This presentation demonstrates how to use Optistruct to predict the vibration levels of a floor pan and how to model Liquid Applied Sound Deadeners to reduce the vibrations with a minimum weight addition.
Speakers
Jean-Paul Allal, R&D Project Leader, PPG Automotive Adhesives and Sealants
New HyperWorks Pedestrian Impact Tool for vehicle engineering and CAE simulationAltair
The engineering challenges according to the pedestrian safety requirements have an important impact on the vehicle development time line and on vehicle design. The different pedestrian safety regulations that a vehicle has to fulfill (legal (ECE, GTR…) or consumer (EuroNCAP)) represent a high number of impact points that have to be defined depending on the regulation protocol. For each impact point, a FEM simulation has to be performed in order to evaluate the overall pedestrian protection performances. The integration of this process into an innovative virtual prototyping method needs a CAE tool allowing the automatic definition of the impact points and the automatic generation of ready-to-run FE models for impact simulation. Moreover, pedestrian requirements have a direct influence on vehicle design. That’s the reason why, an automatic definition of the impact points based on CAD design surfaces is a key to allow engineering judgment and design changes in the early phase of the vehicle development. The new HyperWorks Pedestrian Impact Tool, developed by Altair Engineering in cooperation with the Ford of Europe Pedestrian Protection Team, offers a perfect solution to these challenges. During the presentation, an overview of the tool capabilities will be given as well as results of an application on a Ford vehicle model.
Speakers
Dany Tapigue, Engineer, Ford Werke GmbH
Stress and Durability Analysis of Threaded Connections in a Cast Aluminum Cyl...Altair
Bolted connections involve sharp notched components that are therefore sensitive to fatigue loading. In internal combustion engines, the journal bearings of the crankshaft are supported by bearing caps which are bolted to the cylinder block. These threaded connections are a fatigue concern as cracking may be experienced on dynamometer tests of new engines. The critical element of this application however is not the steel studs rather the threaded bolt holes in the cast engine block. While the nominal stress concept is applicable to the fatigue design of studs, a local stress approach has to be adopted to assess the fatigue strength of threaded bolt holes.
This paper addresses the fatigue design of this kind of threaded connection. Initially alternate methods of FE modeling and analysis of threaded joints by the local approach are critically examined. The parallel development of a simplified experimental test system involving a threaded hole in cast AlSi7 is described and used to generate baseline fatigue data under known loading conditions. The fatigue behavior of the experimental system is then analyzed on the basis of alternate FE models and post processing approaches. Finally, recommendations for the accurate and computationally efficient FE modeling and durability analysis of threaded connections in cast aluminum cylinder block are outlined.
Speakers
Marco Bersella, Engineer, TP Engineering srl
Developing Commercial Vehicles Inspired by NatureAltair
As Germany's largest independent engineering partner to the worldwide automotive industry, EDAG is continuously seeking for new technologies and innovative processes to streamline vehicle development. EDAG has a profound expertise in integrated development and the optimization of vehicles, production facilities, derivatives, and modules. To meet fuel efficiency and emission reduction goals, structurally efficient lightweight designs are demanded in the development of passenger cars and commercial vehicles alike. To fulfill customer demands and to deliver lighter and yet fully functional and validated components in shorter time, EDAG is leveraging its engineering knowledge to combine state-of-the-art computer aided engineering tools, in this case Altair's OptiStruct, with new production technologies such as additive manufacturing. OptiStruct enabled the EDAG engineers to design lightweight and, by being inspired by nature, yet stiff structures of a cabin and a chassis. The components were then manufactured using additive manufacturing methods. To find the optimal solution for the final design the engineers later also conducted multi-physical optimizations, combining strength and crash demands of the vehicle, using an equivalent linear approach. The entire development and manufacturing process for the cabin and chassis structures will be subject of this presentation, showing how a combination of topology optimization and additive manufacturing leads to lighter and stiffer products. The project is a prime example of how mature CAE technology can be adjusted and used in combination with new manufacturing methods to introduce revolutionary structural enhancements within the transportation sector.
Speakers
Andreas Pfeiffer, Development Engineer, EDAG
Model Initialization (Material Orientations using HyperForm, OptiStruct)
Post Processing for Composite Materials
Optimization of the Composite Structure
Failure Criteria for Composite Materials
Aircraft Finite Element Modelling for structure analysis using Altair ProductsAltair
The Airbus airframe design process has considerably evolved since 20 years with the constant improvement of numerical simulation capability and the computational means capacity. Today the size of Finite Element Models for aircraft structural behaviour study is exceeding the boundary of airframe components (fuselage section, wing); for the A350, a very large scale non-linear model of more than 60 million degrees of freedom has been developed to secure the static test campaign. This communication will illustrate the partnership with Altair and the use of Altair products for the creation and verification of very large models at Airbus. It will deal with: - Geometry preparation - Meshing - Property assignment - Assembly - Checking More generally, numerical simulation will play more and more a major role in the aircraft process, from the development of new concepts / derivatives to the support of the in-service fleet. Then, this presentation will also state the coming needs regarding model creation tools to cope with Airbus strategy.
Speakers
Marion Touboul, Ingénieur en Simulation Numérique - Calcul Structure, Airbus Opérations SAS
Simulation methods to assess the brake noise behavior of passenger vehicle br...Altair
An important aspect of vehicle comfort is the silence of the brake system. Especially low velocity braking maneuvers are sometimes accompanied by heavy noise occurrences. Although these noise occurrences do not affect the brake system negatively with respect to braking performance they mostly result in customer insecurity. Therefore, most OEMs invest much time and money on developing silent brake systems. The presentation will illustrate the physical reasons behind such brake noise events. Practical methods for vibration damping will be discussed as well. Different analytical approaches for early estimation of noise potentials of brake systems based on the Finite-Element-Method as well as Multi-Body-Dynamics will be presented. Finally, future steps for the investigation of brake noise occurrences by analytical methods will be offered.
Speakers
Daniel Scharding, Adam Opel AG
New HyperWorks Pedestrian Impact Tool for vehicle engineering and CAE simulationAltair
The engineering challenges according to the pedestrian safety requirements have an important impact on the vehicle development time line and on vehicle design. The different pedestrian safety regulations that a vehicle has to fulfill (legal (ECE, GTR…) or consumer (EuroNCAP)) represent a high number of impact points that have to be defined depending on the regulation protocol. For each impact point, a FEM simulation has to be performed in order to evaluate the overall pedestrian protection performances. The integration of this process into an innovative virtual prototyping method needs a CAE tool allowing the automatic definition of the impact points and the automatic generation of ready-to-run FE models for impact simulation. Moreover, pedestrian requirements have a direct influence on vehicle design. That’s the reason why, an automatic definition of the impact points based on CAD design surfaces is a key to allow engineering judgment and design changes in the early phase of the vehicle development. The new HyperWorks Pedestrian Impact Tool, developed by Altair Engineering in cooperation with the Ford of Europe Pedestrian Protection Team, offers a perfect solution to these challenges. During the presentation, an overview of the tool capabilities will be given as well as results of an application on a Ford vehicle model.
Speakers
Dany Tapigue, Engineer, Ford Werke GmbH
Stress and Durability Analysis of Threaded Connections in a Cast Aluminum Cyl...Altair
Bolted connections involve sharp notched components that are therefore sensitive to fatigue loading. In internal combustion engines, the journal bearings of the crankshaft are supported by bearing caps which are bolted to the cylinder block. These threaded connections are a fatigue concern as cracking may be experienced on dynamometer tests of new engines. The critical element of this application however is not the steel studs rather the threaded bolt holes in the cast engine block. While the nominal stress concept is applicable to the fatigue design of studs, a local stress approach has to be adopted to assess the fatigue strength of threaded bolt holes.
