investigate numerical analysis of power lift gate …

Journal of Analysis and Computation (JAC) (An International Peer Reviewed Journal), www.ijaconline.com, ISSN 0973-2861

Volume - XIV, Issue VII, JULY 2020

Abhijeet S. Salunkhe, Kashinath H. Munde, Ashish R. Pawar 1

INVESTIGATE NUMERICAL ANALYSIS OF POWER LIFT GATE

SPINDLE & SOCKET ASSEMBLY WITH MODIFICATIONS

Abhijeet S. Salunkhe*1, Kashinath H. Munde #1, Ashish R. Pawar#2

*1Post Graduate Scholar, #1Associate Professor, #2Assistant Professor

Mechanical Engineering Department

ABMSP’s Anantrao Pawar College of Engineering & Research, Pune, Maharashtra, India *[email protected]

#[email protected]

ABSTRACT- The purpose of this work is to model and simulate the static and dynamic behavior of an electrically

powered lift gate, e.g., the lift gate itself and its drive system. The resulting model is going to be used for

simulation during development of the lift gate control system software. The simulation model has to be

based on physical equations and be adjustable to different lift gate dimensions and different actuators.

After adaptation to ambient conditions the model is verified and validated. The model should simulate

both static and dynamic behavior of the power lift gate system. Thereby, development of the control unit

software can be tested and evaluated without having to apply it on the real system every time or even

when no real system is available. The practical advantage with simulation is mainly that tests can be done

without endangering the hardware. The drive system itself is composed of a spindle that is driven by a

DC-motor over a gear and a spring. When developing the control system, it is convenient to use a

simulation model instead of having to implement it on the system every time. The simulation analytically

describes how the system is behaving. Ansys Workbench is used to build the simulation model.

Verification is done by comparison between physical test data and simulation results.

Keyword - Power lift gate system, Ansys Workbench, Static behavior, dynamic behavior, verification,

physical test

1. INTRODUCTION

The use of electrically-powered drivers to raise and lower automotive trunk lids, lift gates, and engine

hoods is becoming more common. The most common types of trunk lift gates use a brushed DC motor

that responds to commands from control switches in the cabin or switches on a key fob. These drivers

typically have a series of mechanical gears with a mechanical advantage to supply sufficient torque to

move the large mechanical load. This advantage increases the effective torque from the motor and

decreases the rotation speed. A mechanical arm and connected linkage convert the rotation into a force

that is used to open or close the gate.

INVESTIGATE NUMERICAL ANALYSIS OF POWER LIFT GATE SPINDLE & SOCKET ASSEMBLY

WITH MODIFICATIONS


One consideration in the design of the trunk lift is that some users prefer manual operation without

electrical drive. Manually opening or closing the lid when the unpowered motor must be back-driven is

very difficult because of the mechanical advantage of the gear train from the motor to the lifting arm. A

clutch mechanism is typically used to disconnect the motor and some of the gear train from the remaining

mechanism and the lid to make manual operation easier.

To simulate and validate the design of power lift gate socket and spindle assembly. The simulation of PLG

system consists of dynamic and static analysis of the system. In order to make the simulation of PLG

system the Ansys Workbench software is used. For the CAD modeling CATIAV5 software is used.

In the simulation process all types of the non-linearity is considered. In the material data the nonlinear

materials are used, for the contact non linearity the frictional contacts are used and geometrical non-

linearity is also considered. The simulation is performed at room temperature.

In the testing the test rig to be used for the testing. The setup and environment of testing is already

considered in testing. The assumption regarding material and frictions are also considered.

Vehicle lift gates are operated by a variety of power actuators. The most typical systems are electrically

powered with a computer control system executing driver’s command to open and close the lift gate. The

control system has to have enough power to open and close the lift gate in specified time over the range

of environmental conditions, on inclined roads and so on. It also has to be able to reverse the direction of

motion in a short time when an obstacle is found on the way. In order to develop a reliable controller, the

dynamic properties of the system have to be modeled first. The dynamic model can be used not only to

analyze dynamic properties of the system but also to conceive a model based control strategy based on an

inverse dynamics model. The dynamic model of the litigate should include all major contributors

characterizing the dynamics of the litigate: gate geometry and inertia properties, strut mass effects, power

actuator inertia, strut springs and actuator forces, and possibly spindle and DC motor parameters. It should

be possible to include in the model frictional effects at the gate hinges and strut ball joints, as well as all

frictional losses in the powered struts.

