Your Selections

Finite element analysis
Show Only

Collections

File Formats

Content Types

Dates

Sectors

Topics

Authors

Publishers

Affiliations

Committees

Events

Magazine

   This content is not included in your SAE MOBILUS subscription, or you are not logged in.
new

Non-linear dynamic Modeling, Simulation and Control of Five-Phase 10/8 Switched Reluctance Motor for Electric Vehicle Application

College of Engineering Pune-Rahul Muley
Hella India Automotive Private Limited-Ravi Marravula
  • Technical Paper
  • 2019-28-2473
Published 2019-11-21 by SAE International in United States
The SRM is gaining much interest for EVs due to its rare-earth-free characteristic and excellent performance. SRM possess several advantages such as low cost, high efficiency, high power density, fault-tolerant and it can produce extended constant power region, and this makes SRM as viable alternative over conventional PM drives. Objective: The objective of this paper is to establish proof of theoretical concepts related to SRM. The key to achieve an effective SRM modeling is to use a methodology that allow the nonlinearity of its magnetic characteristics to be represented while maximizing the simulation speed. This paper represents how magnetization data obtained from FEA in the form of look up tables is most appropriate way to represent SRM model. In this paper, performance analysis of SRM is done with the help of Open loop and Closed loop MATLAB simulations. These dynamic simulations of SRM will assist in understanding behavior of SRM in various loading and speed conditions. Methodology: The machine geometry and design are first completed in ANSYS Maxwell 2-D software. Then Non-linear magnetization data is…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.
new

LIGHT WEIGHTING OF ADDITIVE MANUFACTURED PARTS FOR AUTOMOTIVE PRODUCTION APPLICATIONS THROUGH TOPOLOGY OPTIMIZATION TECHNIQUES

General Motors Technical Center India-Abhijith Naik, T Sujan, Suraj Desai, Saravanakumar Shanmugam
  • Technical Paper
  • 2019-28-2544
Published 2019-11-21 by SAE International in United States
Rapidly enhancing engineering techniques to manufacture components in quick turnaround time have gained importance in recent time. Manufacturing strategies like Additive Manufacturing (AM) are a key enabler for achieving them. Unlike traditional manufacturing techniques such as injection molding, casting etc., AM unites advanced materials, machines, and software which will be critical for Industry 4.0. Successful application of AM involves a specific combination and understanding of these three key elements. In this paper the AM approach used is Fused Deposition Modelling (FDM). Since material costs contribute to 60% of the overall FDM costs, it becomes a necessity to optimize the material consumption of the produced parts. This paper reports case studies of 3D printed parts used in an Automobile plant’s production aids, which utilize computational methods(CAE), topology optimization and FDM constrains (build directions) to manufacture the part in the most optimal way. These methodologies were used to validate the current operating conditions, optimize the design, increase the stiffness of the original part and reduce the material costs. The newly optimized designs were verified by successfully passing…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.
new

Enhancement of safety features of steering wheel using experimentally validated finite element model

Key Safety Systems Inc.-Sumit Sharma
  • Technical Paper
  • 2019-28-2556
Published 2019-11-21 by SAE International in United States
Automotive safety is the primary concern in the current world. In order to develop safe and crashworthy vehicles, phenomena behind the energy absorption characteristics of every automotive component must be known. Steering wheel is one of the key players which could cause severe injuries to the driver if sufficient safety measures are not considered. This research focuses on the crash performance of commercial vehicle steering as per head form and body block test prescribed in ECE R12. Detailed FE (Finite Element) model of the steering wheel including armature, horn pad was developed using nonlinear material properties. The model was first validated using the test results. Comparisons between experimental results and finite element analysis results were conducted and correlated using load versus displacement profiles over the duration of impact. A good relationship between test and FE results was found which allows for investigation into the energy analysis of the steering components. The validated FE model was used to improve the energy absorption characteristics the steering wheel. As the steering wheel armature and its soft padding is…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.
new

Design & analysis of 2 point aluminum upper control arm in modular multi link rear suspension system

