Composite Optimisation of the S-Works + McLaren Venge

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Composite Optimisation of the S-Works + McLaren Venge

  1. 1. Composite Optimisation of the S-Works + McLaren Venge Jonathan Heal – Senior Stress Engineer – McLaren Racing Ltd
  2. 2. INTRODUCTION – COMPOSITE OPTIMISATION USING OPTISTRUCT 11.0  Background  Composite Optimisation approach adopted  Free Sizing optimisation  Detailed Sizing optimisation  Model Setup using CompOpt  Discrete and Continuous Phases  Global Iterations  Best Results  Conclusions
  3. 3. McLAREN RACING Ltd  One of the most successful Formula 1 teams: winner of 12 driver and 8 constructor championships  170 Race Victories  46 Years of racing in Formula 1  Worldwide exposure (1.4bn spectators for season)  Based in Woking, Surrey, UK
  4. 4. Role of Structural Simulation at McLaren  Approx 85-90% of the car is FEA’d  A significant number of the composite structures are optimised for maximum performance and minimum weight foutofbal : 12-Aug-2005 19:38:57 (Atlas) 04-GP07-Euro-KR-19Ax04-Q2R01 L2/3: 1m29.14F (Stiffer RARB - #233. 37kg fuel, Set....) << >> << L2 >> << L2 : 1m29.14F >> <<=>> 14h40m01.826s 400 20000 vCar 318.8 km/h FPushRodFL 12539 N 320 17500 FPushRodFR 11181 N FOutOfBalFL (11146) N vCar (km/h) Maximum FOutOfBalFR (11111) N 240 15000 FPushRodFL+FOutOfBalFL 24.227 kN FPushRodFR+FOutOfBalFR 23.675 kN 160 12500 FPushRodFL (N) 80 10000 0 7500 5000 2500 0 -2500 -5000 24 20 FPushRodFL+FOutOfBalFL (kN) 16 12 8 4 0 -4 -8 -12 Time 44.570000 s 0 10 20 30 40 50 60 70 80
  5. 5. COMPOSITE OPTIMISATION PROCESS USED HYPERMESH LAMINATING PROGRAM FE MODEL CREATION LAYUP DEFINED FOR DETAILED SIZING OPTIMISATION (INCLUDE DRAPING EFFECTS) PCOMPG(P) LAMINATE HYPERMESH FREE SIZING LAMINATE SETUP AND OPTIMISATION DATA HYPERMESH (CompOpt) CompOpt SETUP AND CREATION OF DDVAL, OPTISTRUCT DESVAR, DLINK AND DVPREL1 CARDS FREE SIZING OPTIMISATION OPTISTRUCT 11.0 DETAILED SIZING OPTIMISATION INCLUDING HYPERVIEW DGLOBAL ITERATIONS PLY SHAPE EVALUATION HYPERMESH (CompOpt) LAYUP FILE MODIFIED BASED ON BEST SOLUTION. OPTISTRUCT FINAL LAMINATE CHECK
  6. 6. FREE SIZING SETUP (LAYUP)  PARTITION MODEL FOR DESIGNABLE AND NON- DESIGNABLE ELEMENTS  FREE SIZING LAMINATE SETUP  PCOMP NON DESIGNABLE  PCOMPG(P) ELEMENTS DESIGNABLE ELEMENTS
  7. 7. FREE SIZING SETUP 2 (LOAD CASES)  Bottom Bracket Stiffness Test  Tour Magazine Torsion Test Other test not shown in this presentation  Rear Triangle Stiffness  Front Triangle Stiffness  Head Tube Ultimate Strength Fixed at Dropouts and loaded in Torsion Point Load on pedals, Constrained at Fork and Rear Dropouts
  8. 8. FREE SIZING RESULTS (THICKNESS) ELEMENT THICKNESS PROGRESSION FROM INCREMENT 0 TO THE FINAL INCREMENT
  9. 9. FREE SIZING RESULTS (DEFLECTIONS) Bottom Bracket Deflection Tour Test Deflection X% Weight reduction over Stock Frame
  10. 10. COMPOSITE OPTIMISATION PROCESS USED HYPERMESH LAMINATING PROGRAM FE MODEL CREATION LAYUP DEFINED FOR DETAILED SIZING OPTIMISATION (INCLUDE DRAPING EFFECTS) PCOMPG(P) LAMINATE HYPERMESH FREE SIZING LAMINATE SETUP AND OPTIMISATION DATA HYPERMESH (CompOpt) CompOpt SETUP AND CREATION OF DDVAL, OPTISTRUCT DESVAR, DLINK AND DVPREL1 CARDS FREE SIZING OPTIMISATION OPTISTRUCT 11.0 DETAILED SIZING OPTIMISATION INCLUDING HYPERVIEW DGLOBAL ITERATIONS PLY SHAPE EVALUATION HYPERMESH (CompOpt) LAYUP FILE MODIFIED BASED ON BEST SOLUTION. OPTISTRUCT FINAL LAMINATE CHECK
  11. 11. COMPOSITE OPTIMISATION PROCESS USED MATERIAL SETUP HYPERMESH (CompOpt) SETUP THICKNESS AND ORIENTATIONS FOR SPECIFIC MATERIALS SETUP AND CREATION OF DDVAL, CompOpt DESVAR, DLINK AND DVPREL1 CARDS THICKNESS SETUP THICKNESS DESIGNABLE PLY SELECTION AND GROUPING ORIENTATION SETUP ORIENTATION DESIGNABLE PLY SELECTION AND GROUPING
  12. 12. DETAILED SIZING – MATERIAL SETUP THICKNESS LOWER AND ORIENTATION LOWER AND UPPER BOUNDS AND UPPER BOUNDS AND THICKNESS INCREMENT ORIENTATION INCREMENT
  13. 13. DETAILED SIZING – THICKNESS AND ORIENTATION SETUP LIST OF DESIGNABLE PLIES AND THICKNESS LIMITS GROUPED DESIGNABLE PLIES AND THICKNESS LIMITS ALL PLIES IN MODEL
  14. 14. QUESTION:HOW DO WE OBTAIN AN OPTIMAL SOLUTION?TWO PARAMETERS PROVE TO BE VERY HANDY
  15. 15. DETAILED SIZING – DDVOPT PARAMETERS
  16. 16. DETAILED SIZING - GLOBAL ITERATIONS DGLOBAL CARD FOR DEFINITION OF GLOBAL ITERATIONS
  17. 17. DETAILED SIZING - OPTIMAL THICKNESS DISTRIBUTION
  18. 18. DETAILED SIZING – BEST DEFLECTION RESULTS Bottom Bracket Deflection Tour Test Deflection
  19. 19. CONCLUSIONS  McLaren Racing has spent a significant amount of time/effort in improving the Composite Optimization within Altair/OPTISTRUCT .This has resulted in the creation of CompOpt in HyperMesh  Using Free Sizing Optimisation is a efficient way of generating efficient ply shapes  CompOpt in HyperMesh allows fast and efficient setup of Detailed Sizing Optimisation studies  Correct use of DGLOBAL and DDVOPT Parameters are a better way to generate optimal solutions  Composite Optimisation in OPTISTRUCT is essential in delivering optimal structures to the track in very tight timescales
  20. 20. So, what does this really mean?

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