design of a lightweight composite suspension system … · and embed these methods in the abaqus...

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DESIGN OF A LIGHTWEIGHT COMPOSITE SUSPENSION SYSTEM

Advanced Engineering Show

2nd November 2017

David Vickerman

www.grm-consulting.co.uk

Overview

Introduction to GRM Consulting

CLASS Project Introduction

Optimisation Process

TruPly

CLASS Project Outcomes

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Optimisation FEA Simulation CompositesMethods & Software

Development

Product Design CFDPrototype

ManufactureComponent

Testing

Introduction to GRM Consulting

www.grm-consulting.co.uk

UK software reseller, developer and engineering consultancy founded in 2003

Core business focussed around the development and application of optimisation methods

Company has expanded to extend support functions to the engineering community

www.grm-consulting.co.uk

Optimisation FEA Simulation CompositesMethods & Software

Development

Product Design CFDPrototype

ManufactureComponent

Testing

Introduction to GRM Consulting

www.grm-consulting.co.uk

What is CLASS?

A 24 month collaborative research project.

Aims to overcome challenges of high volume production for a lightweight composite tieblade-knuckle for a wheel suspension system.

The project is co-funded by Innovate UK, the UK's innovation agency via the Adapting Cutting Edge Technologies Call.

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GRM’s Role in Class

Explore new CAE techniques which would allow anisotropic multi-material topology optimisation of a composite

tieblade-knuckle.

And embed these methods in the ABAQUS environment through a composite design optimisation plug-in, TruPly, to better match Ford’s current design and analysis workflow.

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RibsSheet

Concept topology to establish pre-preg sheet position and indicate SMC rib placement. Stiffness constraints.

Sheet interpretation

Detailed optimisation of the following performed simultaneously with stiffness and strength constraints:• Topology of SMC – place ribs• Sizing of laminate – determine layup• Topography of tie blade – tweak sheet position and determine swaging

Interpreted Design

Optimisation Process

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Concept Topology

Carbon Fabric Carbon SMC

Stiffness Targets Strength Loads

Baseline Steel DesignOptimisation Package SpaceOptimisation Model

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Load CasesStiffness Max. Stiffness Min.

Strength Linear Buckling

Compliance required to correctly load suspension

Stiffness required to maintain correct geometry

Material failure to be avoided in abuse cases

Ensure geometric buckling is avoided

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Load Cases

Stiffness Load Cases Strength Load Cases

Lateral Lateral

ARB Fore

Camber Aft

Toe Jounce

Caster Rebound

Ear Y Steer Moment

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Initial Sheet Interpretation

Concept topology result is used to position the prepreg.

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Detailed Optimisation

Detailed optimisation performed using the interpreted prepreg sheet position.

Composite layup, ply orientation and local ply position is optimised while topology is performed simultaneously on the SMC ribs.

Lateral Deflection 2.75 mm

Buckling Factor 1.0

PP Thickness 6 mm

Total Mass 3.53 kg

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Optimisation Interpretation

Detailed optimisation is used to generate SMC rib positions and finalise the position of the prepreg including swaging.

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TruPly

All topology optimisation and composite laminate optimisation conducted during the CLASS project was conducted in GENESIS.

As part of the CLASS project GRM developed a composite design optimisation tool for Abaqus, TruPly, using the GENESIS solver to better match Ford’s current design and analysis workflow.

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TruPly Key Features

No modification of Abaqus model required – minimises user interaction.

Standalone Application can be easily integrated into existing composite development workflow.

Topometry capability allows development of ply patterns from a candidate laminate – a key step in developing parts from scratch.

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TruPly WorkFlow

1: Import Abaqus Model

2: Create Ply Design Rules

3: Define Optimisation Settings

4: Run Composite Optimisation

5: View Results in Abaqus Post Processor

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CLASS Project Outcomes

Project Outcomes

Design and manufacture of a composite tieblade-knuckle with a potential 50% reduction in mass over the fabricated steel component.

Development of new manufacturing methods for volume composite production.

Optimisation Innovations

Development of anisotropic multi-material optimisation method.

Development of TruPly to integrate composite optimisation capabilities into Abaqus.