suspension and chassis loads using - altair university and chassis loads using michael white ......
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Suspension and Chassis Loadsusing
Michael White
Product Manager-Durability Director
Presenter:
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 2
Agenda
� Loads Extraction Using Hyperworks
� Introduction
� Loading Methodology
� Building & Running Multibody Models
� Post Processing and Checking the Loads
� Applying Loads to a Finite Element Model
� Summary
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 3
Loads Extraction Using Hyperworks
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 4
Agenda
� Loads Extraction Using Hyperworks
� Introduction
� Loading Methodology
� Building & Running Multibody Models
� Post Processing and Checking the Loads
� Applying Loads to a Finite Element Model
� Summary
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 5
Introduction To Vehicle Loads
-Exact Loads are not known in the design phase
-Past History Can be used to estimate New loads
-You need to verify the loads using some method:-Load measurement using transducers (best)-Strain measurements-Inspection after shakedown and during events (worst)
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Introduction To Vehicle Loads
Concept of “G” loading
-Choose a load condition to design to (“Design load”)-Vehicle sitting on the ground at design load is at 1 “G”-Load on a vehicle is proportional to the vehicle weight
*ignores tire and use case effects
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 7
Agenda
� Loads Extraction Using Hyperworks
� Introduction
� Loading Methodology
� Building & Running Multibody Models
� Post Processing and Checking the Loads
� Applying Loads to a Finite Element Model
� Summary
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 8
Introduction To Vehicle Loads
“G” Load Application
-Calculate Loads in all directions using the “G” concepti.e.-1 G Vertical Load-2 G Vertical Load-3 G Vertical Load-1 G Braking-1 G Lateral-2 G Vertical plus 1 G braking
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Introduction To Vehicle Loads
“G” Load Application
-What Loads should I use?
*1 G Vertical-sanity check of models and hardware•Vertical load to simulate typical fatigue type events•High Vertical load to simulate large vertical events•Lateral Load to simulate cornering (both directions!)•Braking load-forward braking -include weight transfer if it is significant•Braking load-reverse braking•Twist Load- 2 G one side, Zero G other•Miscellaneous Loads significant to your application
•Towing•Jacking•Racing
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Introduction To Vehicle Loads
“G” Load Application
-For each load also assign a stress criteria
Suggestion:-Fatigue loads- 50% of ultimate stress maximum-1-10 time occurrence loads - yield stress-Use a factor of safety based on experience with the vehicle, the manufacturing processes, and vehicle useage.
-Confirm the loads when you have a vehicle
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Introduction To Vehicle Loads
1 G Load CalculationFront Design Weight= 350 lbsRear Design Weight= 400 lbsDesign=car + driver + instrumentation + full fuel
175 lbs
200 lbs
200 lbs
175 lbs
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Introduction To Vehicle Loads
2 G Load CalculationFront Design Weight= 350 lbsRear Design Weight= 400 lbsDesign=car + driver + instrumentation + full fuel
2*350=700 lbs front weight700/2=350 lbs/wheel
2*400=800 lbs rear weight800/2=400 lbs/wheel
350 lbs
400 lbs
400 lbs
350 lbs
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Introduction To Vehicle Loads
1 G Vertical + 1 G Lateral Load CalculationFront Design Weight= 350 lbsRear Design Weight= 400 lbsDesign=car + driver + instrumentation + full fuel
*Note that the loadcase ignores weight transfer and the front/rear roll couple distribution
175 lbs
200 lbs
200 lbs
175 lbs
175 lbs
175 lbs
200 lbs
200 lbs
350lbs frt/2 = 175 lbs/wheel
400 lbs rear/2 = 200 lbs/wheel
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Introduction To Vehicle Loads
1 G Vertical + 1 G Braking Load CalculationFront Design Weight= 350 lbsRear Design Weight= 400 lbsDesign=car + driver + instrumentation + full fuel
*Note that the loadcase ignores fore-aft weight transfer
175 lbs
200 lbs
200 lbs
175 lbs
175 lbs
175 lbs
200 lbs
200 lbs
350lbs frt/2 = 175 lbs/wheel400 lbs rear/2 = 200 lbs/wheel
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 15
Agenda
� Loads Extraction Using Hyperworks
� Introduction
� Loading Methodology
� Building & Running Multibody Models
� Post Processing and Checking the Loads
� Applying Loads to a Finite Element Model
� Summary
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 16
Building & Running Multibody Models
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Building & Running Multibody Models
Load Calculation Methods
-Hand Calcs (2d or 3d Free Body Diagram)
-Excel Spreadsheets
-Complete Suspension Exerciser Models
-Full Dynamic Models
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Building & Running Multibody Models
MotionView - Preprocessor for building suspension models
MotionSolve -complete dynamic solver for MBD solutions
Hyperview -Postprocessor for most CAE results
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Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 20
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 21
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 22
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 23
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 24
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 25
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 26
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 27
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 28
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 29
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 30
Building & Running Multibody Models
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 31
Agenda
� Loads Extraction Using Hyperworks
� Introduction
� Loading Methodology
� Building & Running Multibody Models
� Post Processing and Checking the Loads
� Applying Loads to a Finite Element Model
� Summary
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 32
Post Processing and Checking the Loads
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 33
Post Processing and Checking the Loads
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 34
Post Processing and Checking the Loads
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 35
Post Processing and Checking the Loads
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 36
Post Processing and Checking the Loads
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 37
Post Processing and Checking the Loads
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 38
Post Processing and Checking the Loads
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 39
Post Processing and Checking the Loads
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 40
Post Processing and Checking the Loads
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 41
Agenda
� Loads Extraction Using Hyperworks
� Introduction
� Loading Methodology
� Building & Running Multibody Models
� Post Processing and Checking the Loads
� Applying Loads to a Finite Element Model
� Summary
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 42
Applying Loads to a Finite Element Model
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Applying Loads to a Finite Element Model
Copyright © 2009 Altair ProductDesign, Inc. All rights reserved. 44
Applying Loads to a Finite Element Model
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Summary
Questions?