This paper addresses the fatigue design of this kind of threaded connection. Initially alternate methods of FE modeling and analysis of threaded joints by the local approach are critically examined. The parallel development of a simplified experimental test system involving a threaded hole in cast AlSi7 is described and used to generate baseline fatigue data under known loading conditions. The fatigue behavior of the experimental system is then analyzed on the basis of alternate FE models and post processing approaches. Finally, recommendations for the accurate and computationally efficient FE modeling and durability analysis of threaded connections in cast aluminum cylinder block are outlined.
Speakers
Marco Bersella, Engineer, TP Engineering srl
Developing Commercial Vehicles Inspired by NatureAltair
As Germany's largest independent engineering partner to the worldwide automotive industry, EDAG is continuously seeking for new technologies and innovative processes to streamline vehicle development. EDAG has a profound expertise in integrated development and the optimization of vehicles, production facilities, derivatives, and modules. To meet fuel efficiency and emission reduction goals, structurally efficient lightweight designs are demanded in the development of passenger cars and commercial vehicles alike. To fulfill customer demands and to deliver lighter and yet fully functional and validated components in shorter time, EDAG is leveraging its engineering knowledge to combine state-of-the-art computer aided engineering tools, in this case Altair's OptiStruct, with new production technologies such as additive manufacturing. OptiStruct enabled the EDAG engineers to design lightweight and, by being inspired by nature, yet stiff structures of a cabin and a chassis. The components were then manufactured using additive manufacturing methods. To find the optimal solution for the final design the engineers later also conducted multi-physical optimizations, combining strength and crash demands of the vehicle, using an equivalent linear approach. The entire development and manufacturing process for the cabin and chassis structures will be subject of this presentation, showing how a combination of topology optimization and additive manufacturing leads to lighter and stiffer products. The project is a prime example of how mature CAE technology can be adjusted and used in combination with new manufacturing methods to introduce revolutionary structural enhancements within the transportation sector.
Speakers
Andreas Pfeiffer, Development Engineer, EDAG
Model Initialization (Material Orientations using HyperForm, OptiStruct)
Post Processing for Composite Materials
Optimization of the Composite Structure
Failure Criteria for Composite Materials
Aircraft Finite Element Modelling for structure analysis using Altair ProductsAltair
The Airbus airframe design process has considerably evolved since 20 years with the constant improvement of numerical simulation capability and the computational means capacity. Today the size of Finite Element Models for aircraft structural behaviour study is exceeding the boundary of airframe components (fuselage section, wing); for the A350, a very large scale non-linear model of more than 60 million degrees of freedom has been developed to secure the static test campaign. This communication will illustrate the partnership with Altair and the use of Altair products for the creation and verification of very large models at Airbus. It will deal with: - Geometry preparation - Meshing - Property assignment - Assembly - Checking More generally, numerical simulation will play more and more a major role in the aircraft process, from the development of new concepts / derivatives to the support of the in-service fleet. Then, this presentation will also state the coming needs regarding model creation tools to cope with Airbus strategy.
Speakers
Marion Touboul, Ingénieur en Simulation Numérique - Calcul Structure, Airbus Opérations SAS
Simulation methods to assess the brake noise behavior of passenger vehicle br...Altair
An important aspect of vehicle comfort is the silence of the brake system. Especially low velocity braking maneuvers are sometimes accompanied by heavy noise occurrences. Although these noise occurrences do not affect the brake system negatively with respect to braking performance they mostly result in customer insecurity. Therefore, most OEMs invest much time and money on developing silent brake systems. The presentation will illustrate the physical reasons behind such brake noise events. Practical methods for vibration damping will be discussed as well. Different analytical approaches for early estimation of noise potentials of brake systems based on the Finite-Element-Method as well as Multi-Body-Dynamics will be presented. Finally, future steps for the investigation of brake noise occurrences by analytical methods will be offered.
Speakers
Daniel Scharding, Adam Opel AG
Improving of Assessment Quality of Fatigue Analysis Using: MS, FEMFAT and FEM...Altair
Better correlation of measurement data using Motion Solve and FEFMAT LAB virtual iteration Matching of locally measured data calculating excitations (input) based on MBS process (MotinSolve) to reach local measured data Using this process and the output of MotionSolve for a hybrid MBS- fatigue process
Speakers
Axel Werkhausen, Manager Sales & Support, MAGNA / Engineering Center Steyr GmbH & Co KG
Fatigue life prediction of structures whose natural frequencies lie near the frequencies of the input loading requires the stress results from dynamic analyses. These analyses can be performed in either the time or the frequency domains depending on the nature or the loading. This presentation will outline the approaches available for fatigue life prediction using Altair OptiStruct and APA product, nCode DesignLife for both time and frequency based dynamic analyses. The strengths, weaknesses and assumptions of each approach will be presented, along with typical applications enabling the user to select the proper technique for their particular use case.
Full Frontal, 40% & 20% Offset Impact Analysis on Ford Econoline.Vaibhav porwal
Full Frontal, 40%, and 20% impact analysis of Ford Econoline using LS-PrePost and LS-DYNA, including front airbags, side curtain airbag and a seatbelted to reduce the fatal injuries.
This is related to describing various types of Ansys stimulations and it's application at industrial level. It will give an overview of benefits of using Ansys software.
Rotating machinery can be found in every industry: automotive, aerospace, energy, etc. The generated vibration environment is typically made of harmonic tones superimposed on background noise. Components mounted on rotating machinery must be designed to survive such mechanical environment over their entire service life. This presentation will concentrate on calculating the fatigue life from sine-on-random excitations using Finite Element Analysis (FEA). It is proposed to derive the statistical rainflow cycle histogram from a sine-on-random spectrum of stress or strain data and then use the appropriate material fatigue curve to obtain the estimated life. This new analysis is complementary to existing features such as SineDwell, SineSweep and (uni- or multi-axes) random PSD. It is part of extensive research work that includes the influence of sigma clipping or the effects of a high kurtosis.
Speakers
Frédéric Kihm, Application Engineer, HBM-nCode
Roof Crush Analysis using Test Protocols of FMVSS 216Vaibhav porwal
Validation of Roof Crush analysis involving passenger dummy, side-airbag, and steering wheel. Optimized the roof strength to improve the design of the B-pillar and material property.
Schraubenberechnung "inside"ANSYS nach der Richtlinie VDI 2230
Die Richtlinie VDI 2230 sieht einen Berechnungsablauf vor, der die Montage, die Beanspruchung unter statischen und dynamischen Lasten, die Flächenpressung sowie das Abscheren der Gewindegänge berücksichtigt. Als Nennspannungskonzept sind für den Nachweis keine Auswertungen der Spannungen aus der FEM-Analyse notwendig. Die aus der Analyse ermittelten Kräfte und Momente sind für die Verarbeitung ausreichend.
Wer diese für einen richtlinienkonformen Nachweis nutzen mochte, musste bisher selbst manuell aktiv werden: Die erforderlichen Größen aus der FEM-Berechnung mussten extrahiert, übertragen und in weiterer Folge per Tabellenkalkulation oder separater Software verarbeitet werden. Das neue Softwaremodul von CADFEM „Bolt Assessment inside ANSYS“ bietet mit einem in ANSYS Workbench integrierten Nachweis konform der VDI-Richtlinie 2230 die ideale Lösung.
Lead time reduction in CAE: Automated FEM Description ReportAltair
For each deliverable FE-Model a FEM description report needs to be generated. Since this document contains always the same type of information, it is an ideal candidate to automate the creation of this report. Based on the Hyper Report Tool from Altair, RUAG Space and Altair developed a tool to automatically generate the FEM Description Report. The tool requires the HyperMesh data base and the output files from FEM checks as inputs. Together with the tool template, guidelines are provided on how the data base needs to be set up, such that the report can be created automatically. The main structure of the FEM Description Report is dependent on the assembly structure of the HM data base.
