This document summarizes Kendall Moore's background and a project investigating spot weld modeling. It includes:
1) An introduction to Kendall Moore, including education and experience.
2) A description of the project to compare spot weld modeling using CBAR and CWELD elements to physical coupon testing under different parameters like element quality and connection configurations.
3) Results showing the CBAR model predicted lower stiffness but closer fatigue life to testing than CWELD, and stiffness and fatigue life were not sensitive to element size.
sealing performance of stand-up package with spout and its open easiness would directly influence the shelf-life of product and its properness for usage. Sealing performance has become a focus of manufacturers to monitor.
sealing performance of stand-up package with spout and its open easiness would directly influence the shelf-life of product and its properness for usage. Sealing performance has become a focus of manufacturers to monitor.
Bridges are vulnerable to extreme events such as natural disasters in addition to hazards stemming from negligence and improper maintenance, overloading, collisions, intentional acts of vandalism, and terrorist attacks. These structures must be protected but the current approach to risk is not always rational. Sensitivity analysis will be performed to relate the reliability of bridges and reliability of the transportation network.
Enhancing & Predicting Auto Reliability Using Physics of Failure Software Mod...Cheryl Tulkoff
Background
A leading U.S. automotive manufacturer initiated an update to their product qualification process to help accelerate development and deliver new products to market sooner. To accomplish this goal, the duration of the accelerated life test was reduced by increasing the severity and decreasing the duration of the temperature cycle.
During an initial trial of this updated qualification test on an electronic module, several components experienced failure. A failure analysis identified the failure mode as solder joint fatigue. Contrary to the original intent, these unexpected failures introduced significant delay as the two parties, customer and supplier, worked to determine the root-cause of these failures and their relevance to actual field environments.
Solution
To help accelerate this process, and provide quantitative findings, an analysis of the module design using Sherlock was performed. Sherlock Automated Design Analysis software uses a Physics of Failure analysis to allow design and reliability engineers to predict and prevent product failure earlier in the design process saving time, money, and improving product performance.
Results
Sherlock’s initial evaluation of the module design correctly predicted which parts would fail, confirming the field results of the accelerated life test conducted by the manufacturer. Results from Sherlock also helped both parties understand how the test environment related to ten (10) years of a realistic worst-case use environment. This information, provided by the Sherlock analysis in less than one day, allowed critical, time-sensitive product development to continue as originally planned.
The automotive manufacturer is now using Sherlock Automated Design Analysis to evaluate additional electronic module redesigns. The use of Sherlock will provide the manufacturer with rapid feedback on product design and enable them to deliver more reliable products to market in less time.
Experience in the field of Testing and Commissioning & QA/QC of power system products, look forward for an opportunity to display my skills in the field of Testing, commissioning Operation & Maintenance and Execution of projects related to power systems
Reliserv solution offers protection relay testing services, including relay testing, uninterruptible power supply services, and electrical engineering services for industries. Omicron relay test kit on rent is the perfect guide to providing you with prompt services and preemptive measures.
OCS Training - API 570 piping inspection courseMuanisa Waras
This five-day course will provide an intensive knowledge
regarding inspection, repair and alteration of Piping. The
course fulfills the need for deciding the inspection meth-
ods and Frequency of inspection based on the evaluation
of the condition of the Pipelines.
Entire course content will be consistent with the body of
knowledge for 570 examination. The course will help the
individuals to understand API Recommended Practice
570 along with other referenced standards like ASME.
The participants will be given a thorough coverage of API
570 with emphasis on understanding of ‘stated’ and
‘implied’ requirements in a simple straightforward manner
backed up with several practical examples and case
studies. This course will employ latest audio visuals and
animations and Mock quiz to give the candidates deep
understanding.
Real World Nonlinear Mechanical ApplicationsDesign World
Until recently, most finite element analysis (FEA) applications undertaken by design engineers were limited to linear analysis which provides an acceptable approximation of real-life characteristics for most problems. However, occasionally more challenging problems arise that call for a nonlinear approach.
