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C123 Methodology for concept design of the Chassis Frame

Altair Engineering-AshithKumar Shetty
  • Technical Paper
  • 2019-28-2534
Published 2019-11-21 by SAE International in United States
Objective This paper explores the usage of Altair simulation driven concept process, C123 for developing the chassis frame of the SUV along with Multidisciplinary optimisation tool. C123 process is useful for strategic & systematic usage of optimisation to generate design alternatives, trade-off information, best balanced designs, design sensitivities, to actively support the concept development process on daily basis. Methodology C123 is used for developing initial concept design of the chassis frame of the SUV. C123 process is independent of vehicle architectures, manufacture process (e.g. extrusions, sheet metal) & material selection (e.g. metals, composites, mixed etc.) and platform sharing strategy. C1 process is used for identification of optimum Structural Layout, C2 is for rapid optimum Sizing of idealized Sections, C3 is used for detailed optimum Sizing of Manufacturable Sections. Automatic process is used for handling pre and post processing process very efficiently. Final refinement of the concept design (C3) will be carried out by considering all the possible critical load cases like Durability, stiffness, Modal Frequency & crash/Impact. Author is also explored usage of advanced high-strength…
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IMPROVE NVH CHARACTERISTICS OF ENGINE OIL PAN BY OPTIMIZATION & LIGHT WEIGHING WITH DEEP LEARNING PROCESS

Altair Engineering-Srinivas Tangudu, Padmaja Durgam
Altair Engineering India Pvt , Ltd.-Muralidhar Gumma
  • Technical Paper
  • 2019-28-2552
Published 2019-11-21 by SAE International in United States
Recent Years “NVH” is gaining lots of attention as the perception of vehicle quality by a consumer is closely aligned to NVH Characteristics. Demand on Vehicle Light weighting to compliance the environmental norms with powerful engines challenging the “Vehicle NVH”, powertrain induced noise will be continued to be a primary factor for all IC engine vehicles. Component level NVH refinement is necessary to control the overall NVH characteristics of vehicle with lighter Vehicle goal. Current Paper works starts with physical testing the Engine oil pan of the most popular vehicle and build an equivalent simulation model by reverse engineering the design and match similar performance trend in simulation model. After building baseline simulation model, conduct shape, topology, gauge and material optimization to improve weight and performance of Oilpan. In addition to the Simulation DVPS to study the complete NVH characteristics oil pan models, a deep Learning model developed with power of GPUs to disrupt oil pan design methodology as well as optimizing the weight, Performance and cost . Every design engineer would like to optimize…
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Suspension hard points optimisation

Altair Engineering-AshithKumar Shetty
  • Technical Paper
  • 2019-28-2419
Published 2019-11-21 by SAE International in United States
Objective This paper explores the usage of Altair simulation driven optimisation process, Front Suspension hard points of a sedan Car model are optimised for specific target toe curves using MotionView, MotionSolve and HyperStudy This process gives the optimal hard point values to match the target curves without much iterations. Methodology Parametric Multibody model of the front end of sedan is built in MotionView. To Carry out optimisation HyperStudy is used where few of the suspension hard points which affect the toe curves are chosen as design variable. For the chosen Design variables upper and lower bound limits are specified. Ride, Roll and lateral force tests are performed. Optimisation is performed using HyperStudy where it iterates the suspension hard points to match the target toe curves. Each iteration response can be visualized in HyperStudy and can be compared with the target toe curve. Hyperstudy points the iteration which is closest to the Target curve Advantage • Quick model setup and run time • Parametric model allows quick change in design • Insight at early design stage…
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A Process to Improve Passenger Vehicle Sound and Vibration Quality Using a Combination of SPC and CAE Analysis

Altair Engineering-Xiaolei Song
Bruel & Kjaer North America, Inc.-Giovanni Rinaldi
Published 2019-06-05 by SAE International in United States
A manufacturer of automotive equipment set out to implement a process to include sound and vibration quality targets for powertrain and road noise. CAE models have been successfully used in the early phase of the vehicle development process, but the use of these models to assess the customer’s subjective sound and vibration experience is often missing. The goal here was to use a CAE model driven by sound and vibration quality targets for early identification of problem areas based on jurors’ preference. These quality targets were cascaded via Source-Path-Contribution (SPC), and optimizations were performed to meet the targets using the CAE model.
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Exterior Acoustics Using Infinite Elements

Altair Engineering-Anurag Rajagopal, Dilip Mandal, Junji Saiki, Ujwal Patnaik
Published 2019-06-05 by SAE International in United States
The idea of employing an infinite element to solve acoustic problems in an unbounded domain has demonstrated significant promise. Starting from first principles, the detailed element formulation for a mapped wave-envelope infinite element is presented. This, in conjunction with an efficient search algorithm to map receiver grid locations to the pertinent infinite element on the boundary, is used to enhance an established finite-element based vibro-acoustic solver for frequency response in order to solve large scale industrial problems. The solver is then subjected to a thorough validation and verification study using problems whose solutions are established either through classical texts or alternative approaches to demonstrate the accuracy, robustness and efficiency of the current solution.
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Design of Electric Motor Using Coupled Electromagnetic and Structural Analysis and Optimization