Car makers have to reduce consumption of vehicles and so, are continually looking for solutions to lighten components. For powertrain, components generally mean screwed assembly, contact and fitting interfaces, with different kind of loading to take into account (static and dynamic). Hence, we decided to apply with Altair assistance, a process of topology optimization on an assembly of gearbox housing in order to check its feasibility and efficiency. Several steps had to be solved from exhaustive identification of all mechanical constraints to execution of large models with Optistruct. By the end, the process has been defined and implemented on an existing gearbox and will be soon apply on the next one to design.
Speakers
Philippe Dausse, Modelization Specialist, PSA Peugeot Citroen Automobiles
Improving of Assessment Quality of Fatigue Analysis Using: MS, FEMFAT and FEM...Altair
Better correlation of measurement data using Motion Solve and FEFMAT LAB virtual iteration Matching of locally measured data calculating excitations (input) based on MBS process (MotinSolve) to reach local measured data Using this process and the output of MotionSolve for a hybrid MBS- fatigue process
Speakers
Axel Werkhausen, Manager Sales & Support, MAGNA / Engineering Center Steyr GmbH & Co KG
Fatigue life prediction of structures whose natural frequencies lie near the frequencies of the input loading requires the stress results from dynamic analyses. These analyses can be performed in either the time or the frequency domains depending on the nature or the loading. This presentation will outline the approaches available for fatigue life prediction using Altair OptiStruct and APA product, nCode DesignLife for both time and frequency based dynamic analyses. The strengths, weaknesses and assumptions of each approach will be presented, along with typical applications enabling the user to select the proper technique for their particular use case.
Full Frontal, 40% & 20% Offset Impact Analysis on Ford Econoline.Vaibhav porwal
Full Frontal, 40%, and 20% impact analysis of Ford Econoline using LS-PrePost and LS-DYNA, including front airbags, side curtain airbag and a seatbelted to reduce the fatal injuries.
This is related to describing various types of Ansys stimulations and it's application at industrial level. It will give an overview of benefits of using Ansys software.
Rotating machinery can be found in every industry: automotive, aerospace, energy, etc. The generated vibration environment is typically made of harmonic tones superimposed on background noise. Components mounted on rotating machinery must be designed to survive such mechanical environment over their entire service life. This presentation will concentrate on calculating the fatigue life from sine-on-random excitations using Finite Element Analysis (FEA). It is proposed to derive the statistical rainflow cycle histogram from a sine-on-random spectrum of stress or strain data and then use the appropriate material fatigue curve to obtain the estimated life. This new analysis is complementary to existing features such as SineDwell, SineSweep and (uni- or multi-axes) random PSD. It is part of extensive research work that includes the influence of sigma clipping or the effects of a high kurtosis.
Speakers
Frédéric Kihm, Application Engineer, HBM-nCode
Roof Crush Analysis using Test Protocols of FMVSS 216Vaibhav porwal
Validation of Roof Crush analysis involving passenger dummy, side-airbag, and steering wheel. Optimized the roof strength to improve the design of the B-pillar and material property.
Schraubenberechnung "inside"ANSYS nach der Richtlinie VDI 2230
Die Richtlinie VDI 2230 sieht einen Berechnungsablauf vor, der die Montage, die Beanspruchung unter statischen und dynamischen Lasten, die Flächenpressung sowie das Abscheren der Gewindegänge berücksichtigt. Als Nennspannungskonzept sind für den Nachweis keine Auswertungen der Spannungen aus der FEM-Analyse notwendig. Die aus der Analyse ermittelten Kräfte und Momente sind für die Verarbeitung ausreichend.
Wer diese für einen richtlinienkonformen Nachweis nutzen mochte, musste bisher selbst manuell aktiv werden: Die erforderlichen Größen aus der FEM-Berechnung mussten extrahiert, übertragen und in weiterer Folge per Tabellenkalkulation oder separater Software verarbeitet werden. Das neue Softwaremodul von CADFEM „Bolt Assessment inside ANSYS“ bietet mit einem in ANSYS Workbench integrierten Nachweis konform der VDI-Richtlinie 2230 die ideale Lösung.
Lead time reduction in CAE: Automated FEM Description ReportAltair
For each deliverable FE-Model a FEM description report needs to be generated. Since this document contains always the same type of information, it is an ideal candidate to automate the creation of this report. Based on the Hyper Report Tool from Altair, RUAG Space and Altair developed a tool to automatically generate the FEM Description Report. The tool requires the HyperMesh data base and the output files from FEM checks as inputs. Together with the tool template, guidelines are provided on how the data base needs to be set up, such that the report can be created automatically. The main structure of the FEM Description Report is dependent on the assembly structure of the HM data base.
Car makers have to reduce consumption of vehicles and so, are continually looking for solutions to lighten components. For powertrain, components generally mean screwed assembly, contact and fitting interfaces, with different kind of loading to take into account (static and dynamic). Hence, we decided to apply with Altair assistance, a process of topology optimization on an assembly of gearbox housing in order to check its feasibility and efficiency. Several steps had to be solved from exhaustive identification of all mechanical constraints to execution of large models with Optistruct. By the end, the process has been defined and implemented on an existing gearbox and will be soon apply on the next one to design.
Speakers
Philippe Dausse, Modelization Specialist, PSA Peugeot Citroen Automobiles
The Team H2politO: vehicles for low consumption competitions using HyperWorks Altair
The Team H2politO is a group of students of the Politecnico di Torino. The student’s background and profiles are very diverse, everyone comes from a different discipline of engineering and together they compose a complete Team. The disciplines range from Automotive and Mechanical to Electronics, Aerospace, Energy, Mathematics, Computer Science, Mechatronics, Management, Cinema and Media and Industrial Design. The Team mission is to shape a new generation of engineers, leaders in their fields, who represent the educational excellence in regard of each of their competencies.
The results of Team passion and hard work are three low-energy consumption vehicles completely designed and made by the Team: IDRA - hydrogen powered prototype; XAM – bioethanol powered parallel hybrid urban concept; XAM 2.0 –EREV city vehicle.
The main goal is to take part and win in Shell Eco-marathon, a competition that every year involves more than one hundreds of students teams arriving from all over Europe. Especially we would like to spread the Shell Eco-marathon values through ours, combining the sustainable development with a vehicle that uses the least possible amount of energy.
H2politO is a different, innovative and somehow unique project, is not just a Team but something more: it is a new type of conceiving educational, professional and personal growth. Team members aim at being perceived as an experimental laboratory where competences, capabilities and potentialities of future’s engineers are fostered. Students strive to become not only solid and advanced technical experts but, equally important, down-to-earth managers having excellent communication, leadership and teamwork skills.
Practical and hands-on experiences are doubtlessly a complementary and enriching form of educational path where it is very important the use of simulation software like HyperWorks. Team members have a real opportunity to lead their educational path by building and crafting their own thesis. Final papers are indeed part of a cluster of thesis which combines all the technological and organizational areas of development H2politO has envisioned and embraced.
The Team believes in hard work as the basis of future success. Students crave for continuously improving and strive for exceeding expectations by nurturing the team spirit in order to create those synergies able to add value to individual performances and capabilities. As a consequence, passion and team-spirit are really the foundation of H2politO values.
Speakers
Prof. Massimiliana Carello, Politecnico di Milano
Windscreen Antenna Analysis for broadcasting services in vehicles- Comparison...Altair
Over the last few decades, the defogger of vehicles was increasingly used as an antenna for mobile reception of broadcast services. Ever since, the development of vehicular window antennas was a tedious and time consuming task, because the development procedure was subjected to an iterative series of measurements.
Due to enhanced computing power of workstations and server-systems, it is now possible, to calculate antenna structures including whole vehicle bodies in electromagnetic simulations. Especially for calculating the performance of antenna structures integrated into vehicular windows, the FEKO wind screen function became an indispensable tool for accurate simulations of real world scenarios. With comparable results in simulation and measurements, errors can be identified and fixed faster as ever before. The possibility to consider current flow, 3D directivity, antenna efficiency and further analyses additionally contributes to a significant improvement in the development process of vehicular window antennas. Recent comparisons of simulation and measurement results in a rear window antenna development project were confirming that simulative calculated predictions are in good correspondence to measurements of produced vehicular window antennas.