In this webinar, you will hear about real-world nonlinear applications and case studies associated with Comsol’s and MSC Software’s customers.
Viewers of this webinar will learn:
– How nonlinearities in engineering systems arise from several sources including:
– Material properties including multi-physics behavior
– Geometry variations that involve large deformations and strains
– Boundary conditions that could be continuously changing affecting the response
Bridges are vulnerable to extreme events such as natural disasters in addition to hazards stemming from negligence and improper maintenance, overloading, collisions, intentional acts of vandalism, and terrorist attacks. These structures must be protected but the current approach to risk is not always rational. Sensitivity analysis will be performed to relate the reliability of bridges and reliability of the transportation network.
Enhancing & Predicting Auto Reliability Using Physics of Failure Software Mod...Cheryl Tulkoff
Background
A leading U.S. automotive manufacturer initiated an update to their product qualification process to help accelerate development and deliver new products to market sooner. To accomplish this goal, the duration of the accelerated life test was reduced by increasing the severity and decreasing the duration of the temperature cycle.
During an initial trial of this updated qualification test on an electronic module, several components experienced failure. A failure analysis identified the failure mode as solder joint fatigue. Contrary to the original intent, these unexpected failures introduced significant delay as the two parties, customer and supplier, worked to determine the root-cause of these failures and their relevance to actual field environments.
Solution
To help accelerate this process, and provide quantitative findings, an analysis of the module design using Sherlock was performed. Sherlock Automated Design Analysis software uses a Physics of Failure analysis to allow design and reliability engineers to predict and prevent product failure earlier in the design process saving time, money, and improving product performance.
Results
Sherlock’s initial evaluation of the module design correctly predicted which parts would fail, confirming the field results of the accelerated life test conducted by the manufacturer. Results from Sherlock also helped both parties understand how the test environment related to ten (10) years of a realistic worst-case use environment. This information, provided by the Sherlock analysis in less than one day, allowed critical, time-sensitive product development to continue as originally planned.
The automotive manufacturer is now using Sherlock Automated Design Analysis to evaluate additional electronic module redesigns. The use of Sherlock will provide the manufacturer with rapid feedback on product design and enable them to deliver more reliable products to market in less time.
Experience in the field of Testing and Commissioning & QA/QC of power system products, look forward for an opportunity to display my skills in the field of Testing, commissioning Operation & Maintenance and Execution of projects related to power systems
Reliserv solution offers protection relay testing services, including relay testing, uninterruptible power supply services, and electrical engineering services for industries. Omicron relay test kit on rent is the perfect guide to providing you with prompt services and preemptive measures.
OCS Training - API 570 piping inspection courseMuanisa Waras
This five-day course will provide an intensive knowledge
regarding inspection, repair and alteration of Piping. The
course fulfills the need for deciding the inspection meth-
ods and Frequency of inspection based on the evaluation
of the condition of the Pipelines.
Entire course content will be consistent with the body of
knowledge for 570 examination. The course will help the
individuals to understand API Recommended Practice
570 along with other referenced standards like ASME.
The participants will be given a thorough coverage of API
570 with emphasis on understanding of ‘stated’ and
‘implied’ requirements in a simple straightforward manner
backed up with several practical examples and case
studies. This course will employ latest audio visuals and
animations and Mock quiz to give the candidates deep
understanding.
Real World Nonlinear Mechanical ApplicationsDesign World
Until recently, most finite element analysis (FEA) applications undertaken by design engineers were limited to linear analysis which provides an acceptable approximation of real-life characteristics for most problems. However, occasionally more challenging problems arise that call for a nonlinear approach.
In this webinar, you will hear about real-world nonlinear applications and case studies associated with Comsol’s and MSC Software’s customers.