Figure 1: Drawing of lift gate model

Figure 1 shows the drawing of liftgate model. Assuming rigid bodies, the model has 1 DOF. From control

point of view, the displacement of telescope struts is the input. However, the (rigid body) system is over

actuated since both telescope struts have to move synchronously. The dynamics of complex MBS can be

numerically simulated by means of commercially available software packages. On the other hand, it is

frequently necessary to derive tailored simulation models, with minimal computational overhead. Solving

them using lean code libraries brings clear advantages. Also, most of the available computer packages do

not allow to directly simulate non-collocated cases of the inverse dynamics. The control force or moment




has to be applied directly at the degree of freedom that is prescribed to follow a desired time trajectory. In

most of the practical applications the actuator used to enforce the so-called program constraint does not

act that way, and quite often the constraint expression itself involves more than one of system generalized

coordinates and velocities.

from its aluminium accomplice. Moreover, the shot composite π joint and its aluminium accomplice

showed that the darted composite π joint shows a greater burden passing on limit with a broad weight

decline. Also, it was exhibited that any extension in the shock opening slack prompts an addition in shock

rotate, similarly as a diminishing in shock hole contact zone, and from now on, a decline in joint strength.

The liftgate is attached to the vehicle body by means of two hinges with aligned axes. To avoid redundant

CONSTRAINTS, the two hinges are modeled by one revolute joint. In a typical arrangement, two struts

support the liftgate on both sides. Although spherical joints are used on each end of the strut, in multibody

system it is prudent to treat one of them as a universal or hook joint, to prevent the axial rotation of the

strut when the friction is not applied. Each strut can be modeled as composed of two cylindrical tubes that

can only translate with respect to each other. Actuator inside of the powered strut can apply a force through

a gear transmission and a lead screw. Mechanical struts can also have preloaded screw installed inside

tubular elements. This is one of possible arrangements of the liftgate mechanism; other configurations are

possible for which the same modeling methodology can be applied.

1.1 PROBLEM STATEMENT

The new PLG spindle socket will satisfy the standards as per customer specification. Also other

requirement considered for the design like variable length, low cost. To check this new design for

optimized shape, material and safety point of view with tensile test and buckling test.

In above PLG system we are considering optimization of socket.

In socket optimization we are focusing on shape optimization and material optimization.

In current system the material for the socket is Steel (SS439).

In material optimization we are using polymer materials such which possesses good strength and mold-

ability.

Disadvantages of Steel material:

• High machining cost.

• Noise level is high in system during Close-Open operation.

• Overall weight is high.

1.2 OBJECTIVES

To check plastic strain and principle stress under tension, it should be within limit as per standards.

To optimize socket by using plastic material.

To check plastic strain and principle stress under tension, it should be within limit as per standards

(5000N).

Record force value at point of failure of component under tension.

To validate the design by physical testing.

2. METHODOLOGY

The literature review regarding the PLG spindle and socket system.

Design of PLG system and deciding boundary conditions according to application and

environmental conditions,


WITH MODIFICATIONS


Building FEA model in ANSYS workbench and deciding parameters such as materials,

temperature, loading and boundary conditions, contact behavior, meshing quality

Documentation which will include the theory of PLG system, iteration study from raw model to

final model, results discussion, experimental results and test results.

3. NUMERICAL ANALYSIS

These equation sets are the element equations. They are linear if the underlying PDE is linear, and vice

versa. Algebraic equation sets that arise in the steady state problems are solved using numerical linear

algebra methods, while ordinary differential equation sets that arise in the transient problems are solved

by numerical integration using standard techniques such as Euler's method or the Runge-Kutta method.

FEM is best understood from its practical application, known as finite element analysis (FEA). FEA has

applied in engineering is a computational tool for performing engineering analysis. It includes the use of

mesh generation techniques for dividing a complex problem into small elements, as well as the use of

software program coded with FEM algorithm. In applying FEA, the complex problem is usually a physical

system with the underlying physics such as the Euler-Bernoulli beam equation, the heat equation, or the

Navier-Stokes equations expressed in either PDE or integral equations, while the divided small elements

of the complex problem represent different areas in the physical system.