Speakers
Dr.-Ing. Johannes Kammerer, Senior RF Engineer Kathrein Automotive
Experimental verification and finite element analysis of a sliding door syste...Altair
A sliding door system is used in commercial vehicles and passenger cars to allow a larger unobstructed access to the interior for loading and unloading. The movement of a sliding door on vehicle body is ensured by mechanisms and tracks having special cross-section which is manufactured by rollforming and strech bending process. There are three tracks and three mechanisms which are called upper, central and lower on a sliding door system. There are static requirements as strenght on different directions, rigidity for mechanisms, door drop off, door sag; dynamic requirements as high energy slam opening-closing and durability requirement to validate these products. In addition, there is a kinematic requirement to find out force values from door handle during manuel operating. In this study, finite element analysis and physical test results which are realized for sliding door systems will be shared comparatively.
Speakers
Caner Güven, Analysis Engineer, Rollmech Automotive
Exploring the capabilities of the tight integration of HyperWorks and ESACompAltair
More than 3 years ago RUAG Space started to look into ways how the very powerful meshing and post-processing capabilities of Altair HyperWorks could be combined with the advanced composite failure analysis methods provided by the ESAComp software from Componeering. RUAG’s vision behind this idea was to streamline the time consuming composite analysis process by a tight integration of the two pieces of software, thus eliminating as much as possible unnecessary breaks in the data flow. Both Altair and Componeering carefully listened to RUAG’s needs and eventually it was decided to make a common effort in providing step by step the requested functionality. The initially slow process accelerated considerably when Componeering joined the Altair Partner Alliance in 2012. Today the bi-directional interface between HyperWorks and ESAComp is considered mature enough to be challenged by a demanding real world use case: the dimensioning and verification of the load carrying structure of the MetOp-SG satellite (Meteorological Operational Satellite - Second Generation). The presentation will focus on how HyperWorks and ESAComp were used to set up the finite element model, to run the quasi-static and dynamic load cases and to evaluate the results. It will be shown in which way HyperWorks and ESAComp can support the process, what the benefits of a tight integration are and which limitations still exist.
Speakers
Ralf Usinger, Product Lead Engineer Satellite Structures, RUAG Schweiz AG
Structural analysis of the Baakenhafen Bridge and the optimisation of chosen ...Altair
The following paper consist of two parts. The aim of the first part is to analyse the problem of thermal loads of steel skew bridges and the displacement caused by them. A 3-spanned steel road bridge named Baakenhafen West is being analysed. In the second part, an optimization of the primary beams of the structure was made. Thus was shown, that there was a possibility to reduce the steel tonnage of the bridge by keeping it safe to use.
Speakers
Julia Karasinska, Engineer, BuroHappold Engineering
AVL software and related services support the entire range of virtual prototyping in the powertrain industry. Altair Engineering is used by a number of major automotive companies as their high-fidelity finite element analysis tool. The highest priority is given to the completion of the workflow for different use cases for strength and durability analysis of engine components as well as NVH analysis of engines and power units. All related simulation tasks are connected by specific interfaces to ensure reduction of overall workflow time and increase in project confidence. The dynamic behavior of engine components (crankshaft, connecting rod, piston, etc.) is simulated using AVL EXCITE as Multi-Body Dynamics (MBD) tool and central software in the workflow. Each component of the crank train and the engine/power unit structure is considered as flexible structure, performing local vibrations as well as global motion. The components are coupled within the MBD tool using various non-linear joints like the elasto-hydrodynamic bearing model. The model setup and meshing is performed with Altair SimLab, which has special plugins fulfilling EXCITE mesh requirements like inserting kinematic couplings at journal/pin center nodes and defining retained nodes at predefined areas. The model reduction is performed with Altair OptiStruct using a very efficient multi-level eigensolver (AMSES). OptiStruct directly generates the flexible body input data (.exb) for AVL EXCITE, whereas the required specification data is just a single command in the input file. After the dynamic simulation in AVL EXCITE the transient results can be passed back to OptiStruct for post processing transient or frequency response analysis. OptiStruct will than calculate motion, stresses and strains whereas results can be passed directly to .h3d or .op2 file format for further fatigue or airborne noise analysis with e.g. EXCITE Acoustics. An overview of the workflows for the use cases strength and durability analysis as well as NVH analysis, together with the integrated FEA tasks and the interaction between the different analysis tasks is given in the presentation.
Speakers
Bernhard Loibnegger, Senior software development engineer, AVL List G.m.b.H.
Multiphysics - A New Generation of SimulationAltair
The application of CAE early in a product’s design cycle can make an important difference in its cost and functionality. However the level of fidelity of the design early in the cycle limits the application of many traditional CAE tools. Fortunately this is where systems modeling can be applied due to the nature of utilizing a more abstract representation of the overall system and its components.
Thermostamping simulation for woven thermoplastic composites (PA) with HyperFormAltair
The thermostamping process of thermoplastic composites can be analyzed with simulation software. In addition to the optimization that can be brought to process (defects, raw material quantity …), the main interest is to integrate results from process into the performance simulation. This article presents an approach to simulate thermostamping of thermoplastic composites (PA) with HyperForm.
The material law is identified from Bias test trials, then, the simulation is performed by HyperForm with the solver Radioss or Ls-Dyna. Fiber orientations (for non-linear anisotropic behavior) and defects (global wrinkles, and wrinkles in the thickness, area with failure risk, thickness variation…) are identified and mapped on structural mesh for mechanical simulation.
Based on this approach, several test/simulation comparisons were performed on both static and dynamic. They demonstrate the necessity of considering the process phase, especially for complex geometries.
Regarding advanced application for such simulation tool: Faurecia Automotive Exterior is developing technologies to produce one-shot visible parts (CFRT thermostamping + overmolding injection in one step). This case study is the most challenging application we are working on. Combining thermostamping simulation and one-shot process brings benefits to both sides thanks to cross results on complex application.
Globaly, to improve the prediction of this simulation tool, next steps are the computation of local density; the consideration of thermal exchanges with the mold during the production process; the modelization improvement of boundary conditions during process (woven holding …, frames…).
Speakers
Guillaume CHAMBON, Product Research & Advanced Simulation Manager, FAURECIA Automotive Exterior
Design Methodologies for ALM and Lattice partsAltair
Design for additively made parts has become a very hot topic. Many engineers see the potential for topology optimization when designing ALM parts, but once they start the workflow, they tend to get bogged down in how to complete the process.
Cybersecurity-Anforderungen in IT-Sourcing-Projekten meistern – Ein Leitfaden...Capgemini
Managing Cybersecurity demands in IT sourcing projects: A guideline using the example of Identity & Access Management. This presentation outlines the topic of Identity & Access Management in complex IT landscapes and IT services supply chains by the help of practical examples and by comparing reality and cyberspace. It also makes recommendations for the access management for organizational IT systems.
Advantage of LED Street light with ‘ALG Engine’
Lowest Power consumption compared to other products (nearly half of other LED lights)
Our patented ‘Cooling Fin system’ guarantees the LED lights quality over the life span of 50,000 hours as the patented technology keeps cooling the LED lights system most efficiently no matter how the surrounding temperature soars up.
It retains almost same luminosity even when it lights the ground of up to ,say, 12m apart from the light source while the luminosity of most of other makers tend to decrease drastically when the LED street lights illuminates the ground of such a distance.
The life span is approx. 50,000 hours, which is monumentally big difference from others on the markets.
Its weight is very light, almost one-third less than the others, as the casing is made of polycarbonate material instead of die-casting that most of other makers are using. Thus it makes the installation work easy and so much, the installation cost could be lowered.
