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2018-05-14 ...
  • May 14-25, 2018 (6 Sessions) - Live Online
  • October 29-November 9, 2018 (6 Sessions) - Live Online
Training / Education Online Web Seminars
The Finite Element Analysis (FEA) has been widely implemented by automotive companies and is used by design engineers as a tool during the product development process. Design engineers analyze their own designs while they are still in the form of easily modifiable CAD models to allow for quick turnaround times and to ensure prompt implementation of analysis results in the design process.
2018-02-05 ...
  • February 5-9, 2018 (3 Sessions) - Live Online
  • June 4-8, 2018 (3 Sessions) - Live Online
Training / Education Online Web Seminars
Finite Element Analysis (FEA) is a powerful and well recognized tool used in the analysis of heat transfer problems. However, FEA can only analyze solid bodies and, by necessity thermal analysis with FEA is limited to conductive heat transfer. The other two types of heat transfer: convection and radiation must by approximated by boundary conditions. Modeling all three mechanisms of heat transfer without arbitrary assumption requires a combined use of FEA and Computational Fluid Dynamics (CFD).
2018-01-22 ...
  • January 22-26, 2018 (3 Sessions) - Live Online
  • May 29-June 1, 2018 (3 Sessions) - Live Online
Training / Education Online Web Seminars
Finite Element Analysis (FEA) has been an indispensable tool for design simulation for several decades but this wide spread use has been limited to simple types of analyses. Relatively recently, more advanced analyses have given easy to use interfaces enabling design engineers to simulate problems formerly reserved for analysts. This three-session web seminar targets the FEA users who wish to explore those advanced analysis capabilities.
2017-12-04 ...
  • December 4-15, 2017 (6 Sessions) - Live Online
  • June 11-22, 2018 (6 Sessions) - Live Online
  • November 28-December 10, 2018 (6 Sessions) - Live Online
Training / Education Online Web Seminars
Finite Element Analysis (FEA) has been used by engineers as a design tool in new product development since the early 1990's. Until recently, most FEA applications have been limited to static analysis due to the cost and complexity of advanced types of analyses. Progress in the commercial FEA software and in computing hardware has now made it practical to use advanced types as an everyday design tool of design engineers. In addition, competitive pressures and quality requirements demand a more in-depth understanding of product behavior under real life loading conditions.
CURRENT
2017-11-15
Standard
J840_201711
This SAE Recommended Practice covers equipment capabilities and the test procedure to quantify and qualify the shear strength between the friction material and backing plate or brake shoe for automotive applications. This SAE Recommended Practice is applicable to: bonded drum brake linings; integrally molded disc brake pads; disc brake pads and backing plate assemblies using mechanical retention systems (MRS); coupons from drum brake shoes or disc brake pad assemblies. The test and its results are also useful for short, semi-quantitative verification of the bonding and molding process.
2017-10-13
Technical Paper
2017-01-5018
Subhash Hanmant Bhosale, Manohar Goud Kalal, Ashish Kumar Sahu
Abstract In today’s cost-competitive automotive market, use of finite element simulations and optimization tools has become crucial to deliver durable and reliable products. Simulation driven design is the key to reduce number of physical prototypes, design iterations, cost and time to market. However, simulation driven design optimization tools have struggled to find global acceptance and are typically underutilized in many applications; especially in situations where the algorithms have to compete with existing know-how decision making processes. In this study, systematic multi-phase approach for optimization driven design is presented. Approach includes three optimization phases. In first phase, topology optimization is performed on concept BIW design volume to identify critical load paths. Architectural inputs from topology are used to design base CAD.
2017-10-08
Technical Paper
2017-01-2196
Giuseppe Cicalese, Fabio Berni, Stefano Fontanesi, Alessandro D'Adamo, Enrico Andreoli
Abstract High power-density Diesel engines are characterized by remarkable thermo-mechanical loads. Therefore, compared to spark ignition engines, designers are forced to increase component strength in order to avoid failures. 3D-CFD simulations represent a powerful tool for the evaluation of the engine thermal field and may be used by designers, along with FE analyses, to ensure thermo-mechanical reliability. The present work aims at providing an integrated in-cylinder/CHT methodology for the estimation of a Diesel engine thermal field. On one hand, in-cylinder simulations are fundamental to evaluate not only the integral amount of heat transfer to the combustion chamber walls, but also its point-wise distribution. To this specific aim, an improved heat transfer model based on a modified thermal wall function is adopted to estimate correctly wall heat fluxes due to combustion.