Viewers of this webinar will learn:
– How nonlinearities in engineering systems arise from several sources including:
– Material properties including multi-physics behavior
– Geometry variations that involve large deformations and strains
– Boundary conditions that could be continuously changing affecting the response
Finite Element Analysis is used to simulate crushing of an automotive battery pack as per ISO 12405-3:2014 standard and crashworthiness performance of the battery pack was performed to optimize the structure.
Structural Compliance of Electric Vehicle Battery Pack
FCA Intern Presentation
1. July 29, 2015
Kendall Moore
Vehicle Integration & Validation
Durability & Development Operations
Graduating May 2016
Mechanical Engineering
2. Kendall Moore
Hometown: Newport News, Virginia
Rising 5th year, Virginia Commonwealth University,
Richmond, VA
Degree: Mechanical Engineering, minors in
Math & Physics
RA & Extracurricular Involvement (social justice,
cultural, leadership/honor)
Interests: outdoor activities, live music, Game of
Thrones
Professional Experience
07/29/2015 2
3. Opportunities
CPG Ride and Drive
FCA Intern Social Events Walter P. Chrysler Museum
Mack Engine Plant Tour Cultural immersion Day
Road Test Simulation Lab Mechanical Life Testing Lab
Data Acquisition at Chelsea Proving Grounds
07/29/2015 3
4. 407/29/2015
Background
Resistance Spot Welds
Primary connection for joining vehicle body structures
~80% body structure durability issues are at resistance spot welds
Typical Loading Conditions and Failure Modes of Spot Welds
Lap Shear Coach Peel
5. 507/29/2015
Project Description
Investigate sensitivity of spot weld modeling with CBAR and CWELD
elements on stiffness and fatigue life predictions
• Compare to physical coupon test results
• Help harmonization activity
Testing Parameters:
• Element quality (CBAR) : best, worst
• Connection configurations (CWELD) : best, worst1, worst2
• Sheet metal thickness: 1.0 mm, 1.5 mm/1.6 mm
• Mesh size: 4.0 mm, 5.0 mm, 6.0 mm
• Loading condition: lap shear and coach peel
CBAR weld element CWELD weld element
6. 601/01/2015
Actual Testing/ANSA Model Set-up
Lap Shear Coach Peel
MTS Coupon Cyclic Loading Setup
Lap Shear Coach Peel
Coupon FEA Models
Spot Weld
Constraints
Force
8. 807/29/2015
Analysis Procedure
ANSA
Preprocessing
• Apply Surface Mesh
• Apply Boundary
Constraints and
Loads
HPC SERVER
Run NASTRAN job
• Utilizes Open
Terminal to solve
input deck at
provided parameters
HYPERVIEW
Solution Viewer
• Stress Solution
• Displacement
Solution
nCODE
Postprocessing
• Life fatigue
predictions
• S-N Curves
Report
• Results discussions
• Conclusions
9. 907/29/2015
Results – Stiffness
• CBAR model predicts lower overall stiffness ratio, CWELD predicts higher stiffness ratio
• CWELD Model provide stiffness ratio closer to 1 than CBAR Model.
0.77
0.85
1.20
1.05
0.90
0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60
CBAR BEST
CBAR WORST
CWELD BEST
CWELD WORST1
CWELD WORST2
Ratio to Test
ElementConnectionConfiguration
10. 1007/29/2015
Results – Fatigue Life
• CBAR predicts fatigue ratio closer to 1 compared to CWELD
• Overall Fatigue Life is not sensitive for both CBAR and CWELD models, less than 10%
variation between the Worst to the Best element connection configurations.
1.13
1.13
1.25
1.25
1.15
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
CBAR BEST
CBAR WORST
CWELD BEST
CWELD WORST1
CWELD WORST2
Ratio to Test
ElementConnectionConfiguration
11. 1107/29/2015
Element Size Influence
1
1.1
1.2
1.3
CBAR BEST CBAR WORST CWELD BEST CWELD WORST 1 CWELD WORST 2
RatioAverage
Element Connection Configuration
Fatigue Life
4mm
5mm
6mm
• Spot-weld structural stiffness and fatigue for CBAR and CWELD models are not
sensitive to mesh element size.
0.60
0.80
1.00
1.20
1.40
CBAR BEST CBAR WORST CWELD BEST CWELD WORST 1 CWELD WORST 2
RatioAverage
Element Connection Configuration
Stiffness
4mm
5mm
6mm
Element Size
Element Size
12. 1207/29/2015
Future of Project/Takeaways
Contribution
• Obtain sensitivity results for Stiffness and Fatigue Life for CBAR and CWELD element
types to be utilized for future conclusions
• Played a role in prospective completion of harmonization project
Next Steps:
• More parameters (element size, element quality)
• Full-production model analysis
Takeaways
• Analysis software experience
• Transferrable skills
• Exposure to global company in Automotive Industry
13. 1307/29/2015
The Future and Beyond!
Complete Undergraduate
program (VCU)
CIE
Program
Master’s Degree
Mechanical Engineering
Engineer in Training(EIT)
EXAM
Studio Engineer/
Durability Engineer
Thank you coming to my FCA Intern final summer project presentationI had the pleasure of working in the Durability & Development Operations group
5th year majoring in Mech Eng minors in math and physics
Involved in a lot of Student Orgs
Live music, spending time outside, and a huge game of thrones fan, I guess the Michigan locals would say that winter is coming soon
I have previous experience in Project Management through Huntington Ingalls Shipbuilding
Thanks to FCA I’ve had the chance to explore a good amount of CTC as well as interact and network with other Internsfrom all over the area.
My project this summer was focused on resistance spot welds, let me give you some background on them
It’s important to have accurate CAE modeling because there are over 5,000 spot welds on a car
80% of body structure issues are at spot welds
My project focuses on Lap Shear ( tension shear failure ) and Coach Peel (Bending Moment failure )
This summer I was tasked with a Harmonization using Finite Element Analysis software to compare the sensitivity between two different weld modeling techniques by analyzing the stiffness and fatigue life and comparing those values to the actual testing
CBAR is used by FCA US and CWELD used by FCA Italy and I am trying to see which is better for modeling
CBAR – NODE TO NODE
CEWLD – ELEMENT TO ELEMENT
Looking at Element quality, element configuration, thickness, length of the element
Here you can see the coupon model in ANSA with the applied boundary conditions and loading conditions Top – All DOF constrained
Bottom – All DOF constrained but z (direction of motion)
Here you can see the other configurations for testing also known as element quality, ideal case is uniform
CBAR – the elements were skewed to represent alternatives manners of failure
CWELD – connections of elements altered to represent alternative manners of failure ( Diaganol, Parrallel)
Here is FEA process that I used to calculate the stiffness and life fatigue
Hyper view I calculated stiffness and nCode used for the Life fatigue calculation
The best way for me to gauge effectiveness of the weld method was to use a ratio from the software’s data to the testing data
Here are the ratios calculated for the stiffness calculations, a value of 1 is ideal which means is a good match
CBAR lap shear and coach peel stiffness ratios have little difference between them ( less sensitive )
5mm element size is average target size
CBAR less sensitive – not heavily influence by element configuration
CWELD more sensitive due to larger surface area connection
Real life situation: spot weld loading is combined of coach peel and lap shear
Spot weld fatigue calculation is based on S-N (Cycles) on both so numbers show offset
Element size is not sensitive to fatigue life or stiffness for CBAR and CWELD aligns with what we expect
Trend: as element size increase element becomes stiffer
-larger element size -> force moment is larger ->stress increase -> lower life
Element parameters ( element sizes, CWELD connections)
Spot weld analysis on full vehicle too see how it affects vehicle body structure
Thank you to FCA for this unique opportunity, I will now be taking questions!