It is designed to be very rugged and strong to any external impacts
It is designed to secure perfect water-proof.
With such technical superiority and advantages, it does have unrivaled price competitiveness.
OEM Wiring Harness & ODM Custom Cable Assembly & Wire Harness ( www.China-Cableassembly.com ), IATF 16949-, ISO 9001- and UL-certified | A real manufacturer From small simple cable assemblies to large wiring harnesses
REDCATT TECH PAPER== Speaker Transducer Dome bondingHTCS LLC
The RedCatt Engineering and Manufacturing teams have put a lot of effort into the development of high performance bonding techniques, specifically for use in High Frequency (HF) transducers/speakers and research in the area of HF dome design and manufacturing. The technical paper covers: Dome Forming, In-Process Dome Quality Control, Dome Treatment and Coating Process, Adhesives, UV Curing, SPL Improvement, Power Handling, and the Result Evaluation.
Presentation by Corey Melvin of Owens Corning at CAMX on October 16, 2014. He discusses double digit growth in the use of Long Fiber Thermoplastics (LFT) due to the automotive and transportation markets, where light weighting and improved aerodynamics delivers improved fuel efficiency, reduced CO2 emissions and an increase in commercial payload capacity. The focus is on advantages of LFT and market opportunities for continued growth.
Developing a New Auto-Loading Analytical ProberPhillip Corson
A methodology for selecting a vendor to collaborate with for the development of a new analytical probing system used for on-wafer device characterization in the hardware verification of compact device models in process design kits (PDK).
Altair offers a unique set of simulation tools to evaluate product feasibility, optimize the manufacturing process, and run virtual try-outs for many traditional, subtractive, and additive manufacturing processes.
Smart Product Development: Scalable Solutions for Your Entire Product LifecycleAltair
Being connected to your products opens doors to recurring and value-based revenue streams. It not only solves your customer's toughest challenges; it also helps build a sustainable future for your company. Try SmartWorks IoT today, for free trial .
An engineer working for Northrop Grumman Systems Corporation Marine Systems (NGSC-MS) was given a project to improve their teams’ current NASTRAN results post-processing workflow by writing a script to automate the task. They reached out to Altair for collaboration and Altair engineers were able to quickly determine that Altair’s mathematical modeling environment – “Altair Compose” – would be the ideal solution due to its ability to read, manipulate, and write NASTRAN results. Also, the Open Matrix Language is a scripting language that is familiar to the engineering community. Given sample NASTRAN results and requirements Altair engineers provided a “template” script. The NGSC-MS team was able to quickly understand and modify the script to their goals. The custom results were then viewable in HyperView as a contour plot, which saved a considerable amount of time during post-processing and documentation workflows.
Designing for Sustainability: Altair's Customer StoryAltair
Bush Bohlman was required to perform the structural analysis and timber design for the British Columbia Institute of Technology, (BCIT), student plaza, a pedestrian and public transport user gateway for the institute. The structure needed to establish a strong campus identity with a biophilic design and demonstrable support for sustainable building practices while ensuring structural safety according to local design codes. The hybrid mass timber structure consists of a Cross-Laminated Timber (CLT) canopy, CLT columns, and steel columns. By using S-TIMBER, the engineers were able to simulate the complex two-way bending behavior of the cantilevering roof panels and asymmetrical column layout. Having the model in S-TIMBER allowed for changes to be analyzed and re-designed, without the need to manually design individual timber and steel elements. S-TIMBER's design reports presented the design calculations concisely, yet transparently, for faster and easier reviews.
why digital twin adoption rates are skyrocketing.pdfAltair
Even though digital twin technology isn’t necessarily new, its adoption is sweeping regions and industries at astonishing rates. Organizations are rushing to adopt digital twins, learning how they can use it for different applications and purposes, and foresee even more growth in the coming few years. In this infographic, remember the big story about digital twin adoption and find out what companies worldwide have in store for their digital twin futures.
Digital twin technology has the potential to usher in unprecedented sustainability breakthroughs in industries around the world. As the world sprints toward a net zero future, organizations are rushing to adopt solutions that will create a more sustainable planet filled with technology that will enable people to minimize their impact on the people, wildlife, and environments around them. In this infographic, see how companies are flocking to digital twin technology to meet their sustainability objectives and where digital twin can have the greatest impact.
Altair’s industrial design tools allow designers, architects, and digital artists to create, evaluate, and visualize their vision faster than ever before. Focus on ideas instead of being hindered by shortcomings of the software tools and liberate creativity with design software that lets the user model freely, make changes effortlessly, and render beautifully.
Analyze performance and operations of truck fleets in real timeAltair
Altair’s event processing and data visualization tools enable fleet operators to analyze critical data streaming in from sensors and other sources. This real-time visibility into vehicle and driver performance helps reduce operating costs, improve driver safety, and increase fleet productivity. Analysts can display maps showing the current position of all assets, examine route deviations, program alerts on any set of parameters, and compare drivers’ behavior. Analysts can design and modify analytical dashboards as needed without writing a single line of code.
Knowledge Studio text analytics add-on is an industry-first application that combines visual text discovery and sentiment analysis with the power of predictive analytics. It delivers unparalleled voice of the customer insights to support customer experience management.
Altair’s Data Analytics solutions help reduce healthcare IT complexities and add efficiencies in areas like claims/reimbursement processing, revenue cycle management, interoperability, patient adherence and satisfaction analysis, and physician performance analysis.
Altair allows healthcare organizations to access, cleanse, and transform data—helping to break down data application silos and building automated workflows into standardized, shareable assets for optimizing strategic planning, streamlining operations, and maximizing resources.
Altair’s artificial intelligence (AI) and machine learning (ML) software helps materials scientists understand how to best fill gaps in their material databases, even when it’s impossible to test all possible variants. These advanced tools also optimize testing programs, improve efficiency, and reduce the time required to complete materials testing.
Altair High-performance Computing (HPC) and CloudAltair
Altair’s industry-leading HPC tools let you orchestrate, visualize, optimize, and analyze your most demanding workloads, easily migrating to the cloud and eliminating I/O bottlenecks. Top500 systems and small to mid-sized computing environments alike rely on Altair to keep infrastructure running smoothly. With longstanding hardware and cloud provider partnerships, we handle the integrations for you so your team can focus on moving business forward.
No Code Data Transformation for Insurance with Altair MonarchAltair
Altair Monarch is the fastest and easiest way to extract data from dark, semi-structured sources like PDFs, spreadsheets, and text files, as well as from Big Data and other structured sources. Monarch cleans, transforms, blends, and enriches data with an easy-to-use interface free of coding and scripting. For 30 years Monarch has helped insurers worldwide save time and money by enabling people of different skill sets to transform data quickly and precisely for efficient analysis around calculating premiums, identifying fraudulent claims, optimizing customer retention strategies, and more.
Altair Data analytics for Banking, Financial Services and Insurance Altair
Data is a significant asset for any organization. The older the data get, the more valuable it becomes. But the value of data doesn't lie in that you have it but in how you utilize it. Altair provides you the complete Data analytics, AI, and ML solutions across industries like manufacturing, insurance, finance, and government sectors to help you make smarter data decisions.
Altair data analytics and artificial intelligence solutionsAltair
Altair enables organisations worldwide to compete more effectively by operationalizing data analytics and AI with secure, governed, and scalable strategies. We deliver world-class, self-service analytics solutions for data preparation, predictive modeling, stream processing, visualization, and more. With a no-code, cloud-ready interface, organisations can harness the full power of analytics and AI throughout their complete data lifecycle, driving next-level business results.
Are You Maximising the Potential of Composite Materials?Altair
This presentation provides a summary of the talks given at Altair's Composite Design ATCx seminar which took place in the UK on 26th June, 2018. The presentation includes input from Gordon Murray Design, McLaren, Simpact and many more, describing how they are using Altair technologies to reduce composite product weight, reduce time to market, improve impact performance and much more.
