 4. Comparison/Correlation to Test Data 5. Design Studies • As with any iterative process, several repetitive software functions are used as each iteration requires a new calculation of results • This is further complicated by the need to use Test.Lab for function math and powerful plotting tools • NX 8.5 Journaling has saved significant effort as repetitive functions within NX can be replayed automatically 11/5/2013 7
    8. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 CAE Analysis Process • Predictive Analysis is conducted in NX Advanced Simulation Module Front Axle Model in NX • Models are solved using standard Sol 103 (Normal Modes) • Response Simulation (FRF Calculator) is used to generate functions • Iterative correlation activities occur often requiring the use of both Test.Lab and NX for analysis currently Pinion Nose Vertical Response 100.0 • Test.Lab Functionality allows for more complex operations 30.0 10.0 3.0 • NX does not currently read Test.Lab data • Test.Lab plotting is very advanced Log (...) • Test.Lab has Advanced Function Math Tools m/s 2 • Test.Lab does read NX data 1.0 0.3 0.1 30e-3 10e-3 3.0e-3 1.0e-3 300e-6 100e-6 100 150 11/5/2013 Test CAE Test and CAE Data displayed in Test.Lab 200 250 300 350 400 450 500 Hz 550 600 650 700 750 800 8
    9. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 CAE Analysis Process • While the process could be conducted within NX, efficiency is improved dramatically when post processing is carried out within Test.Lab for the following reasons: Rear Drive Module Model in NX • Advanced function math, data manipulation and calculation “scripting” capability • Very advanced plotting capabilities that enhance ability to review data • Convenient comparison of Test data and model data (overlays) • For reporting purposes, calculated results are displayed in LMS Test.Lab • NX data is in .afu format and is automatically saved externally • LMS created a plugin for AAM that allows Test.Lab to read AFUs directly for comparison to Test data Pinion Nose Vertical Response 100.00 10.00 1.000 0.1000 Test CAE Test and CAE Data displayed in Test.Lab 0.0100 11/5/2013 100 200 400 600 Frequnecy (Hz) 800 1000 9
    10. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 CAE Analysis Process - Correlation Inputs NX 8.5 Advanced Simulation - FEM - Manual remesh of 2D and 3D components - CAD Models - Nastran Models - Gear Contact Info - Boundary Conditions (Dyno, Vehicle, etc.) (if necessary) Solve NX 8.5 Advanced Simulation - FEM NX 8.5 Advanced Simulation - FEM - Generate FEA Mesh (if necessary) Strain Energy Table - Design Studies / Optimization - Auto-mesh most 2D and 3D components NX 8.5 Response Simulation - Apply appropriate damping treatment - Generate functions NX 8.5 Advanced Simulation - FEM - Manual Mesh 1D/0D components - Generate Gear Mesh Kinematics - Ensure proper connectivity between components (Springs, RBEs) Test.Lab - Import calculated functions NX 8.5 Advanced Simulation - SIM - Perform function math (scaling, multiplying, etc.) - Compare to Test Data - Evaluate Effectiveness - Connect to appropriate Boundary Conditions - Add appropriate constraints (MPCs, SPCs, etc.) Acceptable Correlation? Report Yes No 11/5/2013 10
    11. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 CAE Analysis Process – Design Studies Inputs NX 8.5 Advanced Simulation - FEM - Manual remesh of 2D and 3D components - CAD Models - Nastran Models - Gear Contact Info - Boundary Conditions (Dyno, Vehicle, etc.) (if necessary) Solve NX 8.5 Advanced Simulation - FEM NX 8.5 Advanced Simulation - FEM - Generate FEA Mesh (if necessary) Strain Energy Table - Design Studies / Optimization - Auto-mesh most 2D and 3D components NX 8.5 Response Simulation - Apply appropriate damping treatment - Generate functions NX 8.5 Advanced Simulation - FEM - Manual Mesh 1D/0D components - Generate Gear Mesh Kinematics - Ensure proper connectivity between components (Springs, RBEs) Test.Lab - Import calculated functions NX 8.5 Advanced Simulation - SIM - Perform function math (scaling, multiplying, etc.) - Compare to Test Data - Evaluate Effectiveness - Connect to appropriate Boundary Conditions - Add appropriate constraints (MPCs, SPCs, etc.) Acceptable Correlation? Report Yes No 11/5/2013 11