2017-10-08
Technical Paper
2017-01-2455
Vikram Chopra
Abstract This paper reports on the design of a synchronizer brake based on permanent magnets, capable of braking with an active zero-slip load. Eddy-current brakes are widely used in automation and transportation applications; however, their use is limited by the rotor speed. For low-speed and high-torque applications, designs based on permanent magnets are better suited. Zero-slip braking torque is increased by the use of permanent magnets but, consequently, so is the cogging torque. At first, the synchronizer brake was designed with 16 surface magnets on the rotor. However, in order to reduce the permanent magnet mass, the rotor was re-designed with half the number of surface magnets. This novel design helped lower cogging torque and fabrication costs. Simulation of the design, using the 3D transient with motion solver in commercial finite element software, showed promising results.
2017-09-19
Technical Paper
2017-01-2021
Numair Mazgaonkar, Andrew Stankovich
Abstract For large aerospace assemblies in finite element (FE) analysis problems, contact interaction between the surrounding bodies has to be established to simulate the load transferred between the components, like aircraft engine carrying bracket assemblies, spigots assemblies etc., and understand the effects of interaction between respective parts. In some cases, depending upon geometry of the assembly, the region of study may not be contact area but the stresses acting within the parts themselves. If there is no geometric or material non-linearity in such problems, a new contact formulation method known as Fast Contact can be used in these contact regions. In this method, contact non-linearity could be introduced to simulate the problem but friction between the contacting parts should not be present. Currently, there is a scope for applying this method for solving FE problems in the aerospace and rail industry.
2017-09-19
Technical Paper
2017-01-2052
K Friedman, G Mattos, K Bui, J Hutchinson, A Jafri, J Paver PhD
Abstract Aircraft seating systems are evaluated utilizing a variety of impact conditions and selected injury measures. Injury measures like the Head Injury Criterion (HIC) are evaluated under standardized conditions using anthropomorphic dummies such as those outlined in 14 CFR part 25. An example test involves decelerating one or more rows of seats and allowing a lap-belted dummy to impact components in front of it, which typically include the seatback and its integrated features. Examples of head contact surfaces include video monitors, a wide range of seat back materials, and airbags. The HIC, and other injury measures such as Nij, can be calculated during such impacts. A minimum test pulse, with minimum allowable acceleration vs time boundaries, is defined as part of the regulations for a frontal impact. In this study the effects of variations in decelerations that meet the requirements are considered.
2017-09-17
Technical Paper
2017-01-2490
Qianjin Yang, Baozhi Zhang, Kangrong Ding, Liqiang Song
Abstract A brake disc is one of the most critical components in modern vehicle’s brake systems; hence, thorough validation of its performances in the development process by simulations, rig and vehicle tests is essential. In this paper, a disc brake system under a constant braking torque is analyzed using finite element method, and the stress and strain in a rotating ventilated brake disc employed are studied comprehensively. From detailed examination of the stress distribution and the cyclic stress history, it is found that the maximum stress in the rotating brake disc under the constant mechanical loading only occurs at some specified locations; and the stress history is multiaxial and non-proportional. These findings will help, as guidelines, to develop suitable evaluation tools for the strength and the fatigue of the brake discs; to setup proper laboratory test procedures and equipment; and to design strong and durable brake discs.
2017-09-17
Technical Paper
2017-01-2489
Christian Ball, Li Lee, Weicherng Wang
Abstract The standard method for using FEA to predict and eliminate brake squeal has been to use complex eigenvalue analysis (CEA). Energy flow analysis has been adapted for use with FEA for brake squeal as an alternate mechanism for squeal prediction. This paper demonstrates an implementation of energy flow analysis with commercially available FEA software. The approach leverages the ability of commercial FEA solvers to obtain a quasi-static, pre-loaded brake model, as well as their eigenvalue extraction algorithms to create a modal space for energy flow calculations. The modal spaces as well as the pre-loaded stiffness matrix are then utilized to calculate energy flow values between nearby system modes. Three case studies are presented that compare the results of CEA and energy flow to different systems and countermeasures adopted to reduce noise occurrence in physical testing.