COMPLETE DESIGN PROCESS OF A ROOFTOP WIND TURBINE AS A PART OF ISTANBUL COURT...Altair
As EIA indicates, about 6% of the transmitted electricity is lost during transmission and distribution phase. Production of electricity where it is consumed plays an important role in lowering these losses and infrastructure costs. In order to supply the electricity of the İstanbul Courthouse, an 800kW setup renewable energy project, which micro-wind turbines and solar panels would be set up on the roof of the building, was initiated. In order to analyze the wind characteristics of building and near environment according to wind speed changes away from it, transient computational fluid dynamics analyses that have around 12 million elements were solved using AcuSolve including turbulent atmospheric boundary layer assumptions. In addition to CFD analyses, wind data is collected from 37 points obtained from CFD results with 3-D ultrasonic anemometers distributed at the roof for one year, to obtain annual wind characteristics of whole building. After having an insight about the wind distribution a modified savonius wind turbine with rated power of 20kW was designed and efficient setup regions was obtained after engaging CFD results and measured 1 year wind data. Optimum aerodynamic geometry that will convert as much of the wind’s energy as possible to electricity was sought with the aid of AcuSolve. With the help of aerodynamic forces obtained from CFD analyses, thickness of the blades, shape of the blade supports and their thicknesses were found via Optistruct size, shape and topology optimization tools. Static analysis of the turbine frame was solved by Radioss. Vibration analysis of the turbine and rigid body motion controls of all actuators and moving parts were conducted using MotionSolve. After all the design steps are fulfilled, first prototype was manufactured. In order to verify the analysis results, vibration and stress measurements were carried out by Istanbul Technical University Mechanical Engineering Faculty, Strength of Materials Laboratory. Before transferring the turbine to the roof, a 30 million element-CFD analysis with two rotating frames that are on two gradual levels of the roof was solved in order to examine the effect of one turbine on the other. The prototype was then taken to the roof of the building to realize performance tests and measurements.
Speakers
Barış Erdem, Founder/General Manager, NLSS Engineering - R&D Ltd. Comp.
Surrogate Model-Based Reliability Analysis of Composite UAV Wing facilitation...Altair
Numerical simulation becomes increasingly strategic to design innovative products and to set up their manufacturing processes, reducing simultaneously development costs and time to market while increasing quality and reliability.
To support this evolution, SILKAN develops a platform for the integration of various types of simulation software, named BUILDERTM.
BUILDERTM is an efficient, innovative and scalable simulation-based platform designed to deal with the increasing use of complex numerical simulations applied to part design, system design or manufacturing processes.
The principal objectives of this platform are to:
Promote and structure the use of simulation
Standardize, parameterize and automate simulation processes.
Capture and re-use the best practices.
Facilitate coupling between different simulation levels and tools.
Improve collaboration across different project teams.
Facilitate access to simulation means for the uninitiated.
Accelerate design and production cycles.
Democratize the use of optimization and reliability procedures and better control manufacturing processes and failure risks.
An application example using BUILDERTM is addressed in this paper. It deals with the robust design of a composite UAV wing. The associated simulation workflow includes two principal steps.
During the first step, Matlab is used to estimate aerodynamic loads applied to the wing when as a function of flight parameters: air flow speed, angle of attack of the wing and aileron deflection angles. A Design of Experiment (DoE) is built by varying the flight parameters in order to cover all the flight domain of the UAV.
The aerodynamic loads thus obtained are then injected into OptiStruct to estimate Tsai-Wu failure criteria for the composite material. An efficient surrogate model is then built from the obtained Tasi-Wu criteria and covers the entire flight domain. Finally to conclude this first part, a failure probability , based on Tsai-Wu criteria, is estimated using the produced surrogate model.
In the second step the following optimization problem is defined using some design variables of the wing (essentially thicknesses of composite layers of the wing):
Wing Mass is calculated by Optistruct, and being evaluated using the step1. An evolutionary algorithm implemented into Dakota is used to perform this surrogate-model -
based optimization.
The set up, parameterization and automation of this complex simulation workflow is facilitated and achieved through the use of the BUILDERTM platform. The combination of different software at different levels of the workflow is also made accessible by the use of BUILDERTM.
Speakers
Samir Ben Chaabane, Numerical Simulation Manager for EMEA, SILKAN S.A
We have compiled the most important slides from each speaker's presentation. This year’s compilation, available for free, captures the key insights and contributions shared during the DfMAy 2024 conference.
NUMERICAL SIMULATIONS OF HEAT AND MASS TRANSFER IN CONDENSING HEAT EXCHANGERS...ssuser7dcef0
Power plants release a large amount of water vapor into the
atmosphere through the stack. The flue gas can be a potential
source for obtaining much needed cooling water for a power
plant. If a power plant could recover and reuse a portion of this
moisture, it could reduce its total cooling water intake
requirement. One of the most practical way to recover water
from flue gas is to use a condensing heat exchanger. The power
plant could also recover latent heat due to condensation as well
as sensible heat due to lowering the flue gas exit temperature.
Additionally, harmful acids released from the stack can be
reduced in a condensing heat exchanger by acid condensation. reduced in a condensing heat exchanger by acid condensation.
Condensation of vapors in flue gas is a complicated
phenomenon since heat and mass transfer of water vapor and
various acids simultaneously occur in the presence of noncondensable
gases such as nitrogen and oxygen. Design of a
condenser depends on the knowledge and understanding of the
heat and mass transfer processes. A computer program for
numerical simulations of water (H2O) and sulfuric acid (H2SO4)
condensation in a flue gas condensing heat exchanger was
developed using MATLAB. Governing equations based on
mass and energy balances for the system were derived to
predict variables such as flue gas exit temperature, cooling
water outlet temperature, mole fraction and condensation rates
of water and sulfuric acid vapors. The equations were solved
using an iterative solution technique with calculations of heat
and mass transfer coefficients and physical properties.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
CW RADAR, FMCW RADAR, FMCW ALTIMETER, AND THEIR PARAMETERSveerababupersonal22
It consists of cw radar and fmcw radar ,range measurement,if amplifier and fmcw altimeterThe CW radar operates using continuous wave transmission, while the FMCW radar employs frequency-modulated continuous wave technology. Range measurement is a crucial aspect of radar systems, providing information about the distance to a target. The IF amplifier plays a key role in signal processing, amplifying intermediate frequency signals for further analysis. The FMCW altimeter utilizes frequency-modulated continuous wave technology to accurately measure altitude above a reference point.
HEAP SORT ILLUSTRATED WITH HEAPIFY, BUILD HEAP FOR DYNAMIC ARRAYS.
