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Copyright © 2008 Altair Engineering, Inc. All rights reserved. Altair Proprietary and Confidential Information
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Country spirit Packed Sea Food
IFB AGRO
Fine Blanking
Tools Fine Blanking
Components
IFB INDUSTRIES
About IFB
IFB HOME APPLIANCES
Washing machine Refrigerator Dryer
Air conditions Micro-wave Dish washer
IFB AUTOMOTIVE
Seating Systems Door Systems
Latches Motors
Overall Turnover in Crore: Rs.3000 Crores
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Impact Load Testing
Vibration cum Environmental Chamber
Slider Endurance Testing
Seat Belt Anchorage Testing
Dynamic Crash Test
Recliner Operational Durability Testing
Recliner Twisted Hinge Arm Testing
Rising Load Test Machine
Recliner Moment Durability Test
Recliner Static Strength Testing
TEST FACILTIES AT IFB AUTOMOTIVE
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Window Regulator Endurance Testing
Door Slam Testing
Dust Spray Testing
Thermal Shock Testing
Endurance Test Machine – Door Latch
IFB AUTOMOTIVE TEST FACILTIES
Investment in Test Lab: 25 Crores
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IFB Test Facilities at IFB Goa(1)
Mechanical Testing Lab
Environmental Test Rooms Safety Test Lab EMI/EMC testing Lab
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IFB Test Facilities at IFB Goa(2)
Vibration Shaker Test Bevel Hitting
Side Clamping test Drop test Compressive Resist test
Semi Anechoic Chamber
Investment in Test Lab (Only Applinace): ~ Rs.20 Crores
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1. To predict the “Air Flow Rate” of Automotive Radiator Axial Flow
Fan through flow simulation.
2. The results are to be correlated with physical test results by
targeting the correlation level >90%.
Objective
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Product Description
Fan Motor Shroud Assembly (FMSA)
FAN SHROUD
1. Fan Motor Shroud Assembly (FMSA) consists of electrically
driven Fan Motor, Shroud, Blade, Resistor and Wiring Harness.
2. Purpose of the FMSA is to provide adequate airflow across the
Heat Exchanger.
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Test Specifications For Radiator FMSA
• For Performance the Automotive Radiator FMSA has to undergo
following test: • Static strength test
• Flow rate test
• Drop Test
• Vibration test
• Noise test
• Random Vibration test
• Inhibit Abuse Test for Key and Lock-Unlock Knob
• Fitment check
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Governing Equations
• Conservation of mass:
• Conservation of momentum:
• Eddy viscosity based turbulence models compute the eddy
viscosity field from solution of additional transport equations for
turbulent scalars.
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Computational Mesh for Fan and Shroud Assembly
Finite Element Mesh Model
Mesh: Unstructured Grid (Tetrahedral Volume Cells)
Number of Elements: ~5 million
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Fan
MRF ZONE
Wall : U-normal = zero,
(No slip) U-tangential = U-wall
MRF Zone : Moving Reference Frame
Outflow : Atmospheric pressure
Inflow : Static Pressure inlet
Boundary Conditions
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Velocity vector flow at cross section of test rig.
Streamlines plot
Flow Pattern for Axial Fan
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Flow-Out
Physical Test Setup of IFB
Flow-In
Pressure Sensor
FMSA
Experimental Setup
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Turbulence Model: Spalart-Allmaras (RANS model)
Correlation Study
Comparison between computational technique and
physical test (Normalized Data)
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The correlation between the computed data and measured data
has been done and results obtained are found to be close.
Reduced the experimental cost and time.
Conclusions
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IFB CAE Capabilities
FE Simulation
1. Linear Static, Quasi-Static &
Non-linear Static Analysis
2. Crashworthiness & Safety
3. Sequential Drop Analysis
4. Fatigue & Fracture Analysis
5. Buckling Analysis
Manufacturing Simulation
1. Mold Flow Analysis (Plastic)
2. Sheet Metal Stamping & Spring-
back Simulation
3. Fine Blanking Tool Simulation
CFD Simulation
1. Fluid Flow Simulation
2. Multiphase Flow Simulation
3. Thermal Analysis
4. Rotating (Domain)
Simulation
Optimization
1. Topology (Space &
Size)
2. Topography (Geometry)
3. Geometry & Size
MBD Simulation (Rigid &
Flexible)
1. Kinematic Simulation
2. Dynamic Simulation
NVH Simulation
1. Vibration Analysis (All Types)
2. Noise Analysis (All Types)
3. Harshness Analysis
CAE
CAPABILITIES
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Fine Blank & Conventional Blank
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Optimization of Design
Sl. No.
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10 Benchmarking
Optimization
Size reduction using software (FormingSuite, etc.)
Shape (Geometry) Change - if possible
Part Commonization
Part Count Reduction
Weight Reduction
Yield Improvement
IFB Automotive Pvt. Ltd
Option - 1 : Topology Optimization: Generates an optimized material
distribution for a set of loads and constraints within a given design space / size.
Option - 2 : Topography Optimization: Generates an optimized distribution of
shape based reinforcements.
Option - 3 : Shape & Size Optimization: General size and shape optimization
problems can be solved. Variables can be assigned to properties, which control
the thickness, area, moments of inertia, stiffness, and non-structural mass of
elements in the model.
Description
Alternative Raw Material
Change of Tolerance in RM Thickness - if possible
Reduction in Thickness of the Part
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IFB Automotive Private Limited Contact Information:
Mr. M.H.REDDY
Phone:+91 80 398423701
: +919343769874
E-mail: [email protected]
Mr. M.RAMALINGAM
Phone :+ 91 80 39842376
: +919343769920
E-mail: [email protected]