simulation simulation –– driven auto driven auto ... · steering & drive steering column...
TRANSCRIPT
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Simulation Simulation –– Driven Auto Driven Auto Component Development Component Development p pp p
@ @ KdacKdac
* 김 대업
* Korea Delphi Automotive System Corp.
Agenda
1 Kdac Overview
2 CAE Coverage (Functionality & Product)
3 Case Study (Drum Brake)
4 VPD Vision @ Kdac
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Year 1984 : Company establishedYear 2013
- 9 Manufacturing plants in 4 countries (Korea, China, Thailand, India), about 2000 employees- 5 Manufacturing plants & 2 tech center in Korea
KdacKdac OverviewOverview
KdacKdac OverviewOverview
Main products
Electric & Electronics• Alternator
Thermal• HVAC controllerAlternator
• Ignition coil• EGR valve• ECM
HVAC controller• HVAC module• Cooling fan• Radiator• Charge air cooler• Condenser• Compressor
Brake• Caliper brake• Proportioning valve• Power brake• Drum brake• Parking brake
Steering & Drive• Steering column• Power steering pump• Intermediate shaft• Steering gear• Halfshaft• Parking brake • Halfshaft• Intermediate drive shaft
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CAE Coverage CAE Coverage -- FunctionalityFunctionality
Stiffness / Strength
Durability / Fatigue
NVH
ImpactOptimization
Manufacturing
CFD
Original Design Optimized Design
CFD
Available S/W @ Available S/W @ KdacKdac
STAR-CCM+
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CAE Coverage CAE Coverage -- ProductProduct
Steering Column
Power Steering Pump
Intermediate Shaft
Steering Gear
Steering Column / Halfshaft
Steering Column(Impact & Natural Frequency)
Halfshaft
Steering gear : squeak noise (Contact pressure analysis)
Torque Variation Analysis
Brake System
CAE Coverage CAE Coverage -- ProductProduct
Parking Brake
Power Brake
Proportioning Valve
Caliper Brake
Caliper Brake
Drum Brake
Squeal Noise Analysis (Complex Eigenvalue)
Contact Pressure Distribution
BTV (Brake Torque Variation)
(Pad)
Strength Analysis of Drum Brake Back Plate
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HVAC / PTC
CAE Coverage CAE Coverage -- ProductProduct
ModelFlow Rate
(CMH)Torque(N-mm)
OASPL(dB)
7 Blades 2721 38.7 56.89 Blades 2670 37.7 57.2
Mold Flow Analysis
Modified
Original Reaction Force at Mounting of Compressor
Structural Integrity of Shroud
Powertrain / Alternator
CAE Coverage CAE Coverage -- ProductProduct
EGR : Random vibration fatigue
Original
Calculated MeasuredOriginal 99.6 96.5
Mod. Final 97.5 94.0
Final
Mod. Original
Dynamic Stiffness of Ignition coil
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Strength & Fatigue analysis
FE model Strength analysis
Case StudyCase Study
Dynamic analysis
Load history & fatigue material property
Fatigue analysis
Shipping test - Three test types : Vessel, Railcar, Haulaway - Generally haulaway test would be the severest out of three shipping condition- Wheel strap restraint shipping method creates a braking condition during haulaway test.
and parking brake is engaged
Case StudyCase Study
The intensity of the braking caused by haulaway test was bigger than general braking load.
Fatigue crack
Haulaway shipping test Haulaway shipping test results
Fatigue crack
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Model Max. Strain[%]
Haulawaytest results
Legacy A 0.86 Pass
Legacy B 0 52 Pass
Analysis results - Internal target of haulaway test was set to specific Max. plastic strain
0.73 % 4.54 %
Case StudyCase Study
Legacy B 0.52 Pass
Legacy C 0.73 Pass
Legacy D 0.72 Pass
Legacy E 0.58 Pass
Legacy F 0.54 Pass
G 4.54 Not pass
Design proposal
Legacy C model G model
0.92 %
- Modified G
Model Max. Strain[%]
Haulawaytest results
Modified G 0.92 Pass
Modified G model
Purpose : DFSS is used to identify influential design factors in terms of strength.Initial model : Modified G Parameter Diagram
- Response : Static response, Smaller-the-Better- Orthogonal array : L18
Level
Case StudyCase Study
Control factor
Max. plastic strain
Control factorLevel
1 2 3
a Distance 100 150 -----
b Thickness 100 108 120
c Distance 100 108 115
d Distance 100 142 183
e Distance 100 110 119
f Distance 100 111 123
g Height 100 122 143
h Radius 100 150 200
Output responseSystem
Noise factorNoise factor
Noise 1 Durability test load A
Noise 2 Durability test load B
Noise 3 Durability test load C
Unit : Percentage – Level 2,3 to Level 1 ratio
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S/N ratio
Level a b c d e f g h
1 1.33 2.02 1.42 1.38 1.52 1.09 1.34 1.61
2 1.36 1.29 1.36 1.27 1.32 1.51 1.46 1.29
3 ----- 0.73 1.26 1.39 1.21 1.44 1.24 1.14
Level a b c d e f g h
1 -3.10 -7.39 -3.39 -2.46 -4.54 -0.62 -3.27 -4.70
2 -2.82 -3.36 -2.44 -2.99 -3.17 -4.16 -3.11 -2.56
3 ----- 1.87 -3.05 -3.44 -1.17 -4.10 -2.51 -1.61
Mean
Case StudyCase Study
Configuration of optimal design 1 (OPT 1)- Maximize the S/N ratio so that variation is minimized- Minimize the mean value
a b c d e f g h
OPT 1 2 3 2 1 3 1 3 3
Case StudyCase Study
Model S/N ratio Mean
Initial (=Modified G) 2.4 0.65
OPT 1 12.3 0.20
Gain + 9.9 - 0.45
Initial model OPT 1 model Mean : 0.20
Strength analysis with optimal design 1 (OPT 1)- As shown in the below table,
OPT1 model seems to be more robust than the initial model with 5 % mass reduction
Mean : 0.65 Mean : 0.20
0.29 0.92
5 % Mass reduction
Mean : 0.65
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Methods continuously improving, butCAE Role ?
VPD VisionVPD Vision
Productivity Gain
VPD VisionVPD Vision
Key Words of Future State of Key Words of Future State of KdacKdac CAECAE
Up-Front CAE
Simulation Driven
Development
Up Front CAE
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SimulationProcessData
VPD VisionVPD Vision
Path to Future State of Path to Future State of KdacKdac CAECAE
Task Automation
Management
Standardization
Best Practice
VPD VisionVPD Vision
Auto-generate instability chart Import results of chosen case by user
Define FE model file & Analysis ConditionsAuto-generate case#.inp file by user-defined parameter matrix
Display mode shapeCapture image and animation