Heap sort is a comparison-based sorting technique based on Binary Heap data structure. It is similar to the selection sort where we first find the minimum element and place the minimum element at the beginning. Repeat the same process for the remaining elements.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
Modeling of weight and vibration reduction using high performance LASD
1. Modeling of weight and vibration reduction
using high performance LASD
in the automotive industry
Jean-Paul ALLAL R&D Engineering Project Leader
September 2015
2. Aug-15
PPG Automotive Adhesives & Sealants
• Key facts :
> 600 employees
Worldwide presence
Complete paint-shop &
body-shop portfolio
Fundamental research with resin
synthesis capability
2
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
1982 1984 1992 2000 2002 2004 2008 2011 2015
1982
PPG acquired
Hughes Products
(NA-Adrian)
1983
1984
PPG acquired Industrie
Vernici Italiane (IVI)
from FIAT Group
1983
PPG acquired
Cipisa which was
then renamed to
PPI Iberica
2002
PPG acquired
Grow Chemical
2008
PPG acquired Dow
sealants in NA
April 2015
PPG acquired
Revocoat
1992
PPG started a JV
with a Korean A&S
start-up and initiated
A&S activities
Ferndale, Adrian,
Michigan
R&D Synthesis :
Pittsburgh, Pa
Pinhais, Brazil
Wuhan, China
Pondicherry, India
Kolomna, Russia
Bursa, Turkey
St Just, France :
HQ & Center of
Excellence
Camarma,
Valladolid,
Spain
Ahmedabad ,India
Quattordio
Italy
Partnership with Asahi Rubber, Japan &
Bokwang Corporation, Korea
Busan, Korea
3. Aug-15
PPG Adhesives & Sealants : Portfolio
3
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
Body-shop : Adhesives
Body-shop : Antiflutters LASD and BPR UBC & Paint shop sealers
Body-shop : Parts
4. Aug-15
Technical trends at OEM’s
4
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
Reduction of curing conditions
Compact paint-shop,
multifunctional materials
Platform strategy
• Bonding vs. welding
• Lighter materials
• Substrate :
Thin layer as HSS
Alu, Mg
Composites
Reduction fogging & emissions
Mass reduction at targeted
performances
Cost optimization
Clean & greenAcoustical comfort
Engines
NVH treatment
5. Aug-15
WEIGHT SAVINGS in AUTOMOTIVE
• Strategies : Redesign, downsizing, lighter or more efficient materials
5
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
Weight saving to consumption
real cars data :
100 Kg 0.5 L/100 km
6. Aug-15
PPG ENGINEERING SUPPORT
6
Engineering support
Testing
Material
testing
Oberst
Drop Tower
Tensile/compre
ssion
DMA
…
Static
Oil canning
Deformation
Noise
Door slam test
Static / driving
car noise
Vibration
Scanning head
Laser
accelerometers
Modeling
Static
linear
non linear
Thermal
deformation
Modeling of
read through
Stress
calculations
Modal
response
Frequency
response
Random
excitation
Measured
excitation
Dynamic
Linear
Non linear
(CRASH)
0
0,02
0,04
0,06
0,08
0,1
0,12
0,14
0,16
30 50 70 90 110 130 150 170 190 210 230 250
Mobility(mm/s/N)
Frequency (Hz)
0,E+00
1,E-02
2,E-02
3,E-02
4,E-02
5,E-02
6,E-02
7,E-02
AVT DRT
CTR DRT
TUNNEL
AVT GAU
CTR GAU
PIED ARRASSISE
TRAIN
ARR
COFFRE
GAMELL
E
MOYENN
E
RESP_DAMPER
70-250Hz
RESP_NUE 70-
250Hz
The engineering main target is to provide expertise to show the best usage of
our materials.
We have 2 methodologies : Testing and Modeling
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
PPG Modeling : NVH but also Crash, Thermal, …
using Optistruct &/or Radioss
7. Aug-15
Damping products will convert to heat a part of the strain energy of the panels
and reduce the mobility (or the vibration levels) and the acoustical emission.
Vibrations
• Sources
• Amplitudes
Structure
• decoupling
• Transfer path
Panels
• Loud speakers
• Modal shapes
Noise
• Acoustical level
• Perceived quality
What are we speaking about ?
7
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
A car body is made of a rigid frame and of panels.
8. Aug-15
Energy
absorption
Very high
damping (η)
or tg(δ)
different
θ°C
Young’s
modulus /
stiffness
Substrate &
material
Thickness
Material
deformation
strain
What are damping coatings ?
8
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
Common industrial products :
- Parts (mastic pads or constrain layers) most of the time manually fitted
- Pumpable products applied with robots
9. Aug-15
Characterization & Oberst method
The main characteristic of dampers is measured with DMA that provide values of η (or of
tg(δ)) & of product Young’s modulus with no sensitivity to adhesion phenomenon’s or
more frequently in the automotive industry with Oberst method (DIN 53440 – ISO 6721-3 – D45 1809 - … )
9
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
Vibration
response of a
steel bar
•Thickness 1mm
•Coated with product
-3dB (δF/F)
method
•Modes 2, 3, …
•about 100Hz, 300Hz,
…
Linear
Interpolation
•Oberst result
@200Hz (for most
OEMs)
Results in %
•For a given surface
weight & for each θ
°C
Frequency (Hz)
10. Aug-15
Characterization & Oberst method
• The Oberst value is dependant of the material and of the substrate (material &
thickness) and is an interpolated value @200Hz.
• The damping material is frequency dependant (this is masked in a single Oberst value)
and in the calculations it should be used as such. As a consequence there is a
calculation time penalty (It increases a lot and for a full car optimization it comes
difficult).
• For aluminum substrates results are quite different than for steel (because of higher
frequencies). It is also common sense that on such substrates the natural frequencies of
the panels are more important so analysis have to be made more carefully on higher
frequency range.
10
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
11. Aug-15
Modeling techniques are the same for all the chemical basis except for the
constraint layers because of the 3rd layer : the aluminum foil. (1st is the panel
material and 2nd is the damping coating).
Technology Mastic Pads
Constrain
Butyl/alu
EPOXY RUBBER PVC Acrylic EPOXY Rubber
Density (wet/dry)
1,4 à 2 magnetic or
adhesive
1,6 (the paste) 1,6 1,6
1,3
1,3
1,5
,9
1,6 1,6
Surface weight for 14%
damping @200Hz
4 kg/m² 1,8kg/m² 3 kg/m² 3 kg/m² 4 kg/m²
1,8 kg/m² dry
2,3 kg/m² wet
3 kg/m² 3 kg/m²
Maxi oberst damping /
surface weight
30% - 10kg/m² >30 - 4kg/m² 19% - 4kg/m² 19% - 4kg/m² 16% - 6,5kg/m²
>30%: 4kg/m² sec
ou 5,1kg/m² cru
25% - 6,5kg/m² 25% - 6,5kg/m²
VOC / Fogging / Toxproof Low No No No Yes No No Low
Sealing capability No ??? Yes Yes Yes No Yes Yes
Underbody protection No No No No
Yes
(ep>1mm)
No
Yes
(ep>2mm)
No
Print through risk 2/5 1/5 3/5 3/5 2/5 1/5 3/5 3/5
Paint ShopBody ShopAll Shops
Damping products may have different chemical basis.
Technology comparison
11
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
12. Aug-15
Example of real application in an automotive plant.
12
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
VIDEO
13. Aug-15
Example of automotive floor optimization
13
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
• This study is made on a -non real- floor pan to avoid confidentiality issues.
• AS an example, this presentation will focus on the floor pan only. It is always more
efficient to do this study including the floor pan, the firewall, the doors, the roof, …
• Frequency range of optimization depends on mesh quality & size. In this example it’s
up to 250Hz.
• Damping coatings absorb the strain energy of the panels, thus the first modes
(flexion/torsion) of the car body are not interesting. We will focus on panel vibrations
reduction.
• We decided to explain step by step the methodology knowing that in HYPERMESH the
NVH Process manager does all the pre-processing automatically.
• We don’t use automatic optimization since it doesn’t allow to understand the physics.
14. Aug-15
0
50
100
150
200
250
300
350
400
450
500
0 100 200 300 400 500 600 700 800 900
Modefrequency(Hz)
Mode #
Numberof modes / frequency
The first stage of a damping optimization (after validation of the mesh quality) is to
perform a modal analysis of the car body.
- Define the EIGRL card (in this example up to 250 Hz)
- Define the LOAD STEP : Normal modes
- Define the GLOBAL OUTPUT REQUEST : VELOCITY and ESE (Element Strain Energy)
Because of the small number of nodes of this mesh, the standard LANCZOS method
doesn’t create any calculation size or speed issue for OPTISTRUCT.
If the mesh is huge, the AMSES card (Automatic Multi-Level Sub-Structuring Eigensolver
Solution) may be activated and the EIGRL card changed to EIGRA.
The results are vey close and calculation size & speed is much smaller.