2017-09-17
Technical Paper
2017-01-2492
Dejian Meng, Ziyi Wang, Lijun Zhang, Zhuoping Yu
Abstract In this paper, the initial disc thickness variation (DTV) of a ventilated disc in automotive brake system is modeled as sinusoidal function of the second order. The transient thermomechanical coupling properties of the brake system is simulated using finite element (FE) modeling. The system models and results were verified by a thermomechanical coupling test of a disc brake conducted on a brake dynamometer. By using varied evaluation indexes such as the temperature distribution, the normal stress and the elastic deformation of disc surfaces, the influences of the initial DTV and its direction as well as its amplitude on the thermomechanical coupling characteristics were analyzed.
2017-07-10
Technical Paper
2017-28-1949
Johnson Jose, Ramesh M, G Venkatesan, M Khader Basha
Abstract Unmanned Aerial Vehicles (UAV) are being deployed in military, law enforcement, search & rescue, scientific research, environmental & climate studies, reconnaissance and other commercial and non-commercial applications on a large scale. A design and development of landing gear system has been taken up for a UAV. This paper presents the design optimization of structural components of Wheel-Brake & Fork assembly pertaining to the Main Landing Gear (MLG) for a UAV. The wheel, fork, axle and brake unit constitute the wheel assembly. The wheel-brake assembly is assembled with the strut assembly and forms the Landing gear system. The Fork is the connecting member between the shock strut and the axle containing the wheel-brake assembly. As the fork and axle are subjected to shock loads while landing, the strength of these components are very much essential to withstand the dynamic loads.
2017-06-29
Journal Article
2017-01-9453
Tobias Hoernig
Abstract Within the scope of today’s product development in automotive engineering, the aim is to produce lighter and solid parts with higher capabilities. On the one hand lightweight materials such as aluminum or magnesium are used, but on the other hand, increased stresses on these components cause higher bolt forces in joining technology. Therefore screws with very high strength rise in importance. At the same time, users need reliable and effective design methods to develop new products at reasonable cost in short time. The bolted joints require a special structural design of the thread engagement in low-strength components. Hence an extension of existing dimensioning of the thread engagement for modern requirements is necessary. In the context of this contribution, this will be addressed in two ways: on one hand extreme situations (low strength nut components and high-strength fasteners) are considered.
2017-06-28
Journal Article
2017-01-9181
Zhongming Xu, Nengfa Tao, Minglei Du, Tao Liang, Xiaojun Xia
Abstract A coupled magnetic-thermal model is established to study the reason for the damage of the starter motor, which belongs to the idling start-stop system of a city bus. A finite element model of the real starter motor is built, and the internal magnetic flux density nephogram and magnetic line distribution chart of the motor are attained by simulation. Then a model in module Transient Thermal of ANSYS is established to calculate the stator and rotor loss, the winding loss and the mechanical loss. Three kinds of losses are coupled to the thermal field as heat sources in two different conditions. The thermal field and the components’ temperature distribution in the starting process are obtained, which are finally compared with the already-burned motor of the city bus in reality to predict the damage. The analysis method proposed is verified to be accurate and reliable through comparing the actual structure with the simulation results.
2017-06-26
White Paper
WP-0001
NASA has embarked on an ambitious program to integrate additive manufacturing techniques and to develop processes for the microgravity environment. The most recent example of this program is the successful launch and deployment of the first 3D printer on the International Space Station. In this one-year effort, students were required to meet a series of milestones to design, manufacture, and test their ideas in close cooperation with members of the NASA Exploration Augmentation Module (EAM) concept team.The participants in this project were tasked with thinking of new solutions using AM that would simultaneously be recyclable with minimal loss in mechanical properties but also have the capacity for high mechanical properties. Working in interdisciplinary teams, the participant teams investigated the use of recycled materials, characterization, testing, modeling, and tool development.
2017-06-05
Technical Paper
2017-01-1850
Samaneh Arabi, Glen Steyer, Zhaohui Sun, Jeffrey Nyquist
Abstract The Environmental Protection Agency (EPA) requirement for 54.5mpg by 2025 to reduce greenhouse gases has pushed the industry to look for alternative fuels to run vehicles. Electricity is of those green energies that can help auto industry to achieve those strict requirements. However, the electric or hybrid-electric vehicles brought new challenges into science and engineering world including the Noise and Vibration issues which are usually tied up with both airborne and structural noises. The electromagnetic force plays a significant role in acoustic noise radiation in the electric motor which is an air-gap radial Maxwell force. This paper describes an innovative approach to model the physics of noise radiated by the electric motor.
