protecting our soldiers - msc software...

Protecting Our Protecting Our SoldiersSoldiers

Accelerating Product Accelerating Product Development to Armor Development to Armor

US Army Military VehiclesUS Army Military Vehicles

MSC.Software 2004 Virtual MSC.Software 2004 Virtual Product Development Product Development

ConferenceConference

18 October 200418 October 2004

Hugh “Sandy” McLeodHugh “Sandy” McLeodDirector, Land Systems DivisionDirector, Land Systems Division

Mohamed AhmedMohamed AhmedChief, EngineeringChief, Engineering

ObjectiveDesign a cab armor package for the US Army’s Family of Medium Tactical Vehicles.

• Achieve required level of ballistic and blast protection.• Do not degrade driver safety.• Minimize degradation of mobility, reliability, payload capacity.

Photos Courtesy of Stewart & Stevenson

Why?

Project Timeline

Apr 03 Project Start w/ Government Design

Jun - Oct 03 Major Redesign & Systems IntegrationConcurrent Virtual & Physical Prototyping & Testing(Project Schedule – ASAP)

Nov 03 Government Test – Mobility & Ballistic

Dec 03 Government Safety Release

Feb 04 Complete Low Rate Production (35)

Apr 04 Start Full Rate Production (771)

Jun 04 Start Production Installs in Iraq

Today In Operational Use

Concurrent Engineering

Product Design Process

Design Analysis& Simulation

Dynamic ModelsRigid

FlexibleKinematics

Detailed Design3-D Solid Models

CONCEPT ANALYSIS- Requirements- Form, Fit, Function-Layout

Manufacturing ProcessDrawings

2-D Drawings

Collaboration• Design• Build• Share• Manage

RFP

Zero PrototypeDevelopment

Physical Testing & ValidationModeling

Simulation & Research

• Pro-Engineer• Pro-Mechanica• Pro-Motion• Fatigue Advisor• Intralink• Product View

MSC.ADAMS

• Adams/Car• Adams/Chassis• Adams/Tire• Adams/Flex• Adams/Leaf Spring• Adams/Road Utility• MSC.VisualNastran• MSC.Nastran• MSC.Nastran Thermal• MSC.Marc• MSC.Patran• MSC.SimManager

Available Tools

• CATIA V4• CATIA V5• Solid Works

Start Point: FMTV Solid Model

Armored Cab Design Concept

Lifting force =<10,000 lbf Lifting force > 10,500 lbf

Minimum to liftUnable to lift

Armored Cab Design AnalysisCab Lifting Cylinder: Required Force

Cab Lift Bracket RedesignSimulation Predicted Failure

Redesign

Test – No Failure

Armor Cab Front Grill

Front GrillSubject to 5g’s Acceleration Load along x-axis of vehicle

Front grill assumed attached these locations (Bolted)

Material used:• Aluminum 6061• Steel ASTM A36

Units: mm, N, MPa

Stress & Deflection Results

Max Stress= 93 MPaAluminum Yield Stress = 275 MPa Steel Yield Stress =500 MPa

Virtual Testing Full Vehicle Analysis

Army Test Center Mobility CoursesAberdeen Proving Ground, MD

Virtual Testing Suspension Performance

Virtual Testing: Belgian Block CourseArmy Test Center Mobility Course

Virtual Testing: Belgian Block CourseArmy Test Center Mobility Course

9 metersStopping Distance

Virtual Testing: Braking on Flat Course

Virtual Testing: ISO Lane Change

Virtual Testing: Cornering

Prototype & Mobility Test

Live Fire Ballistic Testing

FMTV Crew Protection Kit

FMTV CPK• 360º, Fully Enveloping Cab

Protection– Ballistic Steel

• Bolt-on, Bolt-together Design– Removable / Replaceable– 2275 Parts & Fasteners

• Enhanced Suspension• Air Conditioning• Fuel Tank & Battery Box Armor• Machine Gun Turret Mount• 5200# Total Kit Weight

– 4700# gross vehicle weight increase

» (Cab doors & windshield removed)

Production & Fielding

Supplemental Project

Gun and Troop Carrier Armored Cargo Box

Armored Troop Protection Kit

DoorsExisting Troop Seat

Optional Slat Armor

Virtual Testing: Blast Simulation

Virtual TestingArmor Cab Kit and Box Simulation

Gun Box Prototype

Currently at Army Test Center, APG

Protecting Our Protecting Our SoldiersSoldiers

Accelerating Product Accelerating Product Development to Armor Development to Armor

US Army Military VehiclesUS Army Military Vehicles

Contact InformationContact Information

Hugh “Sandy” McLeodHugh “Sandy” McLeodDirector, Land Systems DivisionDirector, Land Systems Division

(800) 664(800) 664--0310 x 1070310 x 107hmcleod@radianinc.comhmcleod@radianinc.com

Mohamed AhmedMohamed AhmedDeputy Director, EngineeringDeputy Director, Engineering

(800) 664(800) 664--0310 x 1400310 x 140mahmed@radianinc.commahmed@radianinc.com