HTC 2012 Durability Training

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HTC 2012 Durability Training

  1. 1. Vehicle Durability Workshop – 2012 Americas HTC Multi-Body Dynamics Team, AltairInnovation Intelligence®
  2. 2. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Agenda - Vehicle Durability Workshop Start Time Topic3.153 15 PM Introduction3.25 PM HyperWorks for Vehicle Durability3.50 PM MotionView for Durability Modeling4.15 PM MotionSolve4.30 PM CD-Tire Introduction4.45 PM Flexbodies5.00 PM Customer – Altair Development Interaction p 2
  3. 3. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Don’t Miss! - MBD Customer Breakout Session• When? • Thursday May 17th 2012 – 1 15 to 2 45 PM EST Thursday, 1.15 2.45• Who? • Honda H d R&D • Presenter: Hernan Mercado-Corujo • Full-Vehicle Multi-body Simulations on Virtual Roads - The Challenges of Success • Fraunhofer • Presenter: Axel Gallrein • CDTire: State-of-the-Art Tire Models For Full Vehicle Simulation • Altair • Multi-Physics Multi Physics with MotionSolve 3
  4. 4. HyperWorks for Vehicle DurabilityInnovation Intelligence®
  5. 5. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Presentation Outline• Brief Introduction to Durability• How are customers using HyperWorks for Durability?• What are the key elements to assess durability? 5
  6. 6. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.What is Durability?• Ability to withstand to fatigue, corrosion, wear, creep, ...• P d i Predominant failure mode is fatigue t f il d i f ti• Fatigue is failure due to repeated cyclic load, well below the failure strength of the material 6
  7. 7. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Physics of Fatigue (Crack formation) (Crack propagation)• Caused by cyclic plastic deformation in a localized area. • P Presence of a small crack f ll k • Pre-existing defect on the surface of a component• Not possible to model using traditional FE 7
  8. 8. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Causes of Varying Loads Sources of Varying Loads on StructuresRoad Profile Closures Wind Turbine etc.. 8
  9. 9. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Which Areas Of The Vehicle Are Of Interest?Passenger Cars Light Trucks Heavy Trucks Buses Earth-Moving RailAgricultural General Utility Military Vehicles Snowmobiles Motorcycles 9
  10. 10. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Presentation Outline• Brief Introduction to Durability• How are customers using HyperWorks for Durability?• What are the key elements to assess durability? 10
  11. 11. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Application: Fatigue validation of motorcycle frame• Customer: Piaggio, Italy• Objective: • Establish a virtual simulation process for motorcycle frame• Solution: • Roller test bench dynamic simulation using Multi- Multi Body Dynamics (MotionView / MotionSolve) • High fidelity FTire tire model • Accurate load histories = Accurate life prediction!• Benefits: • Exceptional correlation between simulation (MotionSolve) and test data 11
  12. 12. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Application: Radiator test bench study• Customer: Modine, USA• Objective: • Perform multi-axes table simulation using Multi-body Dynamics • The shaker table s bjected to a s ept sine motion subjected swept• Solution: • Flexible Multi-body simulation using MotionView / MotionSolve • Accurate flexbody generation using Radioss• Benefits: • Exceptional correlation between simulation (MotionSolve) and test data • Robust flexbody solution • Seamless durability process within HyperWorks 12
  13. 13. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Application: Durability evaluation of a washer• Customer: MABE, Mexico• Objective: • Accurately study the behavior of the hydraulic balance ring of a washing machine • Extract E tract forces on the suspension rods for fatigue s spension fatig e evaluation• Solution: • A Multi-body model of the flexible rotor and stator in MotionView • A detailed balance ring crescent mechanism as a sub-system simulated in MotionSolve y• Benefits: • MotionSolve (simulation) force histories match well with that of the force transducers (test) 13
  14. 14. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Application: Automotive closures durability• Customer: Toyota, Japan• Objective: • Complete evaluation of closures using CAE • Component load generation using MBD • Reduce no of physical tests no.• Solution: • MotionView to model the closure systems • Model non-linearity of lock, seal and rubber non linearity lock • Consider lap clearance on sealing parts and rubbers • MotionSolve for accurate Multi-body simulations• Benefits: • Excellent correlation between MotionSolve and test • A virtual process for door slam evaluation was established using HyperWorks 14
  15. 15. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.And More…• Honda Reliability Group • Thursday May 17th 2012 – 1 15 to 2 45 PM EST Thursday, 1.15 2.45• Altair Bus Durability Project • Thursday, May 17th 2012 – 8.30 to 10.00 AM EST 15
  16. 16. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Presentation Outline• Brief Introduction to Durability• How are customers using HyperWorks for Durability?• What are the key elements to assess durability? 16
  17. 17. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.The Key Elements of Durability EvaluationReal World Usage Representative Duty Cycle Component Loading Histories Fatigue Assessment 17
  18. 18. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. The Key Elements of Fatigue Life Estimation FE Model Geometry Fatigue S/N E/N Estimated Material Data Analysis life Component Load L d Spectrum Load spectrum MBD modelRoad data acquisition 18
  19. 19. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.HyperWorks for Durability• HyperWorks has comprehensive durability capabilities: • HyperGraph  Duty cycle visualization (eg: Rainflow counting) counting)… • MotionView  Vehicle Library, Load Export,… • MotionSolve  Component load generation, quasi-static and transient analyses.. • Tire models  FTire CD-Tire, RMODK, MF-SWIFT FTire, CD-Tire RMODK MF-SWIFT,.. • Radioss  CMS (flexbodies), unit load analysis, linear static • HyperView  Hot spot visualization.. • OptiStruct, HyperStudy,…. • HWPA  FEMFAT, DesignLife,.. 19
