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.

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
To be published on 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.

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
To be published on 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.

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

Key Safety Systems Inc.-Sumit Sharma
  • Technical Paper
  • 2019-28-2556
To be published on 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.

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
To be published on 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.

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
To be published on 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.

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

JCBL, Ltd.-Yaseen Khan
JCBL,Ltd.-Priyanka Bhola
  • Technical Paper
  • 2019-28-2537
To be published on 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.

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
To be published on 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…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.

Design and Fabrication of CFRP Wheel Centre for FSAE Race-Car

VIT-Sangeet Aggarwal, Renold Elsen
  • Technical Paper
  • 2019-28-0117
To be published on 2019-10-11 by SAE International in United States
In this work, a Carbon Fibre Reinforced Polymer (CFRP) Wheel Centre (WC) is designed targeting key parameters such as reduced un-sprung mass and lower rotational inertia in vehicle dynamics. A Keizer Aluminium Wheel Centre was used by the team previously and it weighed around 1.8 Kg. Designing of CFRP Wheel Centre was based on previously used Keizer Aluminium wheel centre considering the design constraints such as distance between hub and wheel assembly. This was done to ensure the same trackwidth within the Formula Student rules. Initially, the Finite Element Analysis (FEA) was carried out for the Keizer Aluminium wheel centre and the results were analysed. For the same design CFRP material was used and the result was found out to be promising with a wheel centre weight of 1.3 Kg. Further to improve the performance and weight reduction, FEA was done to design a 38 layered CFRP wheel centre giving utmost priority to ease of manufacturability and safe design. After manufacturing, the CFRP wheel centre weighed 950g and was implemented on PRV17 (Pravega Racing’s FSAE…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.

Thumb Design and Optimization for Backhoe Loader

John Deere C&F-Kurtis Langner
John Deere India Pvt. Ltd.-Sandeep Dhotre, Surya Pratap Ponnana, Amit Ghate
  • Technical Paper
  • 2019-28-0109
To be published on 2019-10-11 by SAE International in United States
Product Engineering organizations are committed to provide solutions with the right quality and value to customers. Value improvement and efficient product improvement are key considerations for product engineering.In this paper, the Author summaries thumb design and optimization for backhoe loader. The project goal was to create an in-house thumb design. The backhoe thumb attachment was previously a proprietary design of a supplier. The supplier’s design had two major limitations, limited opportunity of design improvements for resolving customer issues and higher total cost. This paper covers details about overcoming these limitations.Multiple variants of backhoe loaders use four different thumbs. Small and mid- range backhoe machine classes use 4-tine and 2-tine thumb depending upon customer applications. The design team targeted an external customer requirement of a more compact design and internal requirement of accelerating design improvement cycle time and reducing cost. To overcome these concerns, along with few more constraints, a full study of a new thumb design was conducted. Key constraints included compatibility to current design, maintain tip forces, and optimize for a compact design. Verification…
   This content is not included in your SAE MOBILUS subscription, or you are not logged in.

Fatigue Life Prediction of Heavy Duty Automobile’s Brake Drum through Coupled Thermo-Mechanical Analysis

Vellore Institute Of Technology Chenna-Krishnamoorthy Annamalai
Vellore Institute of Technology-Chooriyaparambil Damodaran Naiju
  • Technical Paper
  • 2019-28-0031
To be published on 2019-10-11 by SAE International in United States
The aim of this paper is to demonstrate the methodology to simulate the induced stresses/strains due to thermo-mechanical loading of automobile brake drum.. The brake drum undergoes mechanical load due to applied brake pressure and thermal load due to friction generated between brake pad and brake drum while brake is applied. This coupled thermo-mechanical loading affects the life of the brake drum as the stiffness of the brake drum is reduced. The conventional method of simulating this problem is done using Lagrangian discretization in which the load is applied and inertia effect due to angular velocity is applied to a drum at static condition. In contrast, in this paper Eulerian discretization is adopted for finite element analysis, in which drum brake model is discretized as spatially dependent that facilitates actual rotation of brake drum with simultaneous application of brake load resulting more precise simulation. A sequentially coupled transient thermo-mechanical analysis is carried out using ABAQUS 6.12 simulation tool to predict the induced stresses/strains and fatigue life of the brake drum.