FEM und Sensitivitätsanalysen unter Berücksichtigung von in

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FEM und Sensitivitätsanalysen unter Berücksichtigung von in
Grenzen zulässiger Formtoleranzen zufällig deformierter Körper
FEA and Sensitivity Analysis Taking Into Account Allowable
Tolerances from Randomly Deformed Bodies
Peter Gust und Christoph Schluer
Weimar, 24.11.2011
Fachbereich D, Abt. Maschinenbau Bergische Universität Wuppertal
Gaußstraße 20
D‐42119 Wuppertal
Univ.‐Prof. Dr.‐Ing. Peter Gust
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
eMail: peter.gust@uni‐wuppertal.de
1
• Founded 1972, students > 16.000 from 90 nations
• 250 Professors, 27 institutes and 280 labortories
• 7 Faculties and 91 study paths
Prize Money
25.000€
• Mechanical Engineering positive trend
+110% Beginners
• Chair of Engineering Design
 3D CAD Design(CATIA), FEM: Catopo, ANSYS, Abaqus
 MBS SAM, Recurdyn, Enventive, 3D Tolerancing VisVSA
 Robust Design optiSLang
 Prototyping: colored 3D Printing
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
2
Sensitivity study to optimize the stiffness of automotive hinge systems
(Bachelorthesis)
Randomly deformed bodies
(Masterthesis, Research)
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
3
1. Mark the closed and open position
2. Interconnection
3. Perpendicular bisection
*Source Kirchhoff GmbH, Halver
4. Result: Necessary is a single
point of rotation
4 Joint Hinge*
1 Joint Hinge*
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
4
„ The hinge system must be supported free of slackness and rattle and easily used“
Guidance requirements
Safe Keep of the hood from closed to open state
Wind Stiffness
200N Load max. 2mm z-deformation
Side Stiffness
200N max. 7mm y-deformation
and again
„Easy to use“
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
5
Aluminium Foam Sandwich is nearly
equal to the original hood and is available
in prototype phase for the automotive
supplier!
FG = 200N
+Friction
(Weight)
Pulley
Weight
The results have an accuracy of ± 5%: FEM‐Model, Alu‐Hood and Real Hood includes
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
6
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
7
Analytical Solution
Numerical Solution
fixed
Constant
Cross Section
F
h
Name
breite_DS
hoehe_DS
Name
laenge_DS
total_deformation_maximum
youngs_modulus
Output
Parameter
Input
Parameter
b
force_y_component
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
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Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
9
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
10
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
11
•
•
•
•
All CAD Data is fully parametric designed
The CAD Modell must react robust against parametric automatic changes The model includes 38 control parameters
The assembly consists of 60 Parts
Hood
Parametric Hinge
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
12
Boundary Conditions and Load: • The bushings in the connecting rods are discretizised with a single solid.
• Between the bushes and the other components is one involving friction
contact condition.
• The buffers are mapped using a spring-replacement model.
Wind Force 200 N in z+
(Normal to the hinge surface )
Measuring Point
Buffer contact force 30 N (left/right)
Threading Points (left/right)
(inside the soffit, 000 000)
Latch connection
„100 111“
Gaußstraße 20
D‐42119 Wuppertal
The gravity of the components is taken into
account in the local z-coordinate system
Tel.: +49.202 439‐2046
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13
ca. 320.000 Elements
Hexaeder
Sheet Metal (Hood) discretized with Shells
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D‐42119 Wuppertal
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Start
Simulations with batch‐Script
Parametric CAD‐
Model
Simulation of one spec. Design
bidirectional Interface
(ANSYS WORKBENCH)
Automatic Change of the CAD‐Model
FEM‐Simulation Model
(ANSYS WORKBENCH)
optiSLang
Input Set (CATIA V5)
Number of samples reached?
yes
Generate DOE‐Samples
(optiSLang) no
Post Processing
Sensitivity Study
(optiSLang) Design Table
Finish
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
15
[mm]
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
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±7 mm
±1.0 mm
ascending order
Scharnieroberteil Höhe Umschlag
E-Modul kurzer Lenker
Blechdicke Scharnieroberteil
Befestigungsbohrung vorne in X Richtung
- 1.0
- 0.75
- 0.5
-0.25
0
0.25
Gaußstraße 20
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0.5
0.75
1.0
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ascending order
Stichmaß kurzer Lenker
Stichmaß Gestell
Stichmaß langer Lenker
Scharnieroberteil Länge Umschlag
E-Modul kurzer Lenker
Blechdicke Scharnieroberteil
Befestigungsbohrung vorne in X Richtung
- 1.0
- 0.75
- 0.5
-0.25
0
0.25
Gaußstraße 20
D‐42119 Wuppertal
0.5
0.75
1.0
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
18
1. Methods Sensitivity Study is a suitable
base for the optimization of sheet metal
mechanism like automotive hinge systems.
2. The mechanism become more and
more complex like hinge systems for
pedestrian safety!
3.
We still have unsolved problems!
 Lifetime safety (durability)
 Uncontrolled opening torques at -40°C
Idea: Influence of the Surface Shape Tolerance
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
19
For the reference case is shown below FE analysis is performed to evaluate the influence
of the shape and dimensional tolerances of parts on the stress distribution under load
Load F = 10kN
Piston Guidance
LK Catia Module
Contact Region incl. friction
Flat plate, fixed bottom side 000 000
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D‐42119 Wuppertal
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20
Tolerance Zone t=2mm
Contact surface with randomly deformed shape (inside the given tolerance!)
SPT = 0,2mm
Surface Profile Tolerance (SPT) = 2mm
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
21
First Result
[MPa]
SPT = 0,2mm
SPT = 0,1mm
[MPa]
[MPa]
SPT = 0,0mm
“Nominal Value”
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
22
•
The results of the sensitivity study are very useful for the
optimization of the hinge in relation to the wind stiffness
•
The influence of surface shape tolerance is significant and will be
further examined at the chair of engineering design
 Calculation of the opening torque, hinge at f(T=-40°C)
 Influence on fatigue calculation
 Influence on slide bearings
 Shrink and Press Fits
Gaußstraße 20
D‐42119 Wuppertal
Tel.: +49.202 439‐2046
Mobil:+49.178 717 0467
23

FEM und Sensitivitätsanalysen unter Berücksichtigung von in

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