design robustness & process capability by simufact & · pdf filedesign robustness...

Schaeffler Group Automotive

Simufact 12th Round Table Conference Bamberg, Germany

Design Robustness & Process CapabilityBy

Simufact & 6 SigmaDr. Kunding Wang/Principal FEA Analyst

Luk USA LLCWooster, Ohio, USA

September 28, 2010 12th Simufact Round Table Conference

Product Range Automotive

Variablevalve timing

Finger follower with hydr. pivot element

Hydraulic tappet

Drawn needle bearing

Overrunningalternator pulley

Timing chain drive

Strut bearing

Shifting system

• Engine and Trans-mission Components

Clutch release system CVT componentsDual mass

flywheel

SAC

• Components for Clutch and transmission systems

Torque converterSensor-wheel bering

Tapered roller brg.Tandem angular

contact ball bearing

Deep grooved ball bearing

• Wheel- Modules• Transmission brg. Dual clutch system

dry/wet

Balance shaftwith reduced mass

Toothed chain fortiming drives

Ball screw drive


1. Simufact as simulation tool for

• Manufacturing process.

• Performance evaluation.

• Durability life assessment.

• Robustness and capability prediction.

2. Summary.

3. Q & A.

Outline


Automotive Torque Converter


Integrated Product Development


Started Simufact.forming

Added Simufact.forming GP

Forming

+ Riveting

+ Tooling

+ Welding

+ Heat Treatment

Rapid Process Optimization Demand Growth


Total Simulations

Heat Treatment

Welding

Riveting

Tooling

FormingTypes

Process Simulations

Simufact.forming

Simufact.forming

Simufact.forming

Simufact.forming

Simufact.formingSoftwares

CAE Specialists

Tool Designers

Users

CAE Specialists

Users

Non-Simufact

Non-Simufact

Non-SimufactSoftwares

Product robustness prediction

Product durability assessment

Product function evaluation

TypesPerformance Simulations

Simulation Classification

• Take the model, and use it for further process optimization. • Take the solution (t16), and use it for performance

simulations

CAE Specialists

Simufact

Simufact

Simufact


Objective:• Stamp flange from coil steel instead of machined forging.

Benefits:• Reduce overall cost • More value added in-house

Simufact Flange Forming Optimization


Objective:• Stamp stator instead of die cast aluminum

Benefits:• Cost reduction potential• Performance improvement potential

Simufact Stamp Stator Optimization


Objective:• Design and process optimization

Benefits:• Reduce develop time • Reduce prototypes• Reduce developmental tests• Drive inventive design and process

Simufact Blind Riveting Simulation

Piston

Cover

Riveting Die

Punch

Rivet


Objective:• Eliminate quenching cracks• Avoid excessive quenching distortion

Benefits:• Reduced scraps

Simufact optimized process to eliminate quenching cracks

Quenching crack

Simufact optimized process reduced quenching distortion

Simufact Quenching Process Optimization


Forming Simulation

Overbend stress analysis

Pressure cycling stress analysis

Goodman Analysis

S-N Curve

sfFo

rmin

gGP

σ ε Geo

σ ε

σ ε

Δσ

Cycles

Ove

rben

d Fo

rce

Simufact Durability Life Assessment Methodology

Overbend Piston


Overbend by forming

Pressure Cycling

Permanent Set

Forming

Overbend Pressure cycling

Durability Assessment

Overbend Piston Durability Assessment


Quenching - Forming

Tempering

Shot peening

Testing

Sim

ufac

tDiaphragm Spring Performance Evaluation


F

x

2nd Stroke

Testing

1st Stroke

Simufact Performance Evaluation


Multiple patents

Original Design

Simufact Drives Inventive Process Design

No damage

Some damages


Front coverHub

Back plateDrive ring

ωPDynamic

Bolted to the dyno thru. the flex plate

Simufact MIG Weld Joint Durability Assessment


Functions:

• Join the piston and the drive ring

• Transmitting torque

Requirements:

• Durable pressure cycling• Avoid automatic transmission fluid leakage

TCC Piston plate rivet joint design


1. Concurrent Simulation

4. Pre-Screening Feasible Solutions 3. Robustness & Capability

2. FEA DOE Optimization

Apply Pressure

Simufact 6σ Rivet Joint Robustness


Piston plate Carbon steel HR

Friction paper

Rigid punch

Rigid stripper

Case Hardened Strain limit: < 2%

Rivet Carbon steel

Simufact Rivet Joint Modeling


Control OutputCritical Factors

6 σ Rivet Joint DOE Table


Rivet Joint Robustness & Process Capability


> Requirement20%25%3FEA DOE80%75%9Avoidance

12Prototypes

Ø RequirementDesign RobustnessBudget %Lead Time %

100%100%DOE

Pre-

scre

en F

easi

ble

Solu

tions

Benefits

Benefits


1. Simufact based performance simulation is successfully developed.2. Process simulation is integrated with product development.3. Sophisticated technology is used by tool designer.4. Simufact simulation biomes a strategic tool in product development.5. Simufact based process and performance simulations.q improves accuracy, efficiency, and confidence.q reduces developmental tests.q shortens development cycles.q reduces production cost.q increases knowledge retention.q drives inventive design and process.

• multiple patents• trade secrets

Summary

design robustness & process capability by simufact & · pdf filedesign robustness...

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