  20. 20. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Templates to Meet Specific Needs DUTY MBD FATIGUE POST DUTY Measured MBD Component FATIGUE Loads Loading POST CYCLE ANALYSIS ANALYSIS Load Component Locations & Stress State Orientations FEA FE ANALYSIS 20
  21. 21. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Templates to Meet Specific Needs ROAD ROAD MODEL MBD FATIGUE POST Road + Driver MBD Component FATIGUE POST Inputs ANALYSIS Loading ANALYSIS DRIVER Load Component MODEL Locations & FE Stress State Orientations O i t ti DRIVER FE ANALYSIS 21
  22. 22. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Templates to Meet Specific Needs DUTY FE FATIGUE POST DUTY Measured Loads FEA FATIGUE POST CYCLE Loads Stress State MBD FATIGUE POST Event Component MBD FATIGUE POSTDefinition Loading FE Load Locations & Component Orientations Stress State FEA 22
  23. 23. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Summary• Altair offers a comprehensive solution for Vehicle Durability Task Tool Component modeling  HyperMesh Flex body creation  Radioss System modeling  MotionView Road & Tire Modeling  FTire, CDTire, RMOD-K , MF-SWIFT Loads generation  MotionSolve Fatigue calculation  HWPA (FEMFAT, Design Life) Visualization  HyperView/HyperGraph Optimization  OptiStruct, HyperStudy Putting it all together  Durability Director (ESG)• The solution is industry validated. validated• The solution is available to all HyperWorks customers 23
  24. 24. MotionView for Durability ModelingInnovation Intelligence®
  25. 25. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Durability Analysis – Possible Approaches• Static loads: • Model a representative vehicle in MotionView p • Setup a quasi-static load template • Run (quasi-)static analysis in MotionSolve • Extract loads (body forces) from MotionSolve to RADIOSS • Run inertia li f R i ti relief analysis (INREL -2) i RADIOSS l i 2) in • ….• Semi-analytical durability: • Model a representative vehicle in MotionView • Model a virtual test rig (eg: 4-poster) and input: • Forces directly at spindle – need to control drift (or) • Acceleration at spindle – need to convert acceleration to displacement (or) • Back calculated displacement at tire – need to use Remote Parametric Control p • Run transient simulation in MotionSolve • Extract component loads (and accelerations) from MotionSolve • Unit load analysis in Radioss to extract stress states • …. 25
  26. 26. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Durability Analysis – Possible Approaches• Fully analytical durability: • Model a representative vehicle in MotionView • Model a virtual tire and a digitized rough road (virtual proving ground events..) • Setup a driver (controller) • Run transient simulation in MotionSolve • Extract component loads (and accelerations) from MotionSolve • Unit load analysis in Radioss to extract stress states, etc • …. 26
  27. 27. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.How do you assure model fidelity?• Before starting your durability runs, make sure that: 1. 1 You obtain good K&C correlation in half vehicle models 2. Later assemble the two half’s of the vehicle to build full vehicle 3. Run a static equilibrium analysis to get the CG and tire patch loads right 4. 4 Decide which parts need to be flexible • Key is to capture the “correct” compliance 27
  28. 28. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Static Load Analysis• Definition: • This is a quasi-static simulation to study the effect of various load cases applied at the wheel center and tire patch.• Required input: • Point of application of the load ( wheel center or tire patch ) • Load direction • Load type ( force or displacement ) • Load in Newton, Newton-mm or displacement in mm. • Load multiplier. • Load case number that the load belongs to.• Description of task: D i ti ft k • To begin with a static simulation is performed with all the active loads belonging to a load case. This is followed by resetting the set of loads in the load cases and the next set of load cases is applied. The process is repeated till all load cases are applied. 28
  29. 29. MotionSolve OverviewInnovation Intelligence®
  30. 30. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.What is MotionSolve?• An Industry proven Multi-Body Solver based on the laws of mechanics• Widely applicable across many industries and applications• Deals with overall system behavior where large non-linear motion is the dominating characteristic 30
  31. 31. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.What can MotionSolve do for you?• Supports many types of analyses • Assembly • Kinematics • Statics • Quasi-statics • Eigenvalue and State Matrix Generation • Transient dynamics• Complex analyses modes can be created by chaining a sequence of basic analyses• Capable of multi-disciplinary simulation involving FE, CFD and Controls g , 31
  32. 32. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Why is MotionSolve special?• Accurate • Hundreds of models correlated between MotionSolve & competition and MotionSolve & Test• Comprehensive set of modeling elements • With unmatched solver customization• Easy to use • Support for Python & Matlab user- subroutines. subroutines • No compiler required• Hard to break • A robust solver used in a variety of industries y • >300 companies use MotionSolve!• Fast • Efficient formulation for flexbodies 32
  33. 33. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Summary• Altair is uniquely positioned to offer the combination of MBS, FE, Controls, 1D simulation, Optimization and process based solutions customer wants• Altair offers a comprehensive MBS solution platform• Altair solutions are open and easily customized. Altair is standardizing on Python• Altair’s MBS team partners with customers to ensure their success• Altair’s solution is available to ALL HyperWorks customers at no incremental cost, provided adequate tokens exist 33
  34. 34. Thank You! Keshav (keshavs@altair.com)Innovation Intelligence®

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