ZF India Pvt Ltd.-Mayur Shamkant Kulkarni
  • Technical Paper
  • 2019-28-2564
Published 2019-11-21 by SAE International in United States
In current automobile market, due to the need of meeting future CO2 limits and emission standards, demand for hybrid systems is on the rise. In general, the requirements of modern automobile architecture demands modular chassis structure to develop vehicle variants using minimum platforms. The multi-link modular suspension system provides ideal solution to achieve these targets. To match ideal stiffness characteristics of system with minimum weight, aluminum links are proving a good alternative to conventional steel forged or stamped linkages. Design of current 2-point link (Upper Control Arm) is based on elasto-kinematic model developed using standard load cases from multi body dynamics. CAD system used is CATIA V5 to design upper control arm for rear suspension. This arm connects steering knuckle & rear sub frame. For Finite Element Analysis we used Hyperworks CAE tool to analyze design under all load cased & further optimization is done to resolve highly stressed zones. An optimized solution presented with a balance of ideal stiffness & strength. A CAD model developed with aluminum forged alloy (6082 - T6) is compared…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.
new

Model Based Design of Chassis-Frame with MATLAB

VE Commercial Vehicles Ltd.-Rishabh Singh parihar, Gaurav Sharma, Nitinkumar prabhakar patil, Yogendra Aniya
  • Technical Paper
  • 2019-28-2429
Published 2019-11-21 by SAE International in United States
In the current commercial vehicles market, ride-comfort and handling are crucial parameters for the customer and end user. There are various aspects which determine the vehicle behaviour. One of aspects is the structural rigidity of the vehicle, which has its own effect on vehicle dynamics. To meet the required stiffness of the main structural component of the vehicle i.e. chassis frame, FEA analysis has to be done in current methodology. The number of iterations have to be done to build an appropriate model with low weight, which can meet the design requirements. At first, conceptual design mock-up unit is to be developed then FEA (CAE) analysis to be done on it. If any design criteria are not met, then this cycle repeats again until it fulfils the required stiffness. Today, the direct stiffness procedure is the basic principle of almost every FEA software package. In this paper, computer code based on MATLAB software is provided and presented for the analysis of the chassis frame using the direct stiffness method. The code, models a structure of…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.
new

Passenger "Sleeper Bus" Structure, an Optimization Study using Finite Element Analysis

JCBL, Ltd.-Yaseen Khan
JCBL,Ltd.-Priyanka Bhola
  • Technical Paper
  • 2019-28-2537
Published 2019-11-21 by SAE International in United States
ABSTRACT Sleeper buses are increasingly used as connectivity between cities and remote areas with sleeping comfort for passengers. During the normal operation, the bus body is subjected to several loads, external loads from the road (i.e. crossing over a speed bump, breaking & cornering). Moreover, there is a substantial possibility that these loads may lead to a structural failure. Hence, it is necessary to determine stresses occurred in the bus body to ensure its integrity under these driving scenarios. During the accident, rollover/front/rear/side impact, energy absorbing capacity of bus body structure is crucial for safety of passengers. The objective of this study is to reduce weight of bus structure while maintaining cost & safety as constraint. 3D Model prepared in NX and finite element model created in hypermesh ,LS-dyna/optistruct used as solver and post processing done in hyperview. In this study, fully loaded bus with passengers as well as maximum language mass, considered. The present study is based on the finite element analysis and design optimization of passenger sleeper bus. Number of iterations in stiffness…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.
new

Analysis of occupant dynamics and optimization of Driver airbag performance against all FMVSS208 frontal impact cases using validated Finite element Methodology

Key Safety Systems Inc.-Sumit Sharma
  • Technical Paper
  • 2019-28-2545
Published 2019-11-21 by SAE International in United States
Several people die every year due to vehicle accidents. Federal Motor Vehicle Safety Standards (FMVSS) are U.S. federal regulations stating design, structure, performance, and durability necessities for vehicles. The objective of a crash test for FMVSS No. 208 is to measure how well a passenger vehicle would protect its occupants in the event of a frontal crash. FMVSS 208 consists of series of tests including different impact surface type as well as occupant sizes. It also covers the belted and unbelted occupant behavior at the time of front impact. Each test scenario has different ways to injure the occupant. Airbags are the part of passive safety equipment family in any automobile and play an imperative role to reduce the occupant head and chest injuries at the time of crash or accidents. This study covers the evaluation of airbag performance in all FMVSS 208 load cases using validated Finite Element Methodology (FEM). Finite Element Analysis (FAE) is an advanced tool to simulate the airbag behavior. Airbag deployment phenomena is very complex in nature and depend on…
new

