Dipl.-Ing.

Elmar Teipen
R&A Global Vehicle Dynamics

Dr.-Ing. Michel Paas

Ford of Europe Body Engineering

Dipl.-Ing. Hessel van Dijk

Ford of Europe Body Engineering

Dr.-Ing. Axel Hnschke

Ford of Europe Analytical Prototype

Body Structure & Chassis Optimization

For Improving Driving Maneuvers
2011 European Hyperworks Technology Conference Bonn

2011 European Hyperworks Technology Conference - Bonn

Agenda
Why Body Structure Is Important To Vehicle Dynamics What Is The Body Doing During Driving ? How To Investigate Structural Performance For VD ? Customized Hyperstudy Approach MDO Application Examples Summary & Next Steps

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Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe

2011 European Hyperworks Technology Conference - Bonn

Why Body Structure Is Important To Vehicle Dynamics

Steering
Straight Ahead Controllability (On-Center)
Compliance Response: Amount, Linearity, Delay Steering Wheel Torque Feedback Modulation (Torque vs. Response)

Ride
Primary Ride
Control / Comfort

Secondary Ride
Shake Rolling Feel / Plushness

Impacts

Solidity / Rigidity / Quality Impression

Vehicle Dynamics Performance Influenced By Structural Stiffness & Weight
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2011 European Hyperworks Technology Conference - Bonn

What Is The Body Doing During Driving ?

Front End Lateral Bending
On-Center Compliance Steering Precision Response Delay, Non-Linearity

Torsion
Front-to-Rear Balance Compliance Body Shake, S&R, Rigidity Feel

Vertical Bending
Impact Harshness Front End Shake, (S&R) Trade-Off : Body / Chassis Lightweight Vehicle Dynamics Performance
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2011 European Hyperworks Technology Conference - Bonn

How To Investigate Structural Performance For VD ?

Local EWS

HPC
Competitor SW MNF-Creation

Local EWS

Hypermesh Preprocessing

ADAMS/Chassis Solving

Hyperworks Postprocessing

- ADAMS/Chassis: MBS Pre-Processing (With Vehicle Templates) & Solving

- Embedded FE-Structures Of Body, Subframes, etc. Manual Hypermesh Preparation (Superelements, Interface Nodes, ...) Modal Reduction With Competitor Software On HPC Supercomputer Sequential MNF-Creation: Up To 3 h Per Run / Up To 16 GB mnf To Transfer Implementation With Python-Templates (Manually Edited) - Hyperworks: VD Postprocessing (Based On Maneuver-Dependent Reports) - Body & Chassis Structural Modifications Based On Individual Results Time-Consuming Manual Interactions Limited Variations Not Efficient
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2011 European Hyperworks Technology Conference - Bonn

Customized Hyperstudy Approach

HPC
TCL-Templates Preprocessing Radioss MNF-Creation ADAMS/Chassis Solving TCL-Templates Postprocessing

Customized Hyperstudy Control & PP

- Hyperstudy Customized Integration:

Selection Of Design Variables (In FE And MBS Templates)
In-The-Loop Generation / Calculation Of Combined Models Fully Automated DOE Control From Local EWS Data-Intensive Work Completely On HPC Supercomputer Semi-Parallel Runs Possible Collection Of Final Results (Some kB Per Run) On EWS Optimized License Application User Friendly Automated Pre+Post No Manual Interaction Reduced File Transfer Reduced Run Time Reduced Data Reduced Cost

Customized Hyperstudy = Key Enabler For Statistical FE + MBS Analysis on HPC

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2011 European Hyperworks Technology Conference - Bonn

Application Examples: Stepsteer & Ride 4-Poster

Vehicle Dynamics Metrics vs. Sheets
- Steering (Sinesteer, Stepsteer, On-Center) - Ride (4-Poster, Road 10 Old Part, Blauwe Kei) - Handling - Braking

BIP content within a Trimmed Body + Subframes Design Variables: Sheet Thicknesses + ADAMS Bushings Generic Responses
Wheel Loads (nominal, min, max) Full Vehicle properties Frt Axle Load, Total Weight

Stepsteer Responses (Time Domain):

Peak Yaw Rate, Peak LatAcc Steady-State LatAcc, Sideslip Angle, ...

