12/5/2003

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IAR IAR FENetFENet 2003200344--5 5 DecemDecemberber 20032003

Brian CheungBrian Cheung

Virtual Product Development (VPD)

deployed on Durability

Christoph OrtmannBusiness Development Director

Virtual Product Development (VPD)

deployed on Durability

Christoph OrtmannBusiness Development Director

Agenda

§ Introductions§ VPD Overview§ VPD Durability: The Honda ATV

Story§ Question and Answer Period

Virtual Product Development

PackagingHandling Safety

Ride & Handling NVH

Durability

Durability

§ 1960’s Major warranty issue

§ Today, Design Bottleneck

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MSC Virtual Durability

MSC.NASTRAN

MSC.Fatigue

MSC.ADAMS

Reality

Test LabTestTrack

Real WorldUsage

Durability Testing

EnvironmentEnvironment Fatigue LifeFatigue LifeComponent LoadsComponent LoadsSpindle LoadsSpindle Loads

Durability Testing Replicated Virtually Case Study: John Deere

Business: Agriculture equipment manufacturer

Challenge: Shorten the durability design process

Solution: Replicate the durability testing in a virtual lab

Value: Identify critical locations before the first hardware prototype is built

“Using the new method, we have reduced the number of physical prototypes from three or four previously, down to one on our two most recent designs.

– Terry EwanochkoProduct Engineer, John Deere Welland Works

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Integrated Durability Management

PROVING GROUND

FEA

TEST RIG

FATIGUEEDITING

PROCESS & MANIPULATE

VIRTUALDURABILITY

TESTINGMBD

CORRELATION

The Design Scenario

Can an existing frame be used for avehicle with larger payload capacity?

SAE FD and E Committee

§ Collaborative group focused on researching fatigue and using fatigue tools more intelligently

§ ATV project goals§ “to evaluate the current simulation processes

as they relate to structural durability”§ “to develop new correlated software…to

measure the durability of components of proposed vehicles by means of a ‘digital prototype’ simulation”

§ All data used in this project are public domain at www.fatigue.org

Virtual Load Calculation

Virtual creation of input loads possible for discrete eventsPhysical testing necessary for service life

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ATV Durability Testing

Real World Test Track Test LabDurabilitySchedule

Integrated Durability Management

PROVING GROUND

FEA

TEST RIG

FATIGUEEDITING

PROCESS & MANIPULATE

VIRTUALDURABILITY

TESTINGMBD

CORRELATION

Field Data Collection

Shock tested to withstand up to 20GsIdeal for many industries, including automotive, agricultural, heavy construction, motorcycles, off-highway and railSignal conditioning for all sensors, including vehicle network

Onboard eDAQsallow data acquisition in extreme testing environments

Processing of Acquired Data

§ Transducers acquiring data arerotating with wheels

nCode Flowbuilder

§

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Integrated Durability Management

PROVING GROUND

FEA

TEST RIG

FATIGUEEDITING

PROCESS & MANIPULATE

VIRTUALDURABILITY

TESTINGMBD

CORRELATION

Virtual ATV

Flexible Body Export to MSC.ADAMS

MSC.NastranMSC.Patran MSC.ADAMS

Input Measured Loads

SpindleForces MSC.ADAMS

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Dynamic Simulation

ADAMS/Durability

Integrated Durability Management

PROVING GROUND

FEA

TEST RIG

FATIGUEEDITING

PROCESS & MANIPULATE

VIRTUALDURABILITY

TESTINGMBD

CORRELATION

Stress History Data Transfer

Unit Load CaseDeformations

Time Histories

§ For more than 66 channels…

The New Integrated Solution

ADAMS/Durability Export

Stress ShapesTime Histories

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Fatigue Properties

§ Material database§ Over 200 materials§ Generated properties§ Surface corrections§ Weld data

MSC.Fatigue

Durability of welds

Heat affected zone

§ Welds are typically location of failures§ Detailed analysis is impractical§ Special approaches included to handle welds

Weld Toe

Volvo/Chalmers/nCode Approach

§ Designed and validated for thin sheet automotive structures§ Based on structural stress at weld toe§ Simple shell meshing rules§ Differentiates between “flexible” and

“stiff” joints§ Uses generic “damage” curves

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Integrated Durability Management

PROVING GROUND

FEA

TEST RIG

FATIGUEEDITING

PROCESS & MANIPULATE

VIRTUALDURABILITY

TESTINGMBD

CORRELATION

Fatigue Editing

§ Shorten time histories while retaining damaging cycles§ Check for if resulting load files retain frequency and

damage content§ Multiple channels to maintain phasing across all vehicle

responses

Virtual strains for damage analysis

Input wheel forces

Lab Durability Test

§ Time based to reproduce variable amplitudes and vibratory modes§ Multiple hydraulic

actuators directly coupled to vehicle frame§ Wheel forces for rig control§ Strain gages are desired

for correlation§ High test acceleration

factor needed due to long service life and short development cycle

Integrated Durability Management

PROVING GROUND

FEA

TEST RIG

FATIGUEEDITING

PROCESS & MANIPULATE

VIRTUALDURABILITY

TESTINGMBD

CORRELATION

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Strain Gauge Correlation

Strain gauge

Virtual strain gauge

Correlation

Summary

§ Durability is a major bottleneck in today's design process.§ Durability in VPD increases efficiency of

real world testing.§ Obtain loads for all components, which

are costly to measure if possible at all.§ Streamlined process for optimal exchange

of information between the different technologies greatly shortens the design cycle and reduces cost.

IAR IAR FENetFENet 2003200344--5 5 DecemDecemberber 20032003

Thank youThank you