In present research for analysis ANSYS (Analysis System) software is used. Basically, its present FEM

method to solve any problem. Following are steps in detail

1. Geometry

2. Discretization (Meshing)

3. Boundary condition

4. Solve (Solution)

5. Interpretation of results

Fig. 2 CATIA model of specimen

Three-dimensional model of existing specimen was designed in Catia V5 R20 software.

Initially geometry is designed in CATIA software and analysis is performed in ANSYS software. So, in

present research both Steel and Grivory material are selected to study the effect.




Table 1- Material properties of structural steel

Table 2- Material properties of Grivory

MESH

ANSYS Meshing is a general-purpose, intelligent, automated high-performance product. It produces the

most appropriate mesh for accurate, efficient Multiphysics solutions. In ANSYS after importing geometry

in module meshing is performed also known as discretization process. In meshing whole component is

breakdown or discretized into small elements to solve finite element equation at nodes. In present

hexahedral mesh is used for analysis. A mesh well suited for a specific analysis can be generated with a

single mouse click for all parts in a model.


WITH MODIFICATIONS


Fig. 3 CAD of Spindle

Fig. 4 Meshing of Spindle

Fig. 5 Details of the meshing

Contact Status

Fig. 6 Detail of assembly




Fig. 7 Boundary condition spindle

In the contact status the frictional and bonded contacts are used. The frictional contacts are given with 0.1

COF.

Boundary Condition

In boundary condition displacement of 1mm along length is applied on ball stud. As in the image shown

below faces of ball stud in yellow shades are selected and displacement is applied at distance of 30mm as

per test specification. Here the Tenon is hold in fixed position.

After application of axial pull force on the ball stud, it will make impact on the ball socket which need to

be evaluated in these boundary conditions

Fig. 8 Applied boundary conditions

Total Deformation

In finite element method the total deformation and directional deformation are general terms irrespective

of software being used. Directional deformation may be place because the displacement of the system in

a very particular axis or user defined direction. Total deformation is that the vector sum of all directional

displacements of the systems.

Equivalent Stress (Structural Steel)

Fig. 9 Equivalent stress generated (von-Mises)


WITH MODIFICATIONS


Equivalent Von-Mises Stress=460MPa

Ultimate Strength=460MPa

Fig. 10 Force reaction

Table 3- Total reaction force

Total force reaction in specimen was 5112.1N

Simulation of socket with Grivory6H1

Geometry

Fig. 11 Geometry inserted in ANSYS Software.

Fig. 12 Details of meshing




Fig. 13 Details of applied boundary condition

Fig. 14 Equivalent plastic Strain

Plastic Strain (Tensile region) = 1%

Force at Strain Limit = 5010.8 N

Fig. 15 Principal Stress


WITH MODIFICATIONS


Max. Principal Stress=290.97MPa

Maximum principle stress shown by software in specimens was 290.97MPa

Force Reaction

Fig. 16 Force reaction

Table 4- Force reaction details

Force =5010.8 N

4. RESULT

The results are shown I below table as per the calculated values comes after in numerical analysis i.e.

ANSYS with the help of analysing the both component in Software.

Table 5- ANSYS values at different orientation

SR.

NO. MATERIAL PARAMETERS FEA RESULT

1

ST

RU

CT

UR

AL

ST

EE

L Equivalent Stress 629.29 MPa

Plastic Strain 0.0427 mm

Max. Principle Stress 458.87 Mpa

2

GR

IVO

RY

HT

V

Equivalent Stress 290.97 Mpa

Plastic Strain 0.0199 mm

Max. Principle Stress 302.74 MPa




5. CONCLUSION

In present research ball socket is applied with axial force with steel and polymer material Grivory

HTV.

It is observed from both analysis that force reaction is around 5000N.

So, as observed with polymer material (Grivory HTV) ball socket can sustain force required during

application.


WITH MODIFICATIONS


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investigate numerical analysis of power lift gate …

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