Application of a Novel Metal Folding Technology for Automotive BiW Design - Clemson University


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A long-term initiative at the Clemson University International Center for Automotive Research (CU-ICAR) is advancing the automotive engineering graduate research and education program. Called "Deep Orange," this framework immerses students in automotive engineering master’s and doctoral degree programs in the world of a future OEM (Original Equipment Manufacturer) and supplier.

As part of the 3rd Deep Orange vehicle project, it was decided to engineer, build, and showcase the load bearing structure of the Body-in-White (BiW) based on a novel technology of sheet metal folding developed by Industrial Origami. The approach chosen eliminates metal stamping and high capital investments such as dies and molding presses. The engineering of the BiW involved defining design relevant load cases (such as frontal/side/rear impact and static/dynamic stiffness properties), developing a topology to transfer the loads throughout the BiW, creating design space for occupants, chassis and powertrain components and conduct functional analyses of the BiW in terms of stiffness. This presentation details how Altair HyperMesh, RADIOSS, and HyperView were used for many aspects of this project.

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Application of a Novel Metal Folding Technology for Automotive BiW Design - Clemson University

  1. 1. 33Application of a Novel MetalFolding Technology for AutomotiveBiW Design Prathamesh Marathe June 5, 2012 CUICAR | Deep Orange 3 1
  2. 2. 3CU-ICAR (Clemson University International Center for Automotive Research) • Advanced-technology research campus in collaboration with academia, industry and government organizations • The first and only US Automotive Engineering program so far; Master & PhD program • State-of-the-art equipment & facilities • Technology neighborhood June 5, 2012 CUICAR | Deep Orange 3 2
  3. 3. 3What is Deep Orange• Vehicle prototype program at CU-ICAR that immerses graduate automotive engineering students into the world of a future OEM and/or supplier• Helps students to gain hands on experience – Students are involved from inception to completion in all phases – Students get to interact with cross functional faculty members• Students learn about state of the art technologies and how to integrate these Deep Orange 1 car Deep Orange 3 Spring – Summer ’12 team June 5, 2012 CUICAR | Deep Orange 3 3
  4. 4. 3Deep Orange: A New Teaching Paradigm Product/Production Architectures Market Analyses System Design Start: Day 1 Day 193 Annual new Prototype Vehicle releases from two-year Development Cycles Target Validation Concept Graduation Selection An integral feature of our MS/PhD Research & Education Program Validation System Integration Manufacturing/Assembly Day 523June 5, 2012 End: Day 712 CUICAR | Deep Orange 3 4
  5. 5. 3The Importance of Industry Participation• Provide realistic problem statements and challenges that address current and future (industry) issues.• Give access to new innovations, materials, technologies and processes.• Mentor students during regularly scheduled meetings.• Provide crucial background information on subject matter often not accessible in an academic setting.• Fund the overall program.June 5, 2012 CUICAR | Deep Orange 3 5
  6. 6. 3The Deep Orange 3 Project• Joint Sponsorship of – Mazda North American Operations (MNAO) – Clemson University-International Center for Automotive Research (CU- ICAR) – Arts Center College of Design (ACCD)• Designed to give large scale view of the automobile design and engineering process – Marketing Data – Design and Engineering – Validation and TestingJune 5, 2012 CUICAR | Deep Orange 3 6
  7. 7. 3IOI Technology• Conventional Technology: Stamping of sheets• Drawbacks – High tooling cost – Complicated process Source:• New Technology: Folding of sheets into simple shapes• Advantages – Low cost tooling – Unskilled labor force can be easily trained (Less complicated) – Lesser time requirement – Lower Number of parts – Accurate laser cut holes for mounting components and rivetingJune 5, 2012 CUICAR | Deep Orange 3 7
  8. 8. 3Application of IOI Technology• Topology of vehicle• Packaging of other assemblies • Chassis • Powertrain • Occupants• Analysis of structure for torsion and bending stiffness• Analysis of structure for dynamic loadingJune 5, 2012 CUICAR | Deep Orange 3 8
  9. 9. 3Application of IOI TechnologyJune 5, 2012 CUICAR | Deep Orange 3 9
  10. 10. 3Components of BiW Floor And Spaceframe Front Crash Rear Crash Structure StructureJune 5, 2012 CUICAR | Deep Orange 3 10
  11. 11. 3FEA of IOI Structure• Use of Hypermesh to generate mesh – Sheet metal parts and Space frame pipes as 2D shell mesh – Thicker geometries as 3D tetra mesh 3D Tetra Mesh in 2D Shell Mesh in Floor Assembly Spaceframe AssemblyJune 5, 2012 CUICAR | Deep Orange 3 11
  12. 12. 3FEA of IOI Structure• Adhesives used to connect different sheets• Spot weld connectors used to connect space frame to IOI structure• Boundary conditions and loads – For Torsional Stiffness of the BiW • Loads applied at front strut towers • Constraints at front and rear with beams to simulate real life situationsJune 5, 2012 CUICAR | Deep Orange 3 12
  13. 13. 3FEA of IOI Structure (Contour Plots)• Use of Hyperview to do post processing of analysis results – Displacements – Induced stressesJune 5, 2012 CUICAR | Deep Orange 3 13
  14. 14. 3FEA of IOI Structure (Twist Angle Vs Vehicle Length)June 5, 2012 CUICAR | Deep Orange 3 14
  15. 15. 3Future Steps• Carryout Dynamic Loading of the structure• Test the fold ability of the sheets• Realize the BiW structure form sheets and spaceframe.June 5, 2012 CUICAR | Deep Orange 3 15
  16. 16. 3Acknowledgements• Thanks to Dr Paul Venhovens for support and supervision• Thanks to DO-3 team for timely help• Thanks to Altair and Dr David Schmueser for this opportunity to present the work at this conferenceJune 5, 2012 CUICAR | Deep Orange 3 16
  17. 17. 3 Thank YouJune 5, 2012 CUICAR | Deep Orange 3 17