protecting our soldiers - msc software...
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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 [email protected]@radianinc.com
Mohamed AhmedMohamed AhmedDeputy Director, EngineeringDeputy Director, Engineering
(800) 664(800) 664--0310 x 1400310 x [email protected]@radianinc.com