An Optimization Framework for Fixture Layout Design for Nonrigid Parts: An Automotive Perspective

SAE International Journal of Materials and Manufacturing

Oakland University, USA-Christopher Slon, Vijitashwa Pandey
  • Journal Article
  • 05-13-01-0001
Published 2019-11-19 by SAE International in United States
The inspection process of non-rigid parts during manufacturing and assembly is inherently challenging. This is exacerbated by the need for accurate real-time part data in the digital age. Although many ad hoc techniques exist, there are no rigorous methods to evaluate the quality of a fixture layout before final parts and gauges are available. This typically happens so late in the manufacturing process that errors found can scarcely be remedied. Additionally, the modifications to the gauge are usually costly and can result in significant delays, when performed this late in the process. This article proposes an optimization-driven mathematical approach tailored toward non-rigid parts to identify the best locator layout, early in the part design phase. A metric is proposed using robotic grasping theory to quantify the quality of the locating scheme and serves as the objective of optimization. The proposed method is implemented using a tolerancing software that performs finite element analysis (FEA) on the parts to predict its state given the force and torque inputs, including the effect of gravity. An evolutionary algorithm is…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.
new

Spring Calculations Using Noonan’s XymT Method and an Eccentric Force

SAE International Journal of Engines

Private Researcher, Ireland-Michael Noonan
  • Journal Article
  • 03-13-01-0007
Published 2019-10-14 by SAE International in United States
The usual method of calculating spring deflection is to assume the end force acts through the central axis of the spring. The author takes a different approach where he calculates the eccentricity of the end force and from this calculates the spring deflection due to combined bending and torsion using a completely new model which he names the Noonan XymT Method. Also, the usual method widely used, where a strain energy approach is used, is proven to be in error. That statement is proven using a special example. Rough measurements have shown that the displacements calculated using the Strain Energy Method, can have errors as high as 40%, at a position up 0.6 coils from the bottom of the spring, and 10% at the top of the spring. The reason for this error has been identified, and calculations using Noonan’s XymT Method greatly reduces, if not eliminates, this error. This is particularly relevant in calculating individual coil stiffness and binding. With the displacement calculated, the combined complex stress due to bending tensile stress and torsional…
This content contains downloadable datasets
Annotation ability available
new

Engine Cylinder Head Thermal-Mechanical Fatigue Evaluation Technology and Platform Application

SAE International Journal of Engines

Jiangling Motor Company Limited, China-Xuwei Luo
Jiangling Motor Company, China-Xiaochun Zeng
  • Journal Article
  • 03-13-01-0008
Published 2019-10-14 by SAE International in United States
An in-cylinder combustion analysis and a computational fluid dynamics (CFD) coolant flow analysis were performed using AVL FIRE software, which provided the heat transfer boundary conditions (HTBCs) to the temperature field calculation of the cylinder head. Based on the measured material performance parameters such as stress-strain curve under different temperatures and E-N curve, creep, and oxidation data material performance, the cylinder head-gasket-cylinder block finite element analysis (FEA) was performed. According to the temperature field calculation results, the maximum temperature of the cylinder head is 200°C that is within the limit of ALU material. The temperature of the water is more than 21.1°C below the critical burnout point temperature. The high-cycle fatigue (HCF) and thermal-mechanical fatigue (TMF) analysis of the cylinder head were performed by FEMFAT software. The HCF safety coefficient and TMF life cycle of the cylinder head were calculated, which provided an important guidance for cylinder head structure design of a gasoline engine and diesel engine. The present article establishes a complete simulation and analysis process of cylinder head TMF. The fatigue assessment technology…