2017-06-05
Technical Paper
2017-01-1840
Thierry Bourdon, Rainer Weber, Johann Massinger
Abstract Virtual NVH Engineering is going to be reviewed in this paper for the development of FIE (fuel injection equipment) components. Some examples based on high pressure pumps and SCR air cooling injectors will illustrate the explanation. The use of a 3D FEM vibro-acoustic model is essential to support virtual NVH Engineering. Therefore, a review of techniques to study components is done first. Model correlation is also an important topic which will be discussed and which makes any NVH engineer confident in using a model instead of real HW. It is quite challenging to establish these models, as they must mimic the entire physical phenomenon of real structure borne hardware sound in the whole audible frequency range. Limitations of models are also identified and allow answering one true question: Should we stay considering only each component separately or as an assembly of parts of a larger system in the development process?
2017-06-05
Technical Paper
2017-01-1751
Nicolas Schaefer, Bart Bergen, Tomas Keppens, Wim Desmet
Abstract The continuous pursuit for lighter, more affordable and more silent cars, has pushed OEMs into optimizing the design of car components. The different panels surrounding the car interior cavity such as firewall, door or floor panels are of key importance to the NV performance. The design of the sound packages for high-frequency airborne input is well established. However, the design for the mid-frequency range is more difficult, because of the complex inputs involved, the lack of representative performance metrics and its high computational cost. In order to make early decisions for package design, performance maps based on the different design parameters are desired for mid-frequencies. This paper presents a framework to retrieve the response surface, from a numerical design space of finite-element frequency sweeps. This response surface describes the performance of a sound package against the different design variables.
2017-06-05
Technical Paper
2017-01-1865
Peter Van der Linden, Frank Daenen, Masashi Komada, Hideto Ogawa
Abstract The tendency for car engines to reduce the cylinder number and increase the specific torque at low rpm has led to significantly higher levels of low frequency pulsation from the exhaust tailpipe. This is a challenge for exhaust system design, and equally for body design and vehicle integration. The low frequency panel noise contributions were identified using pressure transmissibility and operational sound pressure on the exterior. For this the body was divided into patches. For all patches the pressure transmissibility across the body panels into the interior was measured as well as the sound field over the entire surface of the vehicle body. The panel contributions, the pressure distribution and transmissibility distribution information were combined with acoustic modal analysis in the cabin, providing a better understanding of the airborne transfer.
2017-06-05
Technical Paper
2017-01-1901
Christian Glandier, Stefanie Grollius
Abstract This paper presents the application to full vehicle finite element simulation of a steady state rolling tire/wheel/cavity finite element model developed in previous work and validated at the subsystem level. Its originality consists in presenting validation results not only for a wheel on a test bench, but for a full vehicle on the road. The excitation is based on measured road data. Two methods are considered: enforced displacement on the patch centerline and enforced displacement on a 2D patch mesh. Finally the importance of taking the rotation of the tire into account is highlighted. Numerical results and test track measurements are compared in the 20-300 Hz frequency range showing good agreement for wheel hub vibration as well as for acoustic pressure at the occupant’s ears.
2017-06-05
Technical Paper
2017-01-1804
Chulwoo Jung, Hyeon Seok Kim, Hyuckjin Oh, Kwang Hyeon Hwang, Hun Park
Abstract An efficient method to determine optimal bushing stiffness for improving noise and vibration of passenger cars is developed. In general, a passenger vehicle includes various bushings to connect body and chassis systems. These bushings control forces transferred between the systems. Noise and vibration of a vehicle are mainly caused by the forces from powertrain (engine and transmission) and road excitation. If bushings transfer less force to the body, levels of noise and vibration will be decreased. In order to manage the forces, bushing stiffness plays an important role. Therefore, it is required to properly design bushing stiffness when developing passenger vehicles. In the development process of a vehicle, bushing stiffness is decided in the early stage (before the test of an actual vehicle) and it is not validated until the test is performed.
2017-06-05
Technical Paper
2017-01-1818
Ramya Teja, T. R. Milind, Rodney C. Glover, Sunil Sonawane
Abstract Helical gears are commonly used instead of spur gears due to their potential higher load carrying capacity, efficiency and lower noise. Transmission Error (TE) is defined as deviation from perfect motion transfer by a gear pair. TE is dominant source of gear whine noise and hence gears pairs are generally analyzed and designed for low TE. In the process of designing helical gears for lower TE, the shuttling moment can become a significant excitation source. Shuttling moment is caused due to shifting of the centroid of tooth normal force back and forth across the lead. The amount of shuttling force or moment is produced by combination of design parameters, misalignment and manufacturing errors. Limited details are available on this excitation and its effect on overall noise radiated from gear box or transmission at its gear mesh frequency and harmonics.
