r. testi piaggio & c. spa – italy () · dynamic simulation in vehicle enginering - may 20 -...

Dynamic Simulation in Vehicle Enginering - May 20 - 21, 2010 - St. Valentin, Austria

Dynamic simulation of a starter support

R. Testi

Piaggio & C. SpA – Italy (www. piaggio. com)

ME


Presentation outline

• Company profile • Object of the study • Analysis methodology • Results • Synopsis


Company profile – Piaggio Group

Business areas

2- wheelers

Commercial Vehicles

Engines

Spare parts and accessories



Brands managed



A few figures

• one of the world’s 4 top manufacturers of two- wheel motor vehicles

• consolidated leadership position on the European 2- wheeler market

• over 7, 000 employees • facilities: Pontedera (Pisa- Italy); Scorzè (Venice- Italy);

Mandello del Lario (Lecco- Italy); Barcelona (Spain); Baramati (India); Vinh Phuc (Vietnam)

• R&D centres: Italy, Spain, China and India • Joint venture with Zongshen: Foshan (China) • vehicle sold in 2009: 607, 700 • net revenues in 2008: 1 , 486. 9 million Euro


Starter support

Object of the study

Small 4- wheeled vehicle Engine

Trouble- shooting activity


Object of the study

Failure during bench test

CAE simulation

New design

Psysical prototype


Analysis methodology

CAD software Geometry

Safety factor Modal content (Craig-Bampton

)

Components’ stiffness evaluation

FEM software FEM software

Multibody software

Modal coordinates

Durability software

Dynamic simulation


FEM analysis - Components’ stiffness evaluation

Rubber bushings

Bench test

O- ring


FEM analysis - Components’ stiffness evaluation – O- ring (1 /2)

FEM model

Rigid surfaces

Rigid bodies in FEM model

Undeformed O- ring

O- ring stiffness curve

Preload


FEM analysis - Components’ stiffness evaluation – O- ring (2/2)

Analysis steps: O- ring preload Radial stiffness evaluation


FEM analysis - Components’ stiffness evaluation

Rubber bushings

Bench test

O- ring


FEM analysis - Components’ stiffness evaluation - Bushings

Bench test

FEM model

Dummy linear material Dummy Young’s modulus





)



Multibody software

Modal coordinates

Durability software

Dynamic simulation


FEM analysis – Modal content evaluation

Bench test Flex bodies in dynamic model Support system

Test rig

Bushing material from component’s simulation





)



Multibody software

Modal coordinates

Durability software

Dynamic simulation


MBS analysis – Modal coordinates evaluation (1 /2)

MBS model

Flex bodies

Gas forces


MBS analysis – Modal coordinates evaluation (1 /2)

MBS model

Test rig actuator

Constant angular velocity actuation

Localized strain field

Partial crankcase meshing justified

Max torque Max power Max speed





)



Multibody software

Modal coordinates

Durability software

Dynamic simulation


Durability analysis

Chosen options Uniform Material Law for fatigue properties Critical plane for multiaxial stress states reduction Relative stress gradient effect taken into account

Safety factor distribution

Critical regions

Good agreement between simulation and

experimental evidence

CAE procedure used to assess a new support

configuration behaviour


New support configuration

Submitted to the same CAE procedure


Durability analysis on new configuration

Safety factor distribution

Min value from < 1 to 1 . 9 New configuration

brought to test bench

No failures

Old New


Main output

Fatigue performance

Synopsis New engine Bench test

failure CAE

troubleshooting

CAE procedure proved to be reliable

Dynamic analysis needed to evalute stress tensor time- history

New design soundness proved by simulation

Thank you for your patience!

No failure of new design after bench

test

r. testi piaggio & c. spa – italy () · dynamic simulation in vehicle enginering - may 20 -...

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