12/5/2003 1 IAR IAR FENet FENet 2003 2003 4-5 5 Decem December ber 2003 2003 Brian Cheung Brian Cheung Virtual Product Development (VPD) deployed on Durability Christoph Ortmann Business Development Director Virtual Product Development (VPD) deployed on Durability Christoph Ortmann Business Development Director Agenda § Introductions § VPD Overview § VPD Durability: The Honda ATV Story § Question and Answer Period Virtual Product Development Packaging Handling Safety Ride & Handling NVH Durability Durability § 1960’s Major warranty issue § Today, Design Bottleneck
9
Embed
IAR FENet 2003 4-5 December 2003 Agenda Virtual Product ...€¦ · 12/5/2003 1 IAR FENet 2003 4-5 December 2003 Brian Cheung Virtual Product Development (VPD) deployed on Durability
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
12/5/2003
1
IAR IAR FENetFENet 2003200344--5 5 DecemDecemberber 20032003
Brian CheungBrian Cheung
Virtual Product Development (VPD)
deployed on Durability
Christoph OrtmannBusiness Development Director
Virtual Product Development (VPD)
deployed on Durability
Christoph OrtmannBusiness Development Director
Agenda
§ Introductions§ VPD Overview§ VPD Durability: The Honda ATV
Durability Testing Replicated Virtually Case Study: John Deere
Business: Agriculture equipment manufacturer
Challenge: Shorten the durability design process
Solution: Replicate the durability testing in a virtual lab
Value: Identify critical locations before the first hardware prototype is built
“Using the new method, we have reduced the number of physical prototypes from three or four previously, down to one on our two most recent designs.
– Terry EwanochkoProduct Engineer, John Deere Welland Works
12/5/2003
3
Integrated Durability Management
PROVING GROUND
FEA
TEST RIG
FATIGUEEDITING
PROCESS & MANIPULATE
VIRTUALDURABILITY
TESTINGMBD
CORRELATION
The Design Scenario
Can an existing frame be used for avehicle with larger payload capacity?
SAE FD and E Committee
§ Collaborative group focused on researching fatigue and using fatigue tools more intelligently
§ ATV project goals§ “to evaluate the current simulation processes
as they relate to structural durability”§ “to develop new correlated software…to
measure the durability of components of proposed vehicles by means of a ‘digital prototype’ simulation”
§ All data used in this project are public domain at www.fatigue.org
Virtual Load Calculation
Virtual creation of input loads possible for discrete eventsPhysical testing necessary for service life
12/5/2003
4
ATV Durability Testing
Real World Test Track Test LabDurabilitySchedule
Integrated Durability Management
PROVING GROUND
FEA
TEST RIG
FATIGUEEDITING
PROCESS & MANIPULATE
VIRTUALDURABILITY
TESTINGMBD
CORRELATION
Field Data Collection
Shock tested to withstand up to 20GsIdeal for many industries, including automotive, agricultural, heavy construction, motorcycles, off-highway and railSignal conditioning for all sensors, including vehicle network
Onboard eDAQsallow data acquisition in extreme testing environments
Processing of Acquired Data
§ Transducers acquiring data arerotating with wheels
nCode Flowbuilder
§
12/5/2003
5
Integrated Durability Management
PROVING GROUND
FEA
TEST RIG
FATIGUEEDITING
PROCESS & MANIPULATE
VIRTUALDURABILITY
TESTINGMBD
CORRELATION
Virtual ATV
Flexible Body Export to MSC.ADAMS
MSC.NastranMSC.Patran MSC.ADAMS
Input Measured Loads
SpindleForces MSC.ADAMS
12/5/2003
6
Dynamic Simulation
ADAMS/Durability
Integrated Durability Management
PROVING GROUND
FEA
TEST RIG
FATIGUEEDITING
PROCESS & MANIPULATE
VIRTUALDURABILITY
TESTINGMBD
CORRELATION
Stress History Data Transfer
Unit Load CaseDeformations
Time Histories
§ For more than 66 channels…
The New Integrated Solution
ADAMS/Durability Export
Stress ShapesTime Histories
12/5/2003
7
Fatigue Properties
§ Material database§ Over 200 materials§ Generated properties§ Surface corrections§ Weld data
MSC.Fatigue
Durability of welds
Heat affected zone
§ Welds are typically location of failures§ Detailed analysis is impractical§ Special approaches included to handle welds
Weld Toe
Volvo/Chalmers/nCode Approach
§ Designed and validated for thin sheet automotive structures§ Based on structural stress at weld toe§ Simple shell meshing rules§ Differentiates between “flexible” and
“stiff” joints§ Uses generic “damage” curves
12/5/2003
8
Integrated Durability Management
PROVING GROUND
FEA
TEST RIG
FATIGUEEDITING
PROCESS & MANIPULATE
VIRTUALDURABILITY
TESTINGMBD
CORRELATION
Fatigue Editing
§ Shorten time histories while retaining damaging cycles§ Check for if resulting load files retain frequency and
damage content§ Multiple channels to maintain phasing across all vehicle
responses
Virtual strains for damage analysis
Input wheel forces
Lab Durability Test
§ Time based to reproduce variable amplitudes and vibratory modes§ Multiple hydraulic
actuators directly coupled to vehicle frame§ Wheel forces for rig control§ Strain gages are desired
for correlation§ High test acceleration
factor needed due to long service life and short development cycle
Integrated Durability Management
PROVING GROUND
FEA
TEST RIG
FATIGUEEDITING
PROCESS & MANIPULATE
VIRTUALDURABILITY
TESTINGMBD
CORRELATION
12/5/2003
9
Strain Gauge Correlation
Strain gauge
Virtual strain gauge
Correlation
Summary
§ Durability is a major bottleneck in today's design process.§ Durability in VPD increases efficiency of
real world testing.§ Obtain loads for all components, which
are costly to measure if possible at all.§ Streamlined process for optimal exchange
of information between the different technologies greatly shortens the design cycle and reduces cost.
IAR IAR FENetFENet 2003200344--5 5 DecemDecemberber 20032003