2017-06-05
Technical Paper
2017-01-1839
Edward T. Lee
Abstract It is common for automotive manufacturers and off-highway machinery manufacturers to gain insight into the system’s structural dynamics by evaluating the system inertance functions near the mount locations. The acoustic response of the operator’s ears is a function of the vibro-acoustic characteristics of the system structural dynamics interacting with the cavity, with the actual load applied at the mount locations. The overall vibro-acoustic characteristics can be influenced by a change in local stiffness. To analyze the response of a system, it is necessary to go beyond analyzing its transfer functions. The actual load needs to be understood and applied to the transfer function set. Finite element (FE) based analysis provides a good foundation for deterministic solutions. However the finite element method decreases in accuracy as frequency increases.
2017-06-05
Technical Paper
2017-01-1851
Taewook Yoo, Ronald W. Gerdes, Seungkyu Lee, Daniel Stanley, Thomas Herdtle, Georg Eichhorn
Abstract Several methods for evaluating damping material performance are commonly used, such as Oberst beam test, power injection method and the long bar test. Among these test methods, the Oberst beam test method has been widely used in the automotive industry and elsewhere as a standard method, allowing for slight bar dimension differences. However, questions have arisen as to whether Oberst test results reflect real applications. Therefore, the long bar test method has been introduced and used in the aerospace industry for some time. In addition to the larger size bar in the long bar test, there are a few differences between Oberst (cantilever) and long bar test (center-driven) methods. In this paper, the differences between Oberst and long bar test methods were explored both experimentally and numerically using finite element analysis plus an analytical method. Furthermore, guidelines for a long bar test method are provided.
2017-06-05
Technical Paper
2017-01-1843
Taejin Shin, Jaemin Jin, Sang Kwon Lee, Insoo Jung
Abstract This paper presents the influence of radiated noise from engine surface according to assembly condition between the engine block and oil pan. At the first, the force exciting the main bearing of cylinder block is calculated by using a multi-body dynamics model of the engine crankshaft. Secondly, the modal analysis is processed to obtain the mode contribution and modal participation factors for the FEM of a virtual cylinder block. Thirdly, the radiated noise from a structure is calculated by acoustic-FEM analysis. This structure is assembled by the virtual oil pan with a rigid connection method and a soft connection method. The sandwich panel connection model is used for the soft connection method. The sound radiated from this assemble structure is calculated according to two different connection properties respectively. The sound matrices for two results are compared using an objective method.
2017-06-05
Technical Paper
2017-01-1847
Asif Basha Shaik Mohammad, Ravindran Vijayakumar, Nageshwar rao.P
Abstract Tractor operators prefer to drive more comfortable tractors in the recent years. The high noise and vibration levels, to which drivers of agricultural tractor are often exposed for long periods of time, have a significant part in the driver’s fatigue and may lead to substantial hearing impairment and health problems. Therefore, it is essential for an optimal cabin design to have time and cost effective analysis tools for the assessment of the noise and vibration characteristics of various design alternatives at both the early design stages and the prototype testing phase. Airborne excitation and Structure Borne excitation are two types of dynamic cabin excitations mainly cause the interior noise in a driver’s cabin. Structure-borne excitation is studied in this paper and it consists of dynamic forces, which are directly transmitted to the cabin through the cabin suspension. These transmitted forces introduce cabin vibrations, which in turn generate interior noise.
2017-06-05
Technical Paper
2017-01-1849
Laurent Gagliardini, Romain Leneveu, Aurélien Cloix, Alexandre Durr
Abstract The door response to audio excitation contributes to the overall performance of the audio system on several items. First, acting as a cabinet, it influences the loudspeaker response. Second, due to the door trim inner panel radiation, the radiated power is disturbed. A third effect is the regular occurrence of squeak and rattle, that will not be considered at this stage. Design issues regarding these attributes are numerous, from the loudspeaker design to door structure and trim definition. Modeling then appears as an unavoidable tool to handle the acoustic response of the loudspeaker in its actual surrounding.
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