weight reduction of bus tubular structure by using … singh sidhu assistant manager,r&d weight...
TRANSCRIPT
Manjinder Singh Sidhu
Assistant Manager,R&D
Weight reduction of bus tubular structure by using
Optistruct/PBS e-Compute
SML ISUZU
Date : ATCx Date 29th July 2016
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Background of Organisation
SML ISUZU LIMITED (formerly SWARAJ MAZDA LIMITED) is engaged in
commercial vehicle & spares. The company products are as under:-
1. TRUCKS
2. BUSES
3. SPECIAL VEHICLES LIKE SLEEPER BUSES, TIPPERS etc.
4. OVERSEAS VEHICLES
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Weight reduction of bus tubular structure
• Objective of case study
The main objective of this simulation is to reduce the weight of Bus
Structure while maintaining Stress constraints. This will be done by
using Optistruct/ PBS e-compute.
• Statement of problem
To simulate the structure by using the thickness/shape optimization
technique with normal static gravitational loading condition(3g).
1. Simulate the base line structure by static 3g loading condition.
2. Then ,simulate low weight structure ,if the stresses in first step
are less than yield stress of structural material.
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SOFTWARE USED
• Weight/Cost reduction is done by using Hyperworks v14/PBS 14.
• Preprocessing is done by using Hyper Mesh.
• Analysis is done by using Optistruct/PBS e-Compute .
• Post Processing is done by using Hyper View.
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Process Methodology (Stage 1)
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Process Methodology (Stage 2)
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BASE LINE DESIGN
• STAGE 1:-ANALYSIS OF BASE LINE DESIGN USING OPTISTRUCT.
• MAXIMUM STRESSES BY USING STATIC 3G LOADING CONDITION
=162 MPa , WHICH ARE VERY MUCH LESSER THAN YIELD 240 MPa
PBS
PBS E-Compute
THERE WILL BE THE SCOPE OF OPTIMIZATION IN STRUCTURE
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OPTIMISED DESIGN
• CONVERT THE DIAGONAL MEMBER OF FLOOR STRUCTURE FROM
30X40X2 TO 20X40X2.
• CONVERT THE FLOOR LONGITUDIONAL MEMBER FROM 30X30X2 TO
30X20X1.5
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OPTIMIZED DESIGN
• RUN THE OPTIMIZED STRUCTURE
• STRESSES OBSERVED =205 Mpa ,LESSER THAN YIELD LIMIT (240 Mpa)
OPTIMIZED DESIGN IS OK
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Benefits summary
• After studying the results and the stress pattern on the bus after
simulation, benefits of Optimization of structure using Hyperworks
/Optistruct are as under:-
1. Weight Saving:-9 kg
2. Cost saving:-Rs 513/bus(250 buses manufactured/month)
3. Time saving:-Weight reduction in quick time with PBS e-compute.
4. Design change suggestion to design team as per analysis report.
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Challenges faced and solutions presented
• Selection of appropriate element type, size and control cards for
element properties for getting accurate results.
• Selection/Availability of material with different thickness/shape.
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Conclusion
• Optimization by using “Optistruct” proved to be an effective method to
reduce the weight of bus super structure. The software gave the
freedom to study and analyze the output in different forms and sections
which is difficult to workout practically. Hyperworks/Optistruct is an
effective tool to validate the result efficiently.
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Acknowledgements/Credits
I would like to thank the followings for kind support:-
• SML ISUZU Ltd.
Mr. SANJIV KUMAR SHARMA, Sr. MANAGER, R&D.
• ALTAIR SUPPORT TEAM