seoul intercontinental coex hotel rdoctober 23 , 2015event-regist.com/3ds/2015/track3_multi-body...

2015 SIMULIA Regional User Meeting Korea Seoul Intercontinental COEX Hotel

October 23rd , 2015

Simulation powers Innovation

tial I

15 Multi-Body Simulation

Simpack Introduction

Qiqi Jiang

MBS business development, SIMULIA AP

MBS Overview

Use case 1: Driveline NVH Investigations at Mercedes Benz

Use case 2: 3D MBS gearbox NVH analysis

Seamless Simpack co-simulation workflow with SIMULIA products

Simpack Highlights and Conclusions

Agenda

Simpack applications in Real Time

DS Acquired SIMPACK in July 2014

MBS vs FEA Higher abstraction level enables MBS to be faster than FEA

Hydrodynamic bearing

Gear contact

Valve train components Chain guides

E.g. linear, nonlinear or frequency dependent bushing

Rigid or modally reduced flexible bodies

Special contact elements e.g. Gear Pair, Rail Wheel

Special bearing elements, e.g. Rolling Bearing, Friction

Bearing (EHD)

MBS Overview

Agenda

Gas pedal tip in/tip out dynamics Gear shift comfort Run up NVH investigation

Automotive application

Purpose

Result

Driveline Investigations at Mercedes Benz

> Driveline booming vs. beating

- Optimize sound pressure due to shaft mount

Purpose

Result

> Beating of three-parted prop shaft

measurement vs. simulation

Purpose

Result

> Investigation of driveline load levels

Purpose

Result

> Investigation of sound pressure level

Purpose

Result

> Homo-kinematic condition of three parted prop shaft

Nonlinear optimization problem

Purpose

Result

> Optimized driveline layout

Purpose

Result

> Sensitivity of optimized driveline layout

Purpose

Result

> Conclusion

⇒ The sensitivity of an optimized driveline layouts is shown.

⇒ Optimized driveline layout is generated by solving the nonlinear

homo-kinematic conditions.

⇒ The excitation and chain of effects of driveline beating is

explicitly illustrated and well understood using Simpack.

MBS Overview

Agenda

Purpose

Result

Simulation Methods for NVH-Development of a

Double Clutch Transmission Gearbox

➢ Source/Reason

• Fluctuation in stiffness (transmission error)

• Macro geometry of gear (Spur bevel- and

Helix Gearwheel)

• Micro geometry (Gear teeth flank correction)

• High load/torque (Pretension)

• Bending stiffness of the shafts

• Structural behavior of housing

• Oil viscosity and temperature

➢ Source/Reason

• Impulsive hits at the gear backlash limits

• Loose gear oscillation of unloaded gearwheels

(also synchrobodies) because of gear backlash

• Torsional vibration excitation of the driven gear

• Angular acceleration amplitude is responsible

for taking off loose gear from the driven flank

of the fix gear

• Oil viscosity and temperature

Purpose

Result

> Methodology for NVH-Simulation

Simpack Pre Simpack Post

Purpose

Result

> Methodology for NVH-Simulation

Linear and nonlinear analysis method options based on the

same model

Domain

(nonlinear)

Frequency

Domain

(linear)

- Eigen frequency calculation

- Mode shape animation

- Linear system analysis

- Linear system matrix export

- Efficient nonlinear time domain integration

- Time domain result analysis and export

- Time domain and ODS animations

- All kind of coupled system dynamics simulation

General nonlinear

SIMPACK

3D MBS Model:

Purpose

Result

> Typical analysis results definitions Rotational acceleration

of rotating parts

Intersection forces /torques

between gear pairs

/shafts/housing; bearing

forces

Accelerations on

gearbox housing

comparison with

measurements on real

test rig

Purpose

Result

Rotational velocity

excitation at gearbox

Constant torque

at gearbox output Rotational velocity runup

at gearbox output

Constant torque

at gearbox input

Torque Torque

Velocity

Velocity Gear whine

Gear rattle

Purpose

Result

> Result

Purpose

Result

> Result: Applied countermeasure based on system understanding

obtained by simulation → reduce input shaft Eigen frequency

SIMPACK Simulation Test

Original

Modified Original

Modified

MBS Overview

Agenda

FEA Multiphysics

Simulation

Abaqus

Non-parametric Optimization

For Fluids and Structures

Durability &

Fatigue

fe-safe

Process Integration &

Design Optimization

Isight

SIMULIA: The Power of the Portfolio

Multi-body Simulation

Simpack SLM

Simulation Lifecycle

Management

Note: Simpack and SLM not included in Extended Packaging

Simpack and Isight

Extending the “Power of the Portfolio”

Simpack component model parameter identification using Isight

Set up communication between Simpack testrig model and Isight

Identify and optimize Simpack element parameters based on test data

reference with Isight

results with initial

element parameters

component element model

testrig optimized component within complete

system simulation

results with optimized

element parameters

Structural Optimization – Simpack, Abaqus, Tosca

Extending the “Power of the Portfolio”

