demands and visions for future works with ansys workbench · demands and visions for future works...
Post on 23-Aug-2020
1 Views
Preview:
TRANSCRIPT
Demands and Visions for future Works with ANSYS Workbench
Demands and Visions for future Works with ANSYS Workbench
06.07.2009Dr.-Ing. Sandro WartzackBrose Fahrzeugteile GmbH & Co KG
06.07.2009Dr.-Ing. Sandro WartzackBrose Fahrzeugteile GmbH & Co KG
Vertraulich. Der Inhalt darf nur mit unserer schriftlichen Genehmigung verwendet, geändert, weitergegeben, veröffentlicht oder in sonstiger Weise verwertet werden. Alle Rechte vorbehalten.Vertraulich. Der Inhalt darf nur mit unserer schriftlichen Genehmigung verwendet, geändert, weitergegeben, veröffentlicht oder in sonstiger Weise verwertet werden. Alle Rechte vorbehalten.
Agenda
Plastic door systems: eco-friendly and resource-saving construction and production technologiesproduction technologies
Simulation of rough design of door system
Virtual validation:- window regulator load cases under consideration of door structure- dynamic door slam simulation- integrative structural analysis for prediction of failure during side crash
Summary – demands and visions
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
Mechatronic Systems and Drives for Automobiles
Closing systems for side-doors, lift gates and sliding doors
Manual and power seat systems
Drives for sunroofs electric
s d g doo s
Drives for sunroofs, electricparking brakes and seatbelt retractors
Cooling fan and ventilation motor
Drives for seatbelt carriers and sun blinds
Drives/Actuators for heating/air-conditioning, automated manual transmission ABS electric
Door systems with functional carrier made of steel
Door control-unit and i d l t
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
automated manual transmission, ABS, electricsteering, window regulators and air suspension units
carrier made of steel,aluminum or plastic
window regulatorelectronics
Plastic Door Systems – State of the Art
Advantages• mass reductionmass reduction• integration of components and
functions• excellent molding potential• experienced in series projectsexperienced in series projects• world-wide available technology
LimitationsLimitations• material price• low Young-Modulus
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
EASC 20094th European Automotive Simulation Conference
Munich, Germany6-7 July 2009
Plastic Door Systems – Achievable Mass Reductionas
s
Arm-Window Regulator2500 g
double-guided cable window regulator with
M steel door system1200 g
plastic door system with integrated, double guided cable window regulatorg600 g
1980 2010
- 76%
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
Stiffness of Door Body in White – FEA Load Cases
load case 1 load case 2
load case 3
Loadcase direction
z
1 neg. y-direction
2 neg. y-direction
3 neg z direction
y
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
3 neg. z-directionx
EASC 20094th European Automotive Simulation Conference
Munich, Germany6-7 July 2009
Analysis of Optimal Cut-Out for Door System- Topology Optimization
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
Virtual Validation –Window Regulator Load Cases with Door Structure
Elasticity of door structure requiresElasticity of door structure requiressimulation of window regulator in the entire system
increasing size of model leads to significant longer time for computation
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
EASC 20094th European Automotive Simulation Conference
Munich, Germany6-7 July 2009
Virtual Validation with CMS Method–Window Regulator Load Cases with Door Structure
Solution:Matrix Reduction Method: CMS (Component Mode Synthesis)( p y )• lower hardware requirements• shorter computation time
very well suited for thevery well suited for thesimulation of large systems
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
Virtual Validation –Dynamic Door Slam Simulation
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
EASC 20094th European Automotive Simulation Conference
Munich, Germany6-7 July 2009
Virtual Validation –
Integration of wall thickness from deep drawing simulation into FEA model
Dynamic Door Slam Simulation
Integration of wall thickness from deep drawing simulation into FEA-model
wall thickness resulted from wall thickness transferred
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
deep drawing simulation into FEA-model
Virtual Validation –
Identification of critical positions
Dynamic Door Slam Simulation
maximum principal stresses in the carrier plate identify potential starting points for cracks
time history curve of maximum principal stresses
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
starting points for cracks
EASC 20094th European Automotive Simulation Conference
Munich, Germany6-7 July 2009
Integrative Structural Analysis for Accurate
elements for the energy-absorption at pelvis area; pushing at seat area
Prediction of Failure during Side Crash
at pelvis area; pushing at seat areadesign with respect to production criteria of plastic partstarget: predictive and reproducibletarget: predictive and reproduciblebehaviour of structure
integration of crash absorberscrash absorbers
integration of pusher bloc
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
Integrative Structural Analysis for Accurate Prediction of Failure during Side Crash
LS-Dyna Crash Simulation V
model of crash pad
rigid wall
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
crash pad
EASC 20094th European Automotive Simulation Conference
Munich, Germany6-7 July 2009
From Injection Molding Simulation to Structural Analysis e-Xstream DIGIMAT
Source: Exstream
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
Drop Tower Test: Comparison Test - Simulation
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
EASC 20094th European Automotive Simulation Conference
Munich, Germany6-7 July 2009
Drop Tower Test: Comparison Test - Simulation
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
Summary – Demands and Visions
Topology optimization with respect to production criteria inside of ANSYS WORKBENCH
Fast computation of complex systems essential with accurate results:- Reduction of computation time through Workbench-integrated CMS method- Fast simulation loops: Modification of design effects real-time visualisation of simulation results
C f t bl i t ti f lt f di d ti i t ANSYSComfortable integration of results of preceding production process into ANSYSWorkbench: - Integration of results of deep drawing analysis into structural analysis - Coupling of a “virtual material compounder” for the consideration of fibre p g porientation resulting from injection molding process
Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09
EASC 20094th European Automotive Simulation Conference
Munich, Germany6-7 July 2009
Demands and Visions for future Works with ANSYS Workbench
Demands and Visions for future Works with ANSYS Workbench
06.07.2009Dr.-Ing. Sandro WartzackBrose Fahrzeugteile GmbH & Co KG
06.07.2009Dr.-Ing. Sandro WartzackBrose Fahrzeugteile GmbH & Co KG
Vertraulich. Der Inhalt darf nur mit unserer schriftlichen Genehmigung verwendet, geändert, weitergegeben, veröffentlicht oder in sonstiger Weise verwertet werden. Alle Rechte vorbehalten.Vertraulich. Der Inhalt darf nur mit unserer schriftlichen Genehmigung verwendet, geändert, weitergegeben, veröffentlicht oder in sonstiger Weise verwertet werden. Alle Rechte vorbehalten.
EASC 20094th European Automotive Simulation Conference
Munich, Germany6-7 July 2009
top related