4-Poster Responses (Frequency Domain):

50 PSDs (each 1 30 Hz) (Tpmnts, Seatrails, FrtBending, FulTors, Engine,...)

Total Time To Complete: 2 Days (1000 Runs) Customized HS : Complete In-/Output Matrix

Vehicle Dynamics Attribute Requirements In Body / Chassis Lightweight MDO

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2011 European Hyperworks Technology Conference - Bonn

MDO Approach
Meta Modelling

HyperStudy DOE

Data Mining

CART Clustering Analysis Correlations

Optimization

Validation

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Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe

2011 European Hyperworks Technology Conference - Bonn

MDO Approach
Meta Modelling

HyperStudy DOE

Data Mining

Optimization

Validation

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Nov 8th, 2011

Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe

2011 European Hyperworks Technology Conference - Bonn

MDO Approach
Meta Modelling

HyperStudy DOE

Data Mining

Optimization

Validation

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Nov 8th, 2011

Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe

2011 European Hyperworks Technology Conference - Bonn

MDO Approach
Meta Modelling

HyperStudy DOE

Data Mining

Optimization

HyperStudy

Validation

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Nov 8th, 2011

Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe

2011 European Hyperworks Technology Conference - Bonn

Application Example: Body Impact @ Full Vehicle Ride

Data-Mining

FV Frequency Responses: Ride

Design Variables
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Zoom: Full Torsion (1 30 Hz)

Body DVs

Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe

2011 European Hyperworks Technology Conference - Bonn

MDO Toolkit Example: Frequency-Dependent Correlations

Data-Mining

FV Response

Body DVs

MDO Toolkit Available To Visualize Structural Effects Against Full Vehicle Metrics
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2011 European Hyperworks Technology Conference - Bonn

MDO Subcase Extension

Meta Modelling & Optimization
1. Total Mass

2. Stat. Stiffness

3. Dyn. Stiffness

4. Modes /Tors. Stiffn.

5. EUNCAP ODB

6. Rear Impact

7. LINCAP

+ +

8. Meta Models incl.Steering eqs. Vehicle Dynamics / constraint 9. Vehicle Dynamics / Ride

DVs

RVs

Additional VD Loadcases To MDO Process = X-Attribute Trade-Off Studies

Page 14 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe

2011 European Hyperworks Technology Conference - Bonn

Summary
Vehicle Dynamics Attribute Significantly Influenced By Structural Stiffness & Weight Lightweight Trend: Potentials & Risks For Vehicle Dynamics Standard Process Inefficient To Systematically Investigate Trade-Offs Customized Hyperstudy Enables X-Attribute MDO Including Vehicle Dynamics
From Manual Iterations To Automatic Process From Local EWS To Supercomputer From Competitor Software To Radioss From Single Attribute Optimization To X-Attribute MDO

Next Steps
Process Refinements Implementation Of Structural Concepts

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Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe

2011 European Hyperworks Technology Conference - Bonn

Contacts
Elmar Teipen
+49 (0)221 9034526 eteipen@ford.com

Dr. Michel Paas

+49 (0)221 9037755 mpaas@ford.com

Hessel van Dijk

+49 (0)221 9036333 hvandijk@ford.com

Dr. Axel Hnschke

+49 (0)221 9033441 ahaensch@ford.com

Special Thanks
Axel Flick, Altair Office Cologne Alexander Koch, Altair Office Cologne Thomas Kowalewski, Altair Office Cologne Arno Klein, P+Z Engineering Matthias Stenkamp, P+Z Engineering

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Nov 8th, 2011

Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe

2011 European Hyperworks Technology Conference - Bonn

Thank you for your attention !

Dipl.-Ing. Elmar Teipen Global Vehicle Dynamics Dipl.-Ing. Hessel van Dijk Body Engineering Europe