Determine dynamic load with Simpack

Apply load data to component model in Abaqus

Define design space and optimization criteria in Tosca

Optimize shape in Tosca

Validate new design with Simpack dynamic load simulation

Simpack Abaqus Tosca Simpack

Co-simulation with Abaqus/Explicit,

is available now in Simpack 9.9

New feature: Co-simulation with Abaqus

MBS Overview

Agenda

SIMPACK Realtime Key Features

Use of latest off-the-shelf hardware

no expensive specialized realtime hardware needed

SIMPACK Realtime (Solver) enables to directly use existing Offline MBS models

“Offline = Online Model”

part based models without model reduction and without redundant model data

zero turnaround time after model changes

Built-in multi-core support e.g. for comfort tire models

Enables also detailed ride simulation realtime applications

Benefits Realtime SOLVER Realtime ANIMATION Realtime LOGGING

Virtual product development (VPD): Simulate physical properties of Vehicle

→ Analyze, evaluate and improve (optimize) design states

Full-Vehicle Real-Time-Simulation with an advanced

flexible Tire-Model on Fraunhofer’s Driving-Simulator

Development of driver/operator

models for detailed offline

simulations

Visualization of simulation

results: motion, visual, sound

Development of assistance

systems

Application: construction and

agriculture machines, passenger

cars, trucks

Engine, ECU, Transmission, TCU as physical hardware

Optimizing NVH performance of load change and gear shift maneuvers

Real time Use Case Daimler Truck: Handling

Simulator

simulator man-in-the-loop

vehicle sensor signals

driver input, road conditions, etc.

simulation tool

realtime

Virtual Truck

Hardware-in-the-Loop (HIL) testing

Exported SIMPACK model (> 100 DOFs)

Longitudinal accelerations up to 20 Hz

2009 High-Dynamic Engine Test Bench, Realtime

Application Examples

Driving simulator at Fraunhofer ITWM:

Application Examples

MBS Overview

Simpack Highlights and Conclutions

Agenda

Conclusion

Highlight compare with other MBS software:

Elaborated Consideration of Flexible Bodies

Huge Library of Application Specific Modeling Elements

Sophisticated Analysis Methods & Optimum Calculation Performance and Stability

Unique Real Time Solution for Detailed MBS Models

Conclusion

Further Synergy :

More Nonlinear flex. body behavior in

SIMPACK integrate with ABAQUS

Improved SIMPACK fatigue solution

based on ABAQUS and FE-Safe

Multi physics simulation solution together

with Dymola

All Relevant Links

www.SIMPACK.com

Conference and user meeting

presentations

Newsletter articles

Users, videos

SIMPACK Website

Qiqi.jiang@3ds.com

Selected references

1993 SIEMENS and Bosch start using Simpack

2007 Vestas, Winergy, Hansen and FVA choose Simpack

2011 First release of Simpack 9

2013 JLR adopts Simpack 9

1987 DLR and MAN Technology starts developing Simpack

1998 BMW, Daimler, Land Rover start using Simpack

2005 Daimler and BMW use Simpack Engine

More than 30 years MBS experience,

R&D and Engineering!

2003 Simpack Rail became worldwide market leader

2014 SIMPACK acquired by Dassault Systemes

SIMPACK History: Select Milestones 3D

tial I

Focus of MBS Multi-Body Simulation

Eigen frequencies

Nonlinear motion

Transients

Chaotic behavior

Flexible bodies

System simulation

0.50 Hz

0.32 Hz 0.76Hz 1.27Hz

0.07 Hz

advance

Focus of MBS Vibration Analysis

Analysis of non-linear system behavior

Resonance analysis

Determine maximum motion and loads

Design of experiments (DOE)

Optimization

Focus of MBS System Behavior

Coupled effects Internal and external

excitations System behavior

Focus of MBS System Behavior

Coupled effects Internal and external

excitations System behavior

Response Surface Modelling

FEA / Durability

Abaqus

fe-safe

Nastran

PERMAS

FEMFAT

CACE-Programs

FMI (model exchange and co-simulation)

Dymola, Simulink, Amesim, SimulationX

CAD-Programs

SOLIDWORKS

Pro/ENGINEER

Optimization

Isight

ModeFrontier

Matlab\

Real-Time

dSpace

Mathworks xPC

Aerodynamics

AeroDyn

AeroModule

vsAero

Flower

Focus of MBS

Simpack Highlights Solver

Fast, accurate, robust, versatile

Flexible body integration

Drivetrain applications

High frequency analysis

Almost zero numerical damping

Multi-core support

Real-time

Simpack Highlights Gear Pair element

Helical, Ring, Bevel, Rack and Pinion

Fast analytical contact

Micro geometry corrections, profile and flank

tial I

Simpack Highlights Realtime for hardware in the loop (HiL),

software in the loop (SiL), and man in the loop (MiL)

Many DOF (degrees of freedom) with higher frequency content

Direct use of high-fidelity parameterized models, i.e. no model reduction

Permits use of non-linear and frequency dependent bushings and mounts

Not restricted to predefined template models

Automatic parallelization

Model Fidelity

Look-up table

Basic component

High fidelity

component model

Low frequency model

testing

(static suspension)

Model correlation up to

high frequencies.

Virtual component

analysis and testing

Attainable

Goals DoF

seoul intercontinental coex hotel rdoctober 23 , 2015event-regist.com/3ds/2015/track3_multi-body...

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