    12. NX and LMS Test.Lab Integration at AAM CAE Analysis Process NX CAE Symposium 2013 • The Strain Energy Tabulation allows the primary contributor to each mode to be clearly identified so that appropriate modifications to the mesh can be easily made to achieve the desired dynamic changes • The table shows clearly that Modes #7 and #8 are Propshaft Bending Modes • The Prop 2D (Tube modeled as shells) group contains more than 90% of the Strain Energy • Mode #9 is Propshaft/Transmission Interface Torsion as the Prop 2D and Prop Joint Groups are the highest contributors • Animation of the mode in conjunction with the Strain Energy table clearly identifies the controlling components in each mode Rear Axle Single Piece Propshaft Example Mode #9 Mode #8 11/5/2013 12
    13. NX and LMS Test.Lab Integration at AAM CAE Analysis Process NX CAE Symposium 2013 • A great improvement to the NX user experience has been the addition of the Journaling Tool • Works like Macros in Microsoft products • Can Record and Playback actions as needed • Very useful for repetitive actions Journal used to Calculate and Display Frequency Response Functions 11/5/2013 13
    14. NX and LMS Test.Lab Integration at AAM CAE Analysis Process NX CAE Symposium 2013 • The calculated functions are easily read into Test.Lab by browsing to the files from the Navigator • Functions are stored locally as .AFU files • LMS created an AFU reader plugin to easily access the data NX AFU files plotted within Test.Lab 11/5/2013 14
    15. NX and LMS Test.Lab Integration at AAM CAE Analysis Process NX CAE Symposium 2013 • The functions are added to the Data Calculator and a previously used Formula Set is loaded • For each iteration the FRFs and the necessary calculations are the same Functions are easily loaded for calculation 11/5/2013 15
    16. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 CAE Analysis Process • The newly calculated Acceleration data is then displayed easily within Test.Lab • The use of tabs in Test.Lab lets the user easily switch between the current plot window and a previously created plot Previous Plot Calculated CAE Surface Acceleration 11/5/2013 16
    17. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 CAE Analysis Process • The plots within LMS can then be copied to the MS Office suite and manipulated as the user sees fit • Plot editing from within PowerPoint includes: • X and Y-Axis modification • Addition of cursors • Curve Color and Line Thickness editing • Statistical calculations (Max, Mean, RMS, etc) • And much more… • CAE data is easily overlaid with Test Data for correlation 1000.00 500 451.92 300 200 100 70 Log m/s 2 50 30 20 10 7 5 F F F F 3 2 1580.49 1.00 0.00 11/5/2013 500 1000 1500 2000 2500 3000 Hz 3500 4000 FRF 60Y:+X/3000:+X 0 / FRF 61Y:+X/3000:+X 0 / FRF 62Y:+X/3000:+X 0 / FRF 63Y:+X/3000:+X 0 / 4500 5000 6000.00 17
    18. NX and LMS Test.Lab Integration at AAM Summary NX CAE Symposium 2013 • The NVH CAE team at AAM has been using NX for almost 18 months • The transition from IDEAS was smooth as old IDEAS models were easily imported into NX • NX provides a very powerful environment for analysis • The primary shortcomings on NX are with Function Math and Data Plotting • Test.Lab serves very well as a supplement to complete the required analyses 11/5/2013 18
    19. NX and LMS Test.Lab Integration at AAM NX CAE Symposium 2013 Title 11/5/2013 19

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