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DESIGN OF A LIGHTWEIGHT COMPOSITE SUSPENSION SYSTEM
Advanced Engineering Show
2nd November 2017
David Vickerman
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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
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Optimisation FEA Simulation CompositesMethods & Software
Development
Product Design CFDPrototype
ManufactureComponent
Testing
Introduction to GRM Consulting
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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.