Reducing Body Development Time by Integrating NVH and Durability Analysis from the Start 2006-01-1228
Due to the trend to build more vehicle models on a common platform, body development is very often on the critical path in the automotive development process. While the virtual assessment of attributes like crash, structural rigidity or production feasibility is common practice today, it is done less systematically for NVH and durability. They are traditionally only considered close to the availability of prototypes. Performance issues discovered at this stage will lead to additional design cycles which conflicts with the need to further shorten the total development time.
The process proposed in this paper results in a better initial design by doing more NVH analysis in the pre-CAD phase and a reduced number of iteration cycles required for NVH and durability engineering by iterating much faster to the final design.
Mesh morphing and beam concept analysis make it possible to evaluate and optimize functional performance characteristics based upon predecessor FE models. The “hybrid road noise” and “hybrid road” concept deliver representative body loads for NVH and durability analysis before any testing on physical prototypes can be done.
A dedicated section will focus on smart approaches to speed up the optimization without compromising the accuracy of these models. “Wave-based substructuring” is a very promising technique that makes it possible to combine detailed FE models of body panels that need to be redesigned with reduced FE models of invariant panels. For the durability assessment of spot and seam welds, a two-step approach is presented that combines computation speed with accuracy. All these accelerated simulation approaches open new perspectives about variability analysis and design for six-sigma.
Finally some practical approaches about multi-attribute optimization are explained.