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Ilankamban, R.
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Validation of Non-linear Load-Controlled CAE Analyses of Oil-Canning Tests of Hood and Door Assemblies

Ford Motor Company-Y. Zhao, M. Singri, R. Ilankamban, S. Perumalswami
Rouge Steel Company-R. Mohan Iyengar, T. Chang
Published 2003-03-03 by SAE International in United States
Two finite element methodologies for simulating oil-canning tests on closure assemblies are presented. Reflecting the experimental conditions, the simulation methodologies assume load-controlled situations. One methodology uses an implicit finite-element code, namely ABAQUS®, and the other uses an explicit code, LS-DYNA®. It is shown that load-displacement behavior predicted by both the implicit and explicit codes agree well with experimental observations of oil-canning in a hood assembly. The small residual dent depth predictions are in line with experimental observations. The method using the implicit code, however, yields lower residual dent depth than that using the explicit code. Because the absolute values of the residual dent depths are small in the cases examined, more work is needed, using examples involving larger residual dent depth, to clearly distinguish between the two procedures. The analysis performed using the implicit code was significant more efficient (in terms of CPU hours) than the analysis done using the explicit code. The effects of forming strains are qualitatively examined. Forming induced thickness changes and plastic strains may not have a significant effect on oil-canning…
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Assembly Variation Analysis of Flexible Parts

Ford Motor Company-R. Ilankamban, S. Alluri
Published 2001-10-16 by SAE International in United States
Build variation is an important aspect of vehicle assembly. However traditional variation analysis assumes parts are rigid, leading to overestimation of variations. A finite element analysis procedure to estimate the build variation due to variations of shape, size and mechanical properties of flexible parts is presented. In addition to the part deformation, assembly force and stress can also be calculated by this method. This procedure is illustrated with an example problem.
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The Effect of Contact Surface and Bolt Torque Variations on the Brake Rotor Run-Out

Ford Motor Company-A. R. Bhat, R. Ilankamban, P. R. Perumalswami
Published 1998-02-23 by SAE International in United States
Deformation of the hub, rotor, and the wheel results in lateral run-out of the rotor. The effect of contact surface variations and bolt forces on the deformation is investigated. It is analytically shown that the run-out due to deformation is caused primarily due to the radial and circumferential moments generated in the hub and the rotor due to bolt tightening. Case studies illustrate the interaction between hub, rotor, and the wheel for various surface conditions. Design guidelines are provided to reduce rotor run-out.
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An Upfront Analysis Driven Design Process for Product Development

Ford Motor Co.-G. Vellathottam, P. R. Perumalswami, R. Ilankamban, S. Sankaranarayanan
Published 1997-04-08 by SAE International in United States
In the current design process, the designer generates the detailed geometry of the component based on experience. Prototypes of this design are built and tested to verify the performance. This design - build - test iterative process is continued until performance targets/criteria are met. Computer Aided Engineering is often used to verify the design.This paper presents a new product development process to substantially reduce the number of design - analysis - build - test iterations. This Upfront Analysis Driven Design process incorporates several state of the art technologies in finite element structural analysis, optimization, and Computer Aided Design. This process ensures a near optimum design in the first design level itself.
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A Finite Element Modeling of the Stretch-Draw Forming Process

B&A Operations Ford Motor Co. Dearborn, MI-P. Ling
Engineering Technology Assoc. Troy, MI-R. Ilankamban
Published 1988-02-01 by SAE International in United States
A finite element program based on the nonlinear shell theory, membrane plus bending, and the flow theory of plasticity has been developed to analyze stresses and deformation during the three stages of the stretch-draw forming process. A surface contact problem with friction is formulated in this paper and solved by means of the developed program. It is applied to two actual body outer-panels in this paper to demonstrate the capability and features of the program. Computing time for an overall analysis of these three forming stages of the stretch-draw forming process is reasonable. Therefore, it is practical to use this program for evaluation of design of the forming process.
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