Number of nodes: 181 887
Number of elements: 184 150
Number of rigid elements: 3 350
Number of rigid element constraints: 23 850
Number of degrees of freedom: 1 084 674
Number of non-0 stiffness terms: 27 242 403
Number of ELAS1 elements: 19 902
Number of HEXA elements: 453
Number of QUAD4 elements: 155 744
Number of TRIA3 elements: 8 051
MODAL ANALYSIS
14
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
15. Aug-15
1. Boundary conditions
In the frequency response calculation (modal response) the
excitation points have to be carefully chosen. They have to be as
close as possible to real excitation forces but also have to be on
parts rigid enough to transfer the excitation to all the body with
small resonance effects.
2. Loads and control cards
a) A set (1) is defined with the nodes to be monitored
A Punch and a H3D files are generated with the speeds of the
nodes defined in the set.
b) This run (Freq. Resp. Modal) has these cards:
i. EIGRL (1): Modal analysis up to 500Hz (has to be at
least 2x the higher frequency response).
ii. FREQ1 (2): calculation of responses from 5 to 250Hz
with steps of 0.5Hz (490 steps)
iii. Loading RLOAD2 (5) is made with a Force (4) of 1N on
a node (5027) and is « multiplied » by the curve Tabled1
(3). This permits –if needed- to have frequency
dependant excitations.
c) A Damping value of 1% is given to all the steel material cards.
This value comes to 2% for aluminum.
It represents the material + the structural damping.
OUTPUT,PUNCH,FL
OUTPUT,H3D,FL
VELOCITY = 1
SET 1 = 19975, …
SUBCASE 1
LABEL REPONSE FREQ
ANALYSIS MFREQ
MPC = 1
METHOD(STRUCTURE) = 1
FREQUENCY = 2
DLOAD = 5
FREQ1 2 5.0 0.5 490
RLOAD2 5 4 3 0
EIGRL 1 500.0
MASS
TABLED1 3 LINEAR LINEAR
+ 0.0 1.0 1000.0 1.0ENDT
FORCE 4 5027 01.0 0.0 0.0
1.000
TABLED1FORCE
FREQUENCY RESPONSE : Models Pre-processing
15
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
16. Aug-15
3. Definition of the control points
a) The control points (nodes) are uniformly selected on every panel to be dampened.
b) We must have a points density high enough to get an average mobility of each panel.
c) In this example we selected 99 points grouped in 10 zones.
d) The Post-treatment may be done in Hypergraph to get the average amplitude for each
area of the floor pan and in total
e) We may also use the ERP (Equivalent Radiated Power) that provide
for each selected panel similar results ( is the area associated to each node and the normal speed of
the node) and it may be minimized using an automatic optimization.*
f) The ERP in very useful when for post-process we use the NVH Process utility to look
at the modal participation of each panel or grid.
g) The PEAKOUT parameter has not been used in this “small” model but is very useful
when model is huge and there are a lot of modes and storage space is limited.
FREQUENCY RESPONSE : Models Pre-processing
16
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
18. Aug-15
0,001
0,01
0,1
1
70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Averagemobility(mm/s/N)
Frequency (Hz)
FLOOR PAN - AVERAGEMOBILITY
Globalpost-processing/strainenergylocations
FREQUENCY RESPONSE : Global Post processing
18
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
19. Aug-15
0,001
0,01
0,1
1
10
70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Averagemobility(mm/s/N)
Frequency (Hz)
FLOOR PAN - AVERAGE MOBILITY FOR EACH AREA
AVERAGE FRT RIGHT CTR RIGHT TUNNEL FRT LEFT CTR LEFT MIDDLE SEAT AREA REAR MEMBER BOOT SPARE WHEEL
Globalpost-processing/strainenergylocations
FREQUENCY RESPONSE : Global Post processing
19
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
21. Aug-15
For the models in OPTISTRUCT, the material card for the composite steel/Damper is PCOMP where we will
fill the field GE that represents the damping of this component. This has not to be done in the material card.
As already mentioned, the materials are frequency dependant so we may also use the MATF1 card and
tables (TABLED1) for Young’s modulus and Damping if needed.
For this study, we will use as example an acrylic material and only one damper thickness.
Here is a HYPERMESH screen copy with the useful parameters:
Damper
measured
Oberst
Damper
on 0,62mm
steel
Damper
on 0,67
steel
Steel thickness mm 1,00 0,62 0,
Damper thickness mm 3,12 3,12 3,
Steel Young's modulus MPa 208000 208000 2080
Damper Young's modulus MPa 250 250 2
Damper density 0,80 0,80 0,
Dampermaterial Damping η 0,91 0,91 0,
Damper surface weight kg/m² 2,50 2,50 2,
Composite Loss Factor GE 20,70% 74,02% 74,0
FREQUENCY RESPONSE : MATERIAL CARDS
21
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
32
32,5
33
33,5
34
34,5
35
35,5
36
110 115 120 125 130 135 140 145 150 155
VALIDATION CARTE MATERIAU - OBERST RESPONSE SP400
X= 113 Hz
Y=32,24 dB X= 152,8 Hz
Y=32,24 dB
Model results :
Freq: 121,8 Hz
Damp : 30,2%
Test results :
Freq: 126,7 Hz
Damp : 30,5%
difference :
Freq: 4,9 Hz --> 3,9%
Damp : 0,3% --> 0,1%
X= 131,8 Hz
Y=35,24 dB
Mode 1 Damping measurement
22. Aug-15
The definition of the damping product mapping is made with these considerations :
Vibration levels / mobilities of each panel and information from strain
energy pictures
The damper material is always more efficient on thin panels, so we avoid to
put on welded panels junctions with double thickness (this is easily
achieved with robotic application).
Keep an homogeneous treatment and instead of too high thickness it’s
sometimes better to increase the treatment surface.
Check the result and optimize the mapping till the target (performance &
product mass) is not reached.
PRODUCT MAPPING
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PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
23. Aug-15
The patterns are defined as per former slides and result mapping is:
Covered surface = 0.69m² - product mass = 1.722 kg
PRODUCT MAPPING
23
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
25. Aug-15
Mastic Pads PVC Acrylic Epoxy Rubber
Mass (kg) 3,822 3,727 1,720 2,867 2,962
Reduction (%) 0,0% 2,5% 55,0% 25,0% 22,5%
0,0%
10,0%
20,0%
30,0%
40,0%
50,0%
60,0%
0,000
0,500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
Massreduction(%).BasisisMasticPads
Productmass(kg)
Product mass for 40% vibration decrease
The floor pan vibration level is reduced from 4.4 mm/s/N to 2.7 mm/s/N so a reduction of
40% with 1.72kg of damping product.
We conducted same study with other generic products and for the same vibration level got :
FUNCTIONAL SUMMARY
25
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
26. Aug-15
All the meshes were generated in HyperMesh, the runs were submitted with OPTISTRUCT
and for Post processing we used : HyperMesh (POST), HyperView, HyperGraph and
Microsoft Excel.
This is only a BIW model, same methodology may be used for trimmed car or other models.
For a trimmed car, number of DOF is huge so required memory and calculation time are
also huge. The use of the AMSES method permits a time reduction up to 90%. For such a
mesh, the number of modes comes to be incredibly high so the relevant strain energy maps
are hard to select and to visualize and the PEAKOUT option is very useful. Also the NVH
utility in Post process help to visualize the panels or grids modal participation.
I would recommend in this case to perform the study in two steps, first doing the
optimization using a simplified mesh (only the BIW) and second as a validation using the
optimized patterns from the first on the trimmed body mesh.
As already mentioned, the use of the ERP calculation is useful to get direct results with
smaller result files. It also reduces the post processing time (no need to perform in the post
process an average of all the nodes) and may be used for optimization purpose.
CONCLUSION
26
PPG REVOCOAT – Modeling of automotive weight and
vibration reduction using high performance LASD
27. THANK YOU FOR YOUR ATTENTION
QUESTIONS ?
Jean-Paul ALLAL
Email: allal@ppg.com