Altair Engineering-Numair Mazgaonkar, Linus Francis Fernandes
Automotive Accessories-Mazharul Chowdhury
Published 2019-04-02 by SAE International in United States
Today, vehicle architectures are changing continuously due to the need for increasing vehicle electrification. Electric motors have helped sustain this requirement. Traditional internal combustion engines are being replaced or coupled with traction motors or in-wheel motor systems in full-electric or hybrid-electric vehicles. With the use of electric motor in a vehicle, the number of parts can be reduced. This leads to reduced packaging size and complexity. Also, CO2 emissions are reduced, and overall efficiency is increased. But the task of designing an electric motor which is assembled in a vehicle could be quite complex. The design of an electric motor can affect the durability, and noise and vibration characteristic of the vehicle structure to which it is connected. The design of the vehicle structure to which the motor attaches should be able to sustain the magnetic torque generated by the motor. Electromagnetic forces generated on the stator of an electric motor affect the vibration characteristic of the motor casings and structure to which it connects. In an internal combustion powered vehicle, engines contribute the maximum…
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Application of Dynamic Mode Decomposition to Influence the Driving Stability of Road Vehicles

Altair Engineering-Daiki Matsumoto, Christoph Niedermeier
Technical University of Munich-Thomas Indinger
Published 2019-04-02 by SAE International in United States
The recent growth of available computational resources has enabled the automotive industry to utilize unsteady Computational Fluid Dynamics (CFD) for their product development on a regular basis. Over the past years, it has been confirmed that unsteady CFD can accurately simulate the transient flow field around complex geometries. Concerning the aerodynamic properties of road vehicles, the detailed analysis of the transient flow field can help to improve the driving stability. Until now, however, there haven’t been many investigations that successfully identified a specific transient phenomenon from a simulated flow field corresponding to driving stability. This is because the unsteady flow field around a vehicle consists of various time and length scales and is therefore too complex to be analyzed with the same strategies as for steady state results. Dynamic Mode Decomposition (DMD) extracts the coherent structures from complex, transient flow fields, which can help to identify certain target phenomena. However, one issue in the practical application of DMD is the difficulty to find a connection between a computed mode and an actual aerodynamic effect on…
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Antenna Design Methodology for Remote Keyless Entry: The Effects of the Human Body and Vehicular Antenna Positions on Coverage

Altair Engineering-Dipen Kumar Das, Aseim Elfrgani
Published 2019-04-02 by SAE International in United States
In this era of technologies, Remote Keyless Entry (RKE) system has become an integral part of motor vehicles. Over the years, a lot of functionalities have been added to RKE systems. To achieve functional communication between key-fob antennas and vehicular receiving antennas, it is necessary to analyze the impact of a human body as well as the receiving antenna placements on the vehicle’s body. Taking these variations into account during the antenna development phase becomes expensive and tedious since achieving an efficient design would require several iterations, testing, and modification, in the design. Hence, Computational Electromagnetic (CEM) techniques become a feasible solution to explore such scenarios and adopt necessary modifications as needed. This paper introduces a methodological process of designing RKE antennas using 3D CEM Simulation tool; namely Altair Feko. Moreover, the presented methodology includes an analysis of variations of remote keyless entry system’s radiation characteristics while placed in the vicinity of the human body. The effects of the vehicular receiving antenna position on the RKE system’s coverage are also investigated and analyzed. This paper…
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Topology Driven Design of Under-Hood Automotive Components for Optimal Weight and NVH Attributes

Altair Engineering-Linus Francis Fernandes, Abhilash Patel
Ford Motor Company-Sushanth Kumareshwar Panchaxrimath, Abdelkrim Zouani
Published 2019-04-02 by SAE International in United States
Weight is a major factor during the development of Automotive Powertrains due to stringent fuel economy requirements. Light weighting constitutes a challenge to the engineering community when trying to deliver quieter powertrains. For this reason, the NVH (Noise Vibration Harshness) CAE engineers are adopting advanced vibro-acoustic simulation methods combined with topology optimization methods to drive the design of the under hood components for Noise Vibration and Harshness. Vibro-acoustic computational methods can be complex and require significant computation effort. Computation of Equivalent Radiated Power (referred to as ERP) is a simplified method to assess maximum dynamic radiation of components for specific excitations in frequency response analysis which in turn affects radiated sound. Topology Optimization is a mathematical technique used to find the best material distribution for structural systems in order to deliver a specific objective under clearly defined constraints.This paper will showcase the process adopted to optimize the weight of an under-hood automotive component while maintaining the ERP performance across several one third octave bands. In order to address the large eigenvalue problem solved during the…
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Tuning Aircraft Engines with OptiStruct Rotor Dynamics Simulation

Altair Engineering-Ujwal Kondavalasa Patnaik, Junji Saiki
GE Aviation-Illya Arcos
Published 2019-03-19 by SAE International in United States
It is typical in aircraft engine design to explore new configurations in a constant effort to achieve greater efficiency with respect to various considerations. An integral component of this process requires a complete and robust simulation of rotor dynamics. Tuning the design with results of rotor dynamics simulations can be made possible with a tool that has adequate modeling techniques to capture the physics associated with engine behavior under various operating conditions accurately.
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