Demands and Visions for future Works with ANSYS Workbench · Demands and Visions for future Works with ANSYS Workbench 06.07.2009 Dr.-Ing. Sandro Wartzack Brose Fahrzeugteile GmbH

Demands and Visions for future Works with ANSYS Workbench


06.07.2009Dr.-Ing. Sandro WartzackBrose Fahrzeugteile GmbH & Co KG


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Agenda

Plastic door systems: eco-friendly and resource-saving construction and production technologiesproduction technologies

Simulation of rough design of door system

Virtual validation:- window regulator load cases under consideration of door structure- dynamic door slam simulation- integrative structural analysis for prediction of failure during side crash

Summary – demands and visions

Verfasser: Sandro Wartzack Funktion: TVE Seite ‹#›/22 Speicher-Dat.: 01. Jul. 09

Mechatronic Systems and Drives for Automobiles

Closing systems for side-doors, lift gates and sliding doors

Manual and power seat systems

Drives for sunroofs electric

s d g doo s

Drives for sunroofs, electricparking brakes and seatbelt retractors

Cooling fan and ventilation motor

Drives for seatbelt carriers and sun blinds

Drives/Actuators for heating/air-conditioning, automated manual transmission ABS electric

Door systems with functional carrier made of steel

Door control-unit and i d l t


automated manual transmission, ABS, electricsteering, window regulators and air suspension units

carrier made of steel,aluminum or plastic

window regulatorelectronics

Plastic Door Systems – State of the Art

Advantages• mass reductionmass reduction• integration of components and

functions• excellent molding potential• experienced in series projectsexperienced in series projects• world-wide available technology

LimitationsLimitations• material price• low Young-Modulus


EASC 20094th European Automotive Simulation Conference

Munich, Germany6-7 July 2009

Plastic Door Systems – Achievable Mass Reductionas

s

Arm-Window Regulator2500 g

double-guided cable window regulator with

M steel door system1200 g

plastic door system with integrated, double guided cable window regulatorg600 g

1980 2010

- 76%


Stiffness of Door Body in White – FEA Load Cases

load case 1 load case 2

load case 3

Loadcase direction

z

1 neg. y-direction

2 neg. y-direction

3 neg z direction

y


3 neg. z-directionx



Analysis of Optimal Cut-Out for Door System- Topology Optimization


Virtual Validation –Window Regulator Load Cases with Door Structure

Elasticity of door structure requiresElasticity of door structure requiressimulation of window regulator in the entire system

increasing size of model leads to significant longer time for computation




Virtual Validation with CMS Method–Window Regulator Load Cases with Door Structure

Solution:Matrix Reduction Method: CMS (Component Mode Synthesis)( p y )• lower hardware requirements• shorter computation time

very well suited for thevery well suited for thesimulation of large systems


Virtual Validation –Dynamic Door Slam Simulation




Virtual Validation –

Integration of wall thickness from deep drawing simulation into FEA model

Dynamic Door Slam Simulation

Integration of wall thickness from deep drawing simulation into FEA-model

wall thickness resulted from wall thickness transferred


deep drawing simulation into FEA-model

Virtual Validation –

Identification of critical positions

Dynamic Door Slam Simulation

maximum principal stresses in the carrier plate identify potential starting points for cracks

time history curve of maximum principal stresses


starting points for cracks



Integrative Structural Analysis for Accurate

elements for the energy-absorption at pelvis area; pushing at seat area

Prediction of Failure during Side Crash

at pelvis area; pushing at seat areadesign with respect to production criteria of plastic partstarget: predictive and reproducibletarget: predictive and reproduciblebehaviour of structure

integration of crash absorberscrash absorbers

integration of pusher bloc


Integrative Structural Analysis for Accurate Prediction of Failure during Side Crash

LS-Dyna Crash Simulation V

model of crash pad

rigid wall


crash pad



From Injection Molding Simulation to Structural Analysis e-Xstream DIGIMAT

Source: Exstream


Drop Tower Test: Comparison Test - Simulation




Drop Tower Test: Comparison Test - Simulation


Summary – Demands and Visions

Topology optimization with respect to production criteria inside of ANSYS WORKBENCH

Fast computation of complex systems essential with accurate results:- Reduction of computation time through Workbench-integrated CMS method- Fast simulation loops: Modification of design effects real-time visualisation of simulation results

C f t bl i t ti f lt f di d ti i t ANSYSComfortable integration of results of preceding production process into ANSYSWorkbench: - Integration of results of deep drawing analysis into structural analysis - Coupling of a “virtual material compounder” for the consideration of fibre p g porientation resulting from injection molding process








Vertraulich. Der Inhalt darf nur mit unserer schriftlichen Genehmigung verwendet, geändert, weitergegeben, veröffentlicht oder in sonstiger Weise verwertet werden. Alle Rechte vorbehalten.Vertraulich. Der Inhalt darf nur mit unserer schriftlichen Genehmigung verwendet, geändert, weitergegeben, veröffentlicht oder in sonstiger Weise verwertet werden. Alle Rechte vorbehalten.



Documents

Demands and Visions for future Works with ANSYS Workbench · Demands and Visions for future Works with ANSYS Workbench 06.07.2009 Dr.-Ing. Sandro Wartzack Brose Fahrzeugteile GmbH