HTC 2012 Durability Training

Vehicle Durability Workshop – 2012 Americas HTC
Multi-Body Dynamics Team, Altair
Innovation Intelligence®

Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Agenda - Vehicle Durability Workshop

Start Time Topic

3.15
3 15 PM Introduction

3.25 PM HyperWorks for Vehicle Durability

3.50 PM MotionView for Durability Modeling

4.15 PM MotionSolve

4.30 PM CD-Tire Introduction

4.45 PM Flexbodies

5.00 PM Customer – Altair Development Interaction
p

2


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

HyperWorks for Vehicle Durability


Presentation Outline

• Brief Introduction to Durability

• How are customers using HyperWorks for Durability?

• What are the key elements to assess durability?

5


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


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


Causes of Varying Loads

Sources of Varying Loads on Structures

Road Profile Closures Wind Turbine etc..

8


Which Areas Of The Vehicle Are Of Interest?

Passenger Cars Light Trucks Heavy Trucks Buses Earth-Moving Rail
Agricultural General Utility Military Vehicles Snowmobiles Motorcycles
9






10


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


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


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


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


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


The Key Elements of Durability Evaluation

Real World Usage

Representative Duty Cycle

Component Loading Histories

Fatigue Assessment

17


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 model

Road data acquisition

18


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


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



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



DUTY FE FATIGUE POST

DUTY Measured Loads
FEA FATIGUE POST
CYCLE Loads Stress State

MBD FATIGUE POST

Event Component
MBD FATIGUE POST
Definition Loading

FE
Load
Locations & Component
Orientations Stress State
FEA

22


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

MotionView for Durability Modeling


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 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


Durability Analysis – Possible Approaches

• Fully analytical durability:
• 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


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


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

MotionSolve Overview


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


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


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


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

Thank You!
Keshav (keshavs@altair.com)

